INITIAL REPORT ON PROCESS AIR COMPRESSOR FOR SEMESTER TRAINING SUBMITTED BY : PRANNOY KUDESIA 400807021 3RD YEAR INE

Thapar University PATIALA

IFFCO India farmer fertilizer corporation it is one of the largest fertilizer manufacturing unit across India .It has five production units in india namely phulpur ,bareilly ahemdabad,Gandhi nagar ,and paradeep orrissa. I m doing my internship in bareilly unit .this unit consist of two ammonia plants(1350 Te/day) which provide a raw material for production of urea(1100 Te/day).ammonia production is governed by Haldor TOPSoE process which was given by DENMARK .process takes place in many steps-

Desulphonation High pressure catalytic reforming Water gas shift reaction Carbondioxide absorbtion and stripping Methanation Ammonia synthesis Refrigeration

I am being placed under mechanical maintainance department of ammonia unit where i m studyng working of process air compressor driven by 25 MW steam turbine.the turbine used to drive the compressor is a impulsereaction turbine with first impulse and 15 reaction stages.the turbine trip speed is 6600 rpm.it consist of one trip throttle walve and one control valve which is used to control the flow of steam .during starting or stopping of turbine a RATCHET motor is provided in THE TURBINE which rotates the shaft at no load condition at very low speed,to avoid damaging the shaft due sudden drop or increase of temperature and also avoids the BENDING STRESSES that dovelop if shaft is kept stationary .the governer of the turbine controls the speed of rotation of the shaft 6200 to 6455 rpm. The steam turbine is then coupled with the compressor by universal coupling The compressor is a multistage Centrifugal Compressor ,the compressed air(upto 3kg/cm2 )is then passed to reformers for the production of nitrogen and hydrogen the basic raw materials for manufacture of ammonia. The compressor consist of two houses Low pressure High pressure Low pressure case compress the atmospheric air and delivers it to suction of high pressure case.each case has a total of 6 wheels divided into two parts forming the twin sections intercooling is provided between two sections of each casing .for high efficiency of the compressor a speed increasing gear box is provided between low pressure and high pressure casing.

The IFFCO always takes a mandatory shut down once a year any one of the ammonia and urea producing units.during this period plant undergoes A brief maintainance period of one month ,all machines problems which cant be dealt during running period are being handled in this period of march april. This shut down gave me a gud opportunity to study the turbine and compressors in great detail.both turbine and compressors were dissassembeled studied repaired and disassembled. So i hereby submit my analysis introductory report Thank you