ACKNOWLEDGEMENTWith due respect, I express my deep sense of gratitude to the respected and learned guides of Indane Bottling Plant, Oil India Corporation Limited (marketing division) for providing their painstaking and untiring supervision. I am thankful to the training center for giving me the opportunity to learn deeper inside the basics of “study of operation of various mechanical units involved in the bottling of LPG cylinders”.

I also express my sincere thanks to Mr. Hitesh Mehta, Assistant Manager (Engineering), Indane Bottling Plant, OIL (Marketing Division) for providing me with a conducive environment and necessary facilities, allowing me to reach the desired accomplishment.

I am heartily thankful to all the Managers, Engineers and all Shift Operators working under them to give me direction and valuable inputs on each and every sections of study of operation of various mechanical units involved in the bottling of LPG cylinders.

MOHIT DHULL

B.Tech 5th semester

Mechanical Engineering

Guru Jambheshwar University of Science and Technology (GJU S&T)

INTRODUCTIONOver 100 million LPG consumers in the domestic sector in India are servicedThrough a network of 9365 LPG distributors who are getting supply from 181 LPGBottling plants located across the country. In 2007-08, India consumed a total ofAbout 1170 TMT of LPG which is around 10% of the consumption of totalPetroleum products in the country. Out of the total LPG consumption during theYear 2007-08, almost 75% was used for cooking, 17% as auto LPG and theRemaining 8% for industrial use. Of the total supply of 11.7 Million Tonnes of LPGDuring 2007-08, the indigenous production was 8868 TMT from crude oil andNatural gas fractionation (3:1). Imports by PSUs and private entrepreneursAccounted for 2156 TMT and 673 TMT respectively.LPG is transported from production installations i.e. Refineries, FractionationPlants and Import terminals to the bottling plants through pipelines, Bulk LPGWagons or Bulk LPG Tank Trucks. This LPG, subsequently, is bottled in 19 Kg,14.2 Kg and 5 Kg cylinders and is then delivered to commercial consumers andIndividual households. Bottling operation of LPG is very critical, as LPG is a highlyInflammable product and the systems are required to be intrinsically safe. TheSystems also require very comprehensive fire safety arrangements.A typical LPG bottling plant has the following major energy consumingEquipments:-

1. LPG pumps 2. LPG compressors 3. Conveyors 4. Blowers 5. Cold repair facilities including painting 6. Air compressors and air drying units. 7. Transformer, MCC & DG sets 8. Firefighting facilities 9. Loading and unloading facilitiesSome of the LPG bottling plants use a comprehensive monitoring technique forKeeping track of energy / fuel Consumption on per tonne basis. PCRA's energy auditStudies in various LPG plants have found 20-25% energy saving potential in theLPG Plant operations. The following are major energy conservation opportunitiesIn a LPG Plan

INTRODUCTION (OIL)Oil India Limited (OIL), an E & P company is a premier National Oil Company engaged in the business of Exploration, Production and Transportation of crude oil and natural gas. A Navratna Company under The Ministry of Petroleum and Natural Gas, Government of India, it is the second largest national oil and gas company in India as measured by total proved plus probable oil and natural gas reserves and production. Incorporated as a private company in 1959, OIL has been present in the Indian oil and gas exploration and production industry for over five decades. The company presently produces around 3.90MMTPA (Metric Million Ton Per Annum) of crude oil, around 7.93MMSCUMD (Metric Million) of natural gas and more than 45,010 tons of LPG annually.Main Producing Areas:-

Assam, Arunachal Pradesh and Rajasthan in India. Customers: Assam-AGCL, BVFCL, ASEB, NEEPCO, IOC and APL Rajasthan-RRVUNL The company operates a crude oil pipeline in the North-East for transportation of crude oil

produced for both OIL and ONGCL in the region to feed Numaligarh, Guwahati, Bongaigaon and Barauni refineries and a branch line to feed Digboi refinery.

Moreover it has also extended its blocks overseas in Iran, Libya, Gabon, Nigeria, Sudan, Yemen, Egypt and Timor Leste.

A reservoir of hydrocarbons from where natural gas and oil are collected through a drilling in the earth is called a well.

Types- Oil and gas well Oil well – crude oil + associated gas Gas well – natural gas(unassociated gas) + condensate

There are various departments in OIL a few are:- Production (Oil & Gas) Civil engineering Chemical engineering LPG Geological Electrical engineering Instrumentation IT Fire and Safety Transport Field communication Field engineering Drilling Well logging Geophysics Materials Medical Finance and maintenance Training and development

OIL’S LPG PLANTThe two major products of Oil India Limited are Crude Oil and Natural Gas, LPG (Liquified Petroleum Gas) being an important value addition to the natural gas produced. It is the first diversification of OIL active since the last 29 years.

LPG department has two installations:-

(i) LPG Recovery Plant

(ii) LPG Filling Plant

The various sections at LPG department are:-

(a) Recovery Plant Operation

(b) Filling Plant Operation

(c) Mechanical and General Maintenance

(d) Electrical

(e) Instrumentation

(f) Quality control

(g) Safety

(h) Planning & Administration

LPG RECOVERY PLANT

This plant indulges in production of LPG and a by-product i.e, Natural Gasoline (Condensate) from natural gas.

Designed and commissioned in 1982 by The Randall Corporation, USA, it is the second plant in India where LPG is produced from natural gas.

Maintenance of high productivity, quality and concern for safety, health and environment in a professional manner has always been the main motto of this department.

The plant was originally designed to handle 2.215 MMSCM/day of natural gas to produce 60,000 TPA of 50:50 (w/w) C3H8:C4H10 LPG and 12,000 TPA of condensate on 350 days working. But due to changes in the feed gas composition the plant design capacity has been re-rated as 55,000 TPA of 49:51 (w/w) C3H8:C4H10 LPG and 25,000 TPA of condensate.

LPG is liquefied petroleum gas which is a mixture of certain light hydrocarbons, derived from petroleum, which are gaseous at ambient temperature and atmospheric pressure but may be condensed to liquid state at ambient temperature by the application of moderate pressure. Liquefaction is accompanied by a considerable decrease in the volume, thus the liquid formed requires much less storage space stored in the liquid phase in pressurized containers and systems, finally allowed to revert to the vapour phase at or near the point of eventual utilization.

The feed gas, i.e ,natural gas is first drilled from oil well and gas well and then collected at the OCS from where it is sent via pipelines to the main plant area.

In the process of LPG production, the plant also produces a high revenue-earning by-product, i.e, Natural Gasoline, which contains pentane and hexane and it is sold to solvent-manufacturing companies like EPC International, Sikkim Organics, etc.

Important Properties of LPGLPG is colourless, odourless, highly volatile and hazardous liquid that mixes quickly with air. It is heavier than air and one litre of LPG when expands produces about 250 litres of vapour.

Max. Vapour pressure at 40 deg. C =1050 kPa, gauge

Volatility i.e. evaporation temp. In deg. C for 95 % by volume at 760 mm of Hg pressure, Max = 2.0

Hydrogen sulphide ======= pass, i.e. Hydrogen sulphide is not more than 5 ppm

Free water content======= none

Min. 20 ppm of ethyl mercaptan for odor.

Auto-ignition temperature==410 to 580 degree Celsius

Flash Point ============== -104.4 degree Celsius

In a closed liquid filled vessel or pipe, for 1 degree rise in temperature, the pressure increases by 14 to 15 kg/cm^2

Explosive Limit =========== 1.85 to 9.5 % v/v in air

PROCESSThe process comprises of broadly the following:-

(a) Compression

(b) Dehydration

(c) Product extraction through:

(i) On stream cooling by heat exchanger

(ii) Turbo expansion

(iii) Removal of non-condensable and undesired lighter fractions

(d) Product fractionation

The different stages are as follows:-

• Compression:- 1st stage ->Inlet Gas Compression Suction Scrubber

The inlet gas enters at 14kg/cm^2, is compressed to 33.8kg/cm2 in a 4 stage centrifugal compressor driven by York Manufacturer’s 4500HP electric motor operating on 11KV power supply.

The heat of compression is partly used in re-boiling the bottom liquid of de-ethanizer and then cooled to 37.8’c in water cooled heat exchanger.

2nd stage ->Booster Compression Suction Scrubber

The gas is then compressed to 41.9 kg/cm2 driven by the turbo expander and then cooled to 37.8’c.

It is then sent through an inlet filter separator wherein any water that may condense out is knocked out.

• Dehydration:- The gas is dried in one dehydrator while the other is being

regenerated.

The pressure of compressed gas decreases to 39.6 kg/m2 as it reaches dehydrator.

Dehydrator consists of molecular sieve made of crystallized metal Aluminum Silicate of 4A’ size of approx. 11650kg weight in which water particles are retained.

This process is required as the temperature of the gas can go down up to minus 100’c where ice crystals form.

The dehydrated gas passes through a dust filter to remove sieve dust etc.

• Product extraction:- 70% (by volume) of inlet gas is exchanged with cold residue from

de-ethanizer and expander separator overhead, 30% (by volume) exchanges heat with the cold separator liquid in the gas-liquid

exchanger and also with the expander separator liquid.

These two streams combine to enter the cold separator.

Liquid condensed is separated by cold separator and then the liquid is pressurised through the de-ethanizer reflux condenser.

The inlet gas from the cold separator enters the expander where the pressure is lowered, following Joule-Thompson Effect.

The gas liquid mixture out of the expander of 1670 HP and 27000 rpm speed reducing temperature to -84’c, is separated in the expander separator.

Liquid thus collected flows to the de-ethanizer feed pre-heater and then to the de-ethanizer.

• Product Fractionations:-

A de-ethanizer column with three separate packed sections and a reboiler.

The liquid formed at the cold separator and the expander separator enter it, by maintaining proper bottom temperature with reboiler and reflux, the undesirable liquefied fraction methane, ethane and excess of propane are knocked out from the top.

The temperature of LPG is increased by exchanging heat with residue gas, whose refrigeration is in turn used in heat gas exchangers.

A de-butanizer column having 34 trays and reboiler provision through closed circuit hot oil systems with direct fired heater.

The bottom liquid flows on to de-butanizer tower where LPG and condensate are separated out.

LPG comes out at the top which is cooled to ambient temperature and sent for storage in bullets and Horton spheres.

The bottom condensate (Natural Gasoline) is similarly stored in separate storage tanks.

Fire Protection & SafetyLPG is a colorless liquid which evaporates easily into a gas, and the leakage of even a small volume can expand into a large hazardous zone. Since it has no smell, a little mercaptan is added to help detect leaks.

It can burn and explode when gets mixed with air and meets a source of ignition and it can also cause cold burns to skin.

Therefore, Fire Protection & safety is of utmost importance in LPG plant.

Safety in LPG plant includes:-

FIRE PROTECTION SYSTEM

ALARM AND SHUT DOWN SYSTEM

ESD DEVICE

SAFETY RELIEF VALVES

FIRE ALARM SYSTEM

GAS DETECTION SYSTEM

FIRE EXTINGUISHERS

FIRE DRILL

COMMUNICATION SYSTEM

REGULAR INSPECTION OF PLANT

Fire Protection SystemIt comprises of:-

1) A continuously pressurized water network of approximately 2 km length, consisting of one 3000 kLs water reservoir, pumps, hydrant points, monitors (water and foam), hose reels, temperature sensing medium velocity water spray system.

2) Portable fire extinguishers and sand buckets.

3) Fire water pumps.

4) Manual fire call points at different locations.

One of the most important components of the safety system is the Deluge Valve, which is the controlling valve of the pressurized water network.

It can be operated either on auto mode or manually.

Auto Operation :-

1) Water pressure is maintained in the hydrant system through a jockey pump.

2) DV is kept closed by maintaining air pressure in the network.

3) Due to rise in temperature, a heat detector bulb (Quartzoid bulb) in the air network bursts releasing air pressure.

4) When air pressure drops, DV opens spraying water on the vessel.

Manual Operation:-

DV can be opened locally through a valve provided at the DV or by operation of a switch provided in the control room.

FIRE SAFETY SYSTEM

EQUIPMENT QUANTITY

FIRE WATER PUMPS

JOCKEY PUMPS

HYDRANTS

FIRE ALARM POINTS

GAS DETECTION SYSTEM

MONITORS

Sr.No.

1

2

4

5

6

3

02

06 (04+02)

28(21+7)

16 (9+7)+2

21 (12+9)

28 (20+8)

DETAILS OF PUMPSPump Capacity Head Drive Auto start pressureM3/ Hr meter WC (on discharge line)

Jockey 20 90 Electric Motor 4.6 kg/cm2Pump [Auto stop pressure = 8.4 kg/cm2](02 Nos.)

Sprinkler 275 88 Electric Motor 4.0 kg/cm2Pump

Spray 410 88 Electric Motor 1.0 kg/cm2Pump ‘B’Spray 410 88 Electric Motor 2.0 kg/cm2Pump ‘A’

Hydrant 410 88 Electric Motor 3.0 kg/cm2Pump

DEFP -1 410 88 Diesel Engine

DEFP -2 410 88 Diesel Engine 2.5 kg/cm2

GAS DETECTION SYSTEM6 28 (20+8)

Alarm and Shutdown SystemThe plant has got automatic in-built shutdown system to protect the vital equipment and the plant as a whole from any abnormal condition of operation. Audio-visual alarms and shutdown indications are displayed in LPG control room.

All the important equipment are provided with alarm and shutdown devices for critical operating parameters.

All the storage devices are provided with high level alarms.

Emergency shutdown switch is provided in control room to shut down the plant in any case of emergency.

Remote shutdown switches are provided in the local panels of two most important equipment- inlet gas compressor and expander compressor.

Status monitoring is done round the clock through DCS work stations. Operation tested during running condition, planned and non-planned shutdown of the plant.

Testing/calibration is done as and when required for smooth running of the plant and also during the annual maintenance of plant.

EMERGENCY SHUT-DOWN SYSTEM(ESD)

The plant is equipped with ESD switches which calls for shut down in emergency situations. The plant has these emergency switches in three locations – (a) Top Control Room (b) Bottom Control Room (c) Expander Compressor Panel

SAFETY RELIEVE VALVESSRVs are required to release the excess pressure build-up in the system due to process upset etc. so that they are protected from failure due to over- pressure. These valves are provided in the scrubbers, inlet filter separators, dehydrators, gas flow lines and in each of the process pressure vessels.

FIRE ALARM SYSTEMThe fire alarm system consists of alarm switch glass, which when broken will lead to an audio –visual alarm at the bottom control room indicating the location of emergency , and also hooting of sirens in LPG Recovery and Filling Plant areas.

GAS DETECTION SYSTEMGas Detectors, located at the vulnerable areas of the plant, detects the leakage of any explosive gas displaying the amount of leakage in terms of %LEL, together with hooting of an alarm in the DCS system of the control room.

FIRE EXTINGUISHERS

Fire Extinguishers are classified into the following categories, as per the nature of associated fire-

Type A: for general fire out of wood, paper and other such stationary sort of stuffs.

Type B : for fire from liquid as diesel, petrol, diesel etc. utilizing dry chemical powder

Type C : for gaseous fire, as LPG gas, Natural Gasoline etc. utilizing carbon dioxide

Type D : for electrical and metallic source fire

FIRE DRILLFire drill is carried out forth nightly in LPG Recovery and also in LPG Filling Plant by the plant personnel from all sections along with personnel from Fire Service Section ( General Engineering Department ) to test the performance of the Fire Protection System of LPG Department and to take corrective action as necessary.

COMMUNICATION SYSTEMBoth LPG Recovery and Filling Plant are provided with 2 fire sirens (1 km and 5 km region) incorporating the entire area. The smaller siren is operated in manual mode in normal fire drill, else the bigger siren is operated. The bigger siren is inter-locked with fire alarm switches which run in auto-operation mode.

The role of this section is to quantify all physical parameters such as pressure, temperature, flow rate and liquid level. It is an integral part of LPG department of OIL.

LPG implements PLC other than DCS dedicated to equipment control only, sequential start and stop of all devices and tripping of plants during emergency is done by PLC. Whereas DCS controls the entire process temperature, flow and level.

=====Two types of control systems are=====• Distributed Control System (DCS ):- is a digital control system based

on distributed control philosophy. It means a control system which works on the principle of power delegation, for which there should be some connectivity to reach the data to all nodes i.e. Ethernet dual ring network called distributed communication network.

• Programmable Logic Control (PLC ):- is a digital computer used for automation of electromechanical processes, designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

• AC 460 is the heart of the system used to execute any function to maintain it, acts as interface and reads and writes over the I/O panel.

• Ethernet connection is used to communicate or integrate all the nodes.

• Graphics package are used to build plant objects.• Text package provides libraries through which the system is

configured and started.• Database management might be there and uses oracle to send

report.• Input devices- transmitter

Instrumentation

The different devices used and maintained by this section are as follows:

• Gas Chromatography : - used for analysing a mixture of a sample, a fully electronically controlled device. It consists of columns and detectors situated in the oven maintained at 80’c.

• MoistureAnalyzer: - If the temperature is less than -80’C, the moisture in the gas will become saturated and form ice crystals which blocks the pipelines and hence has to be prevented. This is done by placing a device at different locations for checking the amount of moisture present and creates an electrical signals.

• TCD (Thermal conductivity detector):- uses the property of thermal conductivity of gases and converts into electrical signals unique for each and every gas imitating the same property which are received by the calibrated and programmed computers.

• Thermocouple is used for sensing temperature.

• Level transmitters work based on Archimedes Principle. =======the different types are=======

Magnetic level gauge

Radar level gauge

Servo level gauge

Floatation method on the basis of buoyancy force

Flow rate indicator: -

• Mass flow meter: - senses both gravity and volume. It carries out a lot of algorithms considering the resonant frequency of the U wire which gives the inertia of the liquid and temperature for gravity calculation.

• Orifice flow meter: - works on the Bernoulli’s principle and specifies only volume.

Types of valves: -

• Shutdown valve

• Deluge valve

• Solenoid valve: - is a logical valve and operated by solenoid coil which opens up at 110V of AC current or 240V DC.

• Safety relief valve: - are protection devices used in the worst conditions and are always maintained.

• Remotely operated valve (ROV): - It is a logical valve which either closes or opens and requires 60-70psi. The feedback signal is received through PLC in control room and is used only for shutdown, can’t be controlled.

• Control valves: - are the ultimate output devices.

• Audio, visual, olfactory and vibration are the four types of alarms used.

Pressure gauges, based on the Hooke’s law relating stress and strain, consists of the following components: -

• C-type tubes

• Spiral type

• Bello

• Diaphragm

• Dead weight tester

• Manometer

DP (Differential Pressure) transmitter: - measures the difference in pressure through micro-controller.

LEL (Lower Explosive Limit): - calibrated optimum quantity of a combustible substance which can support a self-propagating flame when ignited. The device uses the infrared radiation emitted by the gas which is dependent on its concentration. The inner part is maintained at a higher temperature causing convection i.e. the hot air rises due to its lower density sucking in the air below which is at a lower temperature.

• LELs of substances in terms of percentage present in the atmosphere are-

• CH4- 5%• LPG- 1.2%• Condensate- 1.8%

• If LEL exceeds 10% sparking is prohibited.

Process water: -• The pH must be maintained in the alkaline range i.e. more

than 7 as acidic process water may cause scaling in the heat exchangers. This can be done by treating the water with NaOH and KOH.

• The viscosity should not be very high.

• This water cannot be released into the environment without being treated for its salinity, pH, minerals added and oil accumulated.

The methods employed to dispose off this water without causing any damage are: -

Flocculent(gravity) and coagulant(sand) filters

Aerobic and anaerobic treatment

UV rays cleaning system

Bleaching(chlorine)

Demineralization: - is a series of anion and cation exchanger to maintain the pH around 7.

The minerals such as Ca, Mg, SO4-2, Cl-1 can be removed completely but the water cannot be polished off silica if its concentration is below 2ppm.

The water is heated in a high pressure water boiler.

If the toxic level of water is very high and cannot be treated it is injected back into the well.

Quality Control LaboratoryIt is a branch of the Chemical department of OIL, and being a service section its main role is to evaluate the quality of products, LPG and Residue Gas, along with the feed gas that is, Natural Gas.

It mainly performs two types of tests, viz., compositional and physical.

1. Physical Analysis: -

It includes Volatility and Vapor Pressure tests as per IS 4576: 1999 certification, depending on which one can decide whether the product is good or bad.

a) Volatility : - It is measured by Weathering Test. In this test, the sample is taken in a tube called weathering tube and a thermometer is put in it. The temperature is noted at 25, 50, 90 and 95 percent(by volume) evaporation and the temperature corresponding to 95% evaporation is called the Weathering Temperature and it should be in the range of +2 degree C and -2 degree C.

b) Vapor Pressure : - For this we take the sample in a sampler and put it in a temperature bath which is maintained at 40 degree C and we check the pressure building up at this temperature indicated by the pressure gauge.

Apart from these tests, some other tests are also performed to measure the density of sample, moisture level and also the Ethyl Mercaptan (C2H5SH) level in LPG. A hydrometer is used to measure density.

We use Doctor’s Test to check minimum value of Mercaptan added to LPG. For this, Sodium Plumbate solution is taken in a cylinder and LPG sample is added which mixes with it. A positive Doctor’s Test gives a yellow precipitate/solution indicating presence of Mercaptan.

Dew Point Test: -

We have to check dew point at dehydrator inlet and outlet, gas inlet and air inlet. As the feed gas, after compression, needs to be dehydrated using dehydrator, hence we need to check whether the molecular sieves (which are made of alumina silicate) are working.

2. Compositional Analysis: -It includes compositional analysis of the natural gas coming from production department, LPG and Residue gas, done by Gas Chromatography (GC), as explained below: -

GC, a common type of chromatography performed in a Gas Chromatograph, is used in analytical chemistry for separating and analyzing compounds that can be vaporized without decomposition. It is based on different boiling points and retention time for different components. It is used for testing the purity of a particular substance, or separating the different components of a mixture.

GC consists of two phases: -mobile phase and a stationary phase. Here the mobile phase is a carrier gas, usually an inert gas like Helium or a non-reactive gas like Nitrogen.

The stationary phase is a microscopic layer of a liquid or a polymer on an inert solid support, inside a piece of glass or metal tubing called a column.

The molecules move to the wall of the column, coated with different stationary phases, which causes each compound to elute at a different time, known as the Retention Time of the compound.

GC Analysis:-In a GC analysis, a known volume of gaseous or liquid analyte is injected into the column using a micro-syringe. As the carrier gas sweeps the analyte molecules through the column, this motion is inhibited by the adsorption of the analyte molecules either onto the column walls or onto packing materials in the column. The rate at which molecules progress along the column depends on the strength of adsorption, which in turn depends on the type of molecules and on the stationary phase materials. As each type of a molecule has a different rate of progression, the various components of the analyte mixture are separated as they progress along the column and reach the end of the column at different times (retention time). A detector is used to monitor the outlet stream from the column, hence the time at which each component reaches the outlet and the amount of that component can be determined.

Generally substances are identified by the order in which they emerge from the column and by the retention time of the analyte in the column. The chromatographic data is presented as a chromatogram, which is a graph of detector response (y-axis) against retention time (x-axis). This provides a spectrum of

peaks for a sample representing the analyte present in a sample eluting from the column at different times. The area under a peak is proportional to the amount of analyte present in the chromatogram, and by calculating it, the concentration of an analyte in the original sample can be determined.

Electrical maintenance• The power house of OIL generates 14.45 MW with the help of two gas

turbines which are alternatively at running and standby modes.

• The power house supplies 11KV to the substation in the LPG plant through two underground cables.

• This incoming power is sent into the feeder from two different power houses, #1 and #2. These two sections are connected by a bus coupler which is used only when the maintenance job needs to be done.

• From #1 the 11KV is supplied to the spare feeder, 4500HP motor starter panel and to a transformer1 of 1000KVA capacity which steps 11000V down to 415V.

• There are 8 vacuum circuit breakers. It is monitored by protective relays such as VCB, ACB, SF6 of the circuits.

• UPS system gives an uninterrupted power supply normally of AC current with a battery backup of 120KVA capacity. There are 2 types of UPS in which input is 415V but outputs are 415V and 110V.

• A battery converts a voltage input of AC to DC. An 110V Ni-Cd battery set is used.

• Another auto-transformer other than the two in the feeder circuits produce 450V line. It is a part of motor starter panel. During starting of motor the load might reach seven times its full load and then drop back which can’t be allowed. To reduce this we use this auto-transformer starter for 20 seconds and then give back to the normal system.

• Motor control center (MCC) is provided by the 415V bus.

• Tripping is a condition when difference between the incoming and outgoing currents of the isolator is more than a given value and the on-off switch of the isolator turns off automatically.

AUTOTRANSFORMER: -• Auto-transformer is used for applying reduced voltage to stator during

starting. Thereby the starting current is reduced. The auto-transformer is provided with change-over switch. As the motor comes to full speed, the change-over switch is thrown over to run position.

CIRCUIT BREAKER AND ITS TYPES: -

• Circuit Breaker is an automatic device capable of making and breaking an electric circuit under normal and abnormal conditions such as short circuits. The part of the circuit-breakers connected in one phase is called the pole. A circuit-breaker suitable for three phase system is called a triple pole circuit-breaker.

• Each pole of the circuit-breaker comprises one or more interrupts or arc-extinguishing chambers. The interrupters are mounted on support insulators. The interrupter encloses a pair of fixed and moving contact. The moving contacts can be drawn apart by means of the operating links or the operating medium. The operating mechanism of the circuit-breaker gives the necessary energy for opening and closing of contacts of the circuit-breakers.

• The arc produced by the separation of current carrying contacts is interrupted by a suitable medium and by adopting suitable techniques for extinction.

• Circuit Breaker is used for opening and closing circuits for normal switching operations. During short circuits or abnormal conditions, relay operates and gives opening command to circuit-breaker and circuit is opened automatically.

TYPES OF CIRCUIT BREAKERs IN LPG PLANT: -• Moulded Case Circuit Breaker (MCCB):

• Air Circuit Breaker (ACB): It utilizes air at atmospheric pressure for arc- extinction.

• Vacuum Circuit Breaker (VCB): The fixed and moving contacts are housed inside a permanently sealed vacuum interrupter. The arc is quenched as the contacts are separated in high vacuum.

POWER HOUSEPower House generates power for the entire plant using the concept of a Gas Turbine,which is based on the Bryton Cycle.

The following components comprise a Gas Turbine: –

(a)Axial Air Compressor

(b) Combustor

(c)Turbine

(d) Auxiliaries

Axial Air Compressor: -Air after passing through the filter enters the axial compressor and flows parallel to the axis .it consists of a stationary body called Casing and a moving part called Rotor, and Blades , some of which are attached to the casing and some to the rotor . A pair of stationary and moving blades is called a Stage and the compressor has got 15 such stages. Air gets compressed as it passes through the different stages.

Combustor: -

Air from the compressor enters the combustor which has 2 parts –a transition piece and a combustor, the latter being divided into 3 zones, viz, primary, secondary and tertiary, each consisting of a number of holes.

Fuel is injected in the primary zone and ignited using spark from the spark plug, thereby creating a cyclone.

In the secondary zone, complete burning of fuel is ensured. As the temperature of air rises to a high value of 1200 degree C,it needs to be cooled down to 899 degree C at least before entering the transition piece. For this more air is to be supplied to the tertiary zone.

The transition piece has a nozzle which increases the velocity of air.

Turbine: - Air from combustor enters the turbine where it expands and exits as exhaust gas. The rotating turbine then generates power via a generator. The exhaust gas is at a temperature of 370 degree C and this energy can be utilized to produce more electricity using the steam turbine. For this DM(De-Mineralized) plant is required but this is a costly process. This produces about 7Mwatt power in addition to the actual power of 14.45Mwatt.

As the Gas Turbine is not self-starting, a starter diesel engine is required.

A total of 14.45Mwatt electricity is the output from the generator. Out of this 10.4Mwatt is utilized to fulfill the electricity requirement of the different units of the industry.Mechanical Maintenance

The Maintenance Section of the LPG department is responsible for the following: -

1)Maintaining the plant availability to achieve MOU target.2)Maintenance of all rotary and stationary equipment of the

LPG plant to keep them in proper working conditions.3)Execution of various contract jobs under the department

related to maintenance of the plant.4)Planning of maintenance activities for annual plant

maintenance.5)Spare part management for maintenance of the plant.

This section aims to achieve the following targets: -1)To reduce the cost of maintenance activities by 1 % of the

previous year.2)To keep the minimum MTTR of critical equipment for

achieving the MOU target.3)To keep good relations and understanding with the different

sections of the LPG department.4)To keep good relations and understanding with the other

The Mechanical Maintenance Section of the LPG department is responsible to perform the following duties: -

1) Daily plant check up to ensure smooth operation of the plant and to check lube oil level and vibration & sound and other parameters.

2) Monthly vibration measurement to ensure that vibration levels of critical equipment are within limits and take necessary corrective measurements.

3) Periodical lube oil testing to test lube oil of three major equipment of LPG recovery section, namely, Inlet Gas Compressor, Gear Box and Expander-Compressor.

4) Cleaning of cooling tower top chambers to ensure its proper functioning.

5) Testing of SRV to ensure its correct functioning at its Set Pressure.

6) Sound level measurement to measure the intensity of sound at specified locations and compare it with permissible limit.

7) Replacement of damaged or worn out Vee-Belt (Endless belts used between driving pulleys to transfer power).

8) Replacement of empty Mercaptan drum of LPG storage area.

9) Top up lube oil into Expander Surge Tank to maintain a certain oil level in it.

10) Air compressor lube oil top up to maintain the required level of oil.

11) Materials inspection and suitability report for the acceptability of the materials received against direct charge Indents/purchase orders.

12) Engaging staff on overtime to complete the repairing job within the day in view of urgent nature of work for operational as well as safety requirements.

The Maintenance Section of the LPG department is responsible for the following: -

1)Maintaining the plant availability to achieve MOU target.2)Maintenance of all rotary and stationary equipment of the

LPG plant to keep them in proper working conditions.3)Execution of various contract jobs under the department

related to maintenance of the plant.4)Planning of maintenance activities for annual plant

maintenance.5)Spare part management for maintenance of the plant.

This section aims to achieve the following targets: -1)To reduce the cost of maintenance activities by 1 % of the

previous year.2)To keep the minimum MTTR of critical equipment for

achieving the MOU target.3)To keep good relations and understanding with the different

sections of the LPG department.4)To keep good relations and understanding with the other

13) Workshop job requisition to carry out emergency repair and fabrication jobs at general workshop.

14) Breakdown maintenance of machines/ equipment.

15) Preparation of tentative maintenance schedule of air compressor.

16) Ultrasonic thickness measurement to gauge metal surfaces for the thickness.

13) Handling/cleaning services and day-to-day maintenance in LPG recovery and filling plant.

14) Servicing, Inspection and Testing of LPG storage vessels.

15) To replace hot and cold insulation system of LPG recovery plant with new insulation system at a specified time interval.

16) Major overhauling of Inlet Gas Compressor and Expander Compressor to ensure smooth and trouble free operation.

17) De-coupling of various motor devices to carry out maintenance work on driver (motor) or driven side (pumps, compressors, fans, etc.).

18) Hydro-testing of pressure vessels and storage vessels to check the condition/health of vessel.

19) Periodical testing of lifting tools.

20) Storage, handling and disposal of lube oil and other hazardous materials.

LPG Filling Plant• In LPG Filling Plant –

(i) LPG is bottled into cylinders (packed form) in Carousel machine containing 24 number of filling points or guns.

(ii) LPG is filled into road tankers (bulk form). These cylinders and road tankers are handed over to IOCL for marketing.

• The LPG is pumped to LPG Filling Plant from LPG storage vessels at LPG Recovery Plant.

• The incoming LPG pressure in the pipeline is about 14kg/cm2. The cylinder consists of a head ring, 3 fins, valve, high pressure seamed cylinder and a foot ring.

• The inside of the valve is installed with an O-ring and a valve pin. The valve needs to be checked for any leak possible.

• The bottling capacity of the plant is about 6000-7000 cylinders per day.

• The empty cylinders are first marked by TARE WEIGHT MARKING and their marked weights are stored by a HMI (Human Machine Interface) device called pre-check scale.

• The marked cylinders go to Carousel machine by chain conveyor, run by 14 motor driven Gear boxes. In Carousel machine the empty cylinders are first sensed by photo-electric sensors.

• In each filling gun two sensors are linked which are placed at the top and at the bottom side of the cylinder.

• The bottom side sensor is called wheel arm sensor. The bottom photo-cell senses the position of the cylinder on the machine. The top photocell senses the cylinder and gives instruction to the gun. Then the respective gun shoots the respective cylinder.

• The cylinder is filled in the course of one rotation of the carousel, the filling time is approximately 60 seconds.

• When the regulator’s pin when pressed together with the valve pin, two holes are opened.

• The LPG filled in the cylinder should be of weight 14.2 kg. If the gun is unable to fill the cylinder within one minute for delay error, the cylinder will again revolve for one minute.

• In the outlet of the machine has a puller with sensor which allows only those cylinders filled up to the standard weight to go out of the machine, otherwise it will return back the cylinder to the machine again.

• The cylinders are introduced through a check scale, which checks the over weighted cylinders and bypass them to another section called correction unit by pusher with photo-electric sensor.

• The over weighted cylinders are manipulated up to the standard by manual filling. This over weighted range is considered as +200gm.Now the corrected cylinders are lined up with the other cylinders.

• Now the cylinders are fed to Gas detector and O-ring detector unit to check the leakages and damages. In this unit the damaged cylinders are rejected. The tested cylinders are then fed to counting unit to count by a sensor and stored. In hot air sealing unit the cylinders are sealed and fed to transportation section.

• The evacuation unit takes care of the rejected cylinders which are found defective by applying suction pressure on the LPG cylinder and the valuable LPG is sent back in the form of vapor to the storage tanks.

• In the sealing unit i.e. Hot air seal unit, a plastic cap is placed over the cylinder along with a thin PVC seal which then is exposed to 265’C of hot air.

• Compressed air of 7.5kg/cm2 is required for the functioning of the plant, which is done by using V-type, screw-type and vertical air compressor which are manually checked after the working hours which can be done.

• In bulk filling, LPG and condensate are filled into tankers following the same procedure as that of packed form.

• The tanker is checked for a hydraulic testing certificate valid for a period of 5 years from the date of issue.

• The tanker evacuation unit is utilized when excess is sent into the tanker. The liquefied form of LPG filled into the tank is 18% less than the total tanker capacity.

•

CONCLUSION

The vocational training enhanced my practical knowledge. Most importantly, I am oriented to the industrial scenario and its many challenges and subtleties. The smooth functioning of an industry depends to a large extent on the mutual co-operation among its different wings.Nevertheless, I did enjoy the training to the fullest and are very sure that this training will help me in my future endeavors.

Thanking You

A REPORT ON INDUSTRIAL TRAINING

ATOIL INDIA LIMITED

BADSHAHPURINDANE BOTTLING PLANT(MARKETING DIVISION)

Submitted by: -MOHIT DHULL

Bachelor of Technology5th Semester

Department of Mechanical EngineeringGuru Jambheshwar University of Science and Technology

Hisar

APRACTICAL TRAINING REPORT

AT

INDANE BOTTLING PLANT BADSHAHPUR, GURGAONINDIAN OIL CORPORATION LIMITED(MARKETING DIVISION)

Submitted to: - Submitted by:-

Mr. Kaushal Mohit Dhull

Faculty of Mech. Deptt. 12162035

GJUS&T BTECH. 3rd Year

PLANT LAYOUTSCOPE

The general layout principles of LPGStorage, bottling and bulk handling facilities

Have been detailed in this chapter. The variousFacilities within LPG storage and bottling

Premises shall be located based on Table-I andTable-II.

TABLE – IINTERDISTANCES FOR LPG

FACILITIES1 LPG STORAGE

VESSEL2 T-11 T-11 15 T-11

2 BOUNDARY NOT ASSOCIATED

WITH LPG PLANTS

T-11 - 15 15 -

3 LPG SHED T-11 15 15 15 304 TANK TRUCK

GANTRY15 15 15 NA 30

5 FIRE WATER PUMP HOUSE

T-11 * 30 30 -

NOTES : - 1. ALL DIMENSIONS ARE IN MTS.2. NOTATION T-II: REFER TABLE II*: ANY DISTANCE FOR OPERATIONAL CONVENIENCE

3. MAXIMUM PACKED STORAGE LIMITED TO 20000 KGS

TABLE – II

INTERDISTANCES BETWEEN LPG STORAGE VESSELS, FILLING SHED,

STORAGE SHEDAND BOUNDARY/PROPERTY LINE/GROUP

OF BUILDINGS.

CAPACITY OF EACH VESSEL

(CU. MTS. OF WATER)

DISTANCES (MTS.)

10-20 1520-40 20

41 – 235 Note 3 30

LOCATION & SAFETY DISTANCES

LOCATION

While assessing the suitability of any siteFor location of LPG storage facilities, theFollowing aspects shall be considered:

(a)In addition to the requirements for safety thePlant should be located in such a manner soAs not to be contagious to any industryHaving open flame. Property line of thePlant shall be away from the central line ofThe road/railways as per statutoryRequirements and overhead high tensionWire shall not traverse through the batteryLimit of the plant.(b)Adequate availability of water from a nearbyReliable source should be ensured.

(c) The topographical nature of the site witSpecial reference to its effect on the disposalOf LPG, in the even of its escape, if any,Shall be considered.(d) The access for mobile fire fightingEquipment to the storage vessels under allForeseen circumstances, preferably from twoSides and upward prevailing wind directionIs an important parameter.(e) For any expansion beyond the specifiedLimit, all provision under OISD-144 shall beApplicable.(f) Predominant direction of wind and velocityShall be considered.(g)Longitudinal axis of horizontal vessels(Bullets) shall not point towards otherVessels, vital process equipment and otherFacilities.(h) Storage vessels shall be located downward Of processing units, important buildings.(I)Storage vessels shall be laid out in single Row within a group.(j) Storage vessels shall not be located one Above the other.

SAFETY DISTANCES

The safety distances as given in Table-Iand Table-II are the distances in plane between

the nearest point on a vessel other than thefilling/discharge line and a specified feature,

e.g.adjacent vessel, site boundary etc.

TYPE OF STORAGE VESSELS

HORIZONTAL CYLINDRICALVESSELS

Horizontal bullets with the total volumetriccapacity upto 235 Cu. M. Note 3 shall be used

forstoring LPG.

LAYOUTThe following aspects shall be considered while

Establishing layout of LPG storage vessels.

LPG STORAGE FACILITIES

GRADINGArea below the storage vessels

(Bullets) shall be free from vegetation, propertyGraded with the slope of 1.100 (towards one

Side) away from the pipeline manifold.

PIPING(i)Piping manifold shall be away from the

Shadow of the vessel.(ii)Spring loaded quick closing valve with

fusible link or Rov to facilitateimmediate closure in the event of

emergency, if any, shall be provided inthe LPG liquid line of each vesselbetween excess flow check valve

(EFCV) and pipeline manifold.

SURFACE DRAINAGE

In order to prevent the escape of spillageinto the main drainage system, surface waterfrom the storage area and from the manifoldarea shall be directed to the main drainagethrough a water seal designed to avoid the

spread of hydrocarbon.

GROUPING

Vessels shall be arranged in a group andtotal volumetric capacity of the group shall

be ,limited to 235 Cu. M. Note 3. Interdistancesas specified in Table-I and Table-

II shall be maintained.Top surfaces of all the vessels installed in a

group shall be on the same plane so that thesafety blowout from them do not affect each

Other.

LPG BULK HANDLING FACILITIES

1. LPG tank lorry loading/unloading gantryshall be located in a separate block and

shall not be grouped with other petroleumproducts.

2. Space for turning with a minimum radiusof 20 meters for tank lorries shall be

provided commensurate with thecapacities of the tank trucks.

3. LPG tank lorries upto the maximum of 2Nos, at a time should only be taken for

unloading.

4. Adequate permanent protection for TLDpipeline island shall be provided. The

minimum width of such pipeline islandshall be 1 metre.

LPG BOTTLIG FACILITIES

(1)LPG Bottling facilities should be located aa safe distance from other facilities withminimum ingress of trucking traffic anddownward wind direction with respect tobulk storage.There shall not be any deep ditches in thesurrounding area to avoid settling of LPG.

(2) Bottling section shedshall be of single story having asbestosroofing and open from allsides for adequate ventilation to ensurequick dessipation of LPG Vapour in theevent of leakage, if any, RCC roofingshall not be used. Anti-static masticflooring conforming to IS-8374 shall beprovided in the LPG filling shed/cylinderstorage shed to avoid frictional sparks.Anti-static mastic coating up to 1.5 metersHeight from bottom of the supportingColumns in the shed shall be provided.

(3)Stacking area for empty and filledcylinders shall be marked specifically.Cylinders shall always be stackedvertically in two lines. For details ofcylinders stacking pattern refer AnnexurePlant should have one shed each forfilling and storing of filled./emptycylinders.

(4) Valve changing operation should becarried out in a demarcated place withinthe filling shed itself.

(5)Cylinder storage shall be kept on or abovegrade and never below grade in celler orbasement.

(6)Filled cylinders shall not be stored in thevicinity of cylinders containing othergasses or hazardous substances.(7)Escape routes shall be specified in LPGsheds for evacuation of employees in

emergency.

(8)There shall not be any trapping ofpersonnel in LPG sheds by conveyours,cylinders and other facilities. If suchtrapping cannot be eliminated, it should bekept to the minimum. In such placessufficient arrangements for escape routesto be provided. (9)Adequate lighting shall be provided in thecylinder filling area.(10)Water drains from cylinder filling areas toout side drainage system shall be providedwith water seals (near the plant boundary)

PROTECTION OF FACILITIES

(1) There shall be road all around the variousfacilities within the bottling plant areas for

accessibility of fire fighting operations.

(2) There shall be proper industry typeboundary wall all around the Bottling

Plant.

UTILITIES

Utilities consisting of Fire Water Pumps,Admin. Building, Motor Control Center, DGRoom, Air Compressors, Dryers etc. shall beseparated from other LPG facilities and tobe located as per the area classification as

specified in Table-I.

CONTENTS

FACULTY CERTIFICATE

Forwarded here with a summer internship report on “STUDY OF VARIOS

MECHANICAL UNITS INVOLVED IN THE BOTTLING OF LPG CYLINDERS” of Indian

Oil Corporation Limited submitted by Mohit Dhull, Enrollment No-12162035

student of Bachelor of Technology 5th Semester (2014-15).

This project work is partial fulfillment of the requirement for the degree of

Bachelor of Technology from Guru Jambheshwar University of Science and

Technology Hisar, Haryana.

--------------------------------

Mr. Kaushal

Deptt. Of Mechanical Engg.

Guru Jambheshwar University of Science and Technology