An Industrial training Report

on

A PROJECT REPORT ON MECHANICAL

DEPARTMENT AMMONIA UNIT II
Submitted in an partial fulfillment of the requirement of bachelor degree

Submitted by: Supervised By:

Name: Namit Beck Mr. L.N Gehlot

Er. No: 181E014 Engineer Mech.

Submitted to

Department of Mechanical Engineering

Jaypee Universirty of Engineering and Technology
A-B Road, Raghograh, Guna, MP
 Abstract

The present report is the outcome of the vocational training program of NFL organized at the
NFL vijaipur. The objective of the internship programme was to familiarize the student with
the implementation of the knowledge he earned in the campus. The practical knowledge is far
different from the bookish knowledge that a student achieves in an institution.
In this training report I will describe my experiences during my training period. The training
report contains an overview of the company and the activities, tasks and projects that I have
worked on during my training. Writing this report, I will also describe and reflect my learning
objects and personal goals that I have set during my training period.
With these objectives, I have made all possible efforts and the necessary investigations to submit
this paper in an enlightened form in a very short time. I have tried my level best to eliminate
errors from the paper. As I had to complete my training within a short period of time so the
study admits its limitations.

i
 Aknowledgement

I sincerely want to thank National Fertilizers Ltd., for giving me this opportunity to learn and
understand how real time manufacturing plant work and maintain. The training provided to
me during the period 24-06-2021 to 04-08-2021 at the NFL facility situated in Vijaipur, Guna
district, Madhya Pradesh, not only increased my insight into the industrial working and un-
derstanding of the various procedures but also acquainted me with the other processes that are
essentially to be followed in industrial plant like safety rules, drills and discipline.
The entire training process included valuable support, discussions on critical processes and
ideas, constant encouragement and invaluable advice and guidance from the working officials
and mentors. I sincerely thank Shri Mukesh Khare (Chief Manager) and Shri Yogesh Garwal
(Manager) for their guidance and arranged all facilities to make life easier. I choose this mo-
ment to acknowledge his contribution gratefully.
I would also like to extend my deep gratitude towards Mr. A.T Lakra (Dy. Manager), Mr.
L.N Gehlot (Engineer Mech.), Mr. Chandan Jha and Yogeshwar Singh, Mr. Raju Abraham,
Mr. R.K Maheshwari, Mr. Manish Massam, Mr. Dinesh Sahu for their careful and precious
guidance which were extremely valuable for my study both theoretically and practically.
I am also thankful for management and staff at NFL for their whole hearted cooperation
throughout my training period.
At last but not the least, I am indebted to my institution for supporting me in making this train-
ing a success.

Sincerely,
Namit Beck

ii
Certificate

iii
 Contents

Abstract i

Aknowledgement ii

Certificate iii

1 Introduction 1

1.1 ABOUT NFL PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 SALIENT FEATURES OF VIJAIPUR . . . . . . . . . . . . . . . . . . . . . . 3

1.3 VARIOUS POLICIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Plant Processes 5

2.1 WASTE MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 The Ammonia Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Short Description of the Process Units . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Desulphurization Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Hydrogenation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.7 Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.8 Primary Reformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.9 Secondary Reformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.10 Ammonia Synthesis Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Plant Machines 11

3.1 Centrifugal Vertical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

iv
 3.1.2 Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 LUBRICATION PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 PLUNGER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 VALVES & COUPLING 14

4.1 Types of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.1 Spring safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.2 NRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.3 Rupture disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.4 Gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.5 Globe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.1 Love joy coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.2 Flange coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 JOBS DONE IN AMMONIA II PLANT 19

5.1 VERTICAL CENTRIFUGAL PUMP . . . . . . . . . . . . . . . . . . . . . . 19

5.2 OIL CENTRIFUGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.3 POSITIVE DISPLACEMENT PUMP . . . . . . . . . . . . . . . . . . . . . . 20

5.4 ACID PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 CONCLUSION 21

Certificate 22
 List of Figures

1.1 NFL VIJAIPUR UNIT, GUNA (M.P.) . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Production Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Centrifugal Vertical Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Plunger Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Spring safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 Non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3 Gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4 Globe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.5 Love joy coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.6 Flange coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

 Chapter 1

Introduction

National Fertilizers Limited (NFL) - Miniratna (Cat-1) company (BSE: 523630) (NSE: NFL)
is an India state owned producer of chemical fertilizers, organic fertilizers and industrial chem-
icals. As of 2018, it was the second largest producer of fertilizers in India. National Fertilizers
Limited:

• Type - Public Sector Undertaking

• Traded as - BSE: 523630

• NSE - NFL

• Industry - Fertilizers and Chemicals

• Founded - 23 August 1974

• Headquarter - Noida, India

• Key People - Shri N V Datt (Chairman and MD)

• Products - Urea, Ammonia, Organic fertilizers, Industrial chemicals

• Owners - Government of India

• Website - www.nationalfertilizers.com

NFL, incorporated in 1974 is India’s Largest Central Public Sector Enterprise (Govt. of India
Undertaking) in Fertilizers Sector with a turnover of over Rs. 75 billion. Coming under the
administrative control of the Ministry of Chemicals and Fertilizers. It is the second largest
producer of the key fertilizers urea in India. NFL has five gas-based ammonia-urea plants viz
Nangal and Bathinda in Punjab, Panipat in Haryana and two at Vijaipur (Madhya Pradesh).

1
1.1 ABOUT NFL PLANT

National Fertilizers Ltd, Vijaipur unit is one of the four units of M/S National Fertilizers Lim-
ited. With the commencement of commercial production of the Expansion project the gas
based unit at Vijaipur now comprises of two 1864 ton per day (tpd) Ammonia streams and
Urea streams and related off-site facilities. The gas is being received from the HBJ gas pipe
line being operated by M/s Gas Authority of India Ltd (GAIL) another government of India
undertaking .The line one plants (one stream of Ammonia and two streams of Urea ) were built
with a total cost of Rs 533 Crores and the cost of the Expansion Unit (one stream of Ammonia
and two streams of Urea) is estimated at Rs 1067 Crores.

For both streams of Ammonia plants the consultant have been M/S Haldor Topsoe of Den-
Mark and M/S Projects Development India Ltd. (PDIL), and for all the four streams of Urea
consultant have been PDIL and M/S Snam Progetti of Italy.

In order to further reduce energy consumption & augment capacity of the Vijaipur Plant, Com-
pany has revamped both the plants at Vijaipur as a result. The annual installed capacity of
Vijaipur Units have been enhanced by 3.40 LMT (16% in case of Vijaipur -I and 23% in case
of Vijaipur-II ) with the total capacity of the company has been increased from 32.31 LMT to
35.68 LMT.

Figure 1.1: NFL VIJAIPUR UNIT, GUNA (M.P.)

2
1.2 SALIENT FEATURES OF VIJAIPUR

• Installed Capacity: 999900 MTPA

• Capital Investment: Rs 516.00 Crores

• Initial Commencement of Production: November 1, 1988

• Commencement of Revamp: April 24, 2012

• Process -

• Ammonia: Steam reforming of NG

• Urea: Ammonia Stripping

• Raw material: NG, Power, Water

• Captive Power Plant: 3 x 17 MW

Figure 1.2: Production Performance

1.3 VARIOUS POLICIES

• Whistle-blower Policy: Objective is to provide employees, investors, suppliers, lenders,

service providers, etc. An avenue to raise alarms, in line with commitment of National
Fertilizers Limited (NFL) of ethical, moral and legal business conduct and its commit-
ment to open communications. To provide necessary safeguards for protection of Whistle
blowers from reprisals or victimization, for whistle-blowing in good faith.

• No adverse action shall be taken or recommended against a Whistle-blower in retalia-

tion to his disclosure in good faith of any Unethical and improper practices or alleged

3
 wrongful conduct. This policy protects such Whistle-blower from harassment and vic-
timization. However, this policy does not protect a Whistle-blower from an adverse ac-
tion which occurs independent of his disclosure of unethical and improper or alleged
wrongful conduct, poor performance, etc. Unrelated to a disclosure made pursuant to
this policy.

• Environmental: In line with the endeavour of the country to address various issues
of global warming, NFL is also leaving no stone unturned in order to reduce carbon
footprints in terms of energy reduction, recycling of waste & treated effluent and use of
renewable & efficient source of energy etc. In this regard, NFL has successfully executed
the revamps of its three Fuel Oil based plants for changeover of the feed stock from Fuel
Oil to Natural Gas which is highly energy efficient and environment friendly input. NFL
is implementing various energy saving schemes at Vijaipur Unit. By these Energy Saving
Schemes at Vijaipur Unit, NFL will be able to reduce CO2 emission. Similarly NFL
is also working towards bringing down energy consumption of its plant at Panipat and
Bathinda by revamping Urea Plants.

• Water Conservation: Facilities for roof top rainfall harvesting increasing height of best
bear of irrigation ponds. Rejuvenation and improvement of existing water bodies. Con-
struction of sedimentation tanks.
Construction of Stop Dams: It has improved water availability around the year for farm-
ers as well as for animals. Crop production has increased which has resulted in greater
returns to farmers. In the long run it will help in curbing migration from villages. Double
cropping and vegetable production has started.

• Social Forestry: Afforestation has been adopted in all the units to improve the environ-
ment surrounding the units. A total of about 20,000 tree saplings were planted in and
around Units leaving a cleaner and greener earth for future generation. The cumulative
plantation since commencement is about 8 lakhs for all the Units.

• – Personal Protective Equipment (PPE) Like Helmet, Shoes are essential.

– Always wear chemical goggles and adequate skin cover.
– Inspect equipment before each day’s work and correct any abnormal conditions.
– Water is the first aid treatment of choice when ammonia gets into eyes or on the
skin. In case of mishap, flush affected areas for 15 minutes and get medical help as
soon as possible.
– Make sure all valves, lines and connections are secure in order to reduce the chance
of either leaks or being doused during transfer.

4
 Chapter 2

Plant Processes

2.1 WASTE MANAGEMENT

Methods of Treatment of Sewage from Fertilizer Industry:The Treatment of the sewage

from fertilizer industry may consist of the following:

• Segregation of effluents.

• Treatment of effluents for specific pollutants

• Segregation of Effluents

Oils and Greases: Oils and greases normally discharged in fertilizer industry effluents are
mostly in non-emulsified form. Moreover, a majority of these insoluble oils are lighter than
water and therefore they will float on its surface. Thus insoluble oils lighter than water are
usually separated in settling tanks provided with an adjustable skimming weir.

2.2 The Ammonia Plant

Ammonia is produced from a mixture of hydrogen (H2) and nitrogen (N2), where the ratio of
H2 to N2 shall be approximately 3:1. Besides these two components, the synthesis gas will
contain Inert gases - such as argon (AR) and methane (CH4) to a limited degree. The basic
principle for production of ammonia in the Fertilizer Complex is illustrated below:

2.3 Short Description of the Process Units

The process steps necessary for production of ammonia from the above-mentioned raw mate-
rials are as follows:

5
 Figure 2.1: Flowchart

1. Hydrocarbon feed is completely desulphurized in the desulphurization section.

2. The desulphurized hydrocarbon is reformed with steam and air into Raw synthesis gas
(process gas) at a pressure of 30 - 37 kg/cm2g. The gas contains mainly hydrogen,
nitrogen, carbon monoxide (CO) and carbon dioxide (CO2)

3. In the gas purification section, CO is first convened into CO2 and H2 with steam (Shift
reaction). in order to increase the H2 yield. Then CO is removed in the CO2 removal
section. The residual CO and CO2 are converted into CH4 using H2 (methanation).
before the gas is sent to the ammonia synthesis loop.

4. The purified synthesis gas is compressed to about 220 kg/cm2 and sent to the ammonia
synthesis loop where it is converted into ammonia

2.4 Desulphurization Section

The natural gas feedstock that may contain up to 10 ppm (by volume) sulphur compounds must
be desulphurized, as the Adiabatic F1 reformer catalyst, the primary reformer catalyst, as well
as the low temperature CO conversion catalysts are very sensitive to up sulphur, which may
contain up to 70 ppm (by volume) sulphur compounds, must also pass through a desulphuriza-
tion of both natural desulphurization unit. The gas take place in two stages:
- Hydrogenation
- H2S Adsorption

6
The hydrogenation takes place in the Hydrogenator, R 3201, for natural gas and in R 3207 for
naphtha. Both reactors are operating at an inlet temperature of 380 C. After hydrogenation, the
two streams are mixed and the H2S absorption takes place in the two ZnO absorbers, R-3202
A/B, connected in series.

2.5 Hydrogenation

The natural gas feedstock Is passed to the preheater coil, E 3204, In the waste heat section,
where it is preheated to 380 OC before entering the HDS reactor, R 3201 (Hydrogenator).
The hydrogen (recycle H2) required for the hydrogenation is supplied as synthesis gas from
the synthesis gas compressor, K3431, and added to the natural gas Downstream the preheater
E3234. The synthesis gas also contains N2 but this will Just act as an Inert gas in the front end.
It is stripped with natural gas in F 4401 to remove possible dissolved air. Then It Is mixed
with recycled H2, to keep the boiling point at a reasonable value before it is evaporated and
superheated in E 3215 and H 3203, respectively.
The two HDS-Reactors, R 3201 and R3207, are equipped with one catalyst bed of 1850mm
height, containing 9.0 m3 Ni-Mo based catalyst (type TK-251) and Co-Mo catalyst (type 550),
respectively. The catalyst which are installed as 5 mm rings. are especially suitable for hydro-
carbons and or hydrogenation gas containing carbon oxide, due to low tendency of temporary
deactivation.

2.6 Absorption

The outlet steams from the two HDS-reactors are mixed and the hydrogenated hydrocarbon gas
is led to the two ZnO absorbers, R 3202 A and R 3202 B, connected in series.
Each vessel has one catalyst bed with a height of 3600 mm and containing 30 m3 of catalyst,
type HTZ-3. This zinc oxide catalyst is installed as 4 mm extrudates and the normal operating
temperature is between 350- 400°C.

2.7 Reforming

In the reforming section the desulphurization catalytic reforming of the hydrocarbon mixture
with steam and addition of air convert gas into raw ammonia synthesis gas.

The steam reforming process can be described by the following reactions:

7
 • CnH2n + 2H20 - Cn-1H2n + CO2 + 3H2 -heat

• CH4 + 2H20 - CO2 + 4H2 -heat

• CO2+H2 - CO + H2O -heat

Reaction (1) describes the mechanism of reforming the higher hydrocarbons, which are re-
formed in stages to lower and lower hydrocarbons, finally resulting in methane, which is re-
formed according to reaction (2) The reverse shift reaction (3) requires only little heat, whereas
the heat required for (1) and (2) will quite dominate the picture.

2.8 Primary Reformer

In the case of natural gas used as feedstock, the first step of the steam reforming process takes
place in the primary reformer, H 3201.the outlet gas feeds H 3201 from the adiabatic prere-
former, R 3206. In H 3201 the hydrocarbon and steam mixture, which is preheated to 485”C,
is passed down wards through vertical tubes containing catalyst the primary reformer is a fired
healer where the sensible heat and the heat of reaction are transferred by radiation from a num-
ber of wall burners to the catalyst tubes.
In order to ensure complete combustion of the fuel gas the burners are operated with an excess
air ratio of about 5%, which comes ponds to 0.9% of oxygen in the flue gas. The hydrocarbons
in the feed to the primary reformer are converted into hydrogen and carbon oxides. The outlet
gas leaving the primary reformer contains approximately 10-11 mole % of methane (on dry
basis). The exit temperature of the primary reformer is about 800 c, which is also the inlet tem-
perature to the second step of the reforming. The primary reformer has a total of 288 reformer
tubes installed in two radiant sections and loaded with 42.8 m of catalysts. The upper part of
the reformer tubes is loaded with preproduced catalyst, RKNR. The nominal size is 11x 7 mm.
The total volume of this catalyst is 8.6 m3, the remaining part of the reformer tubes is loaded
with the catalyst, R-67-7H. The nominal size is 16 x 11 mm.

2.9 Secondary Reformer

In the secondary reformer, R 3203, the process gas is mixed with air. The partial combustion
takes place in the top part of R 3203 and causes a considerable increase in temperature. From
the ”combustion chamber the gas passes down through a catalyst bed were the last part of the
reforming takes place with simultaneous cooling of the gas. The temperature of the process gas
leaving the secondary reformer is about 990 C and the methane concentration is approximately

8
0.30 mole % (on dry basis). The exit gas from the secondary reformer contains about 13 moles
% CO and 7.3 mole % CO2 and consequently there is a theoretical risk of carbon formation
according to the Bouchard reaction:

2CO - CO2 + O
When the gas is cooled at the actual operating conditions the carbon formation can only take
place at a temperature below 721 °C outlet primary reformer and below 776 °C outlet secondary
reformer, because of the equilibrium conditions. The lower limit for the reaction is 650 °C as
the reaction rate becomes too slow at lower temperatures. Consequently, it is important to pass
the temperature range from 776 °C to 650 ”C reasonably fast, and also contact between gas and
hot metallic surfaces is to be avoided

2.10 Ammonia Synthesis Section

The ammonia synthesis takes place in the ammonia synthesis converter, R 3501, according to
the following reaction scheme:
3H2 + N2 - 2NH2 +heat
The reaction is reversible and only a part of the hydrogen and nitrogen is converted into am-
monia by passing through the catalyst bed. The conversion or the equilibrium concentration of
ammonia is favoured by high pressure and low temperature. In R 3501 only about 30 % of the
nitrogen and the hydrogen are converted into ammonia.
To get maximum overall yield of the synthesis gas, the unconverted part will be recced to the
converter after separation of the liquid ammonia product.
After the synthesis gas has passed through R 3501, the effluent gas will be cooled down to
a temperature which the main part of ammonia is condensed. The circulation is carried out
by means of the recirculator, which is an integrated part of the synthesis gas compressor, K
3431. The punified synthesis gas contains a small number of impurities, mainly the inert Ar
and CH4, to avoid a high concentration or inert, continuous purge from the synthesis Hoop
would be required. As the reaction rate is very much enhanced by high temperature, the choice
of temperature is based on a compromise between the theoretical conversion and the approach
to equilibrium.
The ammonia synthesis loop has been designed for a maximum pressure of 245 kg/cm2g. The
normal operating pressure will be 220kg/cm2g depending on load and catalyst activity.” The
normal operating temperatures will be in the range of 360 to 525 °C for the 1st bed and 370
to 460 °C for the 2nd bed. The heat liberated by the reaction (about 750 kcal/kg produced
ammonia) is utilized for light pressure steam production (in the loop waste heat boiler, E 3501)

9
and preheat of high-pressure boiler feed water.
The water vapour concentration in the make-up gas is in the range of 200-300 ppm, depending
on the operating pressure in the loop. The water is removed by absorption in the condensed
ammonia. The carbon dioxide in the make-up gas will react with both gaseous and liquid am-
monia, forming ammonium carbonate:
2NH2 + CO2 - NH4-CO-NH2
The formed carbamate is dissolved in the condensed ammonia. The carbon monoxide is only
slightly soluble in ammonia and will pass with recirculating gas to the ammonia converter,
where it is hydrogenated io water and methane (methanation). As the water deactivates the am-
monia synthesis catalyst, the content of carbon monoxide in the make-up synthesis gas should
be kept as low as possible.

10
 Chapter 3

Plant Machines

3.1 Centrifugal Vertical Pump

3.1.1 Introduction

Vertical centrifugal pumps are also referred to as cantilever pumps. They utilize a unique shaft
and bearing support configuration that allows the volute to hang in the sump while the bearings
are outside the sump. This style of pump uses no stuffing box to seal the shaft but instead
utilizes a ”throttle bushing”

Figure 3.1: Centrifugal Vertical Pump

3.1.2 Working

Vertical turbine pumps work when water enters the pump at the bottom through a bell-shaped
part called the suction bell. From there it moves into the first stage impeller, which raises the
water’s velocity. ... At the surface is the pump discharge head, which allows the flow to change

11
direction, toward the discharge pipe.

3.2 LUBRICATION PUMPS

3.2.1 Introduction

Lubricating oil pumps are used to supply oil to lubrication points, e.g. for plain bearings. The
lubricating oil pump takes in an amount of oil from a reservoir, forces it through the lubrica-
tion points and then feeds it back to the reservoir. Gear pumps, which are able to generate high
static pressure in the lubricating oil system, are preferably used for this purpose. The manomet-
ric pressure has to be high enough to compensate for pressure drops in the tubing, components
(filters, valves, distributors) and friction points. In a fresh oil or economy lubrication system,
each lubrication point is supplied with a quantity of oil adequate for its needs. Special piston
pumps are usually required for this purpose.

Figure 3.2: Lubrication Pump

For the supply of oil to large plain bearings as in steam turbines or generators, single-stage
volute casing or multistage pumps are used. They are submersible pumps which rest directly
on the oil reservoir and have a throttling bush at the shaft passage, instead of a conventional
shaft seal. The oil leakage thus runs directly back into the oil reservoir.

12
3.3 PLUNGER PUMP

A plunger pump is a type of positive displacement pump where the high-pressure seal is sta-
tionary and a smooth cylindrical plunger slides through the seal. This is designed to move fluids
and generate high pressures. This makes them different from piston pumps and allows them to
be used at higher pressures.

Figure 3.3: Plunger Pump

Rotary piston and plunger pumps use a crank mechanism to create a reciprocating motion along
an axis, which then builds pressure in a cylinder or working barrel to force gas or fluid through
the pump. The volume of the fluid discharged is equal to the area of the plunger or piston,
multiplied by its stroke length.

13
 Chapter 4

VALVES & COUPLING

4.1 Types of Valves

4.1.1 Spring safety valve

Safety valve is a valve that opens when the pressure in a pressure vessel increases and goes on
increasing. The vessel is designed for a particular pressure and will burst if pressure increases
more. In order the valve to open at given pressure it must be kept in closed condition under
calculated force. It can be done by means of a deadweight or by means of a compressed helical
spring. The spring is compressed to such an extent that the force on the valve at given pressure
is able to overcome the opposite force exerted by the spring and the valve opens releasing the
excess pressure and closes again. Such valve is called spring loaded safety valve.

Figure 4.1: Spring safety valve

14
4.1.2 NRV

A non-return valve allows a medium to flow in only one direction and is fitted to ensure that the
medium flows through a pipe in the right direction, where pressure conditions may otherwise
cause reversed flow. The flow through the non-return valve causes a relatively large pressure
drop, which has to be taken into account when designing the system.

Figure 4.2: Non-return valve

4.1.3 Rupture disc

Rupture discs are safety devices with a defined breaking point, which respond to a specific pres-
sure and are used for pressure relief in the most diverse range of applications. They are used
to protect against overpressure or vacuum within a process, for the protection of man, envi-
ronment and machine. They are most commonly used pressure protection devices in industrial
plants. They protect vessels and pipelines from deformation and other damage.

4.1.4 Gate valve

Gate valves work by inserting a rectangular gate or wedge into the path of a flowing fluid. They
are operated by a threaded stem which connects the actuator (generally a hand wheel or motor)
to the stem of the gate. If the valve has a rising stem its position can be seen just by looking at
the position of the stem.

15
 Figure 4.3: Gate valve

4.1.5 Globe valve

A globe valve, different from ball valve, is a type of valve used for regulating flow in a pipeline,
consisting of a movable plug or disc element and a stationary ring seat in a generally spherical
body.
globe valve is primarily designed to stop, start and regulate flow. ... When the handle is turned,
manually or through an actuator, a disc is lowered or raised by means of the valve stem. When
the disc is fully lowered, the fluid flow is shut off.

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 Figure 4.4: Globe valve

4.2 COUPLING

4.2.1 Love joy coupling

Lovejoy are offered in the industry’s largest variety of stock bore/keyway combinations. These
couplings require no lubrication and provide highly reliable service for light, medium, and
heavy-duty electrical motor and internal combustion power transmission application.
A flexible coupling connects two shafts, end-to-end in the same line, for two main purposes.
The first is to transmit power (torque) from one shaft to the other, causing both to rotate in
unison, at the same RPM. The second is to compensate for minor amounts of misalignment and
random movement between the two shafts.

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 Figure 4.5: Love joy coupling

4.2.2 Flange coupling

Flange Coupling is a driving coupling between rotating shafts that consists of flanges one of
which is fixed at the end of each shaft, the two Flanges being bolted together with a ring of
bolts to complete the drive. A flange coupling meant to bring two tube ends together in a flush,
sealed manner.

Figure 4.6: Flange coupling

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 Chapter 5

JOBS DONE IN AMMONIA II PLANT

5.1 VERTICAL CENTRIFUGAL PUMP

PROBLEM : - High vibrations were reported by NDT.

RECTIFICATION : - To solve this problem we firstly started with dismantling the pump and
then lifting and checking of its strainer it was found to be full of mud and dirt so we clean it
then we checked the clearance between casing bearing and impeller bearing it was found to be
in the desired range. further we dismantled the bearing housing the bearing was found to be
rough so we replaced it with new bearing. Its shaft and coupling (bush type) were found ok
and also there was no runout in the shaft as we confirmed with dial gauge readings. We finally
resolved all the issues found and checked all the parts, started assembling it and then fitting it
in its location with the help of a crane.

5.2 OIL CENTRIFUGE PUMP

OCP works on centrifugal action. Its main function in plant is to separate oil from impurities
(mud, dirt, water etc).

PROBLEM : - High vibrations were reported by NDT.

RECTIFICATION : -Opened its top cover and found that the inside walls of pot and bowls
were full of mud. so, to clean it we dismantled its bowl and pot assembly and then cleaned it
using CTC (carbon tetrachloride) and again boxed it up. Now we checked it again and it started
taking proper load as required by us.

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5.3 POSITIVE DISPLACEMENT PUMP

PROBLEM :- Heavy ammoniacal water leakage.

RECTIFICATION : - we dismantled plunger and its gland follower by losing its lock nut. We
found its gland packing and Teflon bushings to be hard and already in a compressed state .So
there is no chance of it compressing around the plunger. so, to stop the leakage we needed to
replace nylon gland packing which was 8mm so we replaced it. We also cleaned the remaining
parts and then we assembled it and fitted it in its section and further on running the pump no
leakage was found.

5.4 ACID PUMP

PROBLEM :- Vibration and noise observed in motor RECTIFICATION : - It was found that
the alignment between shaft and pump was misaligned so with the help of sim plate and dial
gauge we aligned the shaft and pump axially and radially as per requirement. The readings
found during rectification are listed below.

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 Chapter 6

CONCLUSION

• The balanced fertilizers along with manures improved the soil aggradation process as
well as biological activity of soil and maintained soil quality and sustainability of pro-
ductivity.

• The multivariate statistical method (PCA) effectively selected a minimum dataset from
large existing data sets.

• The indexing approach applied in the present study can be used as a tool for adaptive
land management for monitoring the effects of management practices on soil functions
that best meet the goal.

• The present study can be helpful in emphasizing soil quality assessment as a tool that can
be used to evaluate the effects of land management practices on soil functions.

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 Certificate

This is to certify that the content of the report entitled ”A PROJECT REPORT ON MECHAN-
ICAL DEPARTMENT AMMONIA UNIT II” by Mr. Namit Beck is uniquely prepared as a
part of 6 weeks internship at Kota Super Thermal Power Station for consideration in partial
fulfillment of the requirement of Bachelor degree.

The original research work was carried out by him under by supervision in the academic year
2021-22. On the declaration made by him I recommend this internship report for evaluation.

Signature of the Supervisor .......................................................................................

Name of the Supervisor .......................................................................................

Designation of the Supervisor .......................................................................................

Date .......................................................................................

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