TABLE OF CONTENTS

INTRODUCTION TO IFFCO
INTRODUCTION TO IFFCO AONLA
MAIN SUBUNITS / PLANTS OF IFFFCO AONLA UNIT

AMM0NIA PLANT
 Process flow diagram (pfd) of ammonia
 Process/steps involved in ammonia manufacturing
 Desulphurization of natural gas
 Adiabatic pre-reforming
 Reforming section
 Water gas shift reaction
 Methanation
 Ammonia synthesis

UREA PLANT
 PROCESS TECHNOLOGY
 STRIPPING PROCESS
 BRIEF PROCESS DESCRIPTION OF UREA PLANT
 Pressurization of carbon dioxide gas
 Urea synthesis and high pressure recovery
 Urea purification and low pressure recovery
 Urea concentration
 Urea prilling

POWER PLANT
 INTRODUCTION OF POWER PLANT
 PROCESS INTERACTION
 GAS TURBINES
 Introduction
 Thermodynamic principles of operation
 The brayton cycle
 Output power of gas turbine generation unit
 DIFFERENT COMPONENT SPEED OF GAS TURBINE GENERATION

 Name plate details of gas turbine generator

 GAS TURBINE PARTS
 AUXILIARY SECTION
 COMPRESSOR SECTION
 Compressor rotor
 Compressor casing
 Compressor blades

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  Variable inlet guide vanes
 Surging
 COMBUSTION SECTION

 Combustion chambers
 Combustion liner
 Spark plug and cross fire tube
 Spark plug and cross fire tube

 TURBINE SECTION

 First Stage Nozzle

 Second Stage Nozzle & Diaphragm
 Turbine Rotor Assembly
 BEARINGS
 LUBRICATION
 OIL SEALS & SEAL RING
 GEARS
 COUPLINGS
MATERIAL OF CONSTRUCTION OF GAS TURBINE
STARTUP SEQUENCE OF GAS TURBINE
SAFETY TRIP INTERLOCKS OF GAS TURBINE
STOP SEQUENCE OF GAS TURBINE

DETAIL DESCRIPTION OF STEAM GENERATION

Components of boilers
● Drum and internals
● Furnace
● Super heaters
● De – super heater
● Boiler convection bank tubes
● Boiler setting
● Economizer

PERFORMANCE DATA OF BOILER

STARTUP SEQUENCE OF STEAM GENERATOR
SAFETY TRIP INTERLOCKS OF STEAM GENERATOR
NORMAL SHUT-DOWN OF STEAM GENERATOR

AUXILARY SYSTEMS FOR STEAM & POWER GENERATION

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  Fuel system
● Feed water system
● Steam distribution system
● Combustion air system

DETAILED DESCRIPTION OF HRSG

MAINTENANCE
 PROCESS INTERACTION FOR MECHANICAL MAINTENANCE
 INSPECTIONS CARRIED OUT ON GAS TURBINES
 WORK INSTRUCTIONS FOR
 Rotary And Static Equipments

 Overhauling Of Gas Turbine

 Overhauling Of Horizontal Split Case Design

 Boiler Inspection

 Cleaning And Hydraulic Testing Of Heat Exchanger

 Overhauling Of Centrifugal Pump

 Overhauling Of Fan And Blowers

 GENERAL SEALING SYSTEM

 sealing materials in and pipe system valves
 MATERIAL SELECTION BASED ON OPERATING TEMPERATURE
 VIBRATION

 vibration measurement and analysis technique

SUGGESTION

INTRODUCTION TO IFFCO
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Indian Farmers Fertilizers Co-operative Ltd. (IFFCO) was established on
Nov 3, 1967 as multiunit co-operative organization with bound
objective and augmenting fertilizers production & ensuring its
availability at farmer’s doorstep strengthening co-operative fertilizer
distribution system & education training and guiding the farmer for
improving agriculture productivity.

It has membership of over 35000 co-operative societies serving 18

states & 3 Union territories. The number of co-operative societies
associated with IFFCO has risen from 57 in1967 to 39824 at present.

IFFCO has 5 units at Kalol, Kandla, Phulpur, Paradeep and Aonla. It has
3 plants Kandla, kalol & Phulpur operative with overall capacity
utilization of 117% during 1986-1987. It commissioned the ammonia-
urea plant at kalol and NKP/DAP plant at Kandla in the state Gujarat in
1975.

Another ammonia urea complex was setup at Phulpur in the state of

U.P. in 1981. The other unit at Aonla was commissioned in 1988.

Marketing offices in fields co-ordinate the entire activities of

distribution and sale system. In addition, essential inputs for the crop
production are made available to farmers through 167 Farmer Service
Centers (FSC).

IFFCO today is a leading player in Indians fertilizer industry is making

substantial contribution to the efforts of Indian Government to increase
food grain production in the country.

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 INTRODUCTION TO IFFCO AONLA
Aonla project of IFFCO is one of the Natural Gas/Naphtha based
fertilizer plants setup in the country on the Hazira –Bijaipur-Jagdishpur
(H.B.J.) gas pipeline, which runs through four states. Naphtha is
procured from oil companies through rail tankers.
Aonla is IFFCO’s fourth plant with investment of Rs. 696 crores and
present annual capacity of aonla unit is two (2) million MTPA of Urea,
which was commenced production on May 1988.

COMMISSIONING
Aonla –I Ammonia plant : May 15, 1988
Urea plant : May 18, 1988
Aonla –II Ammonia plant : Nov 16, 1996
Urea plant : Nov 16, 1996

AONLA UNIT LOCATION

State : Uttar Pradesh, India

State capital : Lucknow, 250 km, from plant
Distance from New Delhi : 260 Km
Nearest Airport : Lucknow
Railway station : Aonla, 10 km from plant
Road : Plant is on Bareilly-Aonla highway
Area under plant : 260 hectares
Area under township : 220 hectares

PRODUCTS AND RAW MATERIAL

Product name : Urea
Raw material : Natural Gas/Naphtha and water
Production capacity : 1515*4=6060 MTPD
Total products : more than 1 lakh bag/day of 50 kg each

TECHNOLOGY

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Ammonia Plant MTPD 2 x 1740, M/S HALDOR TOPSOE, DENMARK

Urea Plant MTPD 4 x 1515, M/S SNAMPROGETTI, ITALY

PRODUCTION

This plant has been designed to produce 2 million MT of urea per year
with plant capacity of 3480 MT per day ammonia and 6060 MT per day
of urea.
Ammonia : 11, 48,000 TPA
Urea : 20, 00,000 TPA

MAIN SUBUNITS / PLANTS OF IFFFCO AONLA UNIT

There is following main plants inside the Aonla Unit:

1. Ammonia plant:-
There are two plants of ammonia viz. Ammonia –I and Ammonia –II. Each
ammonia plant is designed to produce 1740 MT liquid ammonia per day.

Raw Material:-

Raw material of hydrogen & nitrogen are mixed to produce ammonia

(NH3). Source of nitrogen is air. Natural gas is supplied by GAIL through HBJ
gas pipeline. These gases are mixed with steam and are sent to the primary
reformer. Further reforming takes place in secondary reformer, where air is
added in it. Hot gas from secondary reformer is cooled by Heat Recovery
Unit.

Now this process gas is introduced to shift converter. Here most of the

CO is converted into CO2. This process gas is sent to G.V. solution for CO2
removal.

2. Urea plant:-

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 There are two plants of Urea each having two streams of Urea having
capacity of 1515*2= 3030 MT/day per plant.

To manufacture Urea, raw materials are Ammonia and CO2 which comes
from Ammonia Plant are mixed in multi-unit Reactors as per following
reaction.

2NH3 + CO2  NH2COONH4 + 38.1 Kcal

NH2COONH4  NH2CONH2 – heat

3. Steam & Power generation plant:-

There is huge requirement of steam to produce urea and power to run the
all machinery in this fertilizer complex. To meet these requirements, there
are two Gas Turbine Generators (GTGs), one Steam Generator (SG) and two
Heat Recovery Steam Generation units (HRSG) in the power plant.
GTGs
The GTGs ,manufactured by M/S Hitachi limited Japan has a capacity to
generate 25.28MW at IS0 base rating (Atmospheric temperature of 15 °C &
relative humidity 60 per cent at mean sea level).The GTGs have been
designed to operate on natural gas or naphtha fuels.
HRSGs
The exhaust of GTG goes to HRSG to generate steam at high pressure of
115Kg/cm2g and temperature of 515°C. Two heat recovery steam generating
(HRSG) unit each having capacity to generate 80M T / hr., is manufactured
by Kawasaki Heavy Industries Japan. HRSG is a packaged type boiler having
bank tubes, a set of super heaters, de- super heater & Economizer. The
temperature of exhaust gas from GTG is increased by supplementary firing.
The exhaust of GTG is having sufficient quantity of excess air which is utilized
for combustion of gas as supplement fuel. For steam temperature-control,
direct water spray type attemperator has been provided between primary &
secondary super heaters.

SG

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 The Steam Generator (SG) is water tube, double drum, natural circulation, oil
or natural gas fired boiler manufactured by M/S Mitsui Engg. Co. Japan. The
capacity of SG is 150MT/hr. of superheated steam at pressure of 115Kg/cm2g
& temperature of 515°C.The SG is designed to use NG or oil fuel for regular
firing. For initial light up of the SG, HSD are used. The SG is pressurized
furnace with two nos. Forced Draft (FD) fans, one turbine driven & other
motor driven to supply combustion air. A direct spray type de- super heater
has been provided between primary & secondary super heater to control
steam temperature.

4. Offsite :-
Offsite facilities provide supplementary needs like De-mineralized Water,
Compressed air etc. to the main Plants.

Offsite have the following plants –

 Raw water & De-mineralized water Plant

 Cooling towers
 Inert- gas plant
 Compressed air systems
 Effluent Treatment Plant
 Ammonia Storage Tanks
5. Product handling :-
This Plant handles readymade product for dispatch to different parts of
country. This plant receives final product of Urea from Urea Plants through
Conveyer belts. Urea received at the PH Plant is packed into bags of 50Kgs
each using automatic bagging machines. This product is transported
through rail and road facilities available inside the plant.

AMM0NIA PLANT

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There are two ammonia plants having capacities each to produce 1740 MTPD
(Metric Tone per Day) of liquid NH 3 . The technology is based on the Holder
Topose Technology, Denmark- which process the natural gas and naphtha as a
main raw material.
The production of ammonia requires H2 and N2 in the ratio of 3:1.
The source of hydrogen is either Natural gas or Naphtha or combination of both.
Nitrogen is sourced from atmospheric air. Natural gas is supplied by GAIL through
HBJ pipe line from Bombay High gas fields and Naphtha is supplied by IOCL,
Mathura Refinery, both are used as feedstock which contains hydrocarbons.
Small quantities of Sulphur in feedstock are removed by passing it through
desulphurization unit. Sulphur free gas with Naphtha is then mixed with steam
and sent to the Primary Reformer where reforming reaction takes place in the
presence of catalyst producing a gaseous mixture of H 2 and carbon compounds.
Further, this mixture is reformed in Secondary reformer where air is added to
provide the required N2 for NH3 synthesis. After this reaction, the gas mixture is
cooled in heat recovery boilers and sent for the shift conversion where carbon
compound are converted into co 2. This co2 is separated from gaseous mixture and
sent to urea plant as raw-material for urea production. To avoid traces of co 2
which is harmful in further process, it is converted to methane in methanator.
Pure synthesis gas from methanator outlet is compressed and sent to ammonia
converter where NH3 is formed. The final product of liquid NH 3 is sent to urea
plant as raw-material for urea production. A common purge gas recovery unit
with membrane technology has also done been to recovery hydrogen for energy
saving.

PROCESS FLOW DIAGRAM (PFD) OF AMMONIA

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 Recycle HP
Hydrogen Steam

Waste Heat
Desulphuri Primary Secondary Boiler HT Shift LT Shift
Natural reforming Converter Converter
zation reforming System
gas

Air
Steam Compressor

Waste Heat
To
Boiler
Storage

Syn Gas Ammonia

CO2 Methanation Compressor Synthesis
Removal

To
Refrigeration Urea
Loop

CO2
to Urea

PROCESS FLOW DIAGRAM (PFD) OF AMMONIA

PROCESS/STEPS INVOLVED IN AMMONIA MANUFACTURING

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 DESULPHURIZATION
DESULPHURIZATION

CATALYTICSTEAM
CATALYTIC STEAM
REFORMING
REFORMING

WATERGAS
WATER GASSHIFT
SHIFT
REACTION
REACTION

CO2 2ABSORPTION
CO ABSORPTIONAND
AND
STRIPPING
STRIPPING

METHANATION
METHANATION

AMM0NIASYNTHESIS
AMM0NIA SYNTHESIS&&
REFRIGERATION
REFRIGERATION

1: DESULPHURIZATION OF NATURAL GAS:

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Natural gas contain sulphur compounds in the form of sulphides (H 2S), disulphide
(CH3-S-CH3), mercaptanes (HS-CH3) ,cyclic sulphide(S-CH2).Which are poisonous to
the catalyst used in ammonia plant.
The process of removal of these sulphur compounds is called
desulphurization.
A):1st Step –Hydrogenation of sulphur compound in the presence of a catalyst.
Hydrogen reacts with organic sulphur compounds to form H 2S in the
hydrogenater, R-3207.
H2 + RSH RH + H2
nd
B): 2 Step--The hydrogen sulphide is then removed by passing through beds
of zinc oxide where it is adsorbed and converted to solid zinc sulphide.
H2 S + ZnO ZnS + H2 O

2: ADIABATIC PRE-REFORMING:

The adiabatic pre reforming in case of vaporized naphtha feed is done to

decompose the higher hydrocarbons into lower hydrocarbons for example CH 4
and other components like H2, CO and CO2.
The vaporized naphtha is mixed with steam and preheated to about 490 0C.
The gas is passed through the pre reformer containing nickel catalyst.
In the pre reformer the endothermic reforming reactions are followed by the
exothermic methanation and shift reactions. The overall process is normally
exothermic.
The adiabatic pre reformer reduces the heat load on the primary reformer
thus the life of reformer tubes becomes longer. Pre reformer also acts as an
efficient sulphur guard for the primary reformer catalysts.
The gas from adiabatic reformer is sent to primary reformer and secondary
reformer for further reforming.

3: REFORMING SECTION:

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Steam reforming is usually carried out in two stages using primary and secondary
reformers. De-sulphurised naphtha or natural gas is subjected to steam (thermal)
reforming at about 28-30 kg/cm2g pressure and around 80000C temperature in
the primary reformer consisting of a large number of centrifugally cast, high
temperatures, vertical alloy steel tubes packed with nickel catalyst.
The overall reaction is endothermic and requires a large amount of heat. The gas
leaving the primary reformer containing 5-15% methane is sent to an auto
thermal secondary reformer.
The required amount of nitrogen is fed to the secondary reformer through
addition of air to give the desired 3:1 hydrogen to nitrogen ratio in the synthesis
gas.
Herein methane is converted to H2, CO & CO 2 over a single bed of catalyst. The
carbon monoxide content of the gas is converted to carbon dioxide and hydrogen
by passing over catalyst in presence of steam, thus generating hydrogen by the
water gas shift reaction and is carried out in two stages:
The first stage, high – Temperature (HT) shift conversion, is carried over iron-
chromium catalyst at 3500C-4300C, while the second stage, Low Temperature (LT)
shift conversion, is carried over copper based catalyst at 200 0C-2800C.In the HT
shift conversion, level of CO is reduced from 12% to around 3% and in the L.T.
Shift conversion the CO level is reduced to around 0.2%.
The purified syn-gas mixture containing N2 and H2 in the mole ratio of 1:3 is
reacted at elevated temperature of the order of 4500C-5000C and 150-250kg/cm3g
pressure over an activated iron catalyst promoted with potassium and alumina.
The gas is first cooled by heat exchanger and finally by refrigeration to condense
ammonia as liquid.
Conversion of synthesis gas to NH3 is about 20-30% per pass. The gas
remaining after ammonia condensation is recycled to the converter. The inert
gases built up in the synthesis gas are purged.
Reforming reactions are as follows:-
CH4 + 3H2O + CO + CO2 + 7H2
CH4 + H2O CO + 3H2

4: WATER GAS SHIFT REACTION:

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In this step, the water gas shift reaction is used to convert the carbon monoxide
into carbon dioxide and more hydrogen.
CO + H2 O CO2 + H2
The carbon dioxide is then removed by absorption in aqueous ethanolamine
solutions.

5:METHANATION:

The final step in producing the hydrogen is to use catalytic methanation to

remove any small residual amounts of carbon monoxide or carbon dioxide from
the hydrogen:
CO + 3H2 CH4 + H2O
CO2 + 4H2 CH4 + 2H2O

6: AMMONIA SYNTHESIS:

The desired end product ammonia, the hydrogen is then catalytically reacted with
nitrogen (derived from process air) to form anhydrous liquid ammonia. This step
is known as the ammonia synthesis loop.
3H2 + N2 2NH3

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 UREA PLANT
Urea synthesis is of historical importance, it being the first organic compound to
be synthesized from inorganic compounds in a laboratory. Wholer in 1828, had
obtained urea from ammonium cyanate. Previously this urea had been separated
from urine and the experiment by Wholer showed that organic material could be
prepared from an inorganic chemical.

Commercial production of Urea was started in 1920 by I.C. Farben in Germany

based on ammonium carbamate process. Since then considerable ingenuity was
used to overcome process difficulties such as corrosion problems, recovery of off-
gases and economic process routes which resulted in present day development.

The various commercial Urea manufacturing processes of today use reaction

between liquid ammonia and carbon dioxide gas to form ammonium carbamate
and subsequent dehydration of carbamate to yield Urea and water.

Urea is in fact the diamide of carbonic acid with a chemical formula represented
by: NH2-CO-NH2

PROCESS TECHNOLOGY:

Urea is synthesized from Ammonia and gaseous carbon dioxide. Ammonia and
carbon dioxide react to form ammonium carbamate, a portion of which is
dehydrated and is determined by the ratio of various reactants, the operating
pressures, temperature and the residence time in reactor.
The reaction of Ammonia and Carbon dioxide to produce urea, takes place in two
stages at elevated temperature.

1) 2 NH3 + CO2 ------------------ NH2COONH4+ 38.1 Kcal /gm. Mol.

Liquid Gaseous carbon Ammonium
Ammonia dioxide carbamate

2) NH2COONH4 ------------------ NH2CONH2+H2O-7.1 Kcal/gm.Mol.

Urea

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The first reaction is strongly exothermic and therefore, heat is liberated as this
reaction occurs. With excess NH3, the CO2 conversion to carbamate is almost
100%, provided solution pressure is greater than decomposition pressure.

The decomposition pressure is the pressure at which carbmate will decompose

back into CO2 and NH3 i.e.

NH2COONH4 2NH3 + CO2

Decomposition pressure is a function of NH 3 concentration in the feed & the

solution temperature and if either temperature or NH 3 concentration increases,
recycle is increased. It is desirable to operate at higher pressure with high molar
ratio of NH3 to CO2 provided reactor operating pressure is quite high to prevent
carbamate decomposition into NH3 and CO2. This will maximize CO2 conversion to
urea.

The second reaction is endothermic, i.e., heat is required for this reaction to start,
which comes from the formation of carbamate. This reaction is a function of
temperature and ammonia concentration in the feed.
The solution effluent from the reactor being a mixture of urea solution,
ammonium carbamate, unreacted ammonia water and CO 2 is extremely corrosive
in nature.

The subsequent stage of process consist of decomposition of unconverted

carbamate, recovery of resulting ammonia and carbon dioxide for recycle,
concentration and prilling of urea solution.

Stripping Process:

Efforts to find some additional driving force beyond the usual addition of heat and
reductions in pressure to decompose carbamate from urea reactor effluents have
met with great success.

In this process decomposition of Ammonium carbamate is done at the synthesis

pressure by using either CO2 (stamicarbon CO2 stripping Process) or NH3 vapours
(SNAMPROGETTI NH3 stripping process)in a falling film type decomposer

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normally called stripper tubes in the form of liquid film from the top while the
stripping agent is introduced from the bottom which travels upwards.
Medium pressure steam condensing on the shell side of the stripper supplies heat
for decomposition of ammonium carbamate. Currently Snamprogetti process
does not require injection of Ammonia vapours at stripper bottom, only higher
moler ratio of NH3/CO2 is maintained in the reactor. At higher NH 3/CO2 ratio
Ammonia liberated in stripper is adequate to carry out stripping effectively. Since
the reactor, stripper & condenser system operates at nearly same pressure at a
much higher elevation so as to give the required head or to use a recycle ejector
using a part of the feed reactants as a motive fluid. Snamprogetti was the first to
develop use of such recycle ejector and locate condensers at ground level. Since a
major portion of unconverted carbamate is decomposed and recycled to reaction
at synthesis pressure, load on downstream decomposition and recovery section is
comparatively much less resulting in lower utility consumption.

Further since the synthesis pressure in the stripping process is lower, it is possible
to employ steam driven centrifugal CO 2 compressor which has lower maintenance
and operating cost. In both stamicarbon and Snamprogetti stripping processes
low pressure steam is generated in carbamate condenser which has resulted in
lower consumption of steam and cooling water.

Theory of Stripping:

The theory of stripping is based on Henry’s law. The concentration of components

in solution while in equilibrium with phase is directly proportional to partial
pressure of the components in the vapor phase. By changing partial pressure of a
component concentration of solution can be changed. This is illustrated as
follows:

Let us assume that A & B are two components.

CA = Concentration of component A in solution.

CB = Concentration of component B in solution.
PA&PB = Partial pressures of components A & B in vapor phase.
P = Total Pressure = PA + P B = p.CA + p.CB

Where p is vapor pressure.

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In stripper excess NH3 along with reactor effluent is introduced. This NH 3 is
released as vapor by heating in stripper. This NH 3 vapor increases partial pressure
of ammonia over the solution. As the total pressure remains same partial
pressure of CO2 reduces to a lower value. In accordance with Henry’s law
ammonium carbamate decomposes to increase partial pressure of CO 2 in vapour
phase to approach equilibrium concentration. Stripping action is thus carried out
and heat of decomposition is supplied from as external source by condensation of
medium pressure steam. Partial pressure of either of the components can be
changed and this will result in the decomposition of carbamate.

BRIEF PROCESS DESCRIPTION

OF UREA PLANT

Urea is commercially manufactured by direct synthesis of gaseous Carbon Dioxide

and liquid Ammonia.
The production process consists of the following main operations:

 Pressurization of carbon dioxide gas

 Urea synthesis and High pressure recovery
 Urea purification and Low pressure recovery
 Urea Concentration
 Urea prilling
 Waste water treatment.

PRESSURISATION OF CARBON DIOXIDE GAS:

Carbon dioxide is compressed in a twin case centrifugal compressor K-1 before

being fed into the rector R-1.

CO2 is received at the battery limits at 15 kg/cm 2g and 40 0C. It’s free moisture is
removed in a knock out drum (MV-9). Air is added at the outlet of MV-9. The gas
then enters the compressor K-1.

The compressor consists of two casing of two stages, with inter coolers. By
successive compression and inter cooling the moisture present in CO 2 is removed.

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The gas is pressurized from 1.5 kg/cm 2g to 160 kg/cm2g and 1300C. It then flows
to the reactor R-1 in the HP section.

UREA SYNTHESIS AND HIGH PRESSURE (H.P.) RECOVERY

Urea is produced by synthesis from liquid Ammonia and gaseous Carbon dioxide,
both being supplied by Ammonia plant.

The liquid Ammonia is pumped at high pressure through an ejector which drives
the Carbamate from Carbamate Separator into the Reactor. Carbon dioxide,
mixed with a small measured quantity of air is compressed in a two stage Carbon
dioxide Compressor and is also fed to the reactor. The liquid ammonia and
Carbon dioxide react together here. The product formed is carbamate which
dehydrates, in the Reactor itself, to form Urea and water. The Oxygen in the air
forms a passive Oxide layer on the insides of vessel’s surface to prevent corrosion
by carbamate and Urea.

The reaction product from the reactor overflows to the HP stripper where the
unconverted carbamte is decomposed back into Ammonia and Carbon dioxide.
Heat of decomposition is supplied by MP steam, admitted in Stripper shell side.
Urea solution thus obtained flows out to the MP section through a letdown level
control valve.

The vapours produced on decomposition of carbamate in HP stripper enter the

HP carbamate Condenser through a mixer, along with weak carbamate solution
from MP section. Here they condense to from carbamate again and flow to the
HP Carbamate Separator. Condenser required for generating steam here is
supplied from shell side of MP Decomposer. Vapours, mostly inert, from
carbamate Separator are sent to the bottom of MP Decomposer to passivate the
MP section.

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UREA PURIFICATION AND LOW PRESSURE RECOVERY

1. Medium pressure section

Urea solution from the bottom of the HP Stripper now enters the MP decomposer
after pressure reduction through a level control valve. During expansion much of
the remaining carbamate flashes forming NH 3 and CO2 vapours, thereby
concentrating urea in the solution. This urea solution is further let down in
pressure by a level control valve and enters the LP section.

The vapours from the MP decomposer are condensed in MP condenser using

ammonium carbamate solution from the LP section, with tempered cooling water
on the tube side. The carbamate solution overflows from the MP Condenser in to
MP Absorber where the exess Ammonia, Inerts and little CO 2 separate from the
vapours. These vapours are further purified in the top section of the Absorber
with reflux ammonia. Most of the ammonia with inert gases leaving the top of MP
Absorber is condensed in Ammonia Condensers, with cooling water on tube side.
From Ammonia Condenser both liquid and gas phases are sent to Ammonia
Receiver along with incoming liquid Ammonia. The inert gases, saturated with
Ammonia, leaving the receiver enter the Ammonia Recovery Tower. Here
Ammonia is further condensed by direct contact with cold Ammonia from the
Battery limit and flows down the Ammonia Receiver.

The inert with residual ammonia vapours from the Tower are sent to MP
Ammonia Absorber where the later gets absorbed in cooled condensate, washed
in its inert washing tower and recycled to MP Absorber as ammonia water. The
inert are sent to vent stack.

2 Low Pressure Section:

The Urea solution from MP Decomposer bottom enters the LP Decomposer after
expansion through a level control valve. As a result of expansion, most of the
remaining carbamate undergoes decomposition. Thus Urea solution is further
concentrated through a level control valve.
The vapours enter the LP Condenser shell and get absorbed in an aqueous
carbamate solution from waste water section. LP Condenser has cooling water on
tube side. The liquid thus formed goes to the Carbonate solution from Tank,
where it is recycled back to MP Condenser.

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The inert gases from the Tank containing ammonia vapours are absorbed in
cooled condensate in LP Ammonia Absorber, washed in its Inert Washing Tower
and sent to vent stack. The liquid flows down to the Tank.

Urea Concentration
The liquid from the bottom of LP Decomposer is further concentrated in two
Vacuum Concentrators in series. Here with the help of Low pressure stem, Urea
solution is concentrated from 70% to 99.7% by Wt. The vacuum is created and
maintained by two vacuum systems consisting a set of steam ejectors and
condensers.
Urea melt thus obtained is then pumped to the prilling tower. The vapours from
both the Vacuum separators are condensed in the cooling water condenser and
sent to the waste water tank.

Urea prilling
The molten urea thus obtained from the 2 nd vacuum Separator Holder is pumped
to the top of a Common Prill Tower, into a Prill Bucket. The Urea comes out
through the holes of the rotating Prill Bucket and falls down the Prill Tower. Air,
by natural draught flow upwards counter current to the urea droplets and cools &
solidifies them. The solid prills thus formed fall to the bottom and sent on to a
Belt Conveyor by means of a Rotating Scraper. Urea Prills are then transported to
the bagging plant.
Prill tower

Scraper

Urea solid prill

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 POWER PLANT

For efficient and uninterrupted running of a fertilizer plant a reliable sources of

power is very essential. All the major rotating equipments of Ammonia & Urea
plants are driven by electrical motors.
To meet the demand of high pressure steam & dependable electrical power, the
steam & power generators have been installed. The steam generators supply high
pressure steam to process plants and gas turbine generators supply the power
requirement of the plant.
There are two gas turbine generators (GTG), one steam generator (SG) and two
heat recovery steam generating unit (HRSG).
(1) The GTG, manufactured by M/S Hitachi limited Japan has a capacity to
generate 25.28 MW at ISO base rating ( temp. 150 C & relative humidity 60
per cent at mean sea level). The GTG have been design to operate on natural
gas / high speed diesel or naphtha fuels. The exhaust of GT at about 500 0 C is
used in HRSG to generate steam at high pressure.
There is also provision to bypass the GT exhaust if not required.

(2) Two heat recovery steam generating (HRSG) unit each having capacity to
generate 80 T / hr at 115 kg/cm2 g & 5150 C is manufactured by M/S Kawasaki
Heavy Industries Japan. HRSG is a packaged type boiler having bank tubes, a
set of super heaters, de- super heater & Economizer. The exhaust flue gas of
gas turbine is fed to the furnace zone of HRSG, where the temperature of
exhaust gas from GTG is increased by supplementary firing. The exhaust of
GTG is having sufficient quantity of excess air which is utilized further for
combustion of Natural gas as supplementary fuel. For steam temperature-
controller, direct water spray type attemperator has been provided between
primary & secondary super heaters.

(3) The steam generator (SG) is water tube double drum, natural circulation, oil
or natural gas fired boiler manufactured by M/S Mitsui Engg. Co. Japan .The
capacity of SG is 150T/hr of superheated steam at pressure of 115 kg/cm 2 g
&temperature 5150C. The SG is designed to use NG or oil fuel (furnace oil) for

Page 22 of 95
 regular firing. For initial light up of the SG, HSD is used. Now furnace oil has
been obsolete and not used. The SG is pressurized furnace with no induced
draft fan.

Two forced draft fans, one turbine driven & other motor driven have been
provided to supply combustion air.
A direct spray type de- super heater has been provided between primary & secondary super heater to control
steam temperature.
PROCESS INTERACTION

. AMMONIA
OFFSITES D.M.WATER UREA
STEAM
OFF-SITES
N.G.
POWER
GAIL/I.O.C. FUEL F.O.
NAPHTHA

PLANT
STORES CHEMICALS POWER ELECTRICAL

GAS TURBINES

A. INTRODUCTION
Gas turbines are an energy conversion machine. It converts the energy stored in
the fuel to kinetic energy.
The four factors required to run this combustion engine is
 Air
 Fuel
 Compression
 Ignition

Page 23 of 95
Gas turbine works on the Bryton cycle principle, which can be understood in
following ways:

Basic events in any combustion engine are;

1. Intake
2. Compression
3. Combustion
4. Exhaust

In a four stroke Internal Combustion Engine, the intake is taking place when
piston moves downwards. The inlet valve is open and fresh air is drawn into the
cylinder.
Compression of the air takes place when the piston moves up.
The power stroke takes place when the compressed gas is ignited by spark plug.
Here the piston moves downwards the exhaust stroke is an up-stroke. The piston
pushes the burned gases out of the cylinder.
COMBUSTION

AIR INTAKE COMPRESSION FUEL INJECTION EXPANSION

EXHAUST

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Bryton cycle is a two stroke cycle. The same events that take place in a four
stroke I.C. engine, take place in a Gas Turbine also. The difference is that all
events take place inside the cylinder in I C. engine whereas these events take
place in different areas in a Gas Turbine.

In Gas Turbine, the compression of air takes place in the compressor and the
combustion takes place in the combustion chamber. The combustion process
raises the flue gas temp. to a flame zone value of more than 1200°C, which is
reduced to useful value of around 950°C by mixing with secondary air.

Expansion starts in combustors and continues through the turbine wheel, where
it is allowed to expand down to exhaust temperature.

The flue gas after expansion is exhausted to atmosphere.

B. THERMODYNAMIC PRINCIPLES OF OPERATION

A schematic diagram for a simple-cycle single shaft gas turbine is given below:

FUEL

2 COMBUSTION 3

4 EXHAUSTS
COMPRESSED AIR
ACC LOAD
C T
C TURBINE ROTOR

1 AIR INTAKE

Page 25 of 95
 HEAT ADD.
P 2 3

COMP. EXPANTION

1 4
COOLING

V
THE BRAYTON CYCLE

Air enters the axial flow compressor at point (1) of the schematic at
ambient conditions. Air entering the compressor at (1) is compressed to
some high pressure. Upon leaving the compressor, air enters the
combustion system at point (2) where fuel is injected and combustion takes
place. Combustion process occurs at essentially constant pressure.

In the turbine section of a gas turbine, i.e., in Nozzles, the hot gases are
expanded and thermal energy is converted to kinetic energy (high velocity
flue gases). In subsequent bucket section, this kinetic energy in rotating
buckets and thus the thermal energy is converted to work.

Some of the work developed by the turbine is used to drive the compressor
and the remaining is available for useful work at the output flange.
Typically more than 50% of the work developed by turbine section is used
to power the axial flow compressor.

The figure 1 shows the typical PV diagram for this cycle.

Path 1-2 - Compression occurring in compressor

2-3 - Constant pressure heat addition
3-4 - Expansion occurring in turbine
4-1 - Constant pressure cooling

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 In gas turbine, cooling is done by the atmosphere, which provides fresh, cool air
at point 1 on a continuous basis in exchange for the hot gases exhausted to the
atmosphere at point 4.

OUTPUT POWER OF GAS TURBINE GENERATION UNIT

(-0.3 MW) (-41 MW) (+67 MW) (-0.3 MW) (-1MW)

ACC. AIR LOA

GEAR COMPR GAS D
D.E. BOX ESSOR TURBINE GEA
R
BOX GENERATOR

So that net power output =67-(0.3+41+0.3+1) =25 MW/hr

DIFFERENT COMPONENT SPEED OF GAS TURBINE GENERATION

ACC. AIR LOA

GEAR COMPR GAS D
D.E. BOX ESSOR TURBINE GEA
R
BOX

TORQUE GENERATOR

CONVERTOR

500—2500 rpm 900 rpm 2600-- 3300 rpm 5100 rpm 3000 rpm

 Self sustaining speed =3000 rpm.

 Full speed no load (FSNL) =5100 rpm.
 Reduction/load gear box reduces speed from 5100 rpm to 3000 rpm.
 Air compressor accelerates from 900 rpm to 2600-3300 rpm.
 Diesel engine gives a speed of 500 rpm to 2500 rpm

Page 27 of 95
Name plate details of gas turbine generator

GAS TURBINE PARTS

Introduction
The gas turbine generator (GTG) like any other heat engine, is a device for converting a
part of the chemical energy of fuel into useful available mechanical power. It does this
in a manner similar to the system used by a four stroke cycle reciprocating internal
combustion engine. The main apparent difference is that work is accomplished in an
intermittent manner in the reciprocating engine whereas the turbine power process is
continuous throughout.

The main parts of a GTG are air compressor, combustion chamber, turbine and
generator.

The air compressor when rotated by Diesel engine takes suction from the atmosphere
and supply compressed air to the combustion chambers. Natural gas is supplied to the
combustion chamber which burns in presence of spark and then the combustion takes
place. The hot, high pressure combustion gases are then passed through the turbine
blades which rotates the turbine. When the turbine reaches self sustaining speed, Diesel
engine stops automatically.

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A part of the power generated by the turbine is utilized to run the air compressor and
the remaining part is converted to the electric power by the generator. The exhaust
gases coming out of the turbine are at a high temperature and contains sufficient heat.
This heat is utilized by passing these exhaust gases through a heat recovery steam
generation unit to produce steam.

Many thermodynamic cycles are possible with a gas turbine but basically it is closer to
the Brayton cycle or Joule cycle. In this cycle, there is a longer exhaust stroke than a
compression stroke. In this manner, the gas can be expanded all the way down to
atmospheric pressure before the next stroke is started. For a moment, this cycle can be
thought of as a ‘ batch ’ process. ‘Batch‘ means that a particular chunk of fluid is used
all the way through the cycle. The Brayton cycle has also been worked out for a steady
flow process; and this steady flow process becomes the simple gas turbine cycle.

The description of the various sections of the gas turbine is given as follows :

ACCESSORY SECTION
Any prime mover have-
1. Diesel engine for initial startup independently.

2. Ratchating system: It is actually a dc motor for initial startup; the shaft is rotated 45 0 in
every 3 minute interval to minimize initial torque and provide proper lubrication. In case
of trip stop of gas turbine it works to cool down the rotor to avoid bending stage i.e.
BOWING.

3. Hydraulic oil system: it is shaft driven system maintains pressure of 95kg/cm 2 to operate
gas control valve (GCV), gas stop valve (GSV), inlet guide vane (IGV) of air compressor
etc.

4. Lubrication system: It consists of

a) Emergency oil pump(EOP) ---DC motor driven

b) Auxiliary oil pump(AOP)—AC motor driven

c) Main oil pump(MOP) –Shaft driven

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 COMPRESSOR SECTION
Compressor Rotor
The axial-flow compressor rotor assembly consists of 17 rows of blade (i.e. 17 stage) and wheel
assemblies. An inductor alternator is also incorporated as part of the compressor rotor
assembly and is bolted to the coupling flange of the blade and stub shaft assembly.

The blade and stub shaft assembly and the blade and wheel assemblies are riveted and bolted
together concentrically around the rotor axis. The bolt holes are countersunk in the stub shaft,
this machining keeps the bolt heads and nuts flush with the wheel face and reduces wind
age loss.

COMPRESSOR-TURBINE ROTOR ASSEMBL

Turbine section

Single shaft

Gear

Compressor section

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The compressor rotor assembly is dynamically balanced before it is assembled to the pre-
balanced turbine rotor assembly. This completed assembly is then dynamically balanced. The
balance corrections are carefully and properly distributed so as to compensate for internal
bending moments in the complete assembly.
Compressor Casing
The compressor casing encloses the compressor portion of the rotor and is divided into four
sections: inlet, forward, aft, and discharge. All of these sections are split horizontally to
facilitate servicing. The inlet section directs the flow of outside air from the air inlet equipment
into the compressor blade. This section contains the variable inlet guide vane (IGV) assembly,
the no. 1 bearing assembly, and the low pressure air seals.

The forward section of the compressor casing is downstream of the inlet section. It contains
the stator blades for stages 0 through 3. Bleed air from the 4th rotor stage (between the 3rd and
4th stator stages) can be extracted through four ports which are located about the aft section of
the compressor casing.

The aft section, downstream of the forward section, contains the stator blades for stages 4
through 9. Bleed air from the 10th rotor stage (between the 9th and 10 the stator stages) can be
extracted through four ports which are located in radial alignment with the ports used for
4th stage air extraction.

The discharge section of the compressor casing, downstream of the aft section, contains the
stator blades for stages 10 through 16, and exhaust guide vane stages 1 and 2. A radially
enlarged (bulkhead) portion of this section provides the mounting surface for the combustion
chambers. The space, between the forward portion of the inner barrel and the discharge
section outer shell, forms an annular air path that the high pressure air passes through to enter
the combustion section. This area is designed to decelerate the air flow and increase the static
pressure of the combustion air supply.
Stationary blade

COMPRESSOR BLADE FITTED IN CASING

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BLADES

The stator blades have dovetail-shaped bases that fit into dovetail shaped openings in the two
– piece, semi-circular ring. The ring fits into a groove of the same shape machined in the
compressor casing wall. Locking keys prevent the rotating of the blade rings. The rotor blades
also have dovetailed bases of a wide angle design which fit into the matching dovetail
openings in the wheels. The rotor blades are penned in place.

Blades of rotor

ROTOR BLADES

STATOR BALDES OF COMPRESSOR: ROTOR BLADE SETTTING ON ROTOR

CASING LOWER HALF

VARIABLE INLET GUIDE VANES

The variable inlet guide vanes (in conjunction with 4th and 10th stage air extraction) permit fast,
smooth acceleration of the turbine without compressor surge* (pulsation). A hydraulic cylinder,

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mounted on the base, actuates the inlet guide vanes through a large ring gear and multiple
small pinion gears. At startup, the vanes are set at 420 and when the turbine accelerates to 95%
speed, the vanes are rotated to the 850 position. When the turbine is tripped, the vanes are
immediately rotated to the 420 position. (They do not wait until turbine speed drops below 95
%.) And the variable inlet guide vanes are modulated to maintain high exhaust temperature
during part load for waste heat recovery.

Large ring gear Small pinion gear

*surging:
Surging is an unstable operating condition that occurs in compressors, including centrifugal
compressors used in any systems. It is a case of flow reversal. Such a condition can be caused
by an increase or decrease in compressor discharge pressure or by a reduction in the flow of
gas to the compressor. These events can be triggered by poor maintenance of that system /
compressor, failure of a system component, or human error. Excessive surging, either in
number of occurrences or in magnitude, may result in damage or complete failure of the
compressor. Surging also results in inefficiencies in operation of a mechanical system that result
in excessive power consumption.
Extreme surging may be detectable by inspection of an operating compressor, by those
knowledgeable in the art, but a compressor can operate in a surge condition with little
vibration experienced. Generally surging takes place during start up or shut down of a
multistage compressor. To avoid surging in a multistage centrifugal axial flow compressor,
some tapping points are provided to extract the fluids flowing in the compressor, which is
further used for other purpose like sealing cooling of casing etc.

Different methods of detecting surge conditions in centrifugal compressors are

1. By monitoring vibration of the compressor by mounting a vibration detector on or near the
compressor to sense vibration caused by the compressor in a surged condition.

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 Shortcomings of this method include the need for an extremely sensitive vibration sensor
and false surge indications during start-up of the compressor.
2. By measuring a temperature rise beyond a predetermined value in a space in the impeller
chamber of the compressor, exterior of the flow path of gas through the impeller.
3. By monitoring flow and pressure differences in the vicinity of the compressor.
4. By monitoring temperature upstream of the impeller to detect an increase in temperature
that precedes major surging.
5. By monitoring temperature on the discharge side of an axial flow compressor.
6. By Sensing suction and discharge pressures of the compressor.
7. By monitoring of the current applied to the variable speed motor drive that drives the
compressor.

COMBUSTION SECTION

The combustion section consists of combustion chambers, fuel nozzles, flame detection
equipment, spark plugs and transition pieces.

The combustion chambers are arranged concentrically around the axial – flow compressor
and are bolted to the compressor discharge section bulkhead. Air for combustion is
supplied directly from the axial – flow compressor to the combustion chambers. Fuel is
fed into the chambers through the fuel nozzles that extend into each chamber’s liner
cap.

As a protective measure on oil fired units, a false start drain valve is installed in the
drain line piping at the bottom side of the no. 5 combustion chamber, ( the chamber at
the lowest point of the concentrically arrangement ). This is normally an air to open
operated valve which prevents the accumulation of fuel oil in the combustion chamber
and turbine sections when a start signal is given and the turbine fails to start. The
valve is automatically closed by compressor discharge pressure as the turbine
accelerates.

Combustion Chambers

The compressor discharges the high pressure air into the annular space created by the
aft end of the discharge casing and frame assembly and the forward section of the
turbine shell. Up to this point, the air flow has been in an aft direction; now the air
flow reverses. The air enters the combustion chambers and flows forward, entering the
liner through holes and louvers in the liner wall. A portion of the air reaches the head
of the combustion chamber and enters the liner cap and the turbulator nozzle.

Page 34 of 95
 Comp. body

4th stage exhaust

Fuel nozzle

Combustion cane

.
COMBUSTION CHAMBER OUTER VIEW

Neck of liner

Cross fire tube

COMBUSTION LINER INSIDE COM. CANE Cross fire tube port

COMBUSTION CANE OUTER VIEW COMBUSTION CANE INSIDE VIEW

Page 35 of 95
 Combustion cane

NG line

Fuel nozzle

Cross fire tube assem.

ASSEMBLY OF CROSS FIRE TUBE

COMBUSTION LINER

The air flow through the combustion chambers has three functions; to oxidize the fuel,
to cool the metal parts and to adjust the extremely hot combustion products to the
desired turbine inlet temperature.
Combustion chambers with the turbulator system are designed to eliminate exhaust
smoke air pollution during the operation of the gas turbine after the start sequence.
Lean primary combustion followed by a thermal soaking assures that all soot is burned
during combustion. The turbulator system accomplishes this aerodynamically by stabilizing
the lean combustion zone with a vortex generated by an air nozzle surrounding the
fuel nozzle. Dilution of the combustion products to turbine inlet temperature is delayed
to allow consumption of any soot that was not injecting any air into the liner until the
air reaches the downstream end of the combustion chamber.

Hole

Louver

Page 36 of 95
COMBUSTION LINER OUTER VIEW

Louver

Hole

COMB.LINER END WHICH COMB.LINER PORT FOR CROSS

FITTS INTO T.P FIRE TUBE FITTING

The combustion chamber casing have machined pads for mounting the spark plugs and
flame detectors. The combustion liners have holes through which the spark plugs and
flame detector body projects.

Spark Plug and cross fire tube

Combustion of the fuel and air mixture is initiated by retracting electrode type spark
plugs. The spark plugs, installed in two of the combustion chambers, receive their power
from the ignition transformers. The chambers without spark plug are fired with flame
from the fired chambers through interconnecting crossfire tubes.

Transition Pieces

The transition pieces ( fishtails ) are the hot gas path link between the combustion
chambers and the first stage nozzle. They are clamped to the forward side of the nozzle
assembly. The nozzle assembly is sealed at both its outer and inner periphery to
prevent leakage of hot gases. On the outer periphery of the nozzle, the transition space
is sealed by the turbine wheel shrouds, to which the nozzle assembly is clamped. On
the inner periphery of the nozzle, the transition space is sealed segments installed
between the nozzle inner side wall and the first stage nozzle support assembly. The
nozzle assembly and its support arrangement hold the assembly in proper alignment in
the gas path and makes allowances for the effects of thermal growth.
Fishtail

Page 37 of 95
 TRANSITION PIECES TRANSITION PIECE ASSEMBLY
WITH FIRST STAGE NOZZLE
Fishtail
1st stage nozzle

Before the compressor discharge air flows into the combustion chamber, it must first
pass around the transition pieces. This encounter affords an exchange of heat; cooling
the transition pieces and preheating the combustion air.

TURBINE SECTION

The turbine section is where the high temperature gases from the combustion section are
converted to shaft horsepower. The power required to drive the load package and the
compressor is provided by the two-stage turbine rotor. The first-stage, or high pressure wheel
and the second-stage, or low pressure wheel are bolted together to make up a single unit
through which the first and second stage nozzles direct the flow of combustion gases. These
components, with associated air seals and deflectors, are contained within the turbine shell.

The forward section of the turbine shell forms the casing for the aft end of the compressor
discharge and combustion sections. The aft section of the turbine shell forms the casing for the
first and second-stage nozzles and the shrouds for the first and second stage turbine rotors.

Compressor fourth-stage extraction air is piped to cool the shell and then discharged at the aft
surface of the second stage turbine wheel.

Page 38 of 95
1St & 2Nd STAGE TURBINE TURBINE BUCKET FITTING ON
BUCKETS MOUNTED ON ROTOR
ROTOR
ROTOR
SHAFT
2nd stage turbine bucket

Turbine casing upper half

TURBINE CASING UPPER HALF

First Stage Nozzle

The first-stage nozzle assembly consists of airfoil-shaped partitions between an inner and outer
side wall. The nozzle assembly is divided into segments, with the segments fixed in a retaining
ring assembly sustained in the turbine shell by a clamping ring.

The nozzle ring and partitions are cooled by compressor discharge air which is bleed from the
combustion chamber transition space. The nozzle partitions are hollow with bleed holes drilled
in the trailing edge for cooling. The cooling air circulates about the side walls of the retaining

Page 39 of 95
ring into the hollow nozzle partitions and comes out of the bleed holes into the gas
path.

The design of the nozzle supporting arrangement permits removal for the lower half of the
nozzle assembly without removing the rotor assembly.

2nd stage nozzle 1st stage nozzle

Airfoil-shaped partitions
Second Stage Nozzle & Diaphragm

The second-stage nozzle and diaphragm assembly is located between the first and second-stage
turbine wheels. It is supported by a clamping arrangement in the turbine shell. The assembly
has airfoil-shaped partitions between the inner and outer side wall which direct the gas flow
into the second-stage turbine buckets. Insulating pipes are installed in the drilled partition
holes to minimize the heat exchange between the nozzle partitions and the air flow to the
turbine wheel spaces.

The diaphragm assembly extends inboard from the nozzle assembly to the turbine rotor and
divides the space between the two wheels into the high and low pressure turbine areas. The
diaphragm assembly contains the wheel cooling air deflectors and packing ring that provide
the inner seal between the first and second – stage wheel spaces.

The nozzle assembly and the diaphragm are both split into separate halves at their horizontal
centerline for ease of maintenance. The lower half of the diaphragm assembly is located and
supported on three radial dowel pins in the lower half of the nozzle assembly. Thus the lower
halves of the two assemblies are handled as one during installation and removal, while the top
halves are handled separately. The lower half of the nozzle and diaphragm assembly can be
removed from the turbine shell without removing the rotor assembly.

Page 40 of 95
The second stage nozzle and diaphragm assembly is positioned laterally in the turbine shell by
eccentric pins installed in the top and bottom halves of the shell. The eccentric pins are
concealed under the flange connection for the shell cooling air piping. The vertical position of
the assembly is fixed by a set of ground clamps at the horizontal joint on each side of the
turbine shell. To prevent movement of the nozzle assembly during moving and installation, four
retaining pins are installed through the turbine shell. The retaining pins are positioned to fit
into machined cutouts on the aft our outer side wall ring of the nozzle. The pins two in each
half of the shell, are located at about 440 to the right and left side of the vertical centerline
of the turbine shell assembly.

The seal ring restricts air leakage and directs high velocity cooling air at the dovetail area of the
second-stage wheel. The high velocity is developed when the air passes through the small holes
drilled in the seal ring which is positioned opposite the dovetails.

Turbine Rotor Assembly

The turbine rotor assembly consists of the turbine-to-compressor distance piece and the first
and second-stage turbine wheels and buckets.

The turbine wheels are forged of high temperature alloy steel. The second-stage wheel is
forged with a stub shaft on which the journal and sealing surface is machined for the No.2
bearing and its oil seal. At the stub shaft end is a flange to couple the shaft to the driven device.
The buckets have “pine tree”, axial – type dovetails and are assembled on the rim of the wheel
in matching “pine tree” slots.

The individual components of the rotor assembly are pre-balanced and assembled so that the
complete rotor assembly will require a minimum of correction. The rotor assembly is
dynamically balanced with any required corrections carefully distributed to compensate for
internal bending moments.
The turbine rotor assembly is bolted to the pre-balanced compressor rotor assembly. This
complete rotor assembly is again dynamically with any required corrections carefully
distributed to compensate for internal bending moments.

ROTOR BLADE

Page 41 of 95

GEAR
 TURBINE BUCKET
MOUNTED ON
WHEEL

TURBINE SHAFT

BEARINGS

The gas turbines unit has two main bearings, one located in the inlet casing and the other
located in the exhaust frame, both support the compressor/turbine rotor. The No. 1 bearing
assembly actually contains three bearings; loaded thrust, unloaded thrust, and journal. The
No.2 bearing assembly contains only a journal bearing. The bearing assembly consists of oil seal
assemblies, an oil ring and the housing which surrounds the assemblies, with the assemblies
keyed to the housing to prevent their
rotating with the shaft.

PITTING OF BEARING SURFACE

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DIFFERENT VIEW OF JOURNAL BEARING THURST BEARING PAD

Lubrication

The main turbine bearing are pressure-lubricated by lube oil supplied from the lube oil header.
The lube oil from the header flows through branch lines to an inlet in each bearing housing.

The high pressure oil feed piping, when practical, is run within the low pressure tank drain line,
or drain channels, as a protective measure. This is referred to as double piping. The reason for
this is that in the event of a high pressure pipe line leak, oil will not be sprayed on associated
equipment and creates a hazardous condition.

When the lubricating oil enters the housing inlet, it flows into an annulus around the bearing
liner. From the annulus the oil flows through machined holes in the liner to the journal bearing.
Lubrication oil is prevented from escaping along the turbine shaft by oil seals.

The drain oil, returns through passages in the bearing housing, then into the drain line to the oil
tank.

Oil Seals & Seal Ring

Oil seals control the flow of oil along the shaft. The seals consist of labyrinth packing of teeth
assembled at the extremities of the bearing assemblies. The compressor and turbine shaft is
machined smooth at these extremities. This machining enables a specified clearance to be
established between the seals and the shaft surface. The oil seals are designed with double
rows of packing with an annular space between them into which pressured sealing air is
admitted to prevent the lube oil from spreading along the shaft. The air that returns to the oil
tank, with the drain oil, is vented to atmosphere.

The oil seal ring is a shaft riding type which functions as a miniature bearing in controlling the
amount of the thrust bearing oil spreading along the shaft.

Page 43 of 95
GEARS

Accessory Gear

The accessory gear is furnished to support and drive the turbine driven accessories. In addition,
the gear transmits torque to the gas turbine during startup. It may contain the main lube oil
pump and an over-speed bolt and trip mechanism. The gear is mounted on the accessory
compartment end of the turbine base over a section of the oil tank.

Accessory gear box hydraulic ratchet gear

Hydraulic Ratchet Gear

The hydraulic ratchet gear is mounted on a machined pad on the topside of the accessory gear.
The ratchet gear functions to breakaway the turbine rotor at startup, to turn the rotor during
cool-down, and to jog the rotor during inspection.

The operation of the hydraulic ratchet gear is electrically controlled by signals from the turbine
electric panel. Its function as a breakaway assembly is controlled by the starting circuits of the
gas turbine; as a turning device, its operation is controlled by the stop and cool-down circuits;
and as a jogging device, its operation is controlled by a jog switch which usually is located at
some convenient point where the turbine shaft can be seen.

The operating oil supply for the ratchet gear hydraulic cylinders is supplied by a small hydraulic
pump which takes its oil directly from main bearing lube oil feed header. The ratchet system
cannot operate without first having the turbine oil system pressure established.

Lubrication of Gears

Lubrication of the previously described gears is accomplished with oil from the lube oil system.

Page 44 of 95
COUPLINGS

Accessory Gear to Compressor Rotor

This coupling is a flexible continuously lubricated type which is used for power transmission
between the accessory gear and the compressor. The coupling is lubricated by oil from the
turbine lube oil system.

Turbine Rotor to Load Gear

This coupling is a flexible continuously lubricated type which transmits torque to the load
equipment. The coupling is lubricated by oil from the turbine lube Oil system.

Complete assembly of gas turbine 1 & 2

Page 45 of 95
 GTG 1

GTG 2

Material of construction of gas turbine

NAME OF PARTS MATERIAL STANDERED

TURBINE
1st stage nozzle Cobalt base alloy FS*414(1)
2nd stage nozzle Heat resistant alloy N155(1)
1st stage bucket Nickel alloy precision casting IN738(1)
2nd stage bucket Nickel alloy U-500(1)
1st stage turbine wheel Cr-Mo-V steel 160M91F
2nd stage turbine wheel Cr-Mo-V steel 160A191E
Turbine rotor Cr-Mo-V steel 160A191E
COMPRESSOR
Compressor stator blade Stainless steel AIS1403
Compressor rotor blade Stainless steel AIS1403
Compressor rotor Cr-Mo steel AIS1403

STARTUP SEQUENCE OF GAS TURBINE

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PRECHECKS
1. Level ---lube oil /DM water /Diesel/cram case oil
2. Cooling water pressure/temperature
3. Coolers---L.O. cooler/Atomising air cooler/ Diesel engine cooler/generator air cooler
4. CO2 system
5. Power DC –Emergency Oil Pump/DE starting motor /Ratcheting motor(3 min--45 0)
/liquid fuel/DC clutch 24Vdc /15KV spark plug transformer
AC--- Auxiliary Oil Pump/Compartment lighting

6. NG fuel valve open

7. Diesel Engine (Idling at 500rpm for 5 minute)

Now operators have to work on control panel

Select
Auto Mode/Fuel—Gas/IGV—auto –on/Start command (Two fan starts)
1. Ratcheting sequence stop/Auxiliary oil pump –running
2. Starting clutch engage
3. Diesel engine start 500—2500 rpm
4. Purging ---Air(3 min)
5. Firing --- 1 & 2 combustion chamber (900)
7 & 8 flame sensor (60 sec)

6. Warm up ---60 sec

7. Fuel increase ----speed increase---2600 rpm(self sustaining speed)—3300 rpm
8. At 3300 rpm --Diesel Engine declutch and stop in 5 min
9. Speed increases further ---95%(4600 rpm )
 Auxiliary oil pump stop
 IGV 420—850 full open
 Ventilation fan open
10. Speed become 4600 rpm---5100 rpm(Full Speed No Load)
11. Synchronize

SAFETY TRIP INTERLOCKS OF GAS TURBINE

During operation, the operators have to take care of the following trip limits of gas turbine.
1. over speed
 Electrical Trip at 110% that is at 5310 rpm
 Mechanical over speed bolt trip at 112% =5354 rpm
 Iso trip at 113.5%
 Manual trip

Page 47 of 95
2. over vibrations
 Axial - trust at the time of start and stop
 Radial
Displacement 2/3 mm/sec Normally

12.5 mm/sec alarm on

25 mm/sec Trip

3. over temperature
 Turbine inlet (metal temp) 9570C maxm.
 Exhaust gas if maxm 5380C trip
5710C iso trip

4. Lube oil temperature (Bearing)

 Bearing header temperature
740C Alarm

800C Trip

5. Fire
Fire alarm will on for 30 sec before reaching the trip temperature. After alarm air lowers
are closed. And 6 cylinder CO2 fire extinguishers operate automatically.
 Accessory compartment 1650C trip temp.
 Turbine compartment 2350C trip temp.
 Generator compartment 1070C trip temp.

6. Lube oil pressure –Low;

1.85 kg/cm2 (Bearing Header) gear pump –shaft driven

0.8 kg/cm2 ----- Alarm ---- -Ac--- Auxiliary oil pump start

0.6 kg/cm2 -------Gas turbine trip

0.4 kg/cm2------- Dc –Emergency oil pump start.

At field operators have to take care of the following reading at machines.

1. Lube oil (Tank) temperature 65—700C
2. Lube oil bearing header temperature 50—550C
3. Cooling water temperature 400C
4. Lube oil pump (outlet) pressure 4.2 kg/cm2
5. Lube oil bearing header pressure 1.85 kg/cm 2
6. Lube oil control oil pressure 3.2 kg/cm2

Page 48 of 95
7. Hydraulic oil pressure 995 kg/cm 2
8. Differential pressure across filter - Lube oil filter
- control oil filter
- Hydraulic oil filter
- Air filter
- Coupling oil filter
9. Compartment temperature viz accessory, turbine, and generator.
10. Lube oil tank level >50
Lube oil tank temperature < 100c – heater
11. Ratchet oil pressure load 105 kg/cm 2
12. Dm water tank level
13. Atomizing air temperature <1350c

STOP SEQUENCE OF GAS TURBINE

1. Reduce Load up to 2MW—Governor

2. Open generator breaker at 2MW ----power zero
3. Gas turbine at FSNL—5100 rpm
4. Stop command initiated
5. Speed starting reducing 95%(4600 rpm)
 Auxiliary oil pump start
 IGV close partially -420
 10th stage bleed valve open(Anti-surging)
 Turbine cooling fan stops
6. Fuel cut off ( NG)
7. Speed decreases
8. Zero (0) speed ---Ratchating motor start (for cooling down ) –up to 48 hrs(50 0C)

DETAIL DESCRIPTION OF STEAM GENERATION

Page 49 of 95
Introduction: There is a Steam Generator (SG) boiler to generate the high pressure steam and
to supply it to main consumer plant i.e. to Urea plant or Ammonia plant. Following is name
plate detail of this boiler:

Manufacturer : MITSUI ENG. & SHIP. CO., LTD

Type of boiler : Natural circulation, self – standing, Two-
drum, water tube type, gas fired, packaged type
Parameters of steam generation boiler

Maximum continuous rating (MCR) tones/hr 150

Steam Temperature at super heater outlet, 0C 515
Steam pressure at super heater outlet kg/cm2g 115
Quantity of fuel (NG) required per hour at MCR, Nm3/H 12700

Process: Steam generation requires water, air, fuels and supportive vessel / structure.

DM Water is pumped to boiler as feed water through boiler feed water (BFW) pump at a
pressure of 150-160 kg/cm2. This water enters to Economizer section through feed water
piping.
The MITSUI MD (middle to semi large industrial boiler) type steam generator is of outdoors use,
self – standing and natural circulation type. The steam generator is designed to fire High Speed
Diesel (HSD - for startup), LSHS (Low Speed High Stock)/FO (Furnace Oil) and NG (Natural Gas)
with four sets of oil and gas combustion burners.
At present only NG is used, F.O. has been obsolete.
The steam generator comprises a water cooled furnace, a convection bank, steam and water
drums, headers for collecting and distributing water and steam, primary and secondary supper
heaters, frames, casing insulations etc.

Components of boilers: Following are main components of boilers:

● Drum and internals
● Furnace
● Super heaters
● De – super heater
● Boiler convection bank tubes
● Boiler setting
● Economizer

WATER & STEAM FLOW SYSTEM

Page 50 of 95
 Secondary super ATTEMP PRIMARY
MAIN STEAM heater RATOR SUPER
HEATER

SPRAY WATER

STEAM ECONOMIZER

DRUM

BOILER BOILER
FURANCE BANK
FRONT, BANK
RISER DOWN
REAR & CHAMBER
SIDE
WALL
CBD FEED WATER
Continuous Blow
Down

WATER
DRUM BOILER FEED BOILER FEED
WATER PUMP
PREMETER
WATER PREMETER

WATER & STEAM FLOW SYSTEM

DRUM AND INTERNALS

This boiler is provided with a steam drum and a water drum. Both of the drum have a
manhole on each end for maintenance and inspection. To obtain the pure steam, the inside of
steam drum is equipped with sets of steam purifiers.
The steam drum is equipped with internal pipes for feed water, chemical and continuous
blow down as well as steam purifier. The internal pipes are arranged so as to ensure good
distribution of feed water and chemicals in the drum. The nozzles for feed water and chemicals
are of double pipe type so as to reduce thermal stresses due to the temp difference.

Page 51 of 95
 The steam purifier consists of a baffle plate, a demister pad and number of scrubbers. The
baffle plate covers the riser tubes and prevents the steam and water mixture from directly
mixing into the drum water. The water and steam are separated when they turn into the
central space. The separated water flows back to the drum water and steam flows upward to
the demister.
The demister comprises a number of layers of expanded metal which caught most of the
water droplets in the steam.
Finally the steam passes through the scrubbers. This comprises the number of corrugated metal
plates. When the steam flows through it, any remaining water particles are efficiently removed.
This occurs due to sharp change in the flow direction.

Furnace:
The furnace has an ample volume to secure complete combustion of the specified fuel. The
furnace walls are of welded longitudinal fin tubes panel to form a completely gas tight
enclosure. The furnace floor is covered with a layer of refractory bricks so as to shield the tubes
from radiant heat to secure a good water circulation. The front wall is equipped with burners in
two rows. The sidewalls are provided with lower and upper header, which are connected to
water and steam drums with connecting pipes. Sufficient numbers of observation holes are
provided on the front and side walls to check the firing conditions. In addition, an access door is
provided for maintenance.
Super heaters:
The boiler is provided with two stages of super heaters, i.e., primary and secondary super
heaters. Both of them are of convection and pendent type. The primary super heater is located
at the lower part while the secondary is at higher temperature part.
The steam flows counter to gas in the primary super heater and parallel in secondary super
heater.
The super heater tubes are hung to the super heater headers, which are mounted on the
furnace headers. Therefore, thermal expansion of the tubes and header is free, which avoids
excessive stresses.
De – super heater:
A de–super heater is also provided on the connecting pipe between the primary and
secondary super heater to control the final steam temperature.
Feed water is sprayed into the steam flow through a spray nozzle, which reduce the steam
temperature. Immediately downstream of the nozzle, a thermal sleeve is furnished so as to
avoid direct contact of sprayed water to the connecting pipe wall.
Boiler convection bank tubes:
The convection bank tubes have been provided to the downstream of the super heaters. It
consists of a number of vertical tubes, which are connected to the steam drum and water
drums by expanding their ends.
The higher gas temperature part of convection bank tubes called as riser tubes, while the
lower temperature part tubes are called down comer tubes. In addition to this, both of the
sidewalls are insulated from free gas with refractory bricks.

Page 52 of 95
Adequate no. of access doors and soot blowers are provided for easy maintenance and
effective cleaning of tubes.
Boiler setting: The boiler is supported on the saddle furnished beneath the water drum and the
headers for the furnace sidewalls. One of the saddles beneath the water drum is fixed and
other are made free for horizontal thermal expansion by using oil less shoes. The boiler is also
free upward for vertical expansion. Therefore, there is no restraint by thermal expansion in the
pressure parts.
Two sets of buck stays and tie bars are furnished outside the tube walls to provide sufficient
strength against the gas pressure inside. The tube walls are supported by the buck stays
through a no. of tie bars using pin joints. The buck stays, being isolated from the heat, are
called ‘’cold buck stays’’ and are fastened with links at the four corners of the boiler.
Economizer:
An economizer is furnished in the downstream of the convection bank to recover waste heat
from flue gases. The economizer comprises a no. of spiral wound finned tubes, inlet and outlet
headers and sufficient frames and casing. It is supported by the steel structure using slide shoes
to cater with horizontal thermal expansion.

Super Heater
STEAM TO CONSUMER

STEAM DRUM

FUEL
FURNACE ECONOMISER

WATER DRUM

AIR
HEATER

AIR
DEARATOR

MAKE UP WATER BFW PUMP FEED WATER HEATER CHIMNEY

FIG: STEAM GENERATION

COMPELETE BOILER SET

Page 53 of 95
 STEEM VENT
STEAM DRUM
SILENSCER

MAIN STEAM
HEADER

ECONOMISER

BOILER FEED
WATER TO STEEM
DRUM

FEED WATER
CONTROL STATION

FLUE GAS
DUCT TO
CHIMNEY

GAS AIR HEATER

STEAM COIL AIR

PREHEATER

SUCTION
FILTER FD FAN

STEAM TURBINE
FOR FD FAN

AIR INLET DUCT TO BOILER

Page 54 of 95
 CHIMNEY FOR BOILER
HEIGHT 120 METER

FLU GAS DUCT

TO CHIMNEY

PERFORMANCE DATA
(N.G. Fuel)
Following are the performance data of steam generator boiler, based on
100% MCR (Maximum Continuous Rating):
1. Super heater outlet steam (kg/hr) 1500
2. Super heater outlet press (kg/cm g) 115
3. o
Super heater outlet temp. ( c) 515
4. Feed water flow (kg/hr) 151500
5. Blow down (%) 1
6. Heat release rate base on furnace volume 43.5×10 4
(Heat input basis) (kcal/m2 hr)

7. Maximum net heat in put per plane area of furnace 43.9×10 4

(Heat input basis)

Page 55 of 95
Total heat loss (%) 6.5

Boiler efficiency (%) 93.5

Feed water and steam press (kg/cm2 g)

Economizer inlet 120

Drum 119

Attemperator inlet 118

Super heater out let 115

Attemperator outlet 117.5

Feed water and steam temp. (0c)

Economizer inlet 126

Economizer outlet 190

Drum 323

Attemperator inlet 447

Attemperator outlet 362

Water required for super heater attemperator (kg/hr) 1639

Fuel (N.G.) Quantity as fired (kg/hr) 9216

No. of burners 4

Excess air ratio 1.10

CO2 (Dry) % 10.46

O2 (Dry) % 2.10

Page 56 of 95
 Air Temperature (0c)

Entering steam air-heater 28

Entering gas air-heater * 1 28

Leaving gas air heater 145

Entering burner 145

Gas Temperature (0c)

Leaving furnace 1329

Entering super-heater 1294

Leaving super-heater 755

Leaving boiler 415

Leaving economizer 250

Leaving gas air heater 143

Air and gas pressure (mmAq)

Fan discharge 529

Steam air heater exit 523

Gas air heater exit 453

Wind-box entrance 416

Boiler exit 152

Economizer exit 92

Gas air heater exit 10

Note: *1 It is advisable that steam air heater be used at 50% MCR and below in order to avoid flue gas
temperature at stack exit from decreasing excessively

Page 57 of 95
 STARTUP SEQUENCE OF STEAM GENERATOR
PRECHECKS
1. Mechanical/Electrical/Instrumentation---clearance
2. Instruments air pressure and service air(plant air) pressure are o.k.(6 to 7 kg/cm 2)
3. Instrument control power and Equipment power supply (Gas air heater + scanner air fans
+ FD fans) are o.k.
4. DM water header and cooling water header are charged.
5. All access doors (man holes) are closed.
6. Check the expansion joints and their supports(nut bolts)
7. Suction screen for FD fan is clear.
8. Proper checking of lubrication in all equipment (GAH,FD fan, scanner fan, steam turbine
etc.)
9. Check all valves and dampers operate freely(proper greasing)
10. Check smooth turning of soot blower and check the flame detector.
11. All safety interlocks are operating properly.

Now operators start the steam generator in the following sequence:

1. Close all burner supervisory valves/shut-off valves /main fuel shut-off valves/main fuel
control valves/all igniters shut-off valves.
2. Open fuel gas vent shut-off valve/all igniters vent valves
3. Start gas air heater
4. Open all burner register dampers fully
5. Close FD fan inlet vane and start one of the FD fans
6. Open FD fan inlet vane and increase air flow rate
7. Start air purging for five min.
8. NG header charged
9. Close burner register damper of the burner to be lighted up ,while other burner
dampers are kept open
10. Open NG supply valve
11. Open igniter’s inlet valve to be ignited.
12. Igniters flame is established within 10 sec.
13. Check manual gas vent valve is open
14. Open main gas shut-off valve and vent valve closes automatically
15. Open no 1 gas burner shut-off valve and supervisory valve slowly, establish main burner
flame.
16. Shut-off igniters after conforming stable firing of main burner.

Page 58 of 95
SAFETY TRIP INTERLOCKS OF STEAM GENERATOR

During operation, the operators have to take care of the following limits of steam generator
Important/main interlocks-
ALARM TRIP
1. Drum level very low -150mm -200mm
2. Drum level very high +150mm +200mm
3. Comb air flow very low 30%(4000Nm 3/hr) <25%(3600Nm3/hr)
4. Furnace pressure v.high (50-325mmH2o) 500mmH2O
2
5. Instrument air pressure v. low 4.5kg/cm 4.0 kg/cm2
6. HP steam temp v.high(5150C) 530oC 5380C
7. NG header press v.low(5.5kg/cm2) 2.5 2.0
2
8. NG burner press v.high(0.9kg/cm ) 2.o

Some important/main interlocks for which we get ALARM only

a. Boiler feed water flow H/L

b. FD fan trip
c. Drum metal temperature high (3230C) 3330C
d. O2 analyser H/L ---10/2
e. SH metal temp high (5150C) 5300C
f. FD fan bearing temp high
g. FD fan lube oil pressure low
h. Gas air heater temp (1300C) 1800C

NORMAL SHUT-DOWN OF STEAM GENERATOR

1. Reduce boiler load until main fuel valve is closed.

2. Close burner supervisory valves one by one.
3. Open manual gas vent valve.
4. Close main steam stop valve.
5. Keep F.D. fan running for several min to purge the furnace and flue gas passage.
6. Close F.D. fan inlet vane and stop F.D. fan.
7. Keep drum level normal during boiler shut-down.
8. Supply feed water until the drum level reaches about 300 mm above normal level.
9. When drum pressure decreases, the steam vent valve close.
10. Close feed water valve.
11. All the fitted valves on the boiler should be closed. Drain off perfectly from the pipes
between valves or between boiler and header.

Page 59 of 95
 AUXILARY SYSTEMS FOR STEAM & POWER GENERATION
Description:
● Fuel system
● Feed water system
● Steam distribution system
● Combustion air system
FUEL SYSTEM
Steam generation unit is designed for starting up with HSD(High Speed Diesel) and then
continuous firing with LSHS(Low Sulphur High stock )/FO(Furnace Oil) or alternatively with
natural gases. Gas turbine units are designed to run on natural gas or HSD/Naphtha.

Natural gas system:

NG is received from gas receiving system (GAIL station), which is at around 39 – 40 kg/
2
cm . This NG enters into the knock out drum through control valve where it expends and
pressure reduced to 18 kg/ cm2 inside the knock out drum, there are different wire net for
removing moisture and heavy particles. When the level in the knock out drum rises, draining is
done from the bottom of the drum. This drain mixture is heated by L.P. steam and by heating; it
is evaporated and connected to the atmosphere through vent line for blowing out.
Gas from the knock out drum is led to the one of the NG heater where it can be
heated by LP steam for attending working temperature. This NG is then divided into two
portion one for GTG and HRSG and other for SG unit.

LSHS/FO system for SG unit:

LSHS/FO, which is designed to be fired in SG unit, can be fed from LSHS/FO day tank, which is
having capacity of around 200 kilo liter.
Total LSHS/FO line along with pumps and fitting are having steam tracing line for maintaining
temperature around 800 centigrade for proper flow.
One motor driven and one turbine driven LSHS/FO pump are installed in day tank area.
One steam heater is provided for maintaining LSHS/FO temperature.

HSD/Naphtha system:

A day tank is installed in fuel storage area of capacity 80 KL to meet the demand of GTG
and SG unit start up. Two sets of pump are provided GTG unit and two sets for SG unit.
HSD for SG unit start up is directly fed to the burner system of SG unit. But for GTG unit is
goes via heater and filer skid.
Heater is meant for temperature maintaining around 30 degree centigrade so that wax in diesel
does not solidify on the filter element. Similarly, naphtha for GTG unit also fed through filter
skid.

Page 60 of 95
 FEED WATER SYSTEM

Continuous supply of proper quality feed water is required for steam generation unit and HRSG
unit. This is fed by feed pump, which suck water form de-aerator.
De-aerator: Make up water from DM plant is fed in the de-aerator through control valve which
maintain the de-aerator level (oxygen content at outlet – 0.005 ppm, location at 13.5 meter
level, steam pressure 1.44 kg/cm2, outlet temperature – 1260c). The function of de-aerator is
that it acts as a storage tank and removes the dissolved oxygen and other dissolved gases by
steam heating.

Feed Pump: Three numbers of multi stages feed pumps are installed out of which two are
turbo driven and one is electrical driven.
Turbine:
Inlet pressure : 38 kg/sq.cm
Inlet Temperature : 4810C
Outlet pressure : 3.5 kg/sq.cm
Rated power : 1220 KW
Rated speed : 5700 rpm
Working speed range : 4845 – 5985 rpm
Motor:
Electrical driven feed pump is driven by 11 KV electrical motor of rating 1220 KW at 2980
rpm.

Pump Rating:
Pump capacity : 190 Cu m/hr
Discharge pressure: 162 kg/sq. cm
Suction pressure : 2.7 kg/sq.cm
No. of stages : 7(seven)
These feed pumps are having barrel type double casing which increases the reliability of the
pump.

Page 61 of 95
 Recirculation to Dearator
Injection water to MP and LP reducing i
Dearator
BFW ii
Heater A
Station

BFW Heater
Feed pump B
A
Feed pump Feed
B pump
C

I Feed water to HRSG

II Feed water to SG

FIG: FEED WATER DISTRIBUTION SYSTEM

Page 62 of 95
 STEAM DISTRIBUTION SYSTEM
Mainly steam system can be divided as follows:
1. H.P. steam system
2. M.P. steam system
3. L.P. steam system

H.P. steam system:

Steam generated from SG unit and HRSG unit at 115 kg/cm 2 g and 5150C temperature are
fed in the main H.P. steam line. This H.P. steam header is connected with the steam generating
system of ammonia plant, which also feeds steam at same parameters and is supplied to urea
plant.
Steam header is made of alloy steel material P22 and properly supported to take
care of any shock load. In the header, sufficient no. of drain post provided for avoiding any
water hammer.
M.P. steam system:
Two set of specially designed control valves provision of isolation of each unit are there
to reduce 115kg/cm2 g steam to 39kg/cm2 g steam. Safety valves are provided to take care of
abnormal increase in pressure. This 39kg/cm 2 g steam at a temperature 480 0C is used to run
steam turbine to boiler feed pump and F.D. fans.
A portion of this steam is de-superheated by injecting/spraying feed water to a
temperature of around 4200C.
This 39kg/cm2 g, 4200C steam is used for soot blowing in HRSG &SG unit, atomizing
purpose in fuel oil system in SG unit, boiler feed water heating by steam heater and the same
collector extends outside battery limit to feed handling system. In fuel oil handling system, this
steam is used for driving turbine of fuel oil pump and a reducing station is there which reduces
steam pressure from 39kg/cm2 g to 11kg/cm2 g to meet the heating needs of LSHS system.

L.P. steam system:

A portion of 39kg/cm2 g steam is reduced to 4.5kg/cm 2 g steam by two sets of specially
designed control valves, which can be isolated individually by isolating valves provided. It
This low – pressure steam is de-superheated by injecting feed water and is used for dearator
steam heating and other heating system of different fuels in different heat exchangers. Outlet
of steam turbine of feed pump & FD fans are connected with this header. In SG unit, steam air
heater for heating combustion air gets steam from this low – pressure steam collector. Air vent
of the blow down tank is also connected with this header:
This low – pressure header extends outside the battery limit of power plant and can feed steam
to water treatment plant, ammonia plant, urea plant, fuel – handling system and to ammonia
storage unit. Low – pressure steam collector of ammonia plant is also connected with this
header and as such, L.P. steam can flow (reverse) from ammonia plant side.
From L.P. steam system by another control valve it is further reduced to 3.5 ata and is used for
steam tracing system.

Page 63 of 95
 BURNER & WINDOW BOX

FURNACE

SECONDARY SUPER HEATER

VENTURY METER
PRIMARY SUPER HEATER

BOILER BANK

ECONOMIZER

GAS AIR HEATER

0
50 C

STEAM AIR
HEATER

20-400C ST
AC
K

LEGEND
GAS FLOW
AIR FLOW
F.D FANC.

AIR AND GAS FLOW SYSTEM.

Page 64 of 95
 Combustion Air System
The air is required for combustion of fuel in steam generating unit. To meet this requirement of
air in SG, two centrifugal type forced draft fans (F D fans) have been provided. One fan is driven
by electric motor while other by steam turbine.
The F.D. fan sucks the air from atm. And discharge to the furnace at a pressure of 90 – 550
mm water column gauge. The quantity of air is controlled by the vane provided at the suction
side of the F.D. fan. Two air heaters have been provided in the discharge duct of F.D. fans,
which are known as steam coil heater & Gas air heater (GAH). These air heaters raise the air
temperature to 145 degree cent. The hot air helps in proper combustion of fuel.
The forced draft fans supply cold atm. Air through steam air heater and gas air heater to the
furnace for combustion of fuel. The gas air heater take up waste heat from the flue gas of
steam generator and adds to the combustion air.
The counter current parallel flow between the gas and atmospheric air, results in good heat
transfer, thus bringing coldest metal element of GAH in contact with less hot flue gases. If
metal temperature is too low, there is a chance of condensation of corrosive gas on the
element of GAH and consequent corrosion of heating elements. To prevent or reduce chance of
this type of corrosion, the inlet temperature of cold air to Gas air heater is controlled by
heating it in steam air heater.
.

Page 65 of 95
DETAILED DESCRIPTION OF HRSG:

General: The boiler consists of and is arranged in the same casing as follows:
˃ Super heater
˃ Evaporator with steam drum
˃Economizer
All tubes are spiral finned and are arranged in vertical rows with staggered tub arrangement to
horizontal gas flow. All tube circuit originates from inlet header and discharge to outlet header
and beside tubes and its headers are arranged so that all tube bank sections are fully drainable.
Whole boiler is supported with the bottom casing on the foundation.
Steam drum:
Steam drum is of all welded construction fabricated from carbon steel material and equipped
with steam purifier of baffled screen type in steam drum and necessary nozzle and connections.
The drum has been mounted above the boiler and is supported with down comer pipes.
Evaporator:
Evaporator section is composed of several components which consist of number of tubes with
spiral fin and each inlet and outlet header. Each component is made up water circulation circuit
separately.
Evaporator elements are bottom separated by lower header holding plates.
Water circulation system:
The water circulation circuit consists of steam drum, down-comer pipes, down-comer headers,
supply pipes, steam generating tubes and riser pipes. The basic system functions are as follow:
Sub-cooled water in the steam drum is led to the down-comer headers through heated down-
comer pipes and is distributed to each evaporator inlet header from down-comer headers. The
mixture of water and steam generated by the heat absorption of evaporator flows from
evaporator outlet header to steam drum through riser pipes.
Super-heater:
It is convection type, counter flow, drainable, inverted u looped tubes with spiral fins.
Super-heater section is located in highest gas temperature and materials are designed to satisfy
the requirements of operation conditions.
Super-heater elements are bottom supported by lower header holding plates.
Economizer:
Economizer is of counter flow, drainable, vertical tubes with spiral fins. Economizer section is
composed of several components which consist of number of tubes and inlet header (lower)
and outlet header (upper). These components are connected in series with several economizer
tubes.

BOILER FEED WATER SYSTEM–

The requirement of water for the boiler is met from the water treatment plant. In the water
treatment plant, DM water temp is raised to 60 deg c by passing it through return condensate
cooler before sending to SG plant. In de-aerator dissolve gases oxygen and carbon di oxide are
removed up to ˂ 0.0005 ppm by raising the water temp to 126 deg c and stripping at a pressure
of 1.44 kg/cm sq. by steam in de-aerator storage tank, Cyclohe-xamine and hydrazine are dosed

Page 66 of 95
to raise the ph of water to 8.5 – 9.5 and further chemical treatment of boiler water to remove
the remaining oxygen to nil.
Boiler feed water pump take suction from de-aerator. The pump discharge at pressure of 162
kg/cm sq g and temp 126 deg c through economizer it enters the boilers drum. There is boiler
feed eater pre-heater located between pump discharge economizer to raise the BFW temp
from 126 deg c to 140 deg c in case the boiler is on LSHS firing. This rise in temp is essential to
avoid condensation of oxides of sulphur on coil surface and to prevent corrosion.
The outlet of BFW pre-heater is divided into two branches, the small branch leads to the De –
super-heater of the SG and HRSG units to control the steam temp and other leads water to SG
and HRSG units through respective economizer. In economizer, feed water utilizes the waste
heat from the flue gases and temp of water raised to 190 to 310 deg c respectively.

HEAT RECOVERY STEAM GENERATION UNIT CONTROL

This consists mainly of the following control loops:
1. Three element feed water control.
2. Steam temperature control.
3. Gas by pass damper control.

1. Feed water control: THE feed water flow to the drum is controlled by a three – element
control system, where the steam and feed water flow signals compensated for pressure
and temperature are compared and the error signal positions the feed water control
valve. The signal from the drum level transmitters compensated for density vibrations
further adjust the position of the feed water control valve to maintain a proper drum
level.
2. Steam temperature control: Main steam temperature at HRSG out measured and
compared with respected to a fixed set pt. on a PID controller. The controller output
regulates the flow of supplementary fuel of the burners.
3. Gas bypass damper control: The HRSG units have been provided with a bypass stack and
main stack with a damper in a flue gas path to either stack. This control is affected by
regulation the bypass damper to divert the exhaust gas to the bypass stack. During
normal operation when both service boiler and HRSG are in operation the bypass
damper shall remain fully closed and the damper on the exhaust lion to HRSG shall
remain fully open. However, when service boiler is not in operation, the master steam
pressure shall be maintained by regulating the GT exhaust gas bypass damper through a
controller. When both HRSG are in operation, provision is there to bias the regulating
signal to the respected bypass dampers to account for unequal load sharing b/w the
tow units.
This control loop shall however be totally by pass when the service boiler is in
operation.

Page 67 of 95
 MAINTENANCE
PROCESS INTERACTION FOR MECHANICAL MAINTENANCE

MWR Healthy Equipment

User Mechanical User
Departments Maintenance Departments

1. Maintenance Job Planning

2. Breakdown Maintenance
3. Predictive Maintenance
MPR 4. Preventive Maintenance
Materials 5. Reconditioning of Spares
Department 6. Plant Turnaround Maintenance
(Purchase and
Stores Spares 7. Planning and Documentation
sections)

MWR
 Inspection MPR: Maintenance
 Workshop Purchase
 Req.
P&D
 Electrical MWR: Maintenance
 Civil Work Request
 Instrument

Reconditioning jobs
Urgent Spares
Inspection & Test Reports

MAINTENANCE OF MECHANICAL EQUIPMENTS

PURPOSE: To maintain continuing suitability, effectiveness and process capability of the plant
equipments by execution of predictive, preventive, break down maintenance as
well as turn-around jobs. To identify, control and monitor aspects & impacts
related to environmental & OHS (occupational health and safety) as minimizing
risk to the personnel, plant & environment during various mechanical activities,
also maintaining plant in healthy condition.

SCOPE: All Mechanical equipments, piping and machineries of Steam Generation and
Power Plant including Bulk Liquid Fuel storage and handling

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ABBREVIATION: PMMS- Plant Maintenance Management System
SOR - Schedule of Rates
MWR - Maintenance Work Request
HOD – Head of Department
P&D – Planning and Documentation
MPR – Material Purchase Requisition
PPE - Personal Protective Equipment

1.0 MAINTENANCE JOB PLANNING:

1.1 The maintenance job planning is done daily, at the start of the General Shift by Engineer
In- charge of the respective plant.

A Maintenance Work Request (MWR) in PMMS is generated by concerned

department for plant jobs and is sent to the respective Plant In-charge / Engineer In-
charge depending upon the plant’s structure. For MWR’s received from Production/Utility
departments, the Plant In-charge ensures that the MWR’s approved by Shift In-charge of
the concerned department. Action department shall receive the approved MWR’s.
.
JOB ORDER PRIORITIES

The initiator must definitely give the priority of the respective job for which the work
request is given. The explanation of priority indices are as given below:

Priority: This means without attending to this work it will jeopardize plant operation or
safety of the personnel. The job has to start immediately and to work continuously until
complete.

Normal: It is likely to jeopardize plant operation. The job is to be started at the earliest
possible and to be continued the following work day until complete.

MWR ACTION

Following actions may be taken for the received MWR depending upon the Job status:
Received, Forwarded, Rejected, Deferred, Deferred for Shut Down, Pending Clearance,
Job under progress, Job not accepted and Job Completed

1.2 The maintenance job planning is based upon:

a) The verbal information received from various plant maintenance sections and
Production department.
b) Maintenance Work Request received by the section and action taken up at the earliest
keeping in view that it is not affecting quality of the system.

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 c) Last day balance jobs
d) Scheduled preventive maintenance jobs
e) Jobs for reconditioning of spares.
f) Availability of equipments, technicians, spares, scaffoldings, rigger, welder, helpers
and mobile cranes etc.

For maintenance purpose jobs are categorized as below:

a. Preventive maintenance
b. Predictive maintenance
c. Break down maintenance
d. Reconditioning of spares
e. Shut down / Plant turn around maintenance.

2.0 PREDICTIVE MAINTENANCE :

Inspection section checks all the critical and selective plant’s equipments and machineries
during plant operation and shutdown periods. The data collected by Inspection section is
sent to Sectional Head of respective maintenance section as well as Production department
highlighting the abnormalities with respect to previous reading. In addition to inspection
checks the operation and maintenance section in each plant also observe for any
abnormalities. On the basis of these reports / information further action is initiated by
Sectional Head/ Plant In-charge. Plant In-charge ensures availability and use of PPE’s as per
OHS requirement.

3.0 PREVENTIVE MAINTENANCE :

Preventive maintenance is carried out based upon the supplier’s instructions or on the
basis of reports sent by Inspection section, leakages in the system, high vibrations of the
equipment & piping and undesired behavior of the plant equipments

*OEM: Original Equipment Manufacturer.

S.No. Equipment PM activity Frequency

detail

1. Centrifugal (i) Suction strainer cleaning. 1 Year

Pump (ii) Bearing oil Flushing 3 Months
(iii) Overhauling 5 Years or as per
OEM*
recommendation
2. Vertical Pump (i) Bearing greasing 6 Months
(ii) Overhauling 5 Years or as per
OEM

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 recommendation
3. Steam turbines (i) Bearing & governor oil 3 Months
Flushing 5 Years or as per
(ii) Overhauling OEM
recommendation
4. Horizontally (i) Lube oil suction strainer 1 Year
split cleaning
compressor (ii) Overhauling 5 Years or as per
( OEM
recommendation
5. Barrel type (i) Lube oil suction strainer 1 Year
centrifugal cleaning
compressor (ii) Overhauling 5 Years or as per
OEM
recommendation
6. Reciprocating (i) Lube oil suction strainer 1 Year
compressor cleaning
(ii) Overhauling 5 Years or as per
OEM
recommendation

7. Gear Box (i) Lube oil flushing as per OEM

(ii) Overhauling recommendation
8. Cooling Tower (i) Complete inspection 1 Year
fan & gear box (ii) Oil flushing of gear box 1 Year
9. Gas turbines (i) Combustion inspection 1 Year
(ii) Hot gas path inspection 3 Years
(iii) Overhauling 6 Years
10. Fan & blowers (i) Inspection & Greasing 6 Months
11. Boilers (i) Hydrotest As per schedule of
IBR requirements
12. Heat (i) Cleaning & hydrojetting During turn
Exchangers around on need
basis
13. Pressure (i) Bench testing Once in 3 years
Safety valves

4.0 BREAK DOWN MAINTENANCE:

Operating equipments / piping which directly or indirectly affects the production covers
under break down maintenance.

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 In case of major break down respective Plant In-charge / Shift In-charge of Production
Department informs immediately vide MWR generated in PMMS to concerned Plant In-
charge and Sectional Head regarding the breakdown of the equipment and nature 0f
break down. A team of maintenance as well as production personnel visits the site to
assess the break down and to identify the cause of failure.

5.0 RECONDITIONING OF SPARES :

Reconditioning of small equipment or modular parts of bigger items which are removed
during the break down is serviced during maintenance to avoid longer down time and the
same is for future use. e.g.:
 Spare Pump Assemblies
 Burner guns of furnaces
 Compressor Valves, Drain / Vent Valves, Isolation Valves.
 Auxiliary Boiler Burners
 Mechanical seals of various pumps.
 Cooling tower fan gear box assemblies
 Gear boxes of various equipments
 Governors of various equipments
 Any other spare equipments
 Spare rotor / rotor assemblies of turbines / pumps to be kept ready and time to time
rotated in Stores.

6.0 PLANT TURN-AROUND MAINTENANCE :

The plant turn-around is taken up:

 To attend all the pending MWR and other maintenance jobs which can not be
carried out during the plant operations?
 To attend all the jobs which are obligatory to meet the statutory
requirements?
 To do preventive maintenance related jobs based on condition monitoring.
 To carry out modification jobs.
 To do routine predictive inspections and tests.
 Overhauling of machinery is done based on predictive inspection, preventive
maintenance and for improving the efficiency of equipment from energy point
of view.

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 INSPECTIONS CARRIED OUT ON GAS TURBINES

Gas Turbines are generally trouble-free and are reliable, but demand, high degree of attention
and monitoring for any kind of impending trouble. So Gas Turbines are periodically inspected
after some specified running hours to avoid any major break down by thorough inspection,
identification and rectification/repair/ replacement of damaged parts. Generally, two types of
Inspections are recommended by Gas Turbine manufacturer which are briefly outlined below:

Inspections for Gas Turbines are broadly carried out as Running Inspection and Shut down
Inspections.

As the name indicates, Running Inspection is done while the unit is in operation and operational
data recorded while in service, gives lot of information regarding health of the machine. Thus
typical Running Inspection data include load v/s exhaust temperature, vibrations, fuel flow and
pressure, Exhaust Temperature spread, start up time etc. Variations in above readings are
good indicators of any impending trouble within the machine.
Shut down Inspections are, carried out while the unit is standstill. Thus, there are Stand-by
Inspections, Combustion Inspection, Hot Gas Path Inspection and Major overhaul (Inspection),
which are carried out at predetermined interval depending upon operating conditions and
previous history of the machine.

1. Stand-by Inspection
This type of Inspection is primarily intended for machine working on emergency or peak
load duty. And this inspection include, routine servicing of battery system, lubrication,
checking of filters, checking oil & water levels, cleaning relays etc. and several other
preventive maintenance measures.

2. Combustion Inspection (C.I.)

This inspection is recommended after every 8,000 running hours for Standard machines
& after every 12,000/24,000 hrs (depending upon fuel) for Advanced Technology
machines like in Ammonia-II for Process Air Compressor drive. As the name suggests,
the combustion parts are thoroughly inspected for any cracks, erosion, deposition and
rubbing on Combustion Liners, Cross-Fire tubes, Retainers, Fuel Nozzles, which together
contribute for good combustion conditions. Fuel nozzles being primarily responsible for
flame characteristics, and also exhaust temperature (measured as spread), are
disassembled and internal parts checked for erosion, fouling choking etc. which
normally take place while on liquid fuel firing.

3. Hot Gas Path (HGP) Inspection

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 This is recommended between 16,000 to 24,000 running hours for Standard Machines.
This is not normally stipulated for Advanced Technology machines. (Instead,
Combustion, along with Baroscopic Inspection is usually done, depending upon which
further actions are planned.) In this inspection, all parts / components in Hot Gas Path
are inspected. Thus in addition to combustion parts, Transition Pieces, 1 st Stage Nozzle,
1st Stage Buckets, 2nd Stage Nozzle and 2nd Stage Buckets, 1st & 2nd stage shrouds, 2nd
stage diaphragm seals etc. are inspected for any damage or deterioration. During this
inspection, turbine Upper Half casing is removed and also turbine internal clearances
are checked and worn out / damaged parts normally replaced due to high down time
cost. The damaged parts are later repaired and kept for reuse, if the repairs are within
acceptable limit.

4. Major Inspection
This is recommended between 32,000 to 48,000 running hours for Standard as well as
Advanced Technology Machines. During this inspection, in addition to HGP
components, axial compressor and both bearings (BB1 & BB3) are inspected. Total
Turbine clearances, compressor clearances, bearing clearances are checked. Alignment
between the Turbine Compressor shaft and Accessory Gear box and between Turbine
and Load Gear box are also checked and deviation rectified during re-assembly.
Reduction G.B. and Accessory G.B. are disassembled and their gears and bearings
inspected for deteriorated condition. Thus major inspection encompasses total
disassembly of the Gas Turbine, right from the inlet air duct / plenum to exhaust
plenum and diffuser during which each part is thoroughly cleaned, inspected, defects
repaired / parts replaced and then reassembled to maintain its original conditions /
characteristics.

WORK INSTRUCTION FOR OVERHAULING OF GAS TURBINE

PURPOSE: To maintain and overhaul the gas turbine.

ACTION DETAILS:

A. COMBUSTION INSPECTION AT EVERY 8000 RUNNING HOURS:

1.0 DIS-ASSEMBLY:

1.1 Carry out pre shutdown checks as per check list and note down data of
differential pressure of combustion chambers and temperature spread.
1.2 Start mechanical jobs after wheel space temperature comes down to
45°C.
1.3 Isolate the machine from fuel gas line by fitting the slip plate and arrange
to de-energize diesel engine start up motor.

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 1.4 Remove gas, atomizing air, liquid fuel lines to dual fuel nozzles.
1.5 Remove fuel and air check valves and dismantle for cleaning and
inspection.
1.6 Remove dual fuel nozzles and dismantle for cleaning and inspection.
1.7 Remove combustion chamber covers.
1.8 Take out retainer plates from combustion chambers.
1.9 Remove cross-fire tubes.
1.10 Remove flame detectors and spark plugs.
1.11 Pull out combustion liners.
1.12 Remove baroscopic plugs.

2.0 INSPECTION OF FUEL AND PURGE AIR CHECK VALVES:

2.1 Dismantle fuel and air check valves for cleaning and inspection.
2.2 Clean and re-assemble with new ‘o’ rings.
2.3 Test for opening pressure and back pressure.

3.0 INSPECTION OF DUAL FUEL NOZZLES:

3.1 Dismantle dual fuel nozzles for cleaning and inspection

3.2 Inspect for erosion and burn out of swirl caps.
3.3 Inspect nozzle caps for hole size and any erosion.
3.4 Dismantle and clean transition assemblies and inspect for erosion.
3.5 Check gas fuel hole size.
3.6 Replace the parts if found defective.

4.0 INSPECTION OF COMBUSTION LINERS:

4.1 Inspect for overheating and cracks.
4.2 Check cross fire tube collar thinning.
4.3 Check deformation and thinning due to rubbing of spring seal.
4.4 Carry out D.P. test of the complete liners in association with Inspection
Technician.
4.5 Repair/replace the defective liners if the reduction in thickness is
less/more than 50% of base metal respectively.

5.0 INSPECTION OF TRANSITION PIECES:

5.1 Carry out visual inspection for cracks and wear at the point of contact
with liners.
5.2 Inspect with boroscope for cracks at point of contact with liners and with
1st stage nozzle in association with Inspection Technician.

6.0 RE-ASSEMBLY:

6.1 Put back the combustion liners.

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 6.2 Refix retainer plates.
6.3 Put cross fire tubes.
6.4 Box-up flame detectors and spark plugs.
6.5 Box-up combustion chamber covers.
6.6 Put re-assembled dual fuel nozzles in combustion chambers and tightens
bolts at appropriate torque values.
6.7 Put new/rectified fuel and air check valves.
6.8 Fit back all gas and fuel lines to the dual fuel nozzles.
6.9 After thorough checking, inform Engineer In-charge of the job to
handover machine to operation group.
6.10 Observe differential pressure of combustion chambers, temperature
spread, any leaks and vibration after start up of gas turbine.

B. HOT GAS PATH INSPECTION:

Hot gas path inspection includes the combustion inspection described at ‘A’ and in
addition following detailed inspection of turbine is to be done within 24000 running
hours.

1.0 DIS-ASSEMBLY:

1.1 Carry out pre shutdown checks as per check list and note down data of
differential pressure of combustion chambers and temperature spread.
1.2 Start mechanical jobs after wheel space temperature comes down to
45°C.
1.3 Isolate the machine from fuel gas line by fitting the slip plate and arrange
to de-energize diesel engine start up motor and ratchet motor.
1.4 Remove gas, atomizing air, liquid fuel lines to dual fuel nozzles.
1.5 Remove fuel and air check valves and dismantle for cleaning and
inspection.
1.6 Remove dual fuel nozzles and dismantle for cleaning and inspection.
1.7 Remove combustion chamber covers.
1.8 Take out retainer plates from combustion chambers.
1.9 Remove cross-fire tubes.
1.10 Remove flame detectors and spark plugs.
1.11 Pull out combustion liners.
1.12 Remove roof and side panels of turbine compartment.
1.13 Remove combustion chambers.
1.14 Remove cooling and sealing air pipes.
1.15 Loosen and remove turbine shell bolts as per sequence.
1.16 Jack up turbine shell Upper half with jack bolts.
1.17 Lift turbine shell Upper half with overhead crane.
1.18 Remove transition pieces.
1.19 Remove eccentric pins.

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 1.20 Remove first and second stage nozzles Upper half
1.21 Check and record turbine clearances
1.22 Remove first and second stage nozzles Lower half
1.23 Remove second stage diaphragms

2.0 INSPECTION OF CHECK VALVES, NOZZLES AND TURBINE BUCKETS:

2.1 Dismantle fuel and air check valves for cleaning and inspect.
2.2 Clean and re-assemble with new ‘o’ rings.
2.3 Test for opening pressure and back pressure.
2.4 Clean and inspect first and second stage nozzles upper half & lower half.
2.5 Carry out D.P. Test of the first and second stage nozzles for cracks in
association with Inspection Technician.
2.6 Clean and inspect first and second stage buckets.

3.0 INSPECTION OF DUAL FUEL NOZZLES:

3.1 Dismantle dual fuel nozzles for cleaning and inspect.

3.2 Inspect for erosion and burn out of swirl caps.
3.3 Inspect nozzle caps for hole size and any erosion.
3.4 Dismantle and clean transition assemblies and inspect for erosion.
3.5 Check gas fuel hole size
3.6 Replace the parts if found defective.

4.0 INSPECTION OF COMBUSTION LINERS:

4.1 Inspect for overheating and cracks.

4.2 Check cross fire tube collar thinning.
4.3 Check deformation and thinning due to rubbing of spring seal.
4.4 Carry put D.P. test of the complete liners in association with Inspection
Technician.
4.5 Repair/replace the defective liners if the reduction in thickness is
less/more than 50% of base metal respectively.

5.0 INSPECTION OF TRANSITION PIECES:

5.1 Carry out visual inspection for cracks and wear at the point of contact
with liners.
5.2 Inspect with boroscope for cracks at point of contact with liners and
with 1st stage nozzle in association with Inspection Technician.

6.0 RE-ASSEMBLY:

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 6.1 Install first and second stage nozzles lower half.
6.2 Check and record turbine clearances.
6.3 Install upper half of first and second stage nozzles.
6.4 Install transition pieces with seal.
6.5 Install turbine shell and tighten bolts as per sequence.
6.6 Install cooling and sealing air pipes.
6.7 Install combustion chambers.
6.8 Install turbine compartment roof and side panels.
6.9 Put back the combustion liners.
6.10 Refix retainer plates.
6.11 Put cross fire tubes.
6.12 Box-up flame detectors and spark plugs.
6.13 Box-up combustion chamber covers.
6.14 Put re-assembled dual fuel nozzles in combustion chambers and tighten
bolts at appropriate torque values.
6.15 Put new/rectified fuel and air check valves.
6.16 Fit back all gas and fuel lines to the dual fuel nozzles.
6.17 After thorough checking, inform Engineer Incharge of jobs to handover
machine to operation group.
6.18 Observe differential pressure of combustion chambers, temperature
spread, any leaks and vibration after start up of gas turbine.

C. MAJOR INSPECTION /OVERHAULING OF GTG

Major inspection includes the Hot Gas Path inspection described at ‘B’ and in addition
following detailed inspection of turbine is to be done within 48000 running hours.

1.0 DIS-ASSEMBLY:

1.1 Carryout pre shutdown checks as per check list and note down data of
differential pressure of combustion chambers and temperature spread.
1.2 Start mechanical jobs after wheel space temperature comes down to
45°C.
1.3 Isolate the machine from fuel gas line by slip plate and arrange to de-
energize diesel engine start up motor and ratchet motor.
1.4 Remove compressor and turbine side panels.
1.5 Remove compressor and turbine roof.
1.6 Remove inlet duct and exhaust duct.
1.7 Remove load and acc. gear box couplings.
1.8 Take alignment reading between acc. gear box and compressor and
between turbine and load gear box.
1.9 Remove gas, atomizing air, liquid fuel lines to dual fuel nozzles.
1.10 Remove fuel and air check valves and dismantle for cleaning and
inspection.

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 1.11 Remove dual fuel nozzles and dismantle for cleaning and inspection.
1.12 Remove combustion chamber covers.
1.13 Take out retainer plates from combustion chambers.
1.14 Remove cross-fire tubes.
1.15 Remove flame detectors and spark plugs.
1.16 Pull out combustion liners.
1.17 Remove boroscope plugs.
1.18 Remove combustion chambers.
1.19 Provide jacks under compressor casings.
1.20 Jack up compressor casing as per requirement.
1.21 Remove turbine upper half casing bolts as per sequence only.
1.22 Remove turbine upper half casing.
1.23 Remove top half exhaust frame and diffuser.
1.24 Remove transition pieces.
1.25 Remove discharge casing.
1.26 Remove compressor casing.
1.27 Remove inlet casing.
1.28 Remove 1st stage nozzle upper half.
1.29 Remove 2nd stage nozzle upper half.
1.30 Remove diaphragms upper half and lower half.
1.31 Check rotor thrust.
1.32 Take clearance of Compressor and Turbine.
1.33 Remove No. 1 and No.2 bearing top halves.
1.34 Lift rotor.
1.35 Remove lube oil filters.
1.36 Remove atomizing air pre-cooler cover for cleaning of tubes.
1.37 Remove diesel engine cooler cover for cleaning of tubes.

2.0 INSPECTION

2.1 Dismantle fuel and air check valves for cleaning and inspect.
2.2 Clean and re-assemble with new ‘o’ rings.
2.3 Test for opening pressure and back pressure.
2.4 Clean and inspect first and second stage nozzles U/H & L/H.
2.5 Carry out D.P. test of the first and second stage nozzles for cracks in
association with Inspection Technician.
2.6 Clean and inspect first and second stage buckets.
2.7 Clean, inspect visually and D. P. test of rotor shaft.
2.8 Check shaft O.D. at bearing position.
2.9 Inspect No.1, No. 2 and No.3 bearing and carry out D.P. test.
2.4 Inspect compressor rotor and stator blades.
2.10 Clean and inspect inlet guide vanes.
2.11 Clean and inspect rack & pinion of inlet guide vanes actuator.
2.12 Inspect air seal for rubbing.

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 2.13 Inspect after and forward seal of turbine.

3.0 INSPECTION OF DUAL FUEL NOZZLES:

3.1 Dismantle dual fuel nozzles for cleaning and inspect.

3.2 Inspect for erosion and burn out of swirl caps.
3.3 Inspect nozzle caps for hole size and any erosion.
3.4 Dismantle and clean transition assemblies and inspect for erosion.
3.5 Check gas fuel hole size
3.6 Replace the parts if found defective.

4.0 INSPECTION OF COMBUSTION LINERS:

4.1 Inspect for overheating and cracks.

4.2 Check cross fire tube collar thinning.
4.3 Check deformation and thinning due to rubbing of spring seal.
4.4 D.P .test the complete liners.
4.5 Repair/replace the defective liners if the reduction in thickness is
less/more than 50% of base metal.

5.0 INSPECTION OF TRANSITION PIECES:

5.1 Inspect visually for cracks and wear at the point of contact with liners.
5.2 Inspect with boroscope for cracks at point of contact with liners and with
1st stage nozzle.

6.0 RE-ASSEMBLY

6.1 Install No.1 and No.2 bearing lower half with deflector.
6.2 Put back rotor after inspection and cleaning properly.
6.3 Install thrust bearing lower half.
6.4 Install thrust bearing upper half.
6.5 Install No.1 and No.2 bearings upper half.
6.6 Check rotor thrust.
6.7 Check alignment between acc. gear box & compressor and between
turbine & load gear box.
6.8 Check compressor clearances.
6.9 Rotate the rotor manually and observe any rubbing of blades.
6.10 Install load and acc. coupling and tighten the coupling bolts as per
sequence and at proper torque.
6.11 Install lower half coupling guard of both acc. and load couplings.
6.12 Observe lube oil injector position in both gear couplings.

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 6.13 Install upper half of coupling guard.
6.14 Install lower half and upper half of diaphragms of Turbine.
6.15 Check air seal clearance using lead wire.
6.16 Put new wire packing in first stage nozzle upper half and lower half.
6.17 Install lower half of 1st and 2nd stage nozzle.
6.18 Check turbine clearances.
6.19 Install 1st and 2nd nozzle upper half.
6.20 Put guide pins in lower half casing of turbine.
6.21 Install turbine casing upper half and tighten bolts as per the sequence.
6.22 Install inlet casing upper half and tighten bolts as per sequence.
6.23 Install discharge casing upper half and tighten bolts as per sequence.
6.24 Install compressor casing upper half.
6.25 Install inlet plenum upper half.
6.26 Install top half of exhaust frame and diffuser.
6.27 Install transition pieces with seal.
6.28 Install turbine shell and tighten bolts as per sequence.
6.29 Install cooling and sealing air pipes.
6.30 Install combustion chambers.
6.31 Install turbine compartment roof and side panels.
6.32 Put back the combustion liners.
6.33 Put cross fire tubes.
6.34 Refix retainer plates.
6.35 Box-up flame detectors and spark plugs.
6.36 Box-up combustion chamber covers.
6.37 Put re-assembled dual fuel nozzles in combustion chambers and tighten
bolts at appropriate torque values.
6.38 Put new/rectified fuel and air check valves.
6.39 Fix back all gas and fuel lines to the dual fuel nozzles.
6.40 After thorough checking, inform Engineer In-charge of jobs to handover
machine to operation group along with all the safety Tags.
6.41 Observe differential pressure of combustion chambers, temperature
spread, any leaks and vibration after start up of gas turbine.

WORK INSTRUCTION FOR OVERHAULING OF HORIZONTAL SPLIT CASE DESIGN

COMPRESSOR

PURPOSE: To maintain and overhaul Horizontal Split Case Design Compressor.

RESPONSIBILITY: Technician

1.0 DISMANTLING:

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 1.1 Stop lube oil circulation or put blinds into lube oil inlet lines to compressor
bearings and couplings for isolation.
1.2 Remove all instrument probes connected to bearings and coupling guards.
1.3 Remove the coupling guard.
1.4 Check and record axial float of the coupling and decouple the compressor from
adjacent machines. Inspect the coupling.
1.5 Check and record axial float of the compressor with thrust bearing in position.
1.6 Check and record total float of Rotor without thrust bearing in position.
1.7 Check and record alignment readings of compressor with adjacent machines.
1.8 Check and record run-out of Rotor at coupling end.
1.9 Remove top halves of both journal bearings and thrust bearing.
1.10 Remove all connecting piping connected to compressor upper halves.
1.11 Remove the bolts / studs / nuts and dowels between upper and lower halves of
the compressor casing.
1.12 Remove upper half of the casing carefully and put it on wooden sleepers on
ground floor such that its internals can be cleaned / checked / replaced.
1.13 Check Rotor assembly, diaphragms, and labyrinths for any abnormal wear and
tear / damage.
1.14 Check and record internal clearances of labyrinths, oil guards etc. while keeping
the rotor in running position.
1.15 If the compressor is equipped with mechanical seal then check and record
mechanical seal compression.
1.16 Remove Rotor assembly and put it on the rotor stand.
1.17 Clean all the stationary internals of upper and lower halves of the casing.
1.18 Check and record magnetism level of all the stationary parts of upper and lower
halves of the casing.

2.0 ROTOR DISMANTLING, INSPECTION & REASSEMBLY:

If the compressor is equipped with mechanical seal, then the following dismantling /
inspection activities are to be carried out as under.

2.1 Remove coupling hubs from rotor.

2.2 Thoroughly inspect the thrust collar assembly for any looseness and then
remove the thrust collar.
2.3 Remove mechanical seal assembly and inspect seal components like rotating and
stationary faces, springs and all sealing parts like “0” rings wedges etc. On basis
of above inspection, decide on reuse / replacement of seal components or
complete mechanical seal assembly.
2.4 Clean the Rotor.
2.5 Check and record rotor run out.
2.6 Check and record bearing journal diameters of both ends.
2.7 Check and record coupling hub fitting dimensions & blue match with the
coupling hubs to be fitted.

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 2.8 Check and record magnetism level of journal bearing area, thrust collar area and
shaft and portion.
2.9 After above checks, make a decision for reuse / replacement of rotor.
2.10 If new rotor is to be used then perform all above checks listed at 2.4 to 2.8. Also
check overall dimensions of new rotor and compared with old rotor.
2.11 If the compressor is equipped with mechanical seal then assemble mechanical
seal assembly and coupling hubs on the rotor.

3.0 BEARING INSPECTION:

3.1 JOURNAL BEARING:

3.1.1 Dismantle, clean and inspect the bearing for any abnormal wear & tear / peel off
of white metal lining. Based on above visual inspection decide reuse or
replacement of tilting pads / bearing housing. Perform following checks on
bearing assembly to be installed.
3.1.2 Check and record thickness of all tilting pads and ID of bearing housing.
3.1.3 Assemble the bearing on the mandrill. Check and record the diametrical
clearance of bearing.
3.1.4 If new bearing housing is to be used, then make required drilling / tapping for
fixing vibration probe brake.

3.2 THRUST BEARING:

3.2.1 Dismantle, clean and inspect the thrust bearing assembly components.
3.2.2 Thoroughly inspect any wear & tear / peel off of any white metal lining of thrust
pads. And measure thickness of each individual pad.
3.2.3 Inspect the pivot points of thrust pads for any wear and tear.
3.2.4 Inspect the base rings for wear and tear at pivot point area and its tilting action.
3.2.5 Based on checks at 3.2.2 to 3.2.4 decide reuse or replacement of thrust pads.
3.2.6 If new thrust pads are to be used, record the thickness of each individual new
pad.

4.0 ASSEMBLY:

4.1 Replace the diaphragms wherever required.

4.2 Replace the labyrinths, oil guards etc. wherever required.
4.3 Put journal bearing bottom half on the lower casing.
4.4 Put the Rotor assembly in position.
4.5 Keep the rotor in running position and check for its free rotation and measure
the total float of rotor without active side & inactive side thrust pads.
4.6 Check bedding of journal bearing pads in bottom halves of bearing.
4.7 If the compressor is equipped with mechanical seal, then bring the rotor in
position and measure the seal compression at both the ends.

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 4.8 Check the rotor position by measuring the distance between each respective
impeller to diaphragms. Simultaneously measure the axial float of the rotor with
thrust bearing in position. Match both the adjusting shims to maintain correct
rotor position and axial float of the rotor.
4.9 Check and record internal clearances of labyrinths, oil guards etc. while keeping
the rotor in running position.
4.10 Put the upper half of the casing and tighten the bolts.
4.11 Ensure that oil inlet and outlet passages of journal bearing and thrust bearings
are free from any blockage. Assemble both the journal bearing and thrust
bearing assemblies. Check crushing clearance of both the journal bearing
between bearing housing and bearing cover.
4.12 Adjust instruments probes to match panel reading of axial displacement with
actual axial float of rotor.
4.13 Check and record alignment between compressor and adjacent machine.

4.14 Flush all the oil and gas piping connected to the compressor.
4.15 In case compressor is equipped with mechanical seal, clean and reassemble all
the seal oil traps.
4.16 Assemble all gas and oil piping connected to compressor with proper gaskets.
4.17 Couple the machine with adjacent machine & record coupling float. Keep the
coupling assembly approximately in the center of total coupling float.
4.18 Check coupling lubricating pipe position and finally assemble the coupling guard.
4.19 Put on the oil circulation and handover the machine for alarm and trip checking.
4.20 Compile following major relevant data for entry in the history card.

4.20.1 Rotor position, distance between each respective impeller and

corresponding diaphragm vane.
4.20.2 Total float of the rotor.
4.20.3 Axial float of rotor. Record shim thickness.
4.20.4 Journal bearing clearances
4.20.5 Labyrinth clearances
4.20.6 Alignment reading between compressor & adjacent machine
4.20.7 Spares replaced
4.20.8 Any other significant information.

WORK INSTRUCTIONS FOR ROTARY AND STATIC EQUIPMENTS

PURPOSE: Servicing of rotary and static Equipments by Routine and Preventive

maintenance.
1.0 ROTARY EQUIPMENTS:

1.1 Contact field operator for identifying the job.

1.2 Provide necessary slip plating etc. for equipment isolation.

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 1.3 Receive safety work permit from production department for job clearance.
Ensure all the safety instructions, as stated in the safety work permit, are put
into force / taken care.
1.4 Arrange tools, remove insulation, open coupling guards etc.
1.5 Receive isolation Tag after the equipment is de-energized and ensure the
equipment’s isolation electrically by cross checking manual pushing the start /
on button before start up of maintenance work.
1.6 Record following necessary data’s before dismantling the equipment for keeping
as reference.
 Alignment readings
 Different clearances
 Axial float
 Shaft run out etc.
 Any other significant information
1.7 Arrange necessary spares, lifting equipments, tools and tackles required for the
job.
1.8 Start maintenance work as per procedure and guidelines given by the engineer.
1.9 Record the spares used in the maintenance, the alignment reading and different
clearances maintained during the maintenance for future reference in the
equipment history card ME-01-F-04.
1.10 Return Isolation Tag to shift engineer and check the correct direction of rotation
after electrical energization. Again de-energize, get the Tag.
1.11 Couple the equipment.
1.12 Provide coupling guard, hand over the Tag back to production and hand over
equipment finally for operation.

STATIC AND OTHER EQUIPMENTS:

2.1 Contact field operator for identifying the job after receipt of the Maintenance
Work Request (MWR).
2.2. Receive safety work permit and vessel entry permit from the production job
clearance. The maintenance staff and operation ensure that the equipment is
isolated from operational point of views for job like: slip plating, valve closing,
draining etc. and the isolation Tags are put on isolation valves. Ensure that all the
necessary safety equipments like hamlet, goggles, safety belts etc. have been
provided. Ensure proper illumination with 24V hand lamps inside the vessel.
Ensure air ventilation inside the vessel with proper air hose.
2.3 Start maintenance of equipment as per procedure and the guidelines given by
the engineer.
2.4 Arrange following for facilitating the job.
 Necessary scaffolding
 Lifting tools / tackles
 Mobile equipments if required
 Welding machines, cutting set etc.

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  Removal of insulation
2.5 Ensure following jobs are to be completed if applicable before final hand over of
the jobs.
 Insulation
 Removal of scaffolding
 Removal of lifting equipments tools and tackles
2.6 Inform to shift engineer.
2.7 Record following details for reference purpose before start and completion of
the job.
 Spares replaced
 Any other significant information

WORK INSTRUCTION FOR BOILER INSPECTION

PURPOSE: To overhaul Boiler for inspection and maintenance as per IBR.

1.0 OPEN INSPECTION OF WASTE HEAT BOILERS:

1.1 Take safety permit for entry.

1.2 Open steam drum and clean all the internals.
1.3 Repair / replace fasteners and internals if required.
1.4 Thoroughly clean the steam drum from inside.
1.5 Carry out visual inspection of insulation and repair if needed.
1.6 Boiler Inspector is called at site as per the prefixed date. Then open inspection of
boilers is carried out by him. The thickness measurement report of steam drum is
submitted to him.
1.7 Box up the manholes of steam drum with new gaskets.

2.0 OPEN INSPECTION OF FIRED BOILERS:

2.1 Take safety permit for entry.

2.2 Open steam drum, mud drum and clean all the internals.
2.3 Repair / replace fasteners and internals if required.
2.4 Thoroughly clean steam drum and mud drum from inside.
2.5 Carry out outside cleaning of bank tubes, furnace tubes and super-heater tubes.
2.6 Carry out visual inspection of refractory’s and insulation and repair if required.
2.7 Boiler Inspector is called at site as per the prefixed date. Then open inspection of
boiler is carried out by him.
2.8 Box up the manholes of steam drum and mud drum with new gaskets.

3.0 HYDRAULIC TEST OF SG (STEAM GENERATION) UNIT AND HRSG (HEAT RECOVERY &
STEAM GENERATION) BOILERS:

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 3.1 Open all manhole covers of Boiler Furnace and obtain necessary safety work
permit for vessel entry.
3.2 Provide necessary blinds in the system for hydraulic test.
3.3 Connect hydro-testing pump / Boiler Feed Water Pump with the system and
make all other required arrangements for hydro-test.

3.4 Carry out departmental hydro-test to a required test pressure of respective

boiler as per IBR requirement. If the pressure is not holding then identify the
leakage points in the system loop and attend the same. Repeat the hydraulic test
again till required test pressure is hold.
3.5 Boiler Inspector is called at site as per prefixed date. Then hydraulic test is
carried out in presence of Boiler Inspector.
3.6 Disconnect the hydro-testing pump and other arrangement made from the
system.
3.7 Remove blinds from the system and boxed up the furnace manhole covers.
3.8 Hand over the Boiler for operation.

4.0 INFORMATION FOR HISTORY CARD:

Record the following information in the history card for respective boiler.

4.1 Date of hydraulic test

4.2 Hydraulic test pressure details
4.3 Details of repair carried out on boiler if any.

WORK INSTRUCTION FOR CLEANING AND HYDRAULIC TESTING OF HEAT

EXCHANGER

PURPOSE: Cleaning and Hydraulic Testing of Heat Exchanger.

(I) FIXED TUBE TYPE HEAT EXCHANGER:

1.0 DISMANTLING:

1.1 Make scaffolding

1.2 Prepare taper plugs of suitable material / size to suit tube material / size.
1.3 Open both the end covers.
1.4 Open shell side connections & provide blinds for hydro-testing.
1.5 Clean all gaskets seating area thoroughly & repair, if required.

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 1.6 Clean all removed fasteners & replace with new fasteners if needed.

2.0 HYDROTEST:

2.1 Make necessary arrangement for hydro-test. Connect the hydro-testing

pump with one of the nozzle (Preferably bottom most), of shell side.
2.2 Provide a valve connection to another shell side nozzle for air venting,
while filling the water in the shell side.
2.3 Fill the water in the shell side through the shell side nozzle. While filling
the water, remove the air from the other shell side nozzle through a
valve connected with it. After filling the water in the shell side, close the
air vent valve.
2.4 Gradually pressurize the water in the shell side by a hydro-testing pump
to a required test pressure and then stop the hydro-testing pump. The
test pressure is 1.5 times the operating pressure. Hold the test pressure
for about 15 minutes.

Check both the tube sheet and tubes for any leakage. The leakage is because of
- Tube leak
- Leak through tube sheet to tube joint
Mark the leaky tubes or tube sheet to tube joint as the case may be.

3.0 REPAIR, RETEST AND FINAL ASSEMBLY:

3.1 Plug the leaky tubes by press fitting the taper plugs with the help of hammer
or by welding the plug with the tube sheet followed by dyepenetrant check.
3.2 If there is a leakage through tube sheet to tube joint then take safety permit
for repair of the same. Then repair the leaky tube sheet to tube joint by
grinding and welding, followed by dyepenetrant check. If tubes are expanded,
then carry out re-expansion of the tubes to stop the leakage.
3.3 Again carry out the hydro-test as per the procedure mentioned at Sr. No. 2.
Check for any leakage and rectify the same as per activity at Sr. No. 3.1, 3.2
above. Final Hydro-test is witnessed by operation staff also.
3.4 If hydro-test is okay, then depressurize the system.
3.5 Remove hydro-testing arrangement and blinds provided on the shell side
nozzles.
3.6 Box up both the end covers with new gaskets after checking / repairing
gaskets seating faces.

II) FLOATING HEAD TYPE HEAT EXCHANGER:

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1.0 DISMANTLING:
1.1 Make scaffolding.
1.2 Prepare taper plugs of suitable material / size to suit tube material / size.
1.3 Open shell side as well as tube side connections.
1.4 Provide blinds on shell side.
1.5 Open fixed end side channel and its end cover. If tube bundle is to be
removed for hydro jetting from shell side then dismantle channel also.
1.6 Remove floating head side main cover.
1.7 Remove floating head cover and its split ring.
1.8 If the tube bundle is required to be cleaned from shell side then pull out
the tube bundle with suitable rigging arrangement and place the same on
ground floor on the wooden sleepers.
1.9 If only the tubes are to be cleaned, then do not remove the tube bundle.
1.10 Clean gasket seating faces and repair if needed.
1.11 Issue all gaskets
1.12 Clean all the removed fasteners & issue new fasteners if needed.
1.13 If tube bundle is taken out for external cleaning, then insert the same into
the shell by suitable rigging arrangement after external and internal
cleaning.

2.0 SHELL SIDE HYDROTEST, REPAIR & RETEST:

2.1 Make necessary arrangement for hydro testing for testing the exchanger
from shell side.
2.2 Provide valve connection for air venting while filling the water in shell
side or in tube side.
2.3 Assemble “Test Ring” with floating head side shell flange with proper
gasket.
2.4 Fill the water in the shell side through the shell side nozzle. While filling
the water, remove the air from the other shell side nozzle through a valve
connected with it. After filling the water in the shell side, close the air
vent valve.
2.5 Gradually pressurize the water in the shell side by a hydro testing pump to
a required test pressure and then stop the hydro testing pump. The test
pressure is 1.5 times the operating pressure. Hold the test pressure for
about 15 minutes.

Check both the tube sheet and tubes for any leakage. The leakage is because
of
- Tube leak
- Leak through tube sheet to tube joint
Mark the leaky tubes or tube sheet to tube joint as the case may be.

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 2.6 Plug the leaky tubes by press fitting the plugs with the help of hammer or
by welding the plug with tube sheet and subsequently D.P. checking of
welding.
2.7 If there is a leakage through tube sheet to tube joint then take safety
permit for repair of the same. Then repair the leaky tube sheet to tube
joint by grinding and welding, followed by dyepenetrant check. If tubes
are expanded, then carry out re-expansion of the tubes to stop leakage.
2.8 Again carryout the hydro test as per the procedure mentioned at
Sr.No.2.1 to 2.5. Check for any leakage and rectify the same as per activity
at Sr. No. 2.6 & 2.7 above. Final hydro test is witnessed by operation staff
also.
2.9 If hydro test is okay. Then depressurize the system.
2.10 Remove hydro testing arrangement and blinds provided on the shell side
nozzles.
2.11 Remove “Test Ring”.

WORK INSTRUCTION FOR OVERHAULING OF CENTRIFUGAL PUMP

PURPOSE: To maintain and overhaul all type of centrifugal pumps.

1.0 DISMANTLING:

1.1 De-energize the motor. Get the safety tag (Stub).

1.2 Remove coupling guard, check the free rotation of pump coupled with motor.
1.3 Decouple the pump with motor.
1.4 In case of turbine driven pump, check alignment reading for reference
1.5 Remove pump casing bolts & remove pump assembly.
1.6 Take pump assembly to work place, fix it on fixture for dismantling and check
impeller back plate clearance and bearing end cover gap.
1.7 Remove impeller.
1.8 Remove back plate and seal flange.
1.9 Remove shaft sleeve along with compression unit of mechanical seal.
1.10 Remove coupling from the pump shaft.
1.11 Remove coupling end bearing cover bolts and remove shaft assembly along with
both bearing by tapping the shaft from impeller end.
1.12 Remove bearing end cover, bearings, and oil seals and inspect the same.
1.13 Check shaft run out, wear in oil seal area, bearing area and coupling hub area.
Also check impeller and impeller lock nut threads.
1.14 Based on through inspection of pump components, decide on reuse /
replacement of respective components.

2.0 ASSEMBLY:

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 2.1 Check shaft run out, bearing dia. , oil seal dia. , impeller dia. and coupling hub
dia. dimensions, if new shaft is to be used.
2.2 Fix both bearings on shaft after heating in oil bath or hot plate and locate them
into position.
2.3 Insert the shaft assembly in bearing housing and tighten the bearing end cover.
2.4 Fix oil seals on both the ends of bearing housing end covers.
2.5 Check shaft assembly for free rotation in bearing housing after fixing coupling
hub.
2.6 Fix shaft sleeve and compression unit of mechanical seal on shaft after adjusting
distance of compression unit on shaft sleeve.

. 27 Fix back plate and tighten its bolts.

2.8 Install impeller on shaft and adjust its back plate clearance as per manufacturer’s
recommendation.
2.9 Fix seal flange and confirm its gap for ensuring proper compression of
mechanical seal.
2.10 Put casing gasket between the back plate and pump casing as per previous
reference and tighten the casing bolts and tighten the pump foundation bolts.
Check for the free rotation of the pump.
2.11 Open the suction valve and check the mechanical seal leak.
2.12 If mechanical seal is found okay, align the pump with motor / turbine.
2.13 Handover the safety tag for motor energizing.
2.14 Check direction of rotation of motor.
2.15 Again de-energize the motor and get the Tag.
2.16 Couple the pump with motor / turbine.
2.17 Fill-up oil in bearing housing.
2.18 Place the coupling guard in position.
2.19 Handover the Tag back to production.

WORK INSTRUCTION FOR OVERHAULING OF FAN AND BLOWERS

PURPOSE: To maintain and overhaul centrifugal fan and blowers.

1.0 DISMANTLING:
1.1 Remove the coupling guard.
1.2 Check and record axial float of the coupling and decouple the compressor from
drive motor/ turbine. Inspect the coupling.
1.3 Check and record alignment readings of fan with motor/ turbine.
1.4 Remove both the journal bearings top and check for any wear/damage of
bearing and take clearance of bearings. If found any damage, change bearing.
1.5 Lift the rotor by jack and remove journal bearing bottom.

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2.0 ROTOR CLEANING AND INSPECTION:
2.1 Clean the rotor.
2.2 Check for any deformity and wear & tear.
2.3 Check and record bearing journal diameters of both ends.

3.0 BEARING INSPECTION:

3.1 Dismantle, clean and inspect the bearing for any abnormal wear and tear / peel
off of white metal lining. Based on above visual inspection, decide reuse or
replacement of bearing.

4.0 REASSEMBLY:
4.1 Install bottom journal bearing.
4.2 Remove the jack and put rotor on bearings, pour some oil for initial
lubrication.
4.3 Check the rotor for its free rotation.
4.4 Check for static balance and rectify if necessary.
4.4 Align the fan with motor/ turbine and couple & lubricate.
4.5 Record following major relevant data in the history card-
4.5.1 Journal bearing clearance
4.5.2 Rotor run out readings
4.5.3 Alignment reading between fan and motor/ turbine
4.5.4 Spares replaced
4.5.5 Any other significant information

GENERAL SEALING SYSTEM USED IN ROTORY AND STESTIONARY

EQUIPMENT/SYSTEM

MECHANICAL SEAL
A device, which seals by virtue of axial contact pressure between relatively flat surfaces in
a plane at right angle to the axis of the shaft.

PROBLEMS WITH GLAND PACKING

1. Excessive power consumption
2. More plant down time
3. Atmospheric pollution
4. Effect on plant life
5. Loss of pump age
6. Higher maintenance cost

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CLASSIFICATION OF MECHANICAL SEALS
• By arrangement

1. Single seal
a. inside mounted
b. outside mounted
2. Multiple seals
a. tandem
b. back to back
c. face to face
d. coaxial
• By design

1. Balanced & unbalanced

2. Rotating & stationery
3. Single & multi spring * (* pusher type seal)
4. Metal, Teflon & rubber bellow ** ( ** non-pusher type seal)
5. DIN 24960 / API 682

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ADVANTAGES OF MECHNICAL SEAL
1. 10 to 15 % power saving
2. Better sealing life
3. Insignificant leakage
4. Minimum pollution
5. Increased plant life
SEALING MATERIALS IN AND PIPE SYSTEM VALVES
(Compressed Asbestos Fibre Jointing)
When any fluid, may it be a liquid or a gas, has to be conveyed along a pipeline or harnessed to
do a specific job, the problems of sealing the joints in the pipeline or machines have to be
approached in a rational manner, particularly, when pressures and temperatures are
necessarily high.

By “Gaskets” is meant the fairly thin material placed between two relatively stationary
members, unlike “Packing” are those materials used in a gland to seal against the leakage of
the liquid or gas through the annulus between two concentric components one of which moves
in relation to the other e.g. the shaft and stuffing box of a pump or valve.

GASKETS – COMPRESSED ASBESTOS FIBRE JOINTING SHEETS

In an Engineering field, it is customary to arrange for a flat surface on one member or part of a
machine etc. to match with a similar shaped flat surface on the member to be joined to it.

In the case of pipes and pipelines, the joining flat surfaces are obtained by providing a flange at
each end of the two pipes to be joined together. These flat surfaces are never perfectly smooth
and to take up the imperfections it is necessary to insert a thin liner of deformable material of
somewhat similar shape between the contact faces. This liners is called a “gaskets”

The material of the gasket must be such that with the application of a force to hold the parts
together, the gasket can be compressed to yield or flow into the imperfections of the joint
contact faces. Thus a leak proof joint is made.

Four types of gasket joints are in general use, viz.

a) The flat face or unconfined,
b) The totally confined in a tongue and groove arrangement,
c) Partially confined without support on the pressure side,
d) The self energized, where the pressure in the vessel assists to increase the gasket
sealing force.

Compressed asbestos fibre jointing is not only material used for gaskets, others could be: -

1. Plain vegetable paper or board,

2. Treated papers,

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3. Rubber both natural and synthetic, with or without fabric insertion,
4. Cork sheets,
5. Asbestos products,
6. Plastic – flat or molded or envelope,
7. Metals – formed or fabricated,
8. Composite – partially or fully jacketed and spiral wound of various cross-sections.

The choice of materials for a gasket depends largely on the following factors:

i) Operating condition – Pressure, temperature and fluid to be contained,

ii) Ease of fitment and replacement,
iii) The most economically efficient gasket.

For maintenance purpose materials are selected as per following chart.

Material selection based on operating temperature

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