Professional Documents
Culture Documents
ON
VOCATIONAL TRAINING.
PREPARED BY
MIHIR G. PURABIARAO
[06BEER045]
B.E. 3RD YEAR ELECTRICAL & ELECTRONICS ENG.
INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING.
RANCHARDA, AHMEDABAD.
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INDIAN OIL CORPORATION.
[I.O.C.]
GUJARAT REFINERY
P.O. JAWAHARNAGAR,BAJUWA
DIST. : VADODARA,GUJARAT-391 320.
WEBSITE : www.iocl.com
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ACKNOWLEDGEMENT.
- PURABIARAO MIHIR G.
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GUJARAT REFINERY [I.O.C.L]
The Gujarat Refinery at Bajuva in Gujarat in Western India is
Indian Oil’s largest refinery. The refinery was commissioned in 1965.
Its facilities include five atmospheric crude distilition units. The major
units include CRU,FCCU and first Hydrocracking unit of the country.
The products produced by the refinery is serves to the demand for
petroleum products in western and northern India.
When commissioned , the Gujarat refinery had a design capacity of
3.0 MMTPA. It was subsequently incread to 4.3 MMTPA by the
revamping of three distillation units. In 1978, its processing capacity
was further incread to 7.30 MMTPA by the addition of a crude
distillation unit. A fluidized catalyist cracking unit was added to the
refinery in 1981 to increase production of middle distillates,such as
diesel and LPG. In 1990 capacity of the refinery was further increased to
9.5 MMTPA through low cost revamping / de-bottlenecking and
addition of a hydrocracker in 1992 for maximization of middle
distillates. Susequentely the crude capacity was increased to 12.5
MMTPA in 1999 by addition of new Atmospheric Unit of 3 MMTPA
along with revamp of FCC unit. The capacity was increased to its
present capacity of 13.70 MMTPA by low cost de-bottlenecking. The
company has already comissioned the facilities for MTBE and Butene-1
production. The refinery also produce a wide range of specility products
like Benzene, Toluene, MTO, Food Grade Hexane, Solvents, LABFS,
etc. The refinery achived the distinction of becoming first refinery in the
country to have completed the DHDS (Diesel Hydro De-sulphurisation
refinery started production of HSD with low Sulpher content of 0.25%
wt (max.)).
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A project for production of high value LAB (Linear Alkyle
Benzene) which is one of the major raw materials used in manufacturing
of detergents from kerosene streams is under implementation and
scheduled for completion in 2004. In order to meet future fuel quality
requirements, MS Quality improvement facilities are planned to be
installed by 2006.
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LOW SULPHER HEAVY STOCK
FUEL OIL
BITUMEN
N-HEPTENE
ALUMINIUM ROLLING.
ELECTRICAL SYSTEM
ENGINEERING
INTRODUCTION :-
Gujarat refinery is equipped with two power plants – Co-Generation
Power Plant (CGP) and Thermal Power station (TPS). Complexity of
power system is due to different Generation voltage levels, Groinding
and Protection system employed. Even a small lapse while designing
for the expansion / modification of generation / distribution system may
lead to catastrophic consequence in the stability of power system.
Various equipment specification standards for selection of
equipment are available in the refinery. Expertise for engineering and
selection of equipment are also available. Need has been felt to
consolidate all good design practices gained through experience,
equipment selection dpecification etc. to serve as a guideline to the
electrical design engineers of the refinery to achieve consistency in
design on regular basis.
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The role of an Eletrical engineer in Engineering Services
Department includes but not limited to study the Process scheme,
evaluate the scope of electrical jobs involved, design a suitable electrical
scheme to provide stable power supply and procurement of suitable
materials required for the same etc. Accordingly, the chapter on Design
basis is developed to provide an overview of Power Geneation,
Distribution and Maintenance of the Equipment / System is to be
designed.
POWER GENERATION
The total Power Generation of Gujarat Refinery is 126.5 MW.
TPS (Thermal Power Station) = 12+12+12.5 = 36.5 MW.
CGP (Co-Generation Plant) = 30+30+30 = 90 MW.
Therefore the total Power Generation is 126.5 MW.
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The Power Generation is done at 11 kV is converted to 6.6
using Transformers (which comes from CGP, in case of
backup). The Generation at TPS is done at 6.9 kV using reactor.
These reactors are used for the protection purpose also. It
reduces the fault current. There are also Reserve Reactor for
stand by purpose. In TPS the Bus couples are also used at 6.6
kV and supply system.
There are also PCC Power Control circuit for small supply.
First the Power goes to PCC then to MCC.
There are 3 Russian Boiler steam capacity of 75 tonnes/hour
and one Indian Boiler (BHEL) having capacity of 130
tonnes/hour.
Stem Pressure in drum = 44kg/cm2 .
Steam Pressure after main Steam gate = 39 kg/cm2 .
Super Stem temp. = 440 0 C .
Safety valve drum pressure = 44 kg/cm2.
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Air heater : Regenerative horizontal shaft pressurize
jung storm rotary.
Drum : Twin Drum.
PROCESS IN TPS :
The TPS consist of four boilers and three turbine generators
sets. The boiler generate superheated stem by burning the fuel
obtained from other plants of the refinery itself. This
superheated steam can be utilize to supply steam yo other plants
and can also be used for generating power using steam turbines.
This steam rotates the blades which in turn produce s the
induced voltage. This voltage is then transferred to reactor.
The Steam produced is through fuel OIL or REFINERY
GASSES (RCO).
The feed water to the boiler comes from a CM plant that the
de-minerilize the feed water to prevent the corrosion of boilers
vessels. All Russian Boilers are water tube boiler while the
Indian boiler operates on forced draft.
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EQUIPMENT SPECIFICATIONS
Gas Turbine
Frame : 6
Make : BHEL / GE
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Compressor type & size : Axial flow type 17 state
Generator
Make : BHEL
Frequency : 50 Hz
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Turbine
Number of stages : 3
Type : Impulse
1st , 2nd & 3rd Stage bucket material : Ni based super Alloy
2nd stage : 3 x 16 = 48
3rd stage : 4 x 16 = 64
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No. of Turbine buckets 1st stage : 92
Compressor
No. of stages : 17
Combustors
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Type : Reverse flow type
No. of combustion : 10
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distribution Transformers.
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5. The starting system including the starting device and the
required logic sequence for starting the gas turbine and
bringing it up to operating speed.
6. The cooling and sealing air system which provides the
necessary airflow from the turbine compressor to the other
parts of the turbine rotor and stators to prevent excessive
temperature build up and prevent bearing oil leakage.
7. The fuel system which supplies, controls the flow and
directs the fuel to the fuel nozzles in the gas turbine
combustors . The fuel system includes gas , liquid and dual
fuel systems.
8. The atomizing air system provides sufficient pressure in
the air atomizing chamber of the fuel nozzle to break the
fuel jet up to a fine mist permitting ignition and
combustion with increased efficiency.
9. The ventilating and heating system provides the
ventilation of hot air from compartments so that various
devices in these compartments work in the allowable
compartment temperatures.
10. The fire protection system is provided to extinguish fires
in the compartments, in case any fire takes place.
11. The inlet and exhaust system provides atmosphere air to
be brought into the compressors through inlet ducting and let
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exhaust gases to atmosphere or to heat recovery steam
generators.
ELECTRICAL TESTING.
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In the industries the HRC (HIGH RUPTURING
CAPACITY ) fuses are used. This because they don’t
produce any spark of smoke.
TYPES OF TRIPPING :
1) Electrical Tripping : In case of circuit breaker. The trip
is energized through the actuation of the trip current
either through the control or protection current.
2) Mechanical Tripping : it occurs due to some
mechanism, generally protection releases which are
mechanical in nature. These releases are actuated by
certain insult coils and mechanism.
CONTACTOR :
A contactor is an electromagnetic switchwhich can be
operated remotely. Switchgear is used to the standard
requirements of switching various loads under normal
ndabnormal condition with in built features of protection against
various hazards. One such devuce is contactor.
BREAK DOWN VOLTAGE TEST : (Tranformer Oil)
The BDV test is done to find out the breakdown any
liquid. There is an instrument consist of a box which is
filled with the necessary oil. Two electrodes which is
separated by a small gap of approx. 25mm. voltage is
supplied to both the ends of electrodes. Slowly the voltage
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is incread, the moment the breakdown occur voltage is
noted. This is the breakdown of the liquid.
RELAYS :
A device that is operated by a variation in the condition
in one electric ckt & serves to make one or more connections in
the same or another electric ckt.
In relay one of the pair of the contacts that are closed or
opened by the movement of the armature relay. Relay ckt is
associated with a selector, consisting of magnetic impulse
counter for registering digits & holding a ckt.
ELECTRICAL WORKSHOP
Electrical workshop is a very important and very essential
unit for the primary maintenance of the electrical equipments.
Here as we reffered most of the load the industry in the form of
the INDUCTION MOTOR. So we reffered in the electrical
workshop that here the most of the jobs are related to the
induction motors. We saw no. of induction motors of different
sizes and of different ratings.
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WHY NEED FOR THE WORKSHOP ? :
In IOCL we know that it’s a Petroleum Industry so that
every plant contain different types of pumps, blowers,
compresser, fans of different ranges. For the operation of all
these equipments the motor is very important. Here if there is
any fault or any other constructional or operational failure arises
with any motor then it will be informed to the workshop.
MAINTENANCE AND TESTING OF MOTORS :
• First of all in the workshop Earthing contacts of the motors
are tested.
• Then other testing like Megger test and other Winding
tested done.
• After opening the motor, it will be cleaned by the
Kerosene. Than it will be put in the Oven for removing the
moisture from the motor.
• The motor needs proper insulation over the conductors
throughout the length. So the body and stator windings are
painted with Red Bectol. It improves the insulation
strength.
• Then the bearing maintenance is another important job in
the workshop, here the bearings are tested and replaced (if
necessary) for all the motors.
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• After that motor is once again fitted and again put into yhe
oven for same reason as we mentioned above.
• Now Balancing Process is also done at Workshop. Here
there are three types of the balancing and vibration in the
motor.
Vertical Balancing.
Horizontal Balancing.
Shaft balancing.
• And finally all after test and maintenance we measure the
ratings of the motor.
• Generally we measure the ratings with no load test but for
the high rating of motor ( e.g. above 55 kw ), we have to
test with the on load condition by using Variac.
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