IFFCO is a leading fertilizer producer in India with 5 major production units, including the Aonla unit. The Aonla unit was built rapidly in 36 months and began commercial urea production in 1988. It has received several national awards for its project implementation, safety, and energy conservation efforts. The document then describes various measurement devices like thermocouples, thermistors, and pressure sensors as well as level sensors used at the plant including ultrasonic, capacitance, and flow sensors.

2. CONTENTS
1. INTRODUCTION
2. ABOUT IFFCO
3. AONLA UNIT
4. HIGH LIGHT OF IFFCO AONLA UNIT
5. AWARDS
6. GENERAL CHARACTERISTICS OF DEVICES
7. MEASURING DEVICES-
6.1 TEMPERATURE MEASURING DEVICE
6.2 PRESSURE MEASURING DEVICE
6.3 LEVEL MEASURING DEVICE
7. SENSORS-
7.1 ULTRASONIC LEVEL SENSOR
7.2 FLOW LEVEL SENSOR
7.3 FIRE SENSOR

3. ABOUT IFFCO
INDIAN FARMERS FERTILIZER COOPERATIVE LTD. established
on 3rd
November, 1967 as a multi unit cooperative with board objective
of fertilizer production. India is the third largest fertilizer producer in
the world.
There are 60 large size fertilizer plants in the country, manufacturing a
wide range of nitrogenous, phosphoric and complex fertilizers.
Indian Farmers Fertilizer Cooperative Limited (IFFCO) accounts for
64% of the installed capacity of Nitrogen and the total of the
Phosphate capacity in the cooperative sector.

4. IFFCO presently owns giant units-
1. KALOL Gandhi Nagar, Gujarat.
2. KANDLA Gujarat.
3. PHULPUR Allahabad.
4. AONLA Bareilly.
5. PARADEEP Orissa.
IFFCO today is a leading player in India’s fertilizer industry
and it is making substantial contribution to the efforts of the
India Govt. to increase food grain production in the country.

5. AONLA UNIT
IFFCO, Aonla was one of the plant established by Govt. of India its annual
capacity is 14.9 lacs ton of urea.
The IFFCO, AONLA was built in a record time of 36 months
and started its commercial urea. Production on 16th
July 1988. Aonla II
started commercial production on 25th
December, 1996.
Fig: - ANOLA Unit

6. HIGHLIGHTS OF IFFCO AONLA UNIT-
Aonla-I Ammonia Plant May 15, 1988
Urea Plant May 18, 1988
Aonla-II Ammonia Plant Nov 16, 1996
Urea Plant Nov 16, 1996
COMMERCIAL PRODUCTION
Aonla-I Urea Plant July 16, 1988
Aonla-II Urea Plant Dec 25, 1996
Fig:- ANOLA Unit

7. MAIN FEATURES
Plant Capacity Consultant
Ammonia 2 X 1350 MT/day Haldor T., Denmark
Urea 2 X 1100 MT/day Snam Progetti, Italy
MAJOR INPUT
Natural Gas 3.3Million Cubic meter/day
Water 55,000cubic meter/day
IMPORTANT FIGURES:
Plant and Townships area 1273 Acres
Project actual cost 660 CroresRs. (Aonla I)
955 CroresRs. (Aonla II)
Zero Date 8th
January 1985 (Aonla I)
1st
January 1994 (Aonla II)

8. AWARDS
1). IFFCO Aonla-I has bagged two prestigious national awards –
one for best project implementation, (second award) by Ministry
of Programme implementation.
2). IFFCO Aonla unit has won the FAI(Fertiliser Association of
India) award for excellence in safety for the year 2001-2002.
3). National Energy conservation Award-2003 (Certificate of
Merit) .
4). NSCI(National Sefety Council of India) Safety Award-2002
(Prashansa Patra)

9. The instrument that is used for measurements shall have static and dynamic
characteristics as explained below.
 Accuracy
Accuracy is the difference between the reading of the Instrument and the true values
of that which is measured.
 Sensitivity
Sensitivity of an Instrument is the ability to respond to a small change in the value
being measured. It is the smallest change that will cause effective motion of the
measuring element.
 Performance
Performance is the ability of an Instrument to read without change in accuracy for
day’s weeks, and months, is important. Performance means that the instrument must
be built of the material.

10. A thermocouple is a device consisting of two different
conductors (usually metal alloys) that produce a voltage
proportional to a temperature difference between either end of the
pair of conductors. Thermocouples are a widely used type of
temperature sensor for measurement and control ,it can be also
used to convert a heat gradient into electricity. They are
inexpensive, interchangeable, are supplied with standard
connectors. The main limitation with thermocouples is accuracy
and system errors of less than one degree Celsius (C) can be
difficult to achieve.
Thermocouples are usually standardized against a reference
temperature of 0 degrees Celsius; practical instruments use
electronic methods of cold-junction compensation to adjust for
varying temperature at the instrument terminals. Electronic
instruments can also compensate for the varying characteristics of
the thermocouple, and so improve the precision and accuracy of
measurements.

12. A thermistor is a type of resistor whose resistance varies
significantly with temperature, more so than in standard resistors.
Figure:-Thermistor
Thermistors are widely used as current limiters and temperature
sensors.
Thermistors differ from resistance temperature detectors (RTD) in
that the material used in a thermistor is generally a ceramic or
polymer, while RTDs use pure metals. The temperature response
is also different; RTDs are useful over larger temperature ranges.

13. The relationship between resistance and temperature is linear,
then:
Where-
ΔR = change in resistance
ΔT = change in temperature
k = first-order temperature coefficient of resistance

14. DEFINITION OF PRESSURE:-
The force acting on unit area is
defined as pressure.
When a fluid is contact with a boundary, it produce a force at
right angle to that boundary. The force produced per unit area is
called the pressure of the fluid.
Types of Pressure –
1. Gauge pressure
2. Differential pressure
3. Absolute pressure

15. CAPACITANCE TYPE-
Figure:- Capacitance level sensor.
Capacitance level sensors excel in sensing the presence of a wide variety
of solids, aqueous and organic liquids. The technique is frequently
referred to the radio frequency signals applied to the capacitance circuit.

16. Capacitance level sensors are electronic
devices, phase modulation and the use of higher
frequencies makes the sensor suitable for
applications in which dielectric constants are
similar.
The sensor contains no moving parts, is
rugged, simple to use, easy to clean, and can be
designed for high temperature and pressure
applications.

17. Ultrasonic level sensors are used for non-contact level
sensing of highly viscous liquids, as well as bulk solids. They are
also widely used in water treatment applications for pump control
and open channel flow measurement. The sensors emit high
frequency (20 kHz to 200 kHz) acoustic waves that are reflected
back to and detected by the emitting transducer.
Ultrasonic level sensors are also affected by the changing
speed of sound due to moisture, temperature, and pressures. The
sound wave from being properly reflected to the sensor.
Since the ultrasonic transducer is used both for
transmitting and receiving the acoustic energy. Ultrasonic sensors
can be designed to provide point level control, continuous
monitoring or both.

18. Fig:-Ultrasonic Level
1. FLOW LEVEL SENSOR.
2. FIRE SENSOR.
3. PIEZOELECTRIC SENSOR.
4. MOISTURE SENSOR.

19. 1. My experience was good.
2. In IFFCO plant , I learnt that how to manage
the industry or plant at a high level.
3. I also learnt that how to manage the worker
and employer with politely.
4. I saw that the electronics devices used in
industry level.
5. Over all my experience was superb and i
learnt many thinqs about this industry.