IndianOil Corporation Limited is an Indian state-owned oil and gas company headquartered at Mumbai, India. It is Indias largest commercial enterprise, ranking 86th on the Fortune Global 500 list in 2012. It is also the 18th largest petroleum company in the world and the No. 1 petroleum trading company among the national oil companies in the Asia-Pacific region. IndianOil and its subsidiaries account for a 47% share in the petroleum products market, 34.8% share in refining capacity and 67% downstream sector pipelines capacity in India. The IndianOilGroup of Companies owns and operates 10 of India's 19 refineries with a combined refining capacity of 65.7 million metric tons per year. Products
Indian Oils product range covers petrol, diesel, LPG, auto LPG, aviation turbine fuel, lubricants naphtha, bitumen, paraffin, kerosene etc. Xtra Premium petrol, Xtra Mile diesel, Servo lubricants, Indane LPG, Autogas LPG, Indian Oil Aviation are some of its prominent brands. OIL REFINERY
An Overview
An oil refinery or petroleum refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas. Oil refineries are typically large sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units. In many ways, oil refineries use much of the technology of, and can be thought of as types of chemical plants. The crude oil feedstock has typically been processed by an oil production plant. There is usually an oil depot (tank farm) at or near an oil refinery for storage of bulk liquid products. An oil refinery is considered an essential part of the downstream side of the petroleum industry.
General Operation Raw or unprocessed crude oil is not generally useful. Although "light, sweet" (low viscosity, low sulphur) crude oil has been used directly as a burner fuel for steam vessel propulsion, the lighter elements form explosive vapors in the fuel tanks and are therefore hazardous, especially in warships. Instead, the hundreds of different hydrocarbon molecules in crude oil are separated in a refinery into components which can be used as fuels, lubricants, and as feedstock in petrochemical processes that manufacture such products as plastics, detergents,
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solvents, elastomers and fibres such as nylon and polyesters. Petroleum fossil fuels are burned in internal combustion engines to provide power for ships, automobiles, aircraft engines, lawn mowers, chainsaws, and other machines. Different boiling points allow the hydrocarbons to be separated by distillation. Since the lighter liquid products are in great demand for use in internal combustion engines, a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products.Once separated and purified of any contaminants and impurities, the fuel or lubricant can be sold without further processing. Smaller molecules such as isobutane and propylene or butylene can be recombined to meet specific octane requirements by processes such as alkylation, or less commonly, dimerization. Octane grade of gasoline can also be improved by catalytic reforming, which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such asaromatics. Intermediate products such as gas oils can even be reprocessed to break a heavy, long-chained oil into a lighter short-chained one, by various forms of cracking such as fluid catalytic cracking, thermal cracking, and hydrocracking. The final step in gasoline production is the blending of fuels with different octane ratings, vapour pressures, and other properties to meet product specifications. Oil refineries are large scale plants, processing about a hundred thousand to several hundred thousand barrels of crude oil a day. Because of the high capacity, many of the units operate continuously, as opposed to processing in batches, at steady state or nearly steady state for months to years. The high capacity also makes process optimization and advanced process control very desirable.
Flow diagram of a typical refinery The following image is a schematic flow diagram of a typical oil refinery that depicts the various unit processes and the flow of intermediate product streams that occurs between the inlet crude oil feedstock and the final end products. The diagram depicts only one of the literally hundreds of different oil refinery configurations. The diagram also does not include any of the usual refinery facilities providing utilities such as steam, cooling water, and electric power as well as storage tanks for crude oil feedstock and for intermediate products and end products.
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GUWAHATI REFINERY
Guwahati Refinery, the first public sector refinery of the country, built with Romanian collaboration, was inaugurated by Late Pt. Jawaharlal Nehru, the first Prime Minister of India, on 1st January 1962. The Refinery symbolizes the Nations march towards indigenisation of the refining technology. With a capacity of 1.0 million metric tonnes per annum, Guwahati Refinery processes crude oil received from the Upper Assam Oil Fields and caters to the requirements of the petroleum products of the North Eastern Region.The production of LPG started in 1971 and the effluent treatment plant was started in 1976. This was very essential since it plays the vital role of cleaning and removing waste oil plus toxic elements from the industry and reduces the pollution in the area. Naphtha splitting facilities started from 1984 while the crude distillation unit was revamped in 1986.The de-mineralized water requirement had to be fulfilled by fixing a DM plant in 1993.The LPG recovery from the DCU started by 1994 and new digital distributed control system was set up in 1996. The need of unleaded petrol required the unit of ISOSIV which was set in 2002. In same year, two more units Hydrogen Generation and Hydrogen Treatment were commissioned for the production of low sulphur high speed diesel engine and quality superior kerosene oil. The INDMAX plant was set in 2003 for maximizing the productions of LPG from heavy ends and production of auto fuel. The final products of Guwahati Refinery are motor spirits, ATF (aviation turbine fuel), kerosene, LPG, diesel, petroleum coke, elemental sulphur and bitumen. The refinery has achieved various international certifications alike ISO 14001 and has an integrated management system for quality management including the ISO 9001:2000 and OHSAS 18001. It has a level 8 rating in international safety rating system. The utilities in Guwahati Refinery are:- Thermal Power Station, De-mineralized water plant, Water treatment plant, Cooling water treatment plant, Fire and safety, Nitrogen plant, Hydrogen generation and hydrogen treatment units, Compressed air systems.
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The refinery has been trying to upgrade as well improve its quality from time to time. It has the distinction of being producing green needle coke in India which has a very high import value. The refinery has excelled in every field including environmental concern and new innovations. The refinery has adopted the concept of Total Productive Maintenance (TPM), a Japanese concept which refers to a maintenance process developed for improving by making process more reliable and less wasteful. Department :FIRE AND SAFETY DEPARTMENT Date :05/06/2013 Day : Wednesday Activities :On that particular day we have come across with this department, where the personals of that department taught us the following things. Q1.What is fire safety? Ans. We were taught about Safety, Health and Environment (S, H&E) efficiency as of prime importance in todays industrial ventures and also the value of life and property which necessitates precautionary measures that have to be taken care of by the employees in the refinery. They also talked about the responsibility of ensuring the safety of the entire refinery and keeping it accident free. They also taught us about how an industrial fire occurs which basically comprises of 3 elements; that are Fuel, Oxygen and Heat, so that we can avoid atleast one elment to avoid fire. Q2. What are the different symbols used in IOCL for fire safety?
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Ans. There we have come across a new term i.e. the fire triangle or combustion triangle whichis a simple model for understanding the ingredients necessary for most fires. The triangle illustrates a fire requires three elements: heat, fuel, and an oxidizing agent (usually oxygen). The fire is prevented or extinguished by removing any one of them. A fire naturally occurs when the elements are combined in the right mixture.
Another symbol which is also used to represent the basic elements of fire is the fire tetrahedron whichis an addition to the fire triangle. It adds the requirement for the presence of the chemical reaction which is the process of fire. The fire engineer also told us abuout that combustion is the chemical reaction that feeds a fire more heat and allows it to continue. When the fire involves burning metals like lithium, magnesium, titanium it becomes even more important to consider the energy release. The metals react faster with water than with oxygen and thereby more energy is released. Putting water on such a fire results in the fire getting hotter or even explodes because the metals react with water which in an exothermic reaction.
Q3. What are the Common causes of fire in a Refinery? Ans. The common causes of fire and preventive measures, that we are listing below and it is the responsibility of the employees as well as the trainees of the refinery to strictly abide by the safety rules and to prevent fire accidents. These are as follows :
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Systems that are overloaded, resulting in hot wiring or connections, or failed component. Combustible storage areas with insufficient protection. Combustibles near equipment that generates heat, flame, or sparks. Smoking (Cigarettes, cigars, pipes, etc.). Equipment that generates heat and utilizes combustible materials. Flammable liquids. Fireplace chimneys not properly or regularly cleaned. Cooking appliances - stoves, ovens.
Q4. What are the different types of fire fightingequipments and fire extinguishing agents? Ans. They have mentioned about 4 types of basic firefighting equipment. Hence their knowledge is of prime importance. These are: Soda-acid fire extinguisher. Foam type fire extinguisher. Dry chemical type fire extinguisher : This is an all purpose fire extinguisher. Carbon-dioxide fire extinguisher.
Different Extinguishing Agents: They told us about the following extinguishing agents, which are suitable for different types of fire and their extinguishing action, are as listed below:- Water: Water which is the most effective, cheapest and readily available for fighting the fire and it has the highest heat of vaporization. Water is used in the refinery fire as cooling agent and also for the production of foam required for fighting the oil fire. To achieve this objective, sufficient quantity of water is made available in the refinery premises. Mechanical Foam: Mechanical Foam is one of the suitable fire-fighting agents to tackle the refinery fire. Foam is protein based compound and insoluble in the hydrocarbon products. Foam is nothing but air filled bubbles, so it floats on the surface of the oil and forms a blanket covering the surface of the burning liquid. Dry Chemical Powder: Dry Chemical Powder which is a universal fire fighting agent to tackle all classes of fire. The basic ingredients of the powder are sodium bicarbonate with metallic stearate and additive.
Q5. What are the different types of fire safety regulations that shall be abided by eyeryone while working in IOCL? Ans. To protect the refinery against fire hazards they mentioned the following safety regulations as set: Fire or naked light, matches, petrol or other lighter or any apparatus which is capable of causing ignition is not permitted to be taken within the battery area by any person. No fire shall be lit and no matches ignited in any part of the battery area unless a valid fire permit has been obtained. Smoking is strictly prohibited in all parts of the battery area except in the smoking booths/locations approved for this purpose.
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All the vehicles transporting petroleum products from the refinery must be fitted only with those types of spark arrestors which are duly approved by the Chief Controller of Explosives.
Q6. What are the different types of PPE used in IOCL? Ans.They also instructed us to wear the Personal Protection Equipment (PPE) at work places which is a must for safety. The PPE's generally used at work places are: 1) Helmet,2) Shoes 3) Gas-masks, 4)Gloves. Department :MECHANICAL WORKSHOP/SKILL DEVELOPMENT CENTRE. Introduction :The mechanical workshop section of the industry is one of the most vital part which is liable for proper working and maintenance of the machines used in the sector. The responsibility of the workshop lies not only in checking the parts for defects but also for repairing and sending it to the respective departments within a stipulated time so as to ensure that the departmental work do not suffer from any setback or any job is not delayed. After the workshop prepares a certain job, it is checked by the inspection department before dispatching the same for use. Major sections of the workshop are: Machine Section Welding Section Compressor Section Pump Section Valve Section Heat Exchanger Date:06/06/2013 Day : Thursday Activities:We have come across with the Machine and Welding section of the workshop on that day.The workshop consists of a number of machineries and devices: Lathe machine, Boring machine -> 1) Vertical. 2) Horizontal, Nut splitting and flange splitting machine, Grinding machine, Shaping machine, Vertical milling machine, Pump and motor for alignment training, Pressing machine, Pressure testing bench .
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Welding Section: This section is associated with the fabrication of different components and with the cutting of different types of pipes. Here the personals of the section taught us the different welding process they used. They also showed us different types of electrodes, different types of welding equipment they used during welding. They also demonstrate us the flame cutting of steel pipes with Oxy-Acetylene torch. Date:07/06/2013 Day : Friday Activities:On that day we have visited the Compressor and Pumpsection of the workshop.
Compressor Section:In this section we learn the following things. Q1. What are the different types of compressor used in the refinery? Ans.In the refinery both the Roto-dynamic (Centrifugal) and Positive Displacement(Reciprocating) type of compressor is used to increase the pressure of a compressible fluid. Centrifugal Compressor: Centrifugal compressor use a vanned rotating disk or impeller in a shaped housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A diffuser section converts the velocity head to pressure head. In this type of compressor the flow through the compressor is turned perpendicular to the axis of rotation. It can use a variety of blade orientation including forward and backward curved. Reciprocating Compressor:Reciprocating Compressors use pistons driven by crankshaft. They can be single or multi-staged and can be driven by electric motors and ic engines. This type of compressor is capable of providing high pressure along with variable loading. They are favoured for many gas process applications. Q2. What are the structural parts of Centrifugal and Reciprocating compressor? Ans. The main structural part of a Centrifugal compressor are : 1. Impellers, 2. Vanes, 3. Volutes, 4. Suction Eyes, 5. Discharge lines, 6. Diffuser Plates, 7. Seals, 8. Shaft, 9. Casing.
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The main parts of a Reciprocating Compressor are : 1. Piston, 2. Connecting Rod, 3. Crankshaft, 4. Piston Rings, 5. Suction Line, 6. Discharge Line, 7. Spring -Loaded Suction, 8. Discharge Valves.
Q3. On which factors Performance of a compressor depends ? Ans. They mentioned about different factors on which performance of a compressor depends: 1. Discharge flow, 2. Discharge pressure, 3. Discharge temperature, 4. Suction pressure, 5. Suction temperature, 6. Main bearing temperature, 7. Packing temperature, 8. Lube oil pressure, 9. Lube oil temperature, 10. Rod drop, 11.Frame vibration. Compressor Valve: There is a separate part in the compressor section for repairing the compressor valve. The personals of the section told us what are the different parts of a valve, how it works etc.
Q4. What are the common cause of failure of a compressor valve? Ans. Thecommon causes of failure of a compressor valve are: 1. High Impact Velocity On The Guard, 2. High Impact Velocity On The Seat, 3. Wear, 4. Corrosion, 5. Application Conditions. Pump section: Here we learnedabout the following things:
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Q5. What are the different types of compressor used in the refinery? Ans. In the IOCL refinery Guwahati, both Positive displacement and Roto-dynamic pumps are used. Displacement type: The positive displacement type of pumps operate by forcing a fixed volume of fluid from the inlet suction side of the pump to discharge side of the pump by trapping a required amount of fluid in a fixed volume and subsequently forcing the trapped volume to the discharge point of the pump. The positive displacement pumps are generally larger and tend to be operated at hydraulic systems at pressure of about 5000 psi. This also provides a fixed displacement per revolution within the mechanical limitations. The positive displacement type of pumps are also called as constant flow types of pumps as the pumps can deliver at the same flow rate at constant rpm irrespective of the discharge pressure. But these pumps must not be operated at a closed valve on discharge side of pump because it does not have any shut off head like a centrifugal pump. Roto-dynamic pumps: In this type of pumps, the energy is continuously added to the fluid to increase the fluid velocities within the device. The kinetic energy of the fluid is being continuously increased by increasing the flow velocity and the increased kinetic energy is then used to impart pressure energy to the fluid. The value of the potential energy of the fluid is increased by decreasing the value of the velocity as it tends to leave the pump by the discharge pipe. The change of energy from kinetic to pressure helps in producing the pumping effect.
Q6. What are the main structural parts of a pump? Ans. The main parts of a pump are: 1. Pump suction, 2. Impeller/piston (depending on type), 3. Pump discharge,4. Casing, 5.Shaft, 6.Mechanical seal, 7.Gland plate 8.Pump bearings
Q7. What are the different types of impeller used in a centrifugal pump?
Ans.There are basically three types of impeller used in a centrifugal pump. They are: Open Impeller: The vanes are cast free on both sides. Semi-Open Impeller: The vanes are free on one side andenclosed on the other. Enclosed Impeller: The vanes are located between the twodiscs, all in a single casting. Fig: Reciprocating pump Fig: Centrifugal pump
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Q8. What are the basic considerations of pump selection?
Ans.The following points are considered during the selection of a new pump: Best output, long trouble free life and low maintenance, Temperature, density, viscosity, chemical effect, wear and tear of working fluid on parts of pump, Total head, capacity, NPSH (Net Positive Suction Head), suction connection, method of operating and location, Availability of spare parts, Interchangeable spares.
Q9. What is a Mechanical Seal?
Ans.A mechanical seal is a device which helps join systems or mechanisms together by preventing leakage (e.g. in a plumbing system) containing pressure or excluding contamination .sometimes a seal is also referred to as packing. They were developed to overcome the disadvantages of compression packing or gland packing. Use of mechanical seals reduces leakage level to minimum (~95-100%).All mechanical seals are constructed of three basic sets of parts: A set of primary seal faces: one rotary and one stationary, a seal ring and insert, A set of secondary seals known as shaft packing and insert mountings such as O- rings, Wedges and V- rings, Mechanical seal hardware including glands rings, collar compression rings and bellows.
Q10. How a Mechanical Seal works?
Ans.The personals of the pump section demonstrate us how a Mechanical Seal works. It works as described in the following-
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Fig. Cutaway view of a mechanical seal drawn on CAD software
The primary seal is achieved by two very flat, lapped faces which create a difficult leakage path perpendicular to the shaft. Rubbing contact between these two flat mating surfaces minimizes leakage. As in all seals, one face is held stationary in housing and the other face is fixed to, and rotates with, the shaft. One of the faces is usually a non-galling material such as carbongraphite. The other is usually a relatively hard material like silicon-carbide. Dissimilar materials are usually used for the stationary insert and the rotating seal ring face in order to prevent adhesion of the faces. The softer usually has the smaller mating surface and is commonly called the wear nose. There are four main sealing points within an end face mechanical seal. The primary seal is at the seal face, Point A. The leakage path at Point B is blocked by an O-ring, a V-ring or a wedge. Leakage paths at Points C and D are blocked by gasket or O-rings.The faces in atypical mechanical seal are lubricated with a boundary layer of gas or liquid between the faces. In designing seals for the desired leakage, seal life and energy consumption; the designer must consider how the faces are to be lubricated and select from a numbers of modes of seal face lubrication.
Q11. What are the different types of bearings used? Ans.Bearings are used in rotating parts of machineries. The bearings are used to attain free frictionless movement at the ends so that the losses in the machines are reduced. The bearing contacts the rotating parts with stationary part of the machine.They showed us the following different types of bearings:- Roller: in this type, the outer as well inner parts are separate which has the cage holding the roller and the outer ring moving independently. This can take more load than ball bearings under normal conditions. Roller bearing can be of different types depending on shape of the rollers which are being used. Cylindrical Taper Needle Spherical Ball: The rotating parts move smoothly over some steel balls fitted onto the cage of the bearing. They are of different types depending on type of load it can bear Deep groove, Angular contact, Self-aligning Journal: The inner surface of a journal bearing are covered with a white layer metal covers which being soft gives a fine finishing causing much lesser frictional loss problem. The journal bearing is of two types: These are: 1. Slip, 2. Split.
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Date:08/06/2013 Day : Saturday Activities: On that day we have visited the Valve and Heat Exchanger section of the workshopwhere the personals of that department taught us the following things: Heat Exchanger section: In this section we learn the following things: Q12. What is the application of a heat exchanger in an oil refinery? Ans.Inan Oil Refinery,the various application of a heat exchangerare: Intercoolers and preheaters, Condensers and boilers, Evaporators, Regenerators, Oil coolers. Q13. What are the different types of heat exchangers? Ans. They have mentioned about the following different types of heat exchangers: Shell and tube heat exchanger, Plate heat exchanger, Adiabatic wheel heat exchanger, Plate fin heat exchanger, Pillow plate heat exchanger, Fluid heat exchangers, Waste heat recovery units, Dynamic scraped surface heat exchanger, Phase-change heat exchangers, Direct contact heat exchangers, HVAC air coils, Spiral heat exchangers. Q14. Which type of heat exchanger is most commonly used in a refinery? Ans. A shell and tube heat exchanger is the most common type of heat exchanger used in an oil refinery. It is suited for high-pressure application. It consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids.
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Fig: A shell and tube heat exchanger Valve Section: In this section we learn the following things- Q15. What is a mechanical valve? Ans. They gave us a brief description about mechanical valve. A mechanical valve is a device that regulates, directs or controls the flow of a fluid by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but are usually discussed as a separate category. Valves are used in a variety of contexts, including industrial, commercial, residential, and transport. The refinery uses valves in almost each section for the above mentioned purpose. Valves can be operated manually as in by hand, lever or pedal else it can be operated as automatically by the change in pressure, volume etc. which moves a diaphragm or piston ultimately actuating action inside the valve. Q16. What are the different components of a valve? Ans. Theytold us about the following components of a valve:
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Bonnet: A bonnet acts as a cover on the valve body. It is commonly semi- permanently screwed into the valve body or bolted onto it. During manufacture of the valve, the internal parts are put into the body and then the bonnet is attached to hold everything together inside. Many ball valves do not have bonnets since the valve body is put together in a different style, such as being screwed together at the middle of the valve body. Ports: They are passages that allow fluid to pass through the valve. Ports are obstructed by the valve member or disc to control flow. Valves most commonly have 2 ports, but may have as many as 20. The valve is almost always connected at its ports to pipes or other components. Connection methods include threading, compression fittings, glue, cement, flanges, or welding. Handle or actuator: A handle is used to manually control a valve from outside the valve body. Automatically controlled valves often do not have handles, but some may have a handle for manually overriding an automatic control, such as a stop-check valve. An actuatoris a mechanism or device to automatically or remotely control a valve from outside the body. Some valves have neither handle nor actuator because they automatically control themselves from inside; for example, check valves and relief valves might have neither. Disc: A disc or valve member is a movable obstruction inside the stationary body that adjustably restricts flow through the valve. Although traditionally disc-shaped, discs come in various shapes. Depending on the type of valve, a disc can move linearly inside a valve, or rotate on the stem. A ball is a round valve member with one or more paths between ports passing through it. By rotating the ball, flow can be directed between different ports. Ball valves use spherical rotors with a cylindrical hole drilled as a fluid passage. Seat: The seatis the interior surface of the body which contacts the disc to form a leak-tight seal. In discs that move linearly or swing on a hinge the disc comes into contact with the seat only when the valve is shut. In disks that rotate, the seat is always in contact with the disk, but the area of contact changes as the disc is turned. The seat always remains stationary relative to the body. Stem: The stemtransmits motion from the handle or controlling device to the disc. The stem typically passes through the bonnet when present. In some cases, the stem and the disc can be combined in one piece, or the stem and the handle are combined in one piece.The motion transmitted by the stem may be a linear force, a rotational torque, or some combination. Packing is often used between the stem and the bonnet to maintain a seal. Some valves have no external control and do not need a stem as in most check valves. Valves whose disc is between the seat and the stem and where the stem moves in a direction into the valve to shut it are normally-seated or front seated. Valves whose seat is between the disc and the stem and where the stem moves in a direction out of the valve to shut it are reverse-seated or back seated. These terms don't apply to valves with no stem or valves using rotors. Gaskets: The seals or packing used to prevent the escape of a gas or fluids from valves. Spring: Many valves have a spring for spring-loading, to normally shift the disc into some position by default but allow control to reposition the disc. Relief valves commonly use a spring to keep the valve shut, but allow excessive pressure to force the valve open against the spring-loading. Coil springs are normally used. Typical spring materials include zinc plated steel, stainless steel etc. Trim: The internal elements of a valve are collectively referred to as a valve's trim.
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Q17. What are the different types of valve used? Ans. They have mentioned about the following different types of valves: 1. Gate valve: These valves are ones which open by lifting a round or rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the sealing surfaces between the gate and seats are planar, so gate valves are often used when a straight-line flow of fluid and minimum restriction is desired. The gate faces can form a wedge shape or they can be parallel. On opening the gate valve, the flow path is enlarged in a highly nonlinear manner with respect to percentage of opening. This means that flow rate does not change evenly with stem travel. Also, a partially open gate disk tends to vibrate from the fluid flow. Most of the flow change occurs near shutoff with a relatively high fluid velocity causing disk and seat wear and eventual leakage if used to regulate flow. Typical gate valves are designed to be fully opened or closed.
Fig. Gate Valve 2. Butterfly valve:This is a valve which can be used for isolating or regulating flow. The closing mechanism takes the form of a disk. Butterfly valves are generally favoured because they are lower in cost to other valve designs as well as being lighter in weight, meaning less support is required. The disc is positioned in the centre of the pipe, passing through the disc is a rod connected to an actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow; therefore a pressure drop is always induced in the flow, regardless of valve position. When the valve is closed, the disc is turned so that it completely blocks off the passageway. When the valve is fully open, the disc is rotated a quarter turn so that it allows an almost unrestricted passage of the fluid. The valve may also be opened incrementally to throttle flow.
Fig.Butterfly valve 3. Globe valve: A globe valveis a type of valve used for regulating flow in a pipeline, consisting of a movable disk-type element and a stationary ring seat in a generally spherical body.This has an opening that forms a seat onto which a movable plug can
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be screwed in to close (or shut) the valve. The plug is also called a disc. In globe valves, the plug is connected to a stem which is operated by screw action in manual valves. Automated globe valves have a smooth stem rather than threaded and are opened and closed by an actuator assembly. Globe valves are used for applications requiring throttling and frequent operation.
Fig.Globe Valve 4. Ball valve: A ball valve is a valve with a spherical disc, the part of the valve which controls the flow through it. The sphere has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow will occur. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. They do not offer the fine control that may be necessary in throttling applications but are sometimes used for this purpose. Ball valves are used extensively in industrial applications because they are very versatile, supporting pressures up to 1000 bars and temperatures up to 200C. Sizes typically range from 0.5 cm to 30 cm. They are easy to repair and operate.
Fig.Ball Valve 5. Non return valve: A check valve or a non-return valve is a mechanical device, a valve, which normally allows fluid to flow through it in only one direction. The check valves are two-port valves with the two openings in the body, one for fluid to enter and the other for fluid to leave. The cracking pressure which is the minimum upstream pressure at which the valve will operate has to be checked so that a check valve is specified for a specific cracking pressure.
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Fig.Non-Return Valve 6. Pressure safety valve: A safety valve is a valve mechanism for the automatic release of a substance from a boiler, pressure vessel, or other system when the pressure or temperature exceeds preset limits. The pressure safety valve finds uses in the petroleum refining, petrochemical, chemical manufacturing, natural gas processing, power generation.
Fig. Pressure Safety Valve PSV can be of many types: Relief Valve: automatic system that is actuated by static pressure in a liquid- filled vessel. It specifically opens proportionally with increasing pressure. Safety Valve: automatic system that relieves the static pressure on a gas. It usually opens completely, accompanied by a popping sound. Pilot-Operated Safety Relief Valve: automatic system that relieves by remote command from a pilot on which the static pressure (from equipment to protect) is connected. Low pressure safety valve: automatic system that relieves static pressure on a gas. Used when difference between vessel pressure and the ambient atmospheric pressure is small. Vacuum pressure safety valve: automatic system that relieves static pressure on a gas. Used when the pressure difference between the vessel pressure and the ambient pressure is small, negative and near the atmospheric pressure.
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Date : 09/06/2013 Day : Sunday Activity :No activity.
Department :THERMAL POWER STATION
Thermal power stationis 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 fuel sources. Some prefer to use the term energy centrebecause such facilities convert forms of heat energy into electricity. Some thermal power plants also deliver heat energy for industrial purposes, for district heating, or for desalination of water as well as delivering electrical power. A large part of human CO2 emissions comes from fossil fuelled thermal power plants; efforts to reduce these outputs are various and widespread.
Fig. ARankine cycle with a two-stage steam turbine and a single feed water heater.
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Salient features: Fuel used to generate steam is Low Sulphur Heavy Stock(LSHS). Pressure of the boiler is 37 kg/cm 2 . Various capacities of the boilers are 20 metric tonnes per hour ,40 metric tonnes per hour, maximum capacity being 60 metric tonnes per hour. Super-heated steam which is generated is at a temperature of 400- 500C.
Date:10/06/2013 Day : Monday Activities :On that particular day we met MrDubey who is the incharge of TPS. He gave us a brief description about the Thermal Power Station unit of Guwahati Refinery. The Thermal Power Station meets Guwahati Refinery's needs with three steam Turbo- Generators operating in complete online mode. Assam State Electricity Board (ASEB) grid connection is also available for nonessential loads and standby supply in TPS.
The TPS has five boilers, two Romanian made (BLR3 and BLR4) of 20 tones/hr capacity each, one IJT made (BLR5) with 40 tones/hr and two Thermax made boilers (BLR6 and BLR7) of 50 tones/hr capacity each. Steam generated from these boilers is also used as process steam apart from power generation.
Powering all units of the refinery and providing steam of DM water are main needs of a process industry. TPS is the heart of the refinery and main contributor to successful operation of the refinery. The TPS consists of following units: De-Mineralization plant(D/M plant), De-aerator, Boilers, Steam turbines, Generators, Cooling towers.
A. De-Mineralization plant:The DM plant deals with the de mineralization of water to make it fit for use in the refinery by removing all mineral and waste components as a way of purification through the ion exchange process.
Q1.Why do we need D/M water? Ans. 1.To increase heat thermal capacity, 2. To reduce scaling ,corrosion , carry-over, foaming, 3. To reduce the hardness of water.
3. De-Gasser(DG). 4. Strong Base Cation(SBC). 5.Mixed Bed(MB)
SWF: Water Tank, DMF: Dual Media Filter, SAC: Strong Acid Cation, SDG: Degas Water Pump, SBA: Strong Base Anion, MB: Mixed Bed, SDM: Status for DM water transfer.
Q3.Explain the process involve in D/M plant?
Ans. The impure water is first filtered in the dual media filter to remove the solid impurities like mud etc. Impurities present are then transferred to the SEF tank where it gets drained out. The filtered water is then transferred to the Strong Acid Cation chamber where it is reacted with an acid cation (H+) to remove the minerals like sodium etc. and to form hydrogen and carbon dioxide (reversible H2CO3). This compound is pumped to a Strong Base Anion chamber for form water and impurity compound. The product is further fed into the Mixed Bed which contains both anion and cation beds for more final purification. The de- mineralized water is then fed into a boiler and o other parts of the refinery where it might be needed. The DM plant uses 3 units working together. The main reactions involved are: R-H + NaCl R-Na + HCl R-OH + HCl RCl + H 2 O Note: R is the resin Q4. List out the different mechanical component used in D/M plant with specification? Ans.The mechanical components used are: Water pressure filters, Filter backwash pump (950 rpm), Degas water pump (2900 rpm ), Raw water pump ( 2900 rpm),
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Regeneration pump (2900 rpm), Mixed bed blower (1370 rpm), Service morphine dosing pump, DM transfer pump ( 2935 rpm), Effluent transfer pump (2900 rpm), Acid unloading pump (2880 rpm).
Date:11/06/2013 Day :Tuesday Activities :On that particular day we learn about deaeator and boilers . B. DEAERATORS: Deaerators is a device that is widely used for removal of air and other dissolved gas from the feed water to steam generating boilers. Q5.What are the effect of dissolve gases in boiler feed water on steam system? Ans. The presence of dissolved oxygen in feed water causes rapid localized corrosion in boiler tubes. Carbon dioxide will dissolve in water, resulting in low pH levels and the production of corrosive carbonic acid. Low pH levels in feed water causes severe acid attack throughout the boiler system. Q6.What is DE aeration? Ans. The removal of dissolved gases from boiler feed water is an essential process in a steam system. The dissolved gases and low pH levels in the feed water can be controlled or removed by the addition of chemicals, it is more economical and thermally efficient to remove these gases mechanically. This mechanical process is known as DE aeration and will increase the life of a steam system dramatically. Q7.What are the laws and principle used in deaeration process? Ans. Henrys law is basically used in deaeration process. According to this law gas solubility in a solution decreases as the gas partial pressure above the solution decreases. The second scientific principle that governs DE aeration is the relationship between gas solubility and temperature. Easily explained, gas solubility in a solution decreases as the temperature of the solution rises and approaches saturation temperature. Q8.Explain the process of deaeration? Ans. The feed water is sprayed in thin films into a steam atmosphere allowing it to become quickly heated to saturation. Spraying feed water in thin films increases the surface area of the liquid in contact with the steam, which, in turn, provides more rapid oxygen removal and lower gas concentrations. This process reduces the solubility of all dissolved gases and removes it from the feed water. The liberated gases are then vented from the deaerator.
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C. BOILERS:We also learned about boilers which is one of importent component of Thermal Power Station.The boiler is a type of furnace in which the fluid circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the walls of the furnace to generate steam.
The heated water then rises into the steam drum. Here, saturated steam is drawn off the top of the drum. In some services, the steam will reenter the furnace through a super- heater to become superheated. Superheated steam is defined as steam that is heated abovethe boiling point at a given pressure. Superheated steam is a dry gas and therefore used to drive turbines, since water droplets can severely damage turbine blades.
Cool water at the bottom of the steam drum returns to the feed-water drum via large- bore 'down-comer tubes', where it pre-heats the feed-water supply. To increase economy of the boiler, exhaust gases are also used to pre-heat the air blown into the furnace and warm the feed-water supply. This type generally gives high steam production rates, but less storage capacity than the above. Water tube boilers can be designed to exploit any heat source and are generally preferred in high pressure applications since the high pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall.
The IOCL refinery Noonmatihas 5 boilers. The boilers are 3, 4,5,6,7. Boilers 6 and 7 have a capacity of 50 tonnes. The boiler 5 has a capacity of 40 tonnes and uses single stage economizer but uses pre heated air. Boiler and 4 have a capacity of 20 tonnes. The steam produced is nearly 450oC and pressure of 37 kg/cm2. The air inlet is by forced draught fans. The chimney is 25 meters high and is maintained at nearly 150oC. The boiler unit has also additional equipment and devices as follows: Economizer, Steam drum, Furnace, Super heater coils, Air Pre-Heater(APH),
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Safety valves, Fly ash collectors, Flue gas stack, Phosphate dosing pump, LP dosing pump, Morpholine dosing pump, Boiler feed water pump, F.D. and I.D. suction fan, C.E.P for STG-4, A.O.P for STG-3.
Economizers: Economizers are mechanical devices that are used to reduce some energy consumption else perform useful operation as pre heating fluids. These are an essential part of any boiler. They are heat exchange devices that heat fluids, usually water, up to but not normally beyond the boiling point of that fluid, they do so by making use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a boiler, thereby recovering more useful enthalpy and improving the boiler's efficiency. It saves energy by using the exhaust gases from the boiler to preheat the cold water used.
Date: 12/06/2013 Day :Wednesday Activities:We learned about STEAM TURBINE on that day.
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D. STEAM TURBINE: A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. To maximize turbine efficiency the steam is expanded, doing work, in a number of stages. These stages are characterized by how the energy is extracted from them and are known as either impulse or reaction turbines. Most steam turbines use a mixture of the reaction and impulse designs: each stage behaves as either one or the other, but the overall turbine uses both. Typically, higher pressure sections are impulse type and lower pressure stages are reaction type. Impulse turbines :An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage. As the steam flows through the nozzle its pressure falls from inlet pressure to the exit pressure (atmospheric pressure, or more usually, the condenser vacuum). Due to this higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving the moving blades has a large portion of the maximum velocity of the steam when leaving the nozzle. Reaction turbines :In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor. Q9.What is the difference between Impulse and Reaction turbine? Ans. Difference between Impulse and Reaction Turbine: 1) In impulse turbine, there are nozzle and moving blades are in series while there are fixed blades and moving blades are present in Reaction turbine (No nozzle is present in reaction turbine). 2) In impulse turbine pressure falls in nozzle while in reaction turbine in fixed blade boiler pressure falls. 3) In impulse turbine velocity (or kinetic energy) of steam increases in nozzle while this work is to be done by fixed blades in the reaction turbine. 4) Compounding is to be done for impulse turbines to increase their efficiency while no compounding is necessary in reaction turbine. 5) In impulse turbine pressure drop per stage is more than reaction turbine. 6) The number of stages is required less in impulse turbine while required more in reaction turbine. 7) Not much power can be developed in impulse turbine than reaction turbine. 8) Efficiency of impulse turbine is lower than reaction turbine. 9) Impulse turbine requires less space than reaction turbine.
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10) Blade manufacturing of impulse turbine is not difficult as in reaction turbine it is difficult. Operation and maintenance: When warming up a steam turbine for use, the main steam stop valves (after the boiler) have a bypass line to allow superheated steam to slowly bypass the valve and proceed to heat up the lines in the system along with the steam turbine. Also, a turning gear is engaged when there is no steam to the turbine to slowly rotate the turbine to ensure even heating to prevent uneven expansion. After first rotating the turbine by the turning gear, allowing time for the rotor to assume a straight plane (no bowing), then the turning gear is disengaged and steam is admitted to the turbine, first to the astern blades then to the ahead blades slowly rotating the turbine at 10 to 15 RPM to slowly warm the turbine. Problems with turbines are now rare and maintenance requirements are relatively small. Any imbalance of the rotor can lead to vibration, which in extreme cases can lead to a blade letting go and punching straight through the casing. It is, however, essential that the turbine be turned with dry steam - that is, superheated steam with a minimal liquid water content. If water gets into the steam and is blasted onto the blades (moisture carryover), rapid impingement and erosion of the blades can occur leading to imbalance and catastrophic failure. Also, water entering the blades will result in the destruction of the thrust bearing for the turbine shaft. To prevent this, along with controls and baffles in the boilers to ensure high quality steam, condensate drains are installed in the steam piping leading to the turbine. The IOCL refinery Noonmatihas three turbines: 3,4,5. Set of each turbine has different power capacities. The turbine 3 and 4 runs at 9000 rpm and on coupling runs the generator at 3000 rpm. It produces 8 MW power. The turbine 5 run at 6500 rpm and on coupling rotates the generator at 1500 rpm. It develops nearly about 12 MW power. The ratio between the rpm of generator and turbine varies as the ratio for all 3 pairs so as to maintain the same frequency. Date:13/06/2013
Day : Thursday
Activities:On that particular we were taught about Condenser and we learned the following thing:
A condenseris a device or unit used to condense a substance from its gaseous to its liquid state, typically by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the condenser coolant. Condensers are typically heat exchangers which have various designs and come in many sizes ranging from rather small(hand-held) to very large industrial-scale units used in plant processes.The primary purpose of a surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the steam generator or boiler as boiler feed water.The shell is the condenser's outermost body and contains the heat exchanger tubes.The shell is fabricated from carbon steel plates and is stiffened as needed to provide rigidity for the shell.When required by the selected design, intermediate plates are installed to serve as baffle plates that
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provide the desired flow path of the condensing steam.The plates also provide support that help prevent sagging of long tube lengths.
At the bottom of the shell, where the condensate collects, an outlet is installed and is moved into a hot-well. Condensate is pumped from the outlet or the hot-well for reuse as boiler feed- water.
Q10. What are the different types of condenser? Ans.The steam power plants using condenser are of two types:- 1. Open cycle condensing system: The cooling water used in condenser is not re- circulated again and again but discharged to the downstream side of the river. 2. Closed cycle condensing system: The cooling water is re-circulated again and again by passing through the cooling tower.In this refinery this type of condensing system is used.
Q11.What are the different component of steam condensing plant? Ans. The different components of steam condensing plants are listed below: 1. Condenser, 2. Supply of cooling water, 3. Condenser cooling water pump, 4. Condensate Extraction Pump, 5. Hot-well, 6. Boiler feed Pump, 7. Air extraction pump, 8. Cooling Tower, 9. Make up water pump.
Q12.What are the advantages of condenser? Ans. The advantages obtained by incorporating a condenser in steam power plant are listed below:
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1. The condensate steam from the condenser is used as feed water for boiler. Using the condensate as feed for boiler reduces the cost for power generation as the condensate is supplied at a higher temperature to the boiler and it reduces the capacity of the feed water cleaning system. 2. The efficiency of the plant increases by increasing the vacuum in the condenser.
The specific steam consumption of the plant also decreases as the enthalpy drop or work developed per kg of steam increases with the decrease in back pressure by using condenser. The use of condenser in steam power plant reduces the overall cost of generation by increasing the thermal generation of the plant. The efficient condenser plant must be capable of producing and maintaining a high vacuum with the quantity of cooling water available and should be designed to operate for prolonged periods without trouble. Q13.What are the desirable feature of good condensing plant? Ans.The desirable feature of good condensing plant is: 1. Minimum quantity of circulating water, 2. Minimum cooling surface area per kW capacity, 3. Minimum auxiliary power, 4. Maximum steam condensed per m of surface area.
Date:14/06/2013 Day :Friday Activities: On that particular day we went to learn about Cooling Towers. Cooling towersare heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or in the case of closed circuit dry cooling towersrely solely on air to cool the working fluid to near the dry-bulb air temperature. Common applications include cooling the circulating water used in oil refineries, chemical plants, power stations and building cooling. The towers vary in size from small roof-top units to very large hyperboloid structures (as in Image 1) that can be up to 200 metres tall and 100 metres in diameter, or rectangular structures (as in Image 2) that can be over 40 metres tall and 80 metres long. Smaller towers are normally factory-built, while larger ones are constructed on site. They are often associated with nuclear power plants in popular culture, although cooling towers are constructed on many types of buildings. Industrial cooling towers can be used to remove heat from various sources such as machinery or heated process material. The primary use of large, industrial cooling towers is to remove the heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semi- conductor plants, and for other industrial facilities such as in condensers of distillation columns, for cooling liquid in crystallization, etc.
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Two types of cooling towers are:- 1. Cross-flow type
2. Counter-flow type
Department:CRUDE DISTILLATION UNIT (CDU). Date:15/06/2013 Day:Saturday
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Activities:Since, it the first day of our visit to CDU, and also Saturday is a half day in IOCL, so the personnels just take us to this unit and shown the various machines and equipments. Date : 16/06/2013 Day : Sunday Activity :No activity. Date : 17/06/2013 Day : Monday Activity :The engineers and the technicians gave us a brief introduction about what CDU is. Q1.What is CDU? Ans.They told us that the crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of which are then processed further in the other refinery processing units. The CDU is often referred to as the atmospheric distillation unit because it operates at slightly above atmospheric pressure. They also told us about that crude oil is classified by the location of its origin which refers to it as `sweet, which means it contains relatively little sulphur, or as `sour, which means it contains substantial amounts of sulphur and requires more refining in order to meet current product specifications. The number of carbon atoms determines the oil's relative `weight or density. The plant capacity of any other unit depends on the capacity of main fractional column of CDU. It receives the raw crude oil from its supplier (Oil India Ltd. In case of Guwahati refinery) and it does the required pre-treatments of raw crude like Desalting, Preheating etc. The different outputs from the CDU unit of Guwahati Refinery are LPG, Light gasoline(LG), Heavy Gasoline(HG), Kero-l, Kero-ll, Gas oil & Reduced Crude oil(RCO feed to DCU). Q2. What are the composition of crude oil? Ans. The engineers told us thatpetroleum or crude oil is combustible oily liquid reddish brown or sometimes black colour produced from oil wells. It is a complex mixture of various hydrocarbons and their derivatives containing sulphur, nitrogen, oxygen, metals etc. They told that crude oil contains around (82-87) % Carbon, (11-15) % Hydrogen and Oxygen, Nitrogen and other metals (like Ni, V, etc.) constitute the remaining. It is practically impossible to determine exactly the composition of a particular grade of petroleum, so petroleum is analyzed usually to ascertain their group composition.
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Main Constituents of Petroleum hydrocarbons:- 1. Paraffinic Hydrocarbons (Alkanes), 2. Naphthenic Hydrocarbons (Cyclo-Alkanes), 3. Benzene Hydrocarbons (Arenes), 4. Unsaturated Hydrocarbons(Olefins), 5. Oxygen containing compounds: These includesi. Naphthenic Acids, ii. Phenols and iii. Tarasphaltene compounds. 6. Sulphur compounds, 7. Nitrogen compounds, 8. Mineral substances.
Date : 18/06/2013 Day :Tuesday Activity :The engineers and the technicians told us about what are processes carried in this unit. Q3. Why is the need for desalting? Ans. The purpose of desalting is to separate the impurities from the crude oil which are basically mixture of water and dissolved salts (e.g. Sodium, Calcium, Magnesium, Pottasium and Iron salts). This mixture of salt and water is known as brine. This brine is associated with crude oil both as a fine suspension of droplets and also as a more permanent emulsion. They told us that the impurities in crude oil can be classified as: i. Oleophilic, ii. Oleophobic.
These impurities if not separated from crude oil will lead to: 1. Equipment corrosion in the atmospheric distillation unit caused by HCl, which is liberated due to hydrolysis or dissociation of chloride salts. 2. Increased consumption of ammonia to neutralize HCl. 3. Erosion of crude oil pumps, pipelines and valves by suspended matter through abrasive. 4. Plugging of equipment and fouling of heat transfer surfaces. 5. Product degradation like high ash content in fuel oil. 6. Trace metals in distillates, which act as catalyst poisons.
Department:DELAYED COKER UNIT (DCU) Date:19/06/2013 Day:Wednesday Activity:We have gone to the departmenton Wednesday and as it is the first day, so they started from the basics which includes following.
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Q1. What is coker unit? Ans.they have mention that to us that it is an oil refinery processing unit that converts the residual oil from the vacuum distillation column or the atmospheric distillation column into low molecular weight hydrocarbon gases, naphtha, light and heavy gas oils, and petroleum coke. The process thermally cracks the long chain hydrocarbon molecules in the residual oil feed into shorter chain molecules. As the unit is big and it have many important equipment, so they shown the unit from a meter away. They have also mention it as a secondary processing unit which is designed and installed to process the low value heavy stock to upgrade it to more valuable lighter and middle distillates with petroleum coke as one of the products. The feed that they processed in the unit is Reduced Crude oil (RCU) obtained from the bottom of the main fractionating column of the Crude Distillation Unit (CDU) and the process is Thermal Cracking. DCU can process feed with high 40 metal, asphaltene and resin content and in DCU, metals, sulphur, nitrogen normally end up in coke. Date:20.06.2013 Day:Thursday Activity:On the second day One of the engineer named R.K.singhania have taken us all to the main site of DCU and shown us pipe lines through which LPG, gasoline, kerosene ,gas oil flows. Also he says about another important thing that is Q2. What is theory of coking? Ans. He mentioned that during processing of crude oil in the Crude Distillation Unit, hydrocarbon fractions of different boiling ranges, they separated out. These fractions are LPG, gasoline, kerosene,gas oil and reduced crude obtained from the fractionating column of distillation unit. He also mention that the heavier hydrocarbon fraction, obtained as reduced crude oil (also called long residue) at the bottom of the fractionating column is of less value. He also tells us that the coking process involves two types of reactions:- 1. Primary reaction. 2. Secondary reaction.
PRIMARY REACTION :In these reactions the heavier hydrocarbon molecules decompose into smaller ones. This reaction is known as cracking.
SECONDARY REACTION:In these reactions the smaller reactive molecules combine with one another to produce heavy tarry metals. This reaction is called polymerization. Polymerization of heavier reactive molecules takes place in reaction chambers forming coke in an alternate production time of 24 hours. The coke chamber provides residence time of 24 hours for the cracking and polymerization reaction to take place. For this lengthening of the time of liquid phase cracking and polymerization, the whole process of cracking is known as delayed coking.
The two types of chemical reactions that take place during thermal cracking operation may be represented by the chemical reaction as shown below:-
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DECOMPOSITION OF HEAVIER MOLECULES
CH 3 .CH 2 .CH 2 .CH 3 CH 4 + CH 3 CH=CH 2
n-butane methane propene
CH 3 .CH 2 .CH 2 .CH 3 CH 3 CH 3 + CH 2 CH 2
n-butane ethane ethylene
At high temperature the first of these appears to precede the extent of about 55%and second to 45%. Dehydrogenation reaction as given below appears to represent less than 5% of the total. The tendency to dehydrogenate, leaving an olefin with the same number of carbon atoms as the original paraffin hydrocarbon, rapidly diminishes as the series is ascended. Thus the production of large amount of hydrogen by cracking gas and stocks should not be expected.
They also taught us about the processes that are undergone by the department and the process consists of the following main steps:- Pumping and pre-heating of RCO feed. Introduction of RCO feed to the main fractionations (003-CL-02) control of bottom temperature. Introduction of fractionations (003-CL-02) bottoms into heater and cracking. Cracking to coke and distillates. Removal of RFO. Fractionation. Withdrawal of side-cuts. Cooling of SR. Coke chamber operations.
Department :HYDROGEN GENERATION UNIT (HGU) Date: 21/06/2013 Day: Friday Activity: On this day we have been asked to visit the HYDROGEN GENERATION UNIT where the engineers and the technicians told us about the functions of this particular department.
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They told us that The hydrogen unit consists of desulfurization, pre-reforming and process gas cooling. To increase the hydrogen content of the process gas shift conversion of temperature is done in cycles. Purification is done with a Pressure Swing Adsorption technique to remove H 2 S gas from nitrogen generator units. The feedstock to the hydrogen unit is LRU off gas and Straight Run Naphtha (SRN) feed.These feeds can be converted to hydrogen at high thermal efficiency and low capital cost. They told us that LRU off gas is not used much because of its high diene content. Q1.Why we need HGU in refinery ? Ans. In today's industrial era,the problems of environmental pollution ,global warming are increasing day by day. Industries like oil refineries discharge a lot of harmful products to environment. So they have to be treated before discharge. The sulphur,nitrogen content present in the refinery product are very dangerous. They are the main causes of acid rain and smog. The flue gases(CO 2 ,CO,etc)cause green-house effect which in turn creates problem of global warming.
Q2. How this hydrogen generation unit works? Ans.The hydrogen generation is based on steam reforming technology of KTI using a mixture of LN (SRN) and off gas from the LRU as primary feed. For achieving the required feed flexibility a process reforming step is applied upstream using Kaverners technology. For the purification of low hydrogen after the shift conversion, pressure swing absorption (PSA) process is applied to high purity hydrogen product. The following are the processes by which generation of hydrogen is done: 1. Feed conditioning:The light naphtha is received in a surge drum from its pumped and LRU off gas and is collected in a knock-out put and then compressed. Both feeds are mixed after addition of recycled hydrogen; it is vaporized in a steam heat exchanger. The hydrogen in the operation taken as recycles from the PSA unit.
2. Feed hydrogenation/hydro desulfurization:LRU off gases content significant amount of olefins in addition to H2S .The light naphtha contains marcaptans as well as trace amount of heavy metals such as Arsenic, Lead, Vanadium, Copper, which are catalyst poisons. The olefins are saturated by hydrogen temperature is high enough for complete conversion of marcaptans to H2S and for the efficient removal of H2S in the ZnO beds.
Reactions taking place in the steps are:
R=R + H 2 RH-RH...................... (1) [Olefin saturation]
Hydrogenation of organic sulphur and chlorine compounds to for H 2 S and HCl:
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RSH +H 2 R-H +H 2 S................... (2)
2RCl +H 2 R-H +HCl.................... (3)
3. Pre-reforming and reforming:The hydrocarbon feed in presence of steam reacts over nickel bed catalyst which form an equilibrium mixture of methane, carbon dioxide, carbon monoxide and hydrogen. The reactions taking place in this step are as follows:
C n H 2m + nH2OnCO + (0.5m+n)H 2 (endothermic)..........(5) CO + H 2 OCO 2 +H 2 (exothermic).(6)
For hydrocarbons with a higher carbon number the outlet of the pre-reformer will not almost be completed to the CO side thus resulting in almost complete conversion of C 2 .The conversion of methane with steam to CO is strongly favoured by temperature, low pressure and high steam ratios. Reactions (5) will reach equilibrium at the reformer outlet and reaction (6) is referred as shift reaction.
Three different streams to carbon ratios can be used to determine the amount of steam that has to be added: Steam to feed weight ratio: (A) the ratio at the pre-reformer inlet of the wet flow of stem to the weight flow of total hydrocarbon feed. (B) Steam to carbon ratio: Ratio at the reformer inlet of the moles of steam to the moles of carbon. The moles of carbon are counted as atoms.
Q3) What are types of catalyst used in hydrogen formation?
Ans. Basically 2 types of catalyst are used. They are: 1. Pre-reformer catalyst (CRG) :The most common poisons for CRG catalyst are sulphur, chlorine, silica and occasionally naphtha feeds and heavy metal such as lead. The normal symptoms of poisoning are a slack in the bed temperature profile as the fraction of the bed in the inlet becomes deactivated. 2. Reformer catalyst :The most common poisons for steam reforming catalyst are sulphur, chlorine, arsenic etc.
Department: HYDROTREATER UNIT (HDT) Date:22.06.2013 Day:Saturday Activity:We have gone to the department on Saturday. They have shown us the site of HDT and they said that. The purpose of hydro treating plant is to meet Bharath stage III specification of diesel and to produce kerosene of high smoke pint and the plant receives its hydrogen requirements from the HGU.
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They also mention about different fuels, input, product and mechanical devices that are dealt by HDT and they are as follows: FUEL: Crude oil, Motor spirit, Straight run naphtha (SRN),Aviation turbine fuel (ATF), Superior kerosene (SKO), High speed diesel (HSD), Light diesel oil (LDO), Low sulphur heavy stock (LSHS).
Input feed:Diesel in the form of SRK II, SRGO, CK-I, CGO.
Products: MSP, Superior kerosene, Aviation Turbine Fuel.
Date : 23/06/2013 Day : Sunday Activity :No activity.
Department :INDANE MAXIMIZATION UNIT (INDMAX UNIT) Date : 24/06/2013
Day : Monday
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Activity:We have went to a research and development unit known as INDMAX where recycling of residue is done to get the required fuels.
Function: Residue up gradation to LPG, Light Olefins and High Octane Gasoline.
The personnels has mentioned that Indianoil R&D Centre has developed a patented technology INDMAX known as Indane Maximization, to produce Liquefied Petroleum Gas (LPG) from heavy petroleum fractions to the extent of 40 to 65 wt% of feed. The LPG is highly olefinic (70 wt. % of LPG) rendering the INDMAX process as the best suitable technology for producing propylene and butylene from heavy petroleum fractions including residue. Due to very high olefin quantity, the INDMAX LPG has significant petroleum value. After recycling the residue, the end products that are obtained are: Gasoline, LPG, Total clarified oil, Clarified oil, High pressure steam, Dry gas
Fig. Flow Diagram for Fluidized Catalytic Cracking
Date : 25/06/2013
Day : Tuesday.
Activity: No activity.
Department :ISOM UNIT
Date : 26/06/2013
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Day : Wednesday
Activity :Since, it is the first day of our visit to ISOM unit of IOCL, the engineers and technicians took us with them to show us the different equipments and machineries of that unit.
The mechanical parts used in ISOM are: Feed exchanger, Pumps, Heat exchanger, Cooler, Dryer, Condenser, Caustic recycler heater, Valves.
Date : 27/06/2013
Day : Thursday
Activity :On the second day, they explained the functioning of this unit.
They have told that in the refinery it is a part of the MSQU unit (Motor Spirit Quality Up gradation) units. The MSQU consists of NSU, NHDT and ISOM. Here the quality of the motor spirit processed in the distillation plants is improved to meet the given standard by the authorized organization. It is a unit where the octane number of petrol is increased and where normal paraffins are separated from a mixed stream of normal paraffins and non-normal hydrocarbons. Normal paraffins are used as reaction solvents due to their inherent stability. The feed is of naphtha which is input to reactor, after moving through the reactor it passes to the NHDT (Naphtha Hydro Treating Unit). Inside the NHDT unit, the feed moves into a furnace from which it leads to the NHDT reactor. The reactor passes the output to the stripper column after which it enters the feed dryer section. A part of the feed has the nitrogen dried by a suitable reaction. The moving feed then goes to the series of reactors.The reactors give out the products to the stabilizer unit. After passing from the stabilizer, it moves into the deisohexanizer plant from which a part of impure final output is fed into the NHDT part. The purest form of output is produced as motor spirit products.
Department:OIL MOVEMENT AND STORAGE (OM&S)
Date: 28/06/2013
Day: Friday
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Activity :We have gone to this unit and the personnels have told what is the function of this unit. It is the unit of the refinery where the storage and movement of the products are controlled. All the crude products from respective units come to this unit where it is stored in tanks until it is supplied. In Guwahati Refinery almost all the products are supplied through pipelines except few such as LPG & ATF which are transported by either roadways or railways.Generally after the crude is refined the products are stored in tanks which are well maintained and inspected at regular intervals so that no contamination or failure takes place. The tanks where LPG is stored are called Mound Bullet.
Date : 29/06/2013
Day : Saturday
Activity:No activity.
Date : 30/09/2013
Day : Sunday
Activity :No activity.
Department :PLANNING
Date : 01/07/2013
Day : Monday
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Activity :We have submitted the report to the planning department.
Date : 02/10/2013
Day : Tuesday
Activity :No activity.
Date :03/10/2013
Day : Wednesday
Activity :We have collected our training certificates.
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CONCLUSION
The main objective of an industrial training program is to expose students to engineering experience and knowledge which is required in industry and to apply the knowledge taught in the lecture rooms in real industrial situations. So, during the course of this training, I got an opportunity to relate the experience gained from the training with the knowledge gained from the lecture rooms and to get a feel of the work environment of such a prestigious organization. In a changing industrial world with changing perspectives, the gap between theoretical knowledge and analysis and practical skill and application has widened. This gap can only be bridged by greater interaction between the industry and educational institutions imparting technical know-how. This short vocational training was no doubt a big leap for a technical student like me. By being a part of the Industrial Summer Training Program at Guwahati Refinery, I got to acquire the best possible experience and knowledge of the different units of the refinery, the working procedure, the safety measures as well as an engineers responsibilities and ethics while working in an organization. Finally, it can be concluded that such kind of vocational training is very important for every technical student. And, it has been truly a learning experience for me and for my future endeavors, this kind of experience would be of immense help.