Study of instrumentation in fertilizer plant

1. Study of
Instrumentation
in
Fertilizer
Plant
1
Submitted By:
Chandan
M.E Scholar, EE
Department, NITTTR,
Chandigarh
Submitted to:
MS. Preeti Mam
Research Scholar

2. Study of
Instrumentation in
Fertilizer
Plant
2

3. Fertilizer plant
- What is a fertilizer?
3

4. Fertilizer plant(contd.)
- What is a fertilizer?
Fertilizers are chemical
compounds applied to
promote plant growth.
4

5. Types of Fertilizers
1. Straight Fertilizers
2. Complex fertilizers
3. Mixed fertilizers
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Fertilizer plant(contd.)

6. - Which Fertilizer is produced in
a fertilizer plant?
Urea
“Wohler Synthesis”
6
Fertilizer plant(contd.)

7. What is Instrumentation?
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8. Why do we needed Instrumentation in
Fertilizer Plants?
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9. Why do we needed Instrumentation in
Fertilizer Plants?
To measure and control the
critical parameters of various
processes taking place.
9

10. For example , the production of ammonia
requires mixing of hydrogen and nitrogen in
the ratio 3:1.
Here the ratio of the hydrogen and nitrogen in
controlled using a Ratio Controller.
The amount of Nitrogen and Hydrogen added is
the critical parameter. 10

11. General instrumentation schematic
11

12. pppp
Transmitter
Controller
Control
Valve
Input
Output
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PROCESS

13. Evolution of
instrumentation13

14. Evolution of instrumentation
Pneumatic
Electrical DCS
Field
Bus and
SCADA
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15. 15
Electrical Instrumentation
• Developed standards for
calibration
• 4-20mA
• Example: Pressure Gauge

16. 16
Electrical Instrumentation(contd)

17. 17
DCS

18. 18
SCADA

19. 19
Interconnection of PLC and SCADA
Example: SGP Plant
We have the flow of coolant and
heat as a critical parameter

20. 20
Interconnection of PLC and SCADA(contd)
A PLC may control the flow of cooling
water through part of an industrial
process, but the SCADA system may
allow operators to change the set points
for the flow, and enable alarm conditions,
such as loss of flow and high temperature,
to be displayed and recorded.

21. Use of Instrumentation in a Fertilizer plant
for pressure control
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22. Use of Instrumentation in a Fertilizer plant
for pressure control
Mixing of ammonia and carbon dioxide in a
drum for a chain reaction requires proper
maintenance of level and pressure in that
drum. This can be done using level and
pressure controllers.
22

23. Both ammonia and carbon dioxide are
mixed at a pressure of 220kgs, in a
drum where the pressure has to be
maintained at 218kgs for chain reaction
which forms urea at a pressure of 80 to
90kgs pressure.
23

24. Transmitter
ControllerControl
Valve
Ammonia
at 220kgs
Output
Carbon Dioxide
at 220kgs
Chain
Reaction
at 218-219
kgs 220kgs 80-90kgs
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25. Another important feature of
Instrumentation is
ESD(Emergency Shut Down)
25

26. Flow
Transmitter
Flow
Controller
Control
Valve
Input
Fluid
Output
ESD
Level to be
maintained
at 50%
Danger Level 90%
26

27. As the level in the tank touches the
danger mark of 90% , the ESD is
triggered and it trips the whole
system and cuts off the input flow
to the drum
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28. References:
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1. Mr. P.K Pathak , Control Engineer , National
Fertilizer Limited, Nangal
2. http://www.engineersgarage.com/articles/scada-
systems
3. http://www.wilcoxon.com/4-20mA-sensor-
transimitter.cfm?readmore=yes

29. Thank You
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