EXCURSION REPORT

ON
LPG BOTTLING PLANT
IOCL, BALIDIH,
BOKARO
JHARKHAND





























Submitted by
ASHISH PANDEY
2010JE0868
PETROLEUM ENGG
SERIAL NO 71




ACKNOWLEDGEMENT

I would especially like to thank Mr. B.P Yadav (Chief Engineer, IOCL
bottling Plant, Bokaro) for helping us understand the complete procedure of the
LPG filling process. The various information provided by him helped in making
this short report. The report quality has also been enhanced because of sharing
of his practical experience.

I also take this opportunity to express a deep sense of gratitude to the
Petroleum Engineering Department, Indian School Mines for arranging this
excursion.
I am also obliged to Prof. V P Sharma (Head of the Department,
Petroleum Engineering Dept, Indian School Of Mines) for the valuable
information provided by him in the respective fields. I am also grateful to the
enthusiasm and encouragement provided by him through the course that helped
me reach the heights for preparation.

Lastly, I thank the Almighty, my parents and all my friends for their
constant encouragement without which this assignment would not be possible.



















ASHISH PANDEY
2010JE0868
Petroleum Engg






INTRODUCTION


Indian Oil Corporation Limited, or Indian Oil, is an Indian state-
owned oil and gas corporation with its headquarters in New Delhi India. It is the
world's 88th largest corporation, according to the fortune global 500 list, and the
largest public corporation in India when ranked by revenue Indian Oil and its
subsidiaries account for a 49% share in the petroleum products market, 31% share in
refining capacity and 67% downstream sector pipelines capacity in India. The Indian
Oil Group of companies owns and operates 10 of India's 22 refineries with a
combined refining capacity of 65.7 million metric tonnes per year. Company entered
into LPG business in year 1997 in joint venture with Petronet LNG. In FY 2012 IOCL
sold 75.66 million tonnes of petroleum products and reported a PBT of 37.54 billion,
and the Govt. of India earned an excise duty of 232.53 billion and tax of 10.68
billion.


WHAT IS LPG
LPG is a mixture of commercial butane and commercial propane having
saturated and unsaturated hydrocarbons. LPG is gaseous at normal atmospheric
pressure, but may be condensed to the liquid state at normal temperature, by the
application of moderate pressures. Although they are normally used as gases, they
are stored and transported as Liquids under pressure for convenience and ease of
handling. Liquid LPG evaporates to produce about 250 times volume of gas. Thus, a
large quantity of energy can be packed, stored, transported and used in small
containers.
Most commonly, LPG cylinders are available in compact 5 kg cylinders for rural, hilly
and inaccessible areas and 12 kg as well 14.2 kg cylinders for domestic use. For
commercial and industrial use, 19 kg and 47.5 kgs cylinders are available.


INDIAN LPG SCENARIO
Fourth largest consumer of LPG in the world after USA, China & Japan Third
largest consumer In domestic sector in the world after China & USA Major market of
LPG is Domestic Sector Home Delivery of 3 Million LP Gas cylinders per day(i.e900
Million/ year) Steady Growth @ 8% p.a.in LPG Consumption in India LPG According to
the latest scenario of the Natural Gas Analysis, the Natural Gas market in India is
expected to be the one of the fastest growing in the world during the next two
decades. Among its segments LPG has made a substantial progress to become the
most convenient, cost effective and pollution free means of fuel, especially in the
middle class segment. LPG market in India is not at all versatile and competitive.



INDANE GAS

Indane is today one of the largest packed-LPG brands in the world and has
been conferred the coveted Consumer Superbrand status by the Superbrands
Council of India.

Having launched LPG marketing in the mid-60s, IndianOil has been credited
with bringing about a kitchen revolution, spreading warmth and cheer in millions of
households with the introduction of the clean and efficient cooking fuel. It has led to
a substantial improvement in the health of women, especially in rural areas by
replacing smoky and unhealthy chulha. Indane is today an ideal fuel for modern
kitchens, synonymous with safety, reliability and convenience.

With the status of an exclusive business vertical within the Corporation, the
Indane network delivers 1.2 million cylinders a day to the doorsteps of over 53 million
households, making IndianOil the second largest marketer of LPG globally, after SHV
Gas of The Netherlands. Indane is available in compact 5 kg cylinders for rural, hilly
and inaccessible areas, 14.2 kg cylinders for domestic use, and 19 kg and 47.5 kg for
commercial and industrial use.


LPG is a blend of Butane and Propane readily liquefied under moderate
pressure. LPG vapour is heavier than air; thus it normally settles down in low-lying
places. Since LPG has only a faint scent, a mercaptan odorant is added to help in its
detection. In the event of an LPG leak, the vapourisation of liquid cools the
atmosphere and condenses the water vapour contained in it to form a whitish fog,
which is easy to observe. LPG in fairly large concentrations displaces oxygen leading
to a nauseous or suffocating feeling.
















OVERVIEW OF PLANT OPERATIONS IN LPG (LIQUIFIED PETROLEUM
GAS) BOTTLING PLANT

LPG bottling plant is a plant where LPG is filled into bottles (cylinders) for
storage and distribution among various LPG distributors. The plant has the facility to
receive bulk LPG by Tank trucks (of various capacities e.g. 12MT, 17MT etc) or
pipeline from a reliable source e.g. Refinery or any other LPG Bottling Plant. After
receipt of Bulk LPG, filling of LPG into cylinders is done. Here we shall discuss the
filling operations in LPG Bottling Plant.

OVERVIEW OF PRIMARY OPERATIONS:
Primary Operations in a Bottling plant are main line activities, directly
associated with filling of LPG cylinders. Any obstruction in these activities will hamper
Plant production. Some activities are Cylinder receipt, filling, Check scale weighing,
Tightness testing etc. These are described below:

STAGE - I: RECEIPT OF CYLINDERS
Explanation:
(a) Incoming cylinders fall into following categories:
(info) New cylinders from manufactures
Cylinders in circulation from distributors (empty, under-filled, defective).
Cylinders received from Statutory Testing Plants, duly tested.
Repaired cylinders received from the approved repairers.
(b) All cylinders received should be against valid documents and the actual receipt
should be tallied with the details on the relevant document and shortages or any
other shortcomings should be endorsed on the body of the document.
(c) All new cylinders received should be supported by Test Certificate for ISI (Indian
Standards Institute) inspection and approval from CCE (Chief Controller of
Explosives) before they are put to use.

STAGE -II: VISUAL INSPECTION/SEGREGATION - I
Explanation:
(a) Based on visual inspection, cylinders should be segregated as under:
(i.) Cylinders for Statutory Testing (to be sent to testing Plant).
(ii.) Under-filled cylinders received from distributors, duly tagged (for further
processing).
(iii.) Leaky/defective cylinders received from the distributors, duly tagged (for
further processing)
(iv.) Spurious cylinders (for investigation/scrap).
(v.) Cylinders found unfit for filling (beyond repairs) on visual inspection (e.g.
heavily rusted or heavily dented).
(vi.) Cylinders found defective, but repairable such as:
a. Cylinders having twisted valve spindle (to be segregated for valve
replacement)
b. Cylinders having broken/bent foot ring/valve protection ring (to be
segregated for cold/hot repairs depending upon the condition).(To be rejected as
scrap after closer re-examination).
(vii.) Cylinders owned by other marketing companies, wrongly mixed with own
cylinders. (to be segregated for handing over to OMC).
(viii.) (a) Empty cylinders fit for filling. (to be sent for filling).
(b) Visual inspection of the cylinders should be done.
(c) Under-filled cylinders received from the distributors should be weighed
to verify the extent of under-filling.
(d) Reasons for leaky/defective cylinders received from distributors should
be verified as marked on the tag attached to the cylinder.
(e) Extra care should be exercised to check for spurious cylinders and
efforts made to identify the source of receipt. Spurious cylinders must be segregated
for scraping.
(f) New cylinders or cylinders received from Statutory Testing Plant or any
cylinder which has undergone pneumatic test must be purged before they are taken
up for filling.
(g) Cylinders due for Statutory Testing must not be taken up for filling but
sent to testing Plant.
(h) Cylinders without proper markings or without serial number should not
be taken up for filling.
(info) Cylinders of other marketing companies, unless specifically sent for filling,
should not be taken up for filling but segregated for exchange with concerned
marketing company.
(j) Wherever on-line facilities on the conveyor for cleaning and re-painting of
cylinders are provided within the filling Plant, segregation for these operations also
would be necessary.
(k) At the time of visual inspection during unloading, check should be made
for shortage of removable items such as valve protection caps, security nuts, safety
caps, etc., and appropriate remarks put on the relevant transfer documents.

STAGE - III: CYLINDER FOR FILLING.
Explanation:
(a) Remove valve protection cap wherever provided on the cylinder.
(b) Remove safety cap in case of 'SC' type valve (Self Closing Valve).
(c) Blow the cavity of 'SC' type valve with air to remove any dust particles or water
and also check for the presence of 'O'-ring fixed on the valve outlet.

STAGE - IV: TARE WEIGHT MARKING
Explanation:
(a) Wherever tare weight stenciling is not legible on the cylinder shoulder, mark
tare weight on the cylinder shoulder after checking punched tare weight marking on
the cylinder.
(b) For accuracy of filling, especially in case of filling through overall-weight-system,
the correct and legible marking of tare weight on the cylinder body is essential. To
ascertain the accuracy of tare marking on the incoming LPG cylinders, few cylinders
should be weighed at random. This exercise should invariably be carried out on the
new cylinders. In case any major discrepancies are observed in a particular lot the
matter should be taken up with the manufacturer.
(c) Tare weight, in case of cap type cylinders, is exclusive of the weight of the cap.
In case of cylinders with shroud or ring as valve protection means, the tare weight
includes the weight of the shroud or the ring as they form integral part of the
cylinder.

STAGE - V: FILLING OPERATION
Explanation:
(a) Cylinder with 'SC' type valve.
i. Fix appropriate filling head on to the valve.
ii. Start filling.
iii. Make tare-weight adjustment.
iv. Remove filling head on automatic shut-off the filling operation.
(b) Each filling machine should be checked against standard weight at least once
during a shift.
(c) The above sequence of operations of operations has been described for filling
machines having adjustment for 'tare weight' as well as 'specific weight" for the
product (i.e. LPG)
(d) In case the filling machines operate on 'gross weight' principle, the adjustment
required on the machine would be for gross weight only.
(e) In case the filling machines operate on 'tare-off' principle, no adjustment may
be required. However, in this case it must be ensured that the cylinders are
evacuated or safely drained before putting on to the filling machine.

STAGE - VI: CHECK WEIGHING
Explanation:
(a) Weigh all filled cylinders coming out of the carousel, (i.e. ensure 100% check
weighing)
(b) Check-weighing is performed to verify that the cylinder has been filled correctly
within the permissible limits. This check is very important from safety point of view.
duct to
be filled in the cylinder. Accordingly, for the quantity of 15 kg of LPG, the cylinder
would be termed under-filled if the product weight is less than 14.7 kg and it would
be termed as over-filled if the product weight is more than 15.3 kg.
(d) All the cylinder coming out from the filling machines must be check-weighed to
ensure 100% checks.
(e) In case of change of composition of LPG to be filled in cylinder, the correct safe
weight of the product that can be filled will to be worked out.
(f) Over-filling, if not detected, subjects cylinders to very high pressure (due to
increase in ambient temperature, liquid in the cylinder would expand and hydrostatic
pressure developed may at times burst the cylinder): The danger point is reached
when liquid expands to occupy fully the volumetric capacity of the cylinder, leaving
no space. Once this point is reached there would be pressure rise at the rate of 24
pressure for a LPG cylinder is 16.9 Kg/cm2 (1.66 Mega Pascal), Hydraulic Test
pressure is 25.35 Kg/cm2 (2.45MPa), normal working pressure is approx. 7Kg/cm2 &
burst pressure is approx 100 kg/cm2.
(g) Likewise, under-filling, if undetected, shakes consumer's confidence.
(h) In case any cylinder is heavily covered with mud, the same may result in under-
filling when the method of overall filling is followed. It is, therefore, necessary that
such cylinders are washed before filling. Particular care should be exercised to inspect
the joint between foot ring and dished ends of the cylinder as there is greater
possibility of accumulation of mud there.
(info) Over-filled cylinder must be sent for immediate evacuation of excess
quantity.
(j) Each filling machine should be allotted serial no. at the Plant. Periodically, this
number should be marked on the cylinder under filling on respective machine. When
these cylinders are checked on the check-scales, record of actual observations should
be made. This process helps to identify a filling machine giving incorrect filling.
(k) Check-scales should be certified by the Weights and Measures Department, and
must be tested against standard weights at least once during the shift.

STAGE - VII: SEGREGATION - II
Explanation:
(a) Cylinders rejected at check-weighing are segregated as below:
i. Overfilled cylinders are segregated and sent to evacuation unit for removing excess
quantity.
ii. Under-filled cylinders are segregated and sent for topping up on a separate
stationary weighing scale having a filling point.
(b) Cylinders having apparent leaks should also be segregated at this stage and
corrective action taken to stop the leak. If leak cannot be stopped, the cylinders
should be sent for evacuation.

STAGE - VIII: TIGHTNESS TEST - I
Explanation:
(a) 'SC' type valve
In case of 'SC' type valve the valve seat remains in closed position unless pressure is
applied against the spring. With the valve outlet open, any bubbles emerging out
through the valve outlet would indicate leak through the valve seat.
(b) General
i. At this stage, leakage through bung or cylinder body may also be noticed in the
form of bubbles emerging out from the leaky spot.
ii. In case of any leak of above nature the cylinder is marked for segregation with
appropriate marker to identify the type of leakage.
(c) The tightness tests are intended to check leak through the cylinders which could
be through:
i. Cylinder's parent metal or pin hole in weld joint.
ii. Cylinder/valve joint commonly known as bung-joint.
iii. The valve seat (with valve closed).
iv. The valve spindle (with valve closed or open).
v. The valve body (very rare occurrence)
vi. The special adaptor/valve-outlet joint (in case of 'SC' type valve).
(d) The tightness test-I is basically intended to check leaks past the valve seat.
(e) Carousel type of tightness testing baths, which keep the cylinders in vertical
position, are ideally suited for checks at this stage.
(f) Painting of interior surface of the test bath with white paint, provision of
sufficient lighting arrangement and periodic changing of water for the test to ensure
that it is clean, help in easy detection of the leaks.
(g) Whenever leak is observed, attempts should be made to stop it, if possible
(e.g. by tight closure of 'F' type valve or fixing of security nut/cap etc.)
(h) If the leak cannot be stopped the cylinder should be sent for evacuation.
(info) Suitable markers should be used to identify type of leaks such as valve leak,
bung leak, etc.
(j) The leaky cylinder, before it could be evacuated, should be so placed that the
leakage is that of vapor and not liquid.

STAGE - IX: SEGREGATION - III
Explanation
(a) Leaky cylinders from tightness test bath-I should be segregated and sent to
Evacuation Unit.

STAGE - X: PREPARING CYLINDER FOR TIGHTNESS TEST - II
Explanation:
(a) Cylinder with 'SC' type valve
i. Water to be blown from the cavity of the valve, by air. (The cavity may be full of
water when the cylinder comes out from the test bath - I)
ii. Special type of adaptor (dummy pressure regulator) to be fixed, locked and
adjusted on the valve. After fixing the adaptor, the knob is to be turned in on position
to keep the valve seat open. The adaptor is basically a body of Pressure Regulator
with diaphragm and related parts removed and outlet blocked (i.e. dummy Pressure
Regulator). Alternatively the effectiveness of the 'O'-ring can also be checked
through portable leak-detector which could be mounted on the cylinder valve, and
leak, if any, observed through the fluid in the detector.

STAGE - XI: TIGHTNESS TEST - II
Explanation:
(a) 'SC' type valve
i. With the valve seat in open position with the help of special adapter the
effectiveness of the 'O' ring (making a joint with the inlet of the pressure regulator)
is tested.
(b) General
i. Tightness test is carried out with the valve seat in open position and outlet closed,
with security nut in case of 'F' type valve and with adaptor in case of 'SC' type valve.
ii. At this stage leakages through bung or cylinder body are also checked which may
be noticed in the form of bubbles emerging out from the leaky spot.
(c) Leakage past valve seat having checked at tightness test bath I (STAGE - VII),
other possible leaks are tested through tightness test bath II.
(d) Suitable markers should be used to identify types of leaks such as bung leak,
valve leak etc.
(e) Immediate action should be taken to stop the leak temporarily wherever
practicable. If the leak cannot be stopped, the cylinder should be sent for evacuation
and should receive priority over defective cylinders which are not leaking.
(f) The leaky cylinder, before it could be evacuated, should be so placed that the
leakage is that of vapor and not liquid.

STAGE - XII: SOAP SOLUTION TEST
Explanation:
(a) Soap solution test is applied to check bung leaks in case of both 'F' type and 'SC'
type cylinders. This is in addition to the two tightness tests carried out at stage VIII
and Stage XI. A suitable marker should be placed to identify bung leak.
(b) White applying soap solution to the bung/valve joint it must be ensured that
the solution is applied all around the valve/bung joint.
(c) Soap only should be used for making a soap solution and not a detergent.
(d) Soap solution test is done to detect minute leaks through the joint which
normally remain un-detected in water baths.

STAGE - XIII: SEGREGATION - IV
Explanation:
(a) Leaky cylinders from tightness test-II should be segregated and sent to
Evacuation Unit.

STAGE - XIV: FINISHING OPERATIONS
(b) Cylinders with 'Self-Closing' valve
i. Remove special adaptor (if fixed).
ii. Blow cavity of the valve outlet with air in case any water is observed.
iii. Fix the security cap on the valve outlet.
iv. Fix appropriate neck label.
v. Seal the valve outlet using sealing tape.

STAGE - XV: FINAL INSPECTION
Explanation:
(a) Check the cylinder visually for:-
i. Apparent sound condition.
ii. Presence of cap, and neck label in case of cylinders with 'cap' as valve protection.
(b) Correct deficiency noticed, if any.

STAGE -XVI: DISPOSAL OF FILLED CYLINDERS IN SOUND CONDITION.
Explanation:
(a) At this stage the cylinders are ready for delivery:-
i. If required the fit cylinders can be directly sent to the stake trucks for loading.
ii. If no stake-truck is available, the cylinders can be sent for stacking in the area
earmarked for the purpose



General overview about Bokaro bottling plant:

1. TUP (Tanker unloading plant)

Plant consist of total 6 bay for unloading tankers, it means 6 tankers can be emptied
at a time.

Per tanker capacity : 10 metric tonne
Daily emptied tankers: 12





















2. STORAGE FACILITIES:

(i). Horton sphere:
Numbers : 1
Capacity : 1400 metric tonne
Pressure in stored condition : 7 Kg (variable)
Pressure during unloading : 10 12 Kg






(ii). Bullets:

Numbers: 3
Capacity: 150 metric tonne per bullet
Total capacity: 1850 Metric tonne




Safety measures while storage:
BLEED OFF VALVE: Main use of bleed off valve is in maintaining pressure inside the
storage facilities. If pressure inside the Bullets or Horton sphere increases above
certain limit, then valve is opened to bleed off extra pressure.
WATER SPRINKLER FIRE FIGHTING : A fire sprinkler system is an active fire
protection measure, consisting of a water supply system, providing adequate pressure
and flow rate to a water distribution piping system, onto which fire sprinklers are
connected.




FILLING SHED


WASHING UNIT

The Washing unit is on-line equipment used to wash the incoming cylinders
with multiple forced jet of water to Remove mud, dirt, stains, etc., from the outer
surfaces














DRYING UNIT



The Drying unit is an on - line equipment used to dry the cylinders, coming out
of washing unit by blowing the air on the sides and top surfaces of the cylinders as
they move.

















KEROSEL UNIT


Kerosel Unit is an on-line equipment used to create vacuum in the first stage and filling LPG
vapor in the second stage in new / hot repaired empty cylinders.










WEIGHT CHECK


The digital check weighing system with segregation unit is designed to check
the gross weight of a filled LPG cylinder and reject the cylinder from main stream on
to a loop conveyor if the gross weight is more or less than the stipulated value. The
electronic check scale is programmed in such a way to subtract 14.2 Kg or 19 Kg from
total weight of cylinder and the tare weight will be displayed. Operator has to
compare the displayed tare weight value with the tare weight value punched on the
cylinder and if the value is beyond the permissible limit, the cylinder will be rejected.
The unit is an on-line equipment used to ensure that correct weight of LPG fuel is
carried in the cylinders.
Under-filled cylinders are filled with additional quantity of LPG and the weight
is corrected. Overfilled cylinders are checked and the weight of LPG fuel is corrected
by evacuation process






LEAK CHECK AND O RING


Cylinder is checked for any leak at O-RING valve and if leak detected then it is
changed .Process can be accomplished manually or automatically. After placing O-
RING it is deflected for final sealing by means of placing seal cap on cylinder nozzle.
Again cylinder is checked for further leakage by passing through water bath .And, at
the end plastic cover is fixed on seal cap to ensure complete seal and cylinder is
ready for delivery.










REFERENCES
www.google.com
www.iocl.com
www.wikipedia.com