ACKNOWLEDGEMENT

With 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)

INTRODUCTION Over 100 million LPG consumers in the domestic sector in India are serviced Through a network of 9365 LPG distributors who are getting supply from 181 LPG Bottling plants located across the country. In 2007-08, India consumed a total of About 1170 TMT of LPG which is around 10% of the consumption of total Petroleum products in the country. Out of the total LPG consumption during the Year 2007-08, almost 75% was used for cooking, 17% as auto LPG and the Remaining 8% for industrial use. Of the total supply of 11.7 Million Tonnes of LPG During 2007-08, the indigenous production was 8868 TMT from crude oil and Natural gas fractionation (3:1). Imports by PSUs and private entrepreneurs Accounted for 2156 TMT and 673 TMT respectively. LPG is transported from production installations i.e. Refineries, Fractionation Plants and Import terminals to the bottling plants through pipelines, Bulk LPG Wagons 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 and Individual households. Bottling operation of LPG is very critical, as LPG is a highly Inflammable product and the systems are required to be intrinsically safe. The Systems also require very comprehensive fire safety arrangements. A typical LPG bottling plant has the following major energy consuming

Equipments:- 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 facilities Some of the LPG bottling plants use a comprehensive monitoring technique for Keeping track of energy / fuel Consumption on per tonne basis. PCRA's energy audit Studies in various LPG plants have found 20-25% energy saving potential in the LPG Plant operations. The following are major energy conservation opportunities In 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 PLANT

The 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 LPG

LPG 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

PROCESS

The 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 & Safety

LPG 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 System

It 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.

5

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)

Pump Capacity Head Drive Auto start

pressure M3/ Hr meter WC (on discharge line)

Jockey 20 90 Electric Motor 4.6 kg/cm2

Pump [Auto stop pressure = 8.4 kg/cm2]

(02 Nos.)

Sprinkler 275 88 Electric Motor 4.0 kg/cm2

Pump

Spray 410 88 Electric Motor 1.0 kg/cm2

Pump

‘B’

Spray 410 88 Electric Motor 2.0 kg/cm2

Pump ‘A’

Hydrant 410 88 Electric Motor 3.0 kg/cm2

Pump

DEFP -1 410 88 Diesel Engine

DEFP -2 410 88 Diesel Engine 2.5 kg/cm2

Alarm and Shutdown System

The 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 VALVES

SRVs 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 SYSTEM

The 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 SYSTEM

Gas 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 DRILL

Fire 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 SYSTEM

Both 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.

• Moisture Analyzer: - 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 Laboratory

It 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 HOUSE

Power 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 7 M watt

power in addition to the actual power of 14.45 M watt.

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 departments of the company.

5)To keep close watch on various activities so that there is no misuse of approved funds and that these are properly

utilized.

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.

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

AT

OIL INDIA LIMITED

BADSHAHPUR

INDANE BOTTLING PLANT

(MARKETING DIVISION)

Submitted by: -

MOHIT DHULL

Bachelor of Technology

5th Semester

Department of Mechanical Engineering

Guru Jambheshwar University of Science and Technology

Hisar

A

PRACTICAL TRAINING REPORT

AT

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

Submitted to: - Submitted by:-

Mr. Kaushal Mohit Dhull

Faculty of Mech. Deptt. 12162035

GJUS&T BTECH. 3rd Year

PLANT LAYOUT

SCOPE The general layout principles of LPG

Storage, bottling and bulk handling facilities

Have been detailed in this chapter. The various

Facilities within LPG storage and bottling

Premises shall be located based on Table-I and

Table-II.

TABLE – I INTERDISTANCES FOR LPG

FACILITIES

1 LPG STORAGE

VESSEL

2 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 30

4 TANK TRUCK

GANTRY

15 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 SHED

AND BOUNDARY/PROPERTY LINE/GROUP

OF BUILDINGS.

CAPACITY OF EACH

VESSEL

(CU. MTS. OF WATER)

DISTANCES

(MTS.)

10-20 15

20-40 20

41 – 235 Note 3

30

LOCATION & SAFETY DISTANCES

LOCATION

While assessing the suitability of any site For location of LPG storage facilities, the Following aspects shall be considered:

(a) In addition to the requirements for safety the Plant should be located in such a manner so As not to be contagious to any industry Having open flame. Property line of the Plant shall be away from the central line of The road/railways as per statutory Requirements and overhead high tension Wire shall not traverse through the battery Limit of the plant.

(b) Adequate availability of water from a nearby

Reliable source should be ensured.

(c) The topographical nature of the site wit Special reference to its effect on the disposal Of LPG, in the even of its escape, if any, Shall be considered. (d) The access for mobile fire fighting Equipment to the storage vessels under all Foreseen circumstances, preferably from two Sides and upward prevailing wind direction Is an important parameter. (e) For any expansion beyond the specified Limit, all provision under OISD-144 shall be Applicable. (f) Predominant direction of wind and velocity Shall be considered. (g) Longitudinal axis of horizontal vessels (Bullets) shall not point towards other Vessels, vital process equipment and other Facilities. (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-I

and Table-II are the distances in plane between the nearest point on a vessel other than the filling/discharge line and a specified feature,

e.g. adjacent vessel, site boundary etc.

TYPE OF STORAGE

VESSELS

HORIZONTAL CYLINDRICAL

VESSELS

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

for storing LPG.

LAYOUT The following aspects shall be considered while

Establishing layout of LPG storage vessels.

LPG STORAGE FACILITIES

GRADING Area below the storage vessels

(Bullets) shall be free from vegetation, property Graded 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 facilitate immediate closure in the event of

emergency, if any, shall be provided in the LPG liquid line of each vessel between excess flow check valve

(EFCV) and pipeline manifold.

SURFACE DRAINAGE

In order to prevent the escape of spillage into the main drainage system, surface water from the storage area and from the manifold area shall be directed to the main drainage through a water seal designed to avoid the

spread of hydrocarbon.

GROUPING

Vessels shall be arranged in a group and total volumetric capacity of the group shall

be ,limited to 235 Cu. M. Note 3. Interdistances as 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 the safety blowout from them do not affect each

Other.

LPG BULK HANDLING FACILITIES

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

shall not be grouped with other petroleum products.

2. Space for turning with a minimum radius

of 20 meters for tank lorries shall be provided commensurate with the

capacities of the tank trucks.

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

unloading.

4. Adequate permanent protection for TLD pipeline island shall be provided. The

minimum width of such pipeline island shall be 1 metre.

LPG BOTTLIG FACILITIES

(1) LPG Bottling facilities should be located a a safe distance from other facilities with minimum ingress of trucking traffic and downward wind direction with respect to bulk storage. There shall not be any deep ditches in the surrounding area to avoid settling of LPG.

(2) Bottling section shedshall be of single story having asbestos roofing and open from all sides for adequate ventilation to ensure quick dessipation of LPG Vapour in the event of leakage, if any, RCC roofing shall not be used. Anti-static mastic flooring conforming to IS-8374 shall be provided in the LPG filling shed/cylinder storage shed to avoid frictional sparks. Anti-static mastic coating up to 1.5 meters Height from bottom of the supporting Columns in the shed shall be provided.

(3) Stacking area for empty and filled cylinders shall be marked specifically. Cylinders shall always be stacked vertically in two lines. For details of cylinders stacking pattern refer Annexure Plant should have one shed each for filling and storing of filled./empty cylinders.

(4) Valve changing operation should be carried out in a demarcated place within the filling shed itself.

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

(6) Filled cylinders shall not be stored in the

vicinity of cylinders containing other gasses or hazardous substances.

(7) Escape routes shall be specified in LPG

sheds for evacuation of employees in emergency.

(8) There shall not be any trapping of personnel in LPG sheds by conveyours, cylinders and other facilities. If such trapping cannot be eliminated, it should be kept to the minimum. In such places sufficient arrangements for escape routes to be provided.

(9) Adequate lighting shall be provided in the cylinder filling area.

(10)Water drains from cylinder filling areas to out side drainage system shall be provided with water seals (near the plant boundary)

PROTECTION OF FACILITIES

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

accessibility of fire fighting operations.

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

Plant.

UTILITIES

Utilities consisting of Fire Water Pumps, Admin. Building, Motor Control Center, DG Room, Air Compressors, Dryers etc. shall be separated from other LPG facilities and to be 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