Project Report_Priyadarshini (MSRIT)

8/8/2019 Project Report_Priyadarshini (MSRIT)

1/71

Presentation onthe construction of a

Nitroglycerine Plant atNalanda, Bihar

byPriyadarshini DasM.S.Ramaiah Institute of Technology

Bangalore


2/71

Reviewed by :-

Mr. Mukut Paul

Vice President

Project Division

Nicco Corporation

Kolkata

Mr. Shibaji Banerjee

Senior Manager

Project Division

Nicco Corporation

Kolkata


3/71

Nitro-glycerine plant forOrdnance factory,

Nalanda, Bihar

Contract between The President of India

and M/S Biazzi, SA Switzerland dated

12/06/2008

Indian Collaborators Nicco Corporations

Project


4/71

About Nicco

NICCO Group is a proprietorship with Mr. Rajive

Kaul as Chairman established in 1942.

It is a group of four companies, viz:

Nicco Corporation Limited

Nicco Parks & Resorts Ltd.

Nicco Internet Ventures Ltd.Nicco Engineering Services Ltd.


5/71

Nicco Corporation Limited (NCL) headquartered in

Kolkata is the flagship company of the Nicco

Group. For nearly six decades, NCL has been oneof the pioneers in the Indian Cable

manufacturing industry

It has two divisions:Cable Division

Project Division


6/71


7/71

About the Nitro-glycerine Plant

The plant consist mainly of the Nitration plant and NG emulsion

transfer to storage buildings which is automatically controlled,

remotely operated and continuous.

This is done by means of a BIAZZI patented Eductor

Its rated capacity is 500kg/hrof nitro-glycerine.

The explosives holding at any stage is minimum and the NG mixture

produced meets the strictest quality requirements.

The plant has inbuilt safety controls that takes care of any abnormal

condition during manufacture.


8/71

C3H5 (OH)3 + HNO3 C3H5 (NO3)3 + 3 H2O

In the plant esterification of glycerine occurs

following this equation :-


9/71

NG Physical Properties

Specific gravity is 1.591 at 25C (77F) and 1.6 at 15C

(59F)

Melting point is 13.5C (56.3F)

Solubility in water is 0.18 % at 20C (68F)

Vapour tension is 0.00025 mm of Hg at 25C (77F) and

0.00038 mm of Hg at 30C (86F)

Specific heat is 0.32 kcal/kg (1.3 kJ/kg)


10/71


11/71

Hazardous Properties of Nitro

GlycerineNitro-glycerine represents a dangerous fire and explosion hazard

and is toxic as well.

It is a powerful vasodilatorthat causes reduction in blood

pressure. It also effects the skin and eye.

Severe poisoning is often manifested by confusion,

pugnaciousness, hallucinations and maniacal manifestations.

Physiologically, its introduction into the body will cause severe

headaches, excitement, vertigo, fainting, respiratory ailments and

cyanosis, ultimately death from asphyxiation due to respiratory

paralysis.


12/71

Danger of explosion

The detonation of nitro-glycerine is caused by concentrations of

energy such as sparks, friction, impact, flame orheating.

The setting-off of an explosion is subject to considerations of

probability. With a small amount of energy, the probability of setting

off an explosion is small ; with a large amount of energy, this

probability is greater although not certain.

Nitro-glycerine should be handled with greatest care.


13/71

Scope of Civil Engineering

To provide utmost safety measures in order to avoid explosion inthe first place and to avoid widespread damage in case of an

accidental explosion

To provide separate and viable units for Acid and GlycerineStorage, Nitration, Nitroglycerine emulsion transfer through

specialized eductor, Nitroglycerine Storage and Waste

water treatment

To provide an electrical MCC Room

To provide other buildings such as Security cabin, Changing

room for industrial staff, Canteen etc.

Maximum Utilization with Maximum Safety


14/71

The Plant Concept

All the equipment supplied is ofhigh quality NG type constructions

without any pinch point, pocket potentials or metal-to-metal contacts; it

is also highly polished, free draining and consistent with good

accepted NG practices.

All the parts in contact with acids or acidic fumes are in stainless steel

304 L or 316 L and 329.

All the equipment components located in the process room and the

lubricants used are non-nitratable and compatible with NG.

The equipment construction is carefully supervised by our experts.

Water running trials and X-ray checking of the welding are carried out

in the workshops prior to the shipment of the equipment.


15/71

S. No. Building

No.

Purpose

1 0210 Nitration, Separation and Storage

2 0211 Storage (I)

3 0212 Storage (II)

4 0213 Waste Water Treatment

5 0214 Control House

The Plant consists of the following

buildings :-


16/71

6 0207 Electrical MCC Room

7 0209 Glycerine Storage Area

8 & 9 0215, 0216 Soda Soln. Preparation and Compressed Air

Cooling Unit

10 0208 Acid Storage and Mixing Area

11 0201 Security / Attendant Cabin

12 0202 Unit Office and Store


17/71

13 0203 Industrial Employees Change Room / Canteen

14 0204 Cycle / Scooter Shade for staff

15 0205 Cycle / Scooter Shade for Industrial Employees

16 0206 Non-Explosive Store

17 0217 Water Reservoir

18 401 Electrical MCC Room for Storage (I) 0211


18/71

19 451 Electrical MCC Room for Storage (II) 0212

20 - Static Tank


19/71

The detailed Plot Plan


20/71

A TRAVERSE around the explosivebuildings has been constructed to limit the

effect of an explosion.

Also fire fighting installations such as the

DOUBLE HYDRANT VALVES are used.

Safety measures


21/71

Detailed Drawing of the traverse


22/71

The double dots denote the double hydrant valves

used to prevent fire hazards

(According to STEC Pamphlet 15)


23/71


24/71

Fire Safety


25/71

Detailed Design of the

Plant Sections


26/71

Nitration and Washing Unit Top View


27/71

Important

features of the

Nitration Unit :-

There is aPolycarbonate

Sheet Wall all

around.

On th

e processside flooring is of

epoxy conductive

coating and walls

and ceiling have

acid resistantpaint.

On the motor side

floor, walls and

ceiling have

washable paint.

Nitration and Washing Unit side view


28/71

Key Plan of the Acid Storage

Building


29/71

Acid storage is composed of five tanks :-

1 tank (25 m3) in MS for oleum

1 tank (25 m3) in aluminum for concentrated nitric acid

2 tanks (2 x 25 m3)in stainless steel for the mixed acid needed for nitration

1 tank (30 m3) in stainless steel for the spent acid rejected from nitration

Additionally, a mixing unit for the preparation of mixed acid is needed in the

same area.

This unit can be automatic. This mixing operation can be done even during

the production of NG.

One of the mixed acid tanks is selected for production after acceptance from

the laboratory and the other one is used for mixing.

Loading of the oleum and CNA can be done by means of pumps from the

trucks.

All the tanks are equipped with a moisture trap.

The mixed acid levels tanks are monitored in the control room.

Constructional Aspects


30/71

Key Plan of the Glycerine

Storage Building


31/71


Glycerine storage consists mainly of two tanks (2 x 6 m3), in stainless

steel.

Filling of the tanks can be done either from drums or directly from a

truck.

The tanks are sealed with an air breather trap for preventing moisture

contamination.

A small room, in which at least six drums can be kept, is needed to

preheat the drums during the cold season.

The whole piping, pumps, etc. are in stainless steel.

The tanks are designed so as to permit their easy cleaning and

maintenance.

Levels are monitored in the control room.

Temperatures are monitored in the control room.


32/71

Key plan of the Waste WaterTreatment Building


33/71

Plan at EL. 0.000m level WaterTreatment

Building


34/71

Compressed Air Brine Cooling and Soda Soln.

Preparation Unit


35/71

Soda Solution Preparation Unit

The preparation area for soda solution needed in the neutralization

process consists mainly of one batch dissolver(0.8 m3).The soda ash, contained in normal 25 kg bags, is poured into the

dissolver through a screening in stainless steel, which is filled under

stirring with a fix amount of water.

Once dissolution is completed and concentration accepted, the charge is

drained into the storage tank (3 m3).

A pump transfers the soda solution to the nitration plant. All theequipments are in stainless steel.

The level is monitored in the control room. The temperature is monitored

in the control room.



36/71

Brine Cooling Units

Two compressed air units are required, one of them as a stand-by unit.

A buffer tank receiver allows carrying out the shutdown procedures in case

of main power failure.

Compressed Air Units

Two cooling units are required. One unit is enough for the nitration

process.

The second one is needed during the mixed acid preparation.

The capacity of both units is identical, and one of them can be used as a

stand-by unit if necessary.

The cooling medium is brine/sodium nitrate (or equivalent).The return line from the brine closed loop flows through the evaporator

before going into a buffer tank.

Two pumps from the buffer tank can feed the cooler for mixed acid

preparation or the nitrator.



37/71

The Plant Operation


38/71

Nitration SectionMixed acid and glycerine are pumped from intermediate overhead tanks

into the nitrator by means of gear pumps. These pumps are driven by an

electrical motor controlled by a frequency variator.

The feeding rates can be set at will by remote control and can bechecked volumetrically by means of integrated calibration pots.

Glycerine flows through a mass-flow meter and a retractable arm into the

nitrator. This feeding arm moves forward into the feeding position above

the nitrator only when all the correct operating conditions are fulfilled.

Mixed acid flows through a mass-flow meter provided with an alarm

which signals when flow-rate is not correct.


39/71

The heat of reaction developed in nitrator is removed by the circulation of

refrigerant in the cooling coils. The temperature of nitration is

automatically controlled.

The reaction mixture overflows from the nitrator and enters into thecentrifugal separator. The latter is provided with a speed detector with

alarm and with a vibration detector with alarm which signals to the operator

any irregularities in the operation.

The spent acid coming from the centrifugal separator flows into the post-

separator. The dilution with water is done in the dilutor ; this in order toensure the complete dissolution of possible remaining NG droplets. From

there, spent acid is pumped to the spent acid disposal tank.


40/71

Wash

ing SectionThe washing section is formed of two washing groups in series

equipped with washers provided with a powerful stirrer and a dynamic

separator.

For NG production, neutralization is made in the first washing group.

For other NE, the first washing group is used for pre-washing of the

acidic NG by dilution with water. This water is recycled till nitric acid

concentration reaches 28 30 %. In the first washing group, the acidic

NG separated by the dynamic separator is sucked by a water ejector fedby recycled water delivered by a special pump immersed in an

intermediate water collecting and settling tank.


41/71

The possible NG which separates in the collecting and settling tank is

occasionally recycled by a water ejector into the first washer. This

operation is automatically controlled by a level probe in the tank.

Pre-washed NG is separated and overflows into the second washinggroup formed of two washers where it is neutralized, the pH being

automatically controlled by addition of weak soda solution.

A pH-meter shows the pH of the final emulsion and any irregularity is

signalled by an alarm.

The water-NG emulsion overflows from the last washer into the last

centrifugal separator from which NG is sent by means of water eductor

to the storage building.


42/71

NGTransport

NG is transferred in emulsion form from the nitration house to storage

building I or II by means of a BIAZZI patented eductor, in which the levelof energy is moderate.

The motive water for the eductor is continuously recycled by means of

a specially designed pump immersed in the catch tanks located in both

storage buildings.


43/71

NG StorageThe NG water emulsion form is transferred in either the two storage tanks

of 1'000 kg NG capacity each(max. capacity in each storage building, 2'000

kg NG).

Both tanks are provided with a soda solution feed and an air stirring in the

event a postwashing is required.

The storage tanks are equipped with a mechanical stirring systempermitting to keep the content in emulsion form during storage conditions

only.


44/71

After its separation from NG, the transfer water flows into a catch tank

provided with a NG recycling system. The transfer water is then recycled by

means of the pump. This permits to keep low water consumption and

prevent NG losses, and therefore to decrease drastically the amount of

effluent water.

Each storage tank is provided with a sampling device. During sampling

operation, NG is sucked out from the storage tank by means of an air lift

system and flows into the adequate sample container located under a funnelconnected to the vessel.


45/71

Portions from the SurveyDrawing (Site Plan and Contours)


46/71


47/71

Longitudinal & Cross

Sections (L Sections and X

Sections


48/71

Soil Testing ReportThe geotechnical Investigations comprise of3 boreholes of 150 mm

nominal diameter

Borehole A & B terminate at 15m and c terminate at 7.5m

GWT was not encountered in any of the above three mentioned boreholesduring the time of investigation

Based on lab tests the sub soil stratification is classified as Clayey silt

of intermediate plasticity and having medium compressibility

characteristics

Preliminary analysis indicate that a net SBC of7 9 may be possible for

open foundation & supported in clayey silty stratum at 3 m depth.


49/71

Detailed Technical Specification for Civil Work

As obtained from the original contract between BIAZZI SA Switzerland and NICCO

corp. Ltd.

Earthwork

Concrete

Reinforcement

Shuttering

Brickwork

Plastering

Finishing Works / Colouring scheme


50/71

Flooring

Bitumen Painting

DPC

Foundations, bolts and inserts

Drain

Acid ProofTiling Work

Rolling Shutter

Plant Roads

Static Tanks


51/71

Earthwork

Excavation shall be carried out in all kinds of soil, (soft and hard),

boulder studded etc. Excavated soil shall be always kept dry bypumping out of sub-soil/rain water during construction.

During excavation shoring work shall be provided and proper slopeto be kept during cutting. If good soil at designed depth is not found

then further excavation shall be done to reach a strong foundation

level.

After completion of foundation, back filling shall be done with good

excavated earth in layer of 150 mm and well compacted, rammed,watered before next layer is laid.

Surplus excavated earth shall be dumped at an allotted place within a

lead of1km inside the plant.


52/71

Concrete

Plain cement concrete (PCC) grade M-5shall be used at base of foundation forcolumn. The beam at ground level, equipment foundation, underground pipe,

aggregates of 40 mm and below should be used.

PCC of grade M10 shall be laid below floor and wherever applicable 100 mm

thickness (min) with 40 mm downgraded aggregate withblack trap stone

and coarse sand.

Reinforced cement concrete of grade M-20 with 20mm and below gradedaggregate shall be used for all other places like all foundation, column, beam,

slab retaining wall etc.

Cement shall be eitherPortland cement 43 grade orPortland

blast furnace slag cement conforming to IS : 269 of 1989 or IS : 455

of 1987. Cement shall be kept dry.


53/71

All coarse and fine aggregate shall conform to IS : 383 of 1970.

Fine aggregate shall be approved riverbed and coarse aggregate shall be

approved black trap stone.


54/71

Reinforcement

Reinforcement bars shall be eithercold twisted deformed (CTD) or

thermo mechanically treated (TMT) as per IS : 1786 of 1985

These shall be procured from dealer of SAIL, TISCO and VIZAG

Reinforcements shall be free form mill scales, rust, grease or oil

Cover to reinforcement shall be provided by use ofcement sand mortar

block (1:4)

Binding wire shall be gauge 16 SWG approved annealed wire.

Dowels shall be of12 mm dia / 75 mm long at 750 mm c/c


55/71

Sh

uttering and BrickworkShuttering work shall conform to IS : 456 of 1978. This shall preferably be

made ofsteel

The brickwork shall be mostly 230/340 mm thick conforming to IS : 2212

of 1991. The brick shall be class 50B conforming to IS : 1077 of 1992. The

bricks shall be whole, sound, well burnt, free from cracks, well

shaped, uniform in size

The compressive strength shall be 5 N / m2(min). The cement sand mortar

for brick work shall be 1:6


56/71

PlasteringAll plastering work shall be carried out as perIS : 1961 1972

Walls (outside) : 10 mm thick in cement sand mortar 1:6 1st operation and

0.5 mm th

ick with

water proofing compound varying from 3% to 5% as permanufacturer's specification.

Walls (inside) : 15 mm thick in mortar 1:6

Ceiling : 15 mm thick in mortar 1:4

After plastering wall, it shall be covered by watering for7 days


57/71

Finish

ing WorksLead free fire resistant magazine paint in the interior of magazines,

production / technological buildings in line with STEC pamphlet, shall be

provided.

ForEXPLOSIVE BUILDINGS all RCC / brick surfaces shall be painted

withlead free acid resistant paint two coats as primer( 200 micronDFT) and finish coat (100 micron DFT). Total DFT will be 300 microns.

ForNO

N EXPLO

SIVE BUILDINGSi.e. Electrical generator, pump

house, control room, boiler, chiller etc., two coats ofsynthetic enamel

paint for joinery and two coats of white wash on brick wall shall be applied.


58/71

Colouring Scheme

Services Colouring Scheme

Walls & Pillars from

skirting / dado to ceiling

Pastel Green

Ceiling White

Wood work and interior

face

Marine grey / Admiral Grey

Water Pipes Synthetic Enamel Green


59/71

Electric Pipes, Panels,

Switch gears, switch

boards

Synthetic Enamel Light Brown

Coolant Pipes Synthetic Enamel Leaf Brown

Steel Rolling Shutters Aluminium paints


60/71

FlooringIn general, PCC floor( M10) with 150 mm thickness will be

constructed over boulder filled with earth and moorum. Boulder fill (250

mm) will be laid over compacted earth.

For all EXPLOSIVE BUILDINGS, top of the floors shall be lined withsika floor 381 as coating for disseminating static electricity.

ForNON EXPLOSIVE BUILDINGS top of the floor will be IPSS with

40 mm thick with M-15 concrete (25mm thick) cast in panels having 2 mmwidth metal strip divider.

The floor shall be well finished, free from cracks and crevice. It

shall be treated with sodium silicate and must be strong enough.When the floor is cast in panels, the joints must be carefully prepared to

achieve a smooth finish and to avoid chipping

Bitumen painting D P C


61/71

Bitumen painting, D.P.C.,

Foundation bolts & inserts

All underground structures like column foundation, equipment

foundation etc in contact with earth shall be treated with2 coats of

bitumen painting ofgrade 20/30 as per standard.

D.P.C. shall be 40 mm thick with M20 concrete with6mm down graded

stone coarse aggregate with approved water proofing compound mixedin appropriate proportion on all external walls.

All the materials for foundation bolts, nuts inserts shall conform

to IS : 2062 - 1992


62/71

Drains

All drains along road will be considered as main drain and around the

building as secondary drain connected to main drain. The cross

section of the drain will be trapezoidal made of 230 mm thick brickwall / floor. Inside surface will be cement plastered 15 mm thick (1:6)

All effluent and storm watershall be collected to these drains. Slope

will be as per standard. Where road crossing is ere, box drain will beprovided. Near entry to the building, suitable pre-cast concrete cover

slab shall be provided.

Acid Proof Tiling Work & Rolling


63/71

Acid ProofTiling Work & Rolling

Shutter

Acid resistant tiles ofsize 230mm X 114mm X 40mm thick shall beused in the acid prone area and as per specification is IS : 4860 class II

Acid proof bricks having 64mm thickness shall be required to be fixed inacid prone area in the building periphery.

Rolling shuttershall be provided in boilerhouse, chillerhouse,

pump house, generator room etc.

This shall be made ofMS sheets as per IS 6248


64/71

Plant RoadsThe CBR value is considered as 7.0. Width of the plant roads except CC' will

be 3.00 meter RCC

Width of the approach roads to the plant buildings will be 2.5 m

Minimum berms on both sides of the plant roads will be 1m

All roads should be designed and constructed as per the standards /

stipulations of IRC ( Indian Road Congress ) and MOST( Ministry of surface

transport )

The roads should be designed taking into consideration maximum of50

heavy vehicles / day

Raised road kerbs shall be provided on both sides of concrete road.


65/71

Static Tanks

RCC circular tank having capacity 110 KL shall be constructed forwater storage purpose having following features-

Mix of RCC tank shall not be less than M-20

RCC wall with bottom will be 150mm thickness (min) all around

Base Slab will be 300 mm thick ( min) and size

Depth of the tank will (-) 3.0 m (app) below EGL

Necessary water proofing, plastering will be done inside andoutside the wall, base slab


66/71

There will be a sump at one corner 1200 mm X 300 mm X 150 mm

Minimum 4 to 5 fire hydrant to be provided at side as per requirement.

The tank should be linked with approach road not less than 3.6 m in width andhard standing for quick manoeuvrability of the appliances

One RCC post and 25 mm dia GI pipe will be connected to tank for water inlet.

Necessary insert in wall made of 16mm thick plate will be @ 300 c/c for entry

into the tank.

Sluice valve will be there inside a pit 600 mm X 600 mm size.


67/71

Worked involved

Fabrication

Erection

Painting

Grouting


68/71

FabricationAll the fabrication of trestles, bridges, structural rolled columns,

built up columns, beams, bracings, runners, purlin, chequered

plates etc shall be in accordance with IS-800.

Tolerance of fabrication shall be in accordance with IS : 7215

1974

Fabrication shall be done once in yard and shall be inspected byOFB authority, prior to clearance for despatch

Construction shall involve :

-Welding and erection bolts

-Bolting with black or HT bolts

-Bolting with HSFG bolts

Minimum welding shall be 5mm fillet U.O.W. If there is butt weld,this must be tested radio graphically at 2% of welded joints. For

normal welds, ultrasonic testing at one drill hole for50 m shall be

carried out. Bolt shall be minimum 12mm dia. Holes shall be more

than the bolt dia


69/71

Erection, Painting & Grouting

All fabricated structure on receipt of inspection certificate from Ordnance

Factory Board shall be erected in the site as per erection marking. Erection

procedure shall be as per IS : 800 - 1964

All the fabricated structure shall have at least one coat of primer of approved

quality in the yard inspection. Before erection the structure shall receive at leastone coat of intermediate paints as per specifications. After erection the structure

shall receive final 2 coats of finished paints.

All works related to fabrication, erection, painting, testing, commissioning shall

conform to IS : 800 - 1964

After final alignment all the structural column, trestles shall be grouted with M-25

concrete along with anti-shrinkage compound at least 25 mm thick laid to slope

adjusting levels.


70/71

Acknowledgements

I would like to thank, firstly, Nicco Corporation Limited,

Project Division for giving me the opportunity to pursue

this SummerTraining at this esteemed organization.

I forward my sincere thanks in this regard to Mr. Mukut

Paul, Vice President, Project Division.I would also like to specially thank my guide and mentor,

Mr. Shibaji Banerjee under whose able guidance I learnta lot during this period.

I am also grateful to Ms. Annie Moothedam, Manager,

HRM forher support.Finally, I would take this opportunity to thank Mr. Pradip

Ganguly without whose help this training would not havebeen possible.


71/71

Thank You !

Documents

Project Report_Priyadarshini (MSRIT)