1. In Plant Training Report
In FACT
Submitted by: Guided by:
C V Bhargava,
EEE,
Gitam University
Visakhapatnam. Joy Ukkan
Manager
Training, FACT

2. Acknowledgement
I would like to take this opportunity to thank FACT for giving me such a
wonderful opportunity. I would like to express my sincere gratitude to all the
people who helped me along the way - Mr.T K.Unnikrishna Prasad, (Addl.
Chief Engineer(Electrical Maintenance), Mr.Shajan (Elect Maintenance),
Mr.Thampi Luther(Manager Maintenance), Mr.Anil Kumar (Chief
Engineer,E&I, Petrochemical Division), Mr.Binny (Dy Chief
Engineer(Electrical) Mr.Rajendran, Dy Chief Engineer(CPP), Mr PJ Mathew,
DyChief Engineer(CPP) and Mr.Joy Ukkan(Manager,Training centre) - for
their excellent guidance and support.
I would also like to thank all the other staff members of FACT who have
directly or indirectly, helped me in this journey.

3. Contents
a) Introduction about FACT……….. 1
b) 110 KV substation………………. 6
c) Lightning arrestor……………….. 6
d) Electrical Isolator……………….. 9
e) Circuit Breaker………………….. 10
f) Current Transformer…………….. 11
g) Transformer……………………... 12
h) Captive Power Plant…………….. 14
i) Brief Chemical Processes………... 18
j) Motors……………………………. 19
k) Conclusion……………………….. 21

4. Introduction About FACT
Fertilisers and Chemicals Travancore Ltd. (FACT), a fertiliser and chemical
manufacturing company in Kochi, Kerala, India was incorporated in 1943. In 1947,
FACT started production of Ammonium Sulphate with an installed capacity of 50,000
MT per annum at Udyogamandal near Cochin. It is one of the largest chemical
manufacturing facilities in Kerala. The company has 2 production units - Udyogamandal
Division (UD) and Cochin Division (CD) .The Caprolactam plant was commissioned in
1990. Main products of the company are Factamfos (NP 20:20), Ammonium Sulphate
and Caprolactam. It also manufactures, as intermediate products, Ammonia, Sulphuric
Acid and phosphoric acid. Gypsum, Nitric acid and Soda ash are the major byproducts.
The factory commenced production of ammonium sulphate in 1947 at the dawn of Indian
independence using wood as the raw material for production of ammonia. With the
passage of time, wood gasification became uneconomical and was replaced with naphtha
reforming process. Through a series of expansion programmes, FACT soon became the
producer of a wide range of fertilizers suited for all crops and all soil types in India. It
became a Kerala State public sector enterprise in 1960 and in 1962, it came under the
Government of India. Diversification into full-fledged engineering services in the
fertilizer field and allied areas followed in the form of establishment of FEDO (FACT
Engg and Design Organisation) and FEW (FACT Engg Works). The next major step
forward was the diversification into petrochemicals, an important milestone in the growth
of the company. FACT has also formed a Joint Venture Company with Rashtriya
Chemicals & Fertilizers Limited for manufacturing load bearing panels and other
building products using phosphogypsum.
FACT Udyogamandal Plant, the oldest division of FACT, which started production of
Ammonium Sulphate in 1947 using the firewood gasification process, has during the last
few decades undergone several stages of expansion and diversification, giving up old and
obsolete technology and installing new and sophisticated plants making use of naphtha as
raw material. Today, the Udyogamandal Plants have an installed capacity of 76,050
tonnes of N and 29700 tonnes of P2O5. Apart from fertilisers like Ammonium Sulphate
and Ammonium Phosphate Sulphate (FACTAMFOS 20:20:0:13) FACT Udyogamandal
Plants also manufactures chemicals as intermediate products like Sulphuric Acid,
Anhydrous Ammonia, Sulphur Dioxide, Oleum, etc. Ammonium Sulphate liquor
obtained as a by product from the Caprolactam Plant is crystallised as a useful fertiliser
product in a New Ammonium Sulphate Plant of 2,25,000 TPA capacity put up in October
1990, at a cost of Rs.35 crore.

5. As a replacement to the old high energy consuming old Ammonia plants at
Udyogamandal, a new 900 TPD capacity Ammonia Plant at a cost of Rs.642 crore was
put up in March 1998. FACT Udyogamandal plants received ISO 14001 certification in
March 2000 for conforming to the Environmental Management System standard.
FACT’s Products:
a) Straight Fertilisers :
Ammonium Sulphate is a nitrogenous fertilizer containing 21% nitrogen, entirely in
ammonical form. It has excellent physical properties- crystalline and free flowing. It
is ideal as a straight nitrogenous fertilizer and also as an ingredient in fertilizer
mixtures. It is the most widely preferred nitrogenous fertilizer for top dressing on all
crops. Another unique advantage is that it contains 24% sulphur, an important
secondary nutrient.
b) Complex Fertilizer :
Factamfos 20-20-0-13 is a chemical blend of 40 parts of ammonium phosphate and
60 parts of ammonium sulphate. It contains 20% nitrogen and 20% P2O5. The entire
N is in ammonical form and P is completely soluble in water. In addition, Factamfos
contains 13% sulphur, a secondary plant nutrient which is now attaining great
importance in the agriculture industry.
c) FACT mix :
FACT prepares on a large scale all the standard NPK mixtures under the brand name
“FACTMIX” for different crops for Kerala as stipulated by the Department of
Agriculture. In addition, FACT prepares special tailor made fertilizer mixture of any
required grade for plantation crops like coffee, tea etc.
d) Caprolactam :
Caplrolactam is the raw material for nylon-6 which in turn is used in the manufacture
of tyre chord. The product quality of FACT’s caprolactam is among the best available
in the world.
e) Gypsum :
A by product of phosphoric acid production, gypsum is an ingredient in the
manufacture of Portland cement, plaster of paris, Gypcrete etc and also is used as
inert filler in Pharmaceuticals, paper, paints etc.

6. f) Imported Fertilizer :
FACT imports Urea and Potash from the gulf and Russia for the consumption in all 4
southern states as per requirement.
g) Bio Fertilizer :
Three types of bio fertilizers namely Azospirillium, Phosphobacter and Rhizobium
are produced and marketed as “BIO FACT”.
h) FACT Organic :
FACT is also marketing organic manure produced from city compust, in brand name
FACT Organic.
i) Zincated FACTAMFOS :
This special product containing 0.3% Zinc in FACTAMFOS has been launched to
address the wide spread deficiency of zinc in most soils in South India.
j) Zincated Gypsum :
This soil amendment and ameliorant contains 2% zinc in addition to 16% Sulphur and
22% Calcium for rectifying alkaline soils and improving soil fertility and physical
properties.

7. 110 KV SUBSTATION
A substation is a part of an electrical transmission and
distribution system. Substations transform voltage from high to low, or the
reverse, or perform any of several other important functions. Between the
generating station and consumer, electric power may flow through several
substations at different voltage levels. Substations may be owned and
operated by an electrical utility, or may be owned by a large industrial or
commercial customer. Generally substations are unattended, relying on
SCADA for remote supervision and control.
A substation may include transformers to change voltage
levels between high transmission voltages and lower distribution voltages, or
at the interconnection of two different transmission voltages. The word
substation comes from the days before the distribution system became a
grid. As central generation stations became larger, smaller generating plants
were converted to distribution stations, receiving their energy supply from a
larger plant instead of using their own generators. The first substations were
connected to only one power station, where the generators were housed, and
were subsidiaries of that power station.
The layout or the outline of the 110 KV substation here is as shown.
A brief description of the components follows.
LIGHTNING ARRESTOR
A lightning arrester (in Europe: surge arrester) is a device used on electrical
power systems and telecommunications systems to protect the insulation and
conductors of the system from the damaging effects of lightning. The typical
lightning arrester has a high-voltage terminal and a ground terminal. When a
lightning surge (or switching surge, which is very similar) travels along the
power line to the arrester, the current from the surge is diverted through the
arrestor, in most cases to earth.

8. Operation:
A potential target for a lightning strike, such as a television antenna, is
attached to the terminal labeled A in the photograph. Terminal E is attached
to a long rod buried in the ground. Ordinarily no current will flow between
the antenna and the ground because there is extremely high resistance
between B and C, and also between C and D. The voltage of a lightning
strike, however, is many times higher than that needed to move electrons
through the two air gaps. The result is that electrons go through the lightning
arrester rather than traveling on to the television set and destroying it.
A lightning arrester may be a spark gap or may have a block of a
semiconducting material such as silicon carbide or zinc oxide. Some spark
gaps are open to the air, but most modern varieties are filled with a precision
gas mixture, and have a small amount of radioactive material to encourage
the gas to ionize when the voltage across the gap reaches a specified level.
Other designs of lightning arresters use a glow-discharge tube (essentially
like a neon glow lamp) connected between the protected conductor and
ground, or voltage-activated solid-state switches called varistors or MOVs.
Lightning arresters built for power substation use are impressive devices,
consisting of a porcelain tube several feet long and several inches in
diameter, typically filled with disks of zinc oxide. A safety port on the side
of the device vents the occasional internal explosion without shattering the
porcelain cylinder.

9. Lightning arresters are rated by the peak current they can withstand, the
amount of energy they can absorb, and the breakover voltage that they
require to begin conduction. They are applied as part of a lightning
protection system, in combination with air terminals and bonding.
ELECTRICAL ISOLATOR
Isolator is a mechanical switch which isolates a part of circuit from
system as when required. Electrical isolators separate a part of the system
from rest for safe maintenance works. So definition of isolator can be
rewritten as Isolator is a manually operated mechanical switch which
separates a part of the electrical power system normally at off load
condition.
Types:
There are different types of isolators available depending upon system
requirement such as:
a) Double Break Isolator
b) Single Break Isolator
c) Pantograph type Isolator
Depending upon the position in power system, the isolators can be
categorized as:
a) Bus side isolator – the isolator is directly connected with main bus
b) Line side isolator – the isolator is situated at line side of any feeder
c) Transfer bus side isolator – the isolator is directly connected with
transfer bus

10. Operation:
As no arc quenching technique is provided in isolator it must be operated
when there is no chance current flowing through the circuit. No live circuit
should be closed or open by isolator operation. A complete live closed
circuit must not be opened by isolator operation and also a live circuit must
not be closed and completed by isolator operation to avoid huge arcing in
between isolator contacts. That is why isolators must be open after circuit
breaker is open and these must be closed before circuit breaker is closed.
Isolator can be operated by hand locally as well as by motorized mechanism
from remote position. Motorized operation arrangement costs more
compared to hand operation; hence decision must be taken before choosing
an isolator for system whether hand operated or motor operated
economically optimum for the system. For voltages up to 145KV system
hand operated isolators are used whereas for higher voltage systems like 245
KV or 420 KV and above motorized isolators are used.
CIRCUIT BREAKERS
A circuit breaker is an automatically operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit.
Its basic function is to detect a fault condition and interrupt current flow.
Unlike a fuse, which operates once and then must be replaced, a circuit
breaker can be reset (either manually or automatically) to resume normal
operation. Circuit breakers are made in varying sizes, from small devices
that protect an individual household appliance up to large switchgear
designed to protect high voltage circuits feeding an entire city.
The type of CB used here is SF6 CB.
A sulfur hexafluoride circuit breaker uses contacts surrounded by sulfur
hexafluoride gas to quench the arc. They are most often used for
transmission-level voltages and may be incorporated into compact gas-
insulated switchgear. In cold climates, supplemental heating or de-rating of
the circuit breakers may be required due to liquefaction of the SF6 gas.
Operation:

11. All circuit breakers have common features in their operation, although
details vary substantially depending on the voltage class, current rating and
type of the circuit breaker. The circuit breaker must detect a fault condition;
in low-voltage circuit breakers this is usually done within the breaker
enclosure. Circuit breakers for large currents or high voltages are usually
arranged with pilot devices to sense a fault current and to operate the trip
opening mechanism. The trip solenoid that releases the latch is usually
energized by a separate battery, although some high-voltage circuit breakers
are self-contained with current transformers, protection relays, and an
internal control power source.
Once a fault is detected, contacts within the circuit breaker must open to
interrupt the circuit; some mechanically-stored energy (using something
such as springs or compressed air) contained within the breaker is used to
separate the contacts, although some of the energy required may be obtained
from the fault current itself. Small circuit breakers may be manually
operated; larger units have solenoids to trip the mechanism, and electric
motors to restore energy to the springs.
CURRENT TRANSFORMER
A current transformer (CT) is used for measurement of alternating electric
currents. Current transformers, together with voltage transformers (VT)
(potential transformers (PT)), are known as instrument transformers. When
current in a circuit is too high to directly apply to measuring instruments, a
current transformer produces a reduced current accurately proportional to the
current in the circuit, which can be conveniently connected to measuring and
recording instruments. A current transformer also isolates the measuring
instruments from what may be very high voltage in the monitored circuit.
Current transformers are commonly used in metering and protective relays
in the electrical power industry.
Operation:
Like any other transformer, a current transformer has a primary winding, a
magnetic core, and a secondary winding. The alternating current flowing in

12. the primary produces an alternating magnetic field in the core, which then
induces an alternating current in the secondary winding circuit. An essential
objective of current transformer design is to ensure that the primary and
secondary circuits are efficiently coupled, so that the secondary current bears
an accurate relationship to the primary current. A current transformer works
on the same principle as that of a simple transformer however it steps down
the high current into a low level so that it can be measured using an ammeter
of a suitable range. In some current transformers extra cores are provided.
This is done in order to prevent the faulty currents i.e. the over currents,
earth faults, differential protections. The extra cores of a C.T. gets saturated
as soon as the faulty currents starts flowing and thereby does not harm the
main core of the transformer and the ammeter connected. The C.T. is always
connected in the line carrying current. It first steps down the current to a
measurable form and further gives this current to the ammeter.
TRANSFORMERS
A transformer is a static electrical device that transfers energy by inductive
coupling between its winding circuits. A varying current in the primary
winding creates a varying magnetic flux in the transformer's core and thus a
varying magnetic flux through the secondary winding. This varying
magnetic flux induces a varying electromotive force (emf) or voltage in the
secondary winding. Transformers range in size from thumbnail-sized used in
microphones to units weighing hundreds of tons interconnecting the power
grid. A wide range of transformer designs are used in electronic and electric
power applications. Transformers are essential for the transmission,
distribution, and utilization of electrical energy.
Transformers are used to increase voltage before transmitting electrical
energy over long distances through wires. Wires have resistance which loses
energy through joule heating at a rate corresponding to square of the current.
By transforming power to a higher voltage transformers enable economical
transmission of power and distribution. Consequently, transformers have
shaped the electricity supply industry, permitting generation to be located
remotely from points of demand. All but a tiny fraction of the world's
electrical power has passed through a series of transformers by the time it
reaches the consumer. Transformers are also used extensively in electronic
products to step-down the supply voltage to a level suitable for the low

13. voltage circuits they contain. The transformer also electrically isolates the
end user from contact with the supply voltage. Signal and audio transformers
are used to couple stages of amplifiers and to match devices such as
microphones and record players to the input of amplifiers. Audio
transformers allowed telephone circuits to carry on a two-way conversation
over a single pair of wires. A balun transformer converts a signal that is
referenced to ground to a signal that has balanced voltages to ground, such
as between external cables and internal circuits.
Substation Operation:
The 110n KV supply from KSEB (Kerala State Electricity Board) is stepped
down to 11 KV in this substation. A further step down from 11 KV to 3.3
KV and to 433 V also occurs for the use of various loads.
There are two incoming feeders from the KSEB, one for main line and one
for standby. The bus is thus separated into two parts using a bus isolator or a
bus coupler. There are 4 main transformers, 2 for each feeder. For feeder
one, the transformers used are old and are of 15 MVA capacities each. For
the second feeder, the transformers are new and have on load tap changing
facility, and are of 20 MVA capacities. The 15 MVA transformers are oil
cooled whereas 20 MVA ones have forced air cooling facility.
For the distribution purpose, there are 3 switchboard panels as shown,
namely Jyoti panel, Alind panel and NGEF panel. Jyoti and Alind panels are
11 KV boards whereas NGEF panel is of 3.3 KV rating. Transformers 1 and
2 are connected to Jyoti as shown, and 3 and 4 to Alind.
There are 2 more transformers rated 11 KV/ 3.3 KV each with a capacity of
5 MVA. Two outlets, one each from jyoti and alind are given to these
transformers and the other ends are given to NGEF panel. From here, the
supply is distributed to various 3.3 KV motors. For the 11 KV loads, the
outgoings are from Alind panel.
Mainly 3.3 KV motors are used. Only one 11 KV motor is used, in ammonia
plant.

14. CAPTIVE POWER PLANT
Captive Power Plant in FACT is basically a Thermal Power Plant. As it is
working for the smooth functioning of Ammonia plant, it is known as a
Captive Power Plant. A thermal power station is a power plant in which the
prime mover is steam driven. Water is heated, turns into steam and spins a
steam turbine which drives an electrical generator. After it passes through
the turbine, the steam is condensed in a condenser and recycled to where it
was heated; this is known as a Rankine cycle. The greatest variation in the
design of thermal power stations is due to the different fossil fuel resources
generally used to heat the water. Some prefer to use the term energy center
because such facilities convert forms of heat energy into electrical energy.
Certain thermal power plants also are designed to produce heat energy for
industrial purposes of district heating, or desalination of water, in addition to
generating electrical power. Globally, fossil fueled thermal power plants
produce a large part of manmade CO2 emissions to the atmosphere, and
efforts to reduce these are many, varied and widespread. In FACT the main
fuel used is Furnace oil. As it is not that economical now they are modifying
the plant so that it can use Liquefied Natural Gas (LNG) as its fuel.
There are two captive plants. One producing a power of 16MW and other
producing a power of 6MW.Their voltage rating is 11kV and current rating
comes to around 1050Amps.
The 6 MW power plant is for ammonia plant and the 16 MW one is for the
petrochemical division (PD). There are two boilers for ammonia CPP and 3
for PD CPP.
In the Ammonia CPP, the turbine has a rated speed of 9000 rpm and the
generator is a 6 MW one with a synchronous speed of 1500 rpm.
Ammonia CPP :
WORKING:
Layout:

15. The CPP is basically used to provide supply to the critical equipment in the
plant. If KSEB supply was to be given to such equipment, in case of any
fluctuations, a tripping of the equipment could occur. This may trip the
whole plant. Restarting the plant would incur a lot of loss. Thus, to avoid
such fluctuations, a CPP actually acts as a UPS to the respected plant. The
whole working of the CPP is as discussed below:
The CPP used here is a steam power plant. This means that the turbine is
actually turned with the help of steam. This steam is produced from water.
The water is taken into DM tanks and de mineralized. This is done because
the water may have various minerals in it which may go on and contaminate
the boiler. Thus, the minerals and salts are removed from the water in the de
mineraliser.
The steam is now taken to the de aerator where the oxygen is removed from
it. This is because the oxygen may corrode the inner walls of the boiler.
Thus, it is necessary to remove the oxygen from the steam before letting it
into the boiler.
From the de aerator, the steam is sent to the economizer through 4
centrifugal pumps. The centrifugal pumps increase the pressure of the steam
as it goes through them. This is done so as to create a pressure difference
between the steam and the inside of the boiler, thus enabling the steam to
pass through. On its way to the boiler, the steam is heated in the economizer
and the pre heater. The economizer uses the heat from the flue gases and
heats the steam, thus utilizing the waste heat.
2 of the pumps are motor driven while the other two are steam driven.
There are 2 boilers in the Ammonia CPP and 3 in PD CPP. Inside the boiler,
the steam is pressurized to 110 atm, and 5250
C. From the boiler, the steam is
sent to the turbine. But the steam isn’t let out all at once. The steam may
come at high pressure or may have moisture, either of which may result in
pressure building in the pipe and may result in the bursting of the pipe. Thus,
an isolator valve is used to let the steam out in steps and this maintains the
flow of steam into the turbine.
There are two other important valves that the steam has to pass through
before entering the turbine. The High Pressure Valve closes if the pressure in

16. the turbine goes too high and stops the steam from proceeding. The
Emergency Stop Valve closes and stops the steam if there is any difference
in the speed of the turbine or in the generator. The current in the generator is
actually converted to hydraulic pressure and this valve operates based on this
pressure.
The turbine used is both impulse as well as reaction turbine. Its volume is
gradually increased so as to decrease the pressure. Thus, in the first turbine,
there is one impulse blade and 11 reaction blades whereas in the second part,
there is 1 impulse blade and 9 reaction blades.
It is important to note here that the pressure of the steam is brought down
from 110 atm to 41 atm and the difference in the enthalpies between 110 atm
steam and 41 atm steam is used for producing electricity. This is becaue 41
atm steam is needed for various purposes in the CPP as well as in the
Ammonia plant.
The steam from the turbine is directed to the condenser where it is cooled
and collected in the hot well just below it. The pressure in the hot well is
maintained constant with the help of two centrifugal pumps, of which,
usually only one operates. The other pump operates only in case the pressure
deviates from the normal values.
Vaccum is created in the condenser so that it can absorb more steam from
the turbine and thus increase its efficiency. This vaccum is created in the
condenser using an ejector which sucks out the air/water from the condenser.
The condensed steam from the condenser and the ejector is sent to the DM
tank to be used again.
The turbine rotates at a synchronous speed of 9000 rpm as stated above. This
turbine is connected to a gear box of ratio 6:1 and reduces this speed to 1500
rpm and is connected to the generator shaft.
The generator is a synchronous generator. The field excitation is given to the
rotor which rotates and produces flux which induces an emf in the stator.
The power supply of 11 KV, 6 MW is taken from the stator.
To excite the rotor, we need a pilot exciter. The pilot exciter is nothing but a
permanent magnet generator ( 6 pole, 75 Hz, 220V ac). The supply from the
pilot exciter is given to an AVR (Automatic Voltage Regulator). The AVR
has a thyristor bridge rectifier which converts this 220 V ac to 120 V dc and
gives it to the ac exciter. The AVR checks for the voltage, pf, and current

17. and correspondingly increases or decreases the excitation, thus changing the
supply with respect to the load.
The ac exciter is another generator whose rotor is connected to the generator
rotor. The supply from the AVR is given to this rotor. The supply is given to
the armature and through induction, this supply is fed to the rotor of the
main generator. Thus, the rotor being excited and carrying current, induces
an emf in the stator and through the stator, we collect the supply using
tappings.
Protection System:
Oil is used for two main purposes here.
The first is the basic lubrication purpose. The oil is supplied to the bearing
and the rotating parts of the generator.
There are 3 main pumps here that are important to note, namely: The Main
Oil Pump (MOP), Auxiliary Oil Pump (AOP) and the Emergency Oil pump
(EOP).
The Main Oil pump is the only one among the above 3 that operates usually.
The MOP pumps the oil to the generator bearing etc and maintains the
pressure for the control of the steam entry to the turbine.
As we have seen earlier, the control of the pressure is actually through
hydraulic means in which, the control oil is fed to the servomotor which
converts it to electrical impulses which are again converted to hydraulic
pressure.
All these pressures are thus maintained based on the oil levels. If there is a
decrease in the pressure of oil, the AOP supplies the excess oil needed along
with the MOP. If in case, the AOP also fails, the turbine would come to a
stop. If this happens, the generator bearing would come to a sudden stop.
But this shouldn’t happen as it would result in the bearings getting burnt.
Thus, to prevent this, the EOP supplies oil to the bearings and thus they keep
rotating and do not come to an abrupt stop.
If in case the KSEB supply fails, all the equipment are run on the supply
from the t-g set. If the t-g set also fails, the power for the lights as well as for

18. the EOP is given from the Diesel Generator (DG) set. This is used only in
case of emergencies.
In case the DG also fails, there is an overhead tank that stores oil initially.
This tank provides oil to the generator bearings so that they do not come to
an abrupt stop.
Coupling of supplies:
Before the different supplies are coupled, we need to make sure that the
frequency, voltage and the phase sequence of both the supplies are the same.
If there is any change in any of the parameters, there could be burn out of the
grid.
PD CPP:
The main difference between the generators of the Ammonia CPP and the
PD CPP is that the PD CPP has a self exciting generator. It completely
avoids the pilot exciter.
Here, the rotor is excited through slip rings. Initially, the KSEB supply is
used to excite the generator. But once it starts producing power, some of its
own power is used to excite the rotor. This may add complexity to the circuit
by using a series compounding transformer and a neutral point, but it avoids
using the pilot exciter.
Also, the use of slip rings is not recommended since the brushes get burnt
after some uses. Thus, excitation through slip rings is disadvantageous.

19. A Brief description about the chemical process in the
manufacture of Ammonia:
A typical modern ammonia-producing plant first converts natural gas (i.e.,
methane) or LPG (liquefied petroleum gases such as propane and butane) or
petroleum naphtha into gaseous hydrogen. The method for producing
hydrogen from hydrocarbons is referred to as "Steam Reforming". The
hydrogen is then combined with nitrogen to produce ammonia via the
Haber-Bosch process.
Starting with a naphtha as feedstock (which will shortly be replaced with
liquefied natural gas), the processes used in producing the hydrogen are:
The first step in the process is to remove sulfur compounds from the
feedstock because sulfur deactivates the catalysts used in subsequent steps.
Sulfur removal requires catalytic hydrogenation to convert sulfur
compounds in the feedstocks to gaseous hydrogen sulfide:
H2 + RSH → RH + H2S (gas)
The gaseous hydrogen sulfide is then absorbed and removed by passing it
through beds of zinc oxide where it is converted to solid zinc sulfide:
H2S + ZnO → ZnS + H2O
Catalytic steam reforming of the sulfur-free feedstock is then used to form
hydrogen plus carbon monoxide:
CH4 + H2O → CO + 3H2
The next step then uses catalytic shift conversion to convert the carbon
monoxide to carbon dioxide and more hydrogen:
CO + H2O → CO2 + H2
The carbon dioxide is then removed either by absorption in aqueous
ethanolamine solutions or by adsorption in pressure swing adsorbers (PSA)
using proprietary solid adsorption media.

20. 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 + 2 H2O
To produce 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 (also referred to as the Haber-Bosch process):
3H2+ N2→ 2NH3
The steam reforming, shift conversion, carbon dioxide removal and
methanation steps each operate at absolute pressures of about 25 to 35 bar,
and the ammonia synthesis loop operates at absolute pressures ranging from
60 to 180 bar depending upon which proprietary design is used.
A Brief description about the chemical process in the
manufacture of Caprolactum:
Caprolactam (CPL) is an organic compound with the formula
(CH2)5C(O)NH. This colourless solid is a lactam or a cyclic amide of
caproic acid. Caprolactam is the precursor to Nylon 6, a widely used
synthetic polymer.
Caprolactam is synthesised from cyclohexanone
(1) which is first converted to its oxime
(2) Treatment of this oxime with acid induces the Beckmann rearrangement
to give caprolactam.

21. The immediate product of the acid-induced rearrangement is the bisulfate
salt of caprolactam. This salt is neutralized with ammonia to release the free
lactam and cogenerate ammonium sulfate. In optimizing the industrial
practices, much attention is directed toward minimizing the production of
ammonium salts.
The other major industrial route involves formation of the oxime from
cyclohexane using nitrosyl chloride. The advantage of this method is that
cyclohexane is less expensive than cyclohexanone. In earlier times,
caprolactam was prepared by treatment of caprolactone with ammonia
MOTORS
There are two kinds of motors:
a) Synchronous motors
b) Induction motors
Only the Induction motors are used here. The generators used in CPP are
synchronous generators.
An induction motor is an asynchronous AC motor where power is
transferred to the rotor by electromagnetic induction, much like transformer
action. An induction motor resembles a rotating transformer, because the
stator (stationary part) is essentially the primary side of the transformer and
the rotor (rotating part) is the secondary side. Polyphase induction motors
are widely used in industry.
There are two kinds of Induction Motors :
SQUIRREL CAGE INDUCTION MOTORS:
SCIMs have a heavy winding made up of solid bars, usually aluminum or
copper, joined by rings at the ends of the rotor. When one considers only the
bars and rings as a whole, they are much like an animal's rotating exercise
cage, hence the name.

22. Currents induced into this winding provide the rotor magnetic field. The
shape of the rotor bars determines the speed-torque characteristics. At low
speeds, the current induced in the squirrel cage is nearly at line frequency
and tends to be in the outer parts of the rotor cage. As the motor accelerates,
the slip frequency becomes lower, and more current is in the interior of the
winding. By shaping the bars to change the resistance of the winding
portions in the interior and outer parts of the cage, effectively a variable
resistance is inserted in the rotor circuit. However, the majority of such
motors have uniform bars.
Slip Ring Induction Motors:
Slipring Induction motors have high starting torques. Their rotor is in the
shape of a slip ring connected to external resistance, varying which, the
speed can be controlled, hence the name. Slip ring induction motors are
costly and hence, nearly all the motors used in FACT are squirrel cage
induction motor.
Usually, for motors above 150 KW, we use star delta starters and for motors
below 150 KW, we use DOL (Direct Online starter). This is because DOL
starters are easy and less expensive to use. But the major disadvantage that
prevents it from being used for high power motors is that when it is started,
there is a dip in the line voltage. This happens because the starting current
drawn by the motor is high and hence, a large amount of voltage is needed.
Since this is supplied by the main supply, which is again connected to other
loads, the fluctuations caused may damage the other loads. Thus, for high
power motors, above 150 KW, we use star delta starters. For motors above
625 KV, we use auto transformer starter.

23. FEDO (FACT Engineering And Design
Organisation)
FEDO, a division of FACT, designs and selects the equipment for
purchasing depending upon the needs of the plants.
The Electrical wing of FEDO is given the list of motors or loads needed by
the mechanics. Depending upon this load, they select the equipment such as
the transformers, circuit breakers, motors, cables etc.
To design any electrical system, it is foremost important to know the load.
Once the load is provided, we get an idea on the capacities required for the
various equipment mentioned above. We also need to calculate the fault
level and make sure that the system is safe and has minimum losses possible.
Fault level:
The fault level is of great significance. The fault level is nothing but the
product of the system voltage and the fault current. The fault current is
calculated for various different faults to get the fault level.
The fault level is required to get an idea of the cables to be laid. When we
lay the cables, we make sure that they are able to sustain the current passing
through them. The current that normally passes is the Normal current. This
current rating is important for obvious reasons. But along with this, we need
to know that fault current. In case a short circuit occurs somewhere, a fault
current of a greater magnitude passes through the line. The line has to be
able to carry this current without breaking till the relay trips the trip circuit.
Thus, while laying the cables, we need to calculate the fault level.
The fault current is limited by the line impedance as well as the transformer
impedance. The impedance of the transformers used here is 12%.
One more important use for the fault level is the reduction in losses. Any
cable or line will have certain impedance. This causes a voltage drop in the
line. The higher this impedance, the higher the voltage drop. But this is not
good as it may cause fluctuations. Thus, we need to limit this impedance. To
do this, we need to reduce the length of the line or increase the cross section.

24. Since it is economical to reduce the length than increasing the cross section,
we place substations wherever possible. This helps to avoid these
fluctuations as well as is economical.
Design of motors:
Along with the transformers and cables, the motors also have to be designed.
The push buttons for the motors are to be placed in the switchboards and the
connections must be given to the motors from there. Since the actual
switching on and off of the motors takes place only at the location, an
ammeter has to be provided there for noting the load current.
The cables also have to be laid from the push buttons to the motors.
Interlocking systems have to be used sometimes. These are used in
conditions when the operation of one motor has to be dependent on another.
If one motor has to be switched on or off based on another motor,
interlocking system is used. This could be electrical or mechanical system.
Electrical systems consist of Boolean algebra and complex circuits. Here,
simpler mechanical systems are used.
Relays and Circuit Breakers:
Various relays have to be used for the protection of the generators and
motors. These relays are provided in the switchboards and have to be
provided with dc supply. The various relays are provided with code names
indicating their functions. Under voltage relay, over current relay, definite
time relay, negative sequence relay, under frequency relay are some
examples of the relays used here.
Various circuit breakers also have to be provided. The ammonia CPP uses
SF6 CBs whereas the 110 KV substation uses the new and more compact
Vaccum CBs. The old panels use the huge and large air CBs while in come
cases, like in PD CPP, Minimum Oil CBs are used.

25. CONCLUSION
The whole of generation, transmission and distribution of Electric Power for
the operation of various motors in plants was thoroughly studied. The
synchronous generators are coupled with the KSEB supply, matching the
frequency, phase sequence and the voltage of both the lines and then
distributed to the various parts.
The critical equipments in the plant are driven by the power from CPP
whereas all the other equipments are driven by the power from KSEB. The
billing aspects of KSEB have also been studied and it has been learnt that
FACT comes under the bulk consumer part.
An in depth study has been made about the various aspects involved in
distribution from the substation. Different kinds of CBs are used depending
upon when the section of the plant was established or the needs of the place.
The theory learnt at the classroom level has been well complemented in the
training. Under the guidance of the respected sirs, it has been a rich learning
experience as a student and a thoroughly enjoyable one.