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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
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 100c 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 -84c, 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.
Sr.No. EQUIPMENT QUANTITY
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.
Instrumentation
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
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 80c.
Moisture Analyzer: - If the temperature is less than -
80C, 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 Bernoullis 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, cant 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 Hookes 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 Doctors 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 Doctors 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 cant 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.
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: -
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
TABLE II
CAPACITY OF EACH
VESSEL
DISTANCES
(CU. MTS. OF WATER) (MTS.)
10-20 15
20-40 20
41 235 Note 3 30
LOCATION & SAFETY DISTANCES
LOCATION
TYPE OF STORAGE
VESSELS
HORIZONTAL CYLINDRICAL
VESSELS
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
PROTECTION OF FACILITIES
This project work is partial fulfillment of the requirement for the degree of Bachelor
Hisar, Haryana.
--------------------------------
Mr. Kaushal