SUMMER TRAINING REPORT

ON

INDIAN OIL CORPORATION

LIMITED
MATHURA

BY

SOURAV KUMAR SINGH (1509121057)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

JSS ACADEMY OF TECHNICAL EDUCATION

C-20/1 SECTOR-62, NOIDA

2018-2019

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 Acknowledgement

My indebtedness and gratitude to the many individuals who have helped to

shape this report in its present form cannot be adequately conveyed in just a
few sentences. Yet I must record my immense gratitude to the brains and hands
that worked overtime to support my efforts in making a near comprehensive
report on the vocational training in Indian oil corporation Ltd. Mathura.

I am highly obliged to Mr. Pawan Rawat and Mr. Kulbir Singh for giving me this
opportunity to work under his supervision and lending me his learning over the
month and continuous guidance in his capacity. The thank list would be far from
incomplete without the mention of all such supervisors, associates and all the
employees of IOCL, Mathura. Special thanks to Mr.Nishikant Prasad for
providing us valuable knowledge and his guidance.

Last but not the least I am thankful to Almighty God, my parents, my uncle, my
friends for their immense support and cooperation throughout.

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IOCL Mathura :

Mathura Refinery was commissioned in the year 1982. At present it has the capacity
of processing 8.0 MMTPA of crude oil. The refinery meets the demand of Northwest
region of India including Delhi. The crude oil with low Sulphur from Bombay High,
imported crude with low Sulphur from Nigeria, and crude with high Sulphur from Middle
East Countries are processed at this refinery.
The original refinery configuration had one primary Atmospheric Vacuum unit
and the secondary units were the Vis-breaker Unit, Bitumen Unit, Sulphur Recovery
unit and Fluidized Catalytic cracking Unit.
Gradually Mathura Refinery in Uttar Pradesh made certain changes to follow
the strict product specification that aroused due to environmental considerations. The
secondary units such as Once Through Hydro-cracker unit (OHCU). Catalytic
Reforming Unit (CRU), MS quality up gradation, Diesel hydro desulphurization Unit,
(DHDS), new Sulphur Recovery unit (SRU), DHDT etc. were integrated in the refinery
configuration. These changes in the configuration of the Refinery were made so that
there is minimal impact on the environment.
Mathura Refinery has taken a number of initiatives to save the environment,
public health and also to preserve the national monuments in and around the city of
Mathura. A lot of research has been done to produce more and more clean fuels that
would have minimal negative effect on the environment.
Mathura refinery has been producing highly eco-friendly petrol and diesel for
the NCT, NCR and Agra region. The Refinery enjoys the distinction of being the first
refinery in India capable of producing 100% auto fuels that meets Euro - III norms.
Products from this refinery are dispatched through rail, road and Mathura- Delhi –
Ambala - Jalandhar pipeline. The LPG bottling plant situated within Mathura refinery
premises bottles nearly seven million cylinder per annum for catering domestic market.
Major fertilizer industries at Kanpur, Panipat, Nangal, Bhatinda, and Kota are supplied
with Naphtha or furnace oil. Also, thermal power plants of Nangal, Obra, and Badarpur
get fuel oil supply from this refinery. Mathura refinery was the first in Asia and third
refinery in the world to have been honored with the coveted ISO- 14001, certification
on July 22- 1996. It was also awarded the Golden peacock national quality award 1996.
It bagged first prize in national energy conservation award in 1996 in public sector in
ministry of power.

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 CONTENTS:

1. THERMAL POWER STATION (TPS)

2. PROCESS IN TPS
3. CO-GENERATION PLANT (CGP)
4. NEW UNIT

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THERMAL POWER STATION (TPS).

In Thermal Power Station Power Generation is done at 11 kV is converted to 6.6 using

Transformers. In TPS the Bus couples are also used at 6.6kV. There are also PCC
Power Control circuit for supply. First the Power goes to PCC then to MCC. Through
MCC Machine Control Circuit power is supplied to number of motors for operating
pumps and compressors.

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PROCESS IN TPS

The TPS consist of three boilers and three turbine generators

sets. The boiler generates superheated stem by burning the fuel
obtained from other plants of the refinery itself. This superheated
steam can be utilizing to supply steam to other plants and can
also be used for generating power using steam turbines.
This steam rotates the blades which in turn produces the induced
voltage. This voltage is then transferred to reactor.
The Steam produced is through fuel oil or refinery gases.
The feed water to the boiler comes from a CM plant that de-
mineralize 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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CO-GENERATION PLANT (CGP):

The CGP has at present 3 nos. BHEL make, Gas turbine Generators (GTG) with
individual Heat Recover Steam Generator (HRSG). The GTGs are rated 20.2 MW
each. The generation voltage is at 11 KV. For further distribution voltage is stepped
down by of 11/0.415KV, 11/6.6KV and 6.6/0.415KV distribution Transformers.
Here is the figure showing the flow diagram of the gas turbine generator. A gas
turbine, also called a combustion turbine, is a type of internal combustion engine. It
has an compressor coupled to a turbine, and a combustion chamber in-between. The
basic operation of the gas turbine is similar to that of the steam power plant except that
air is used instead of water. Fresh atmospheric air flows through a compressor that
brings it to higher pressure. Energy is then added by spraying fuel (here in Mathura

Refinery Natural Gas is used as a fuel) into the air and igniting it so the combustion
generates a high-temperature flow. This high-temperature high-pressure gas enters a
turbine, where it expands down to the exhaust pressure, producing a shaft work
output in the process. The turbine shaft work is used to drive the compressor and other
devices such as an electric generator that is coupled to the shaft. The energy that is
not used for shaft work comes out in the exhaust gases, so these have either a high
temperature or a high velocity. The waste heat (thrust) is ducted to a boiler to generate
steam.
Cogeneration provides a means of recovering the “waste heat” from an engine
which would ordinarily be discarded in cooling water or air exhaust, and using this heat
to make steam or hot water. The heat from the electricity generation process is
captured in a heat recovery system, usually based on a boiler using water. This

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generates steam or hot water for the process, or for heating, or even for generating
more electricity in a steam turbine generator.

SYNCHRONOUS GENERATOR DRIVEN BY GAS TURBINE TECHNICAL DATA:

Output rating: 25275 MVA
Rated voltage: 11000 V
Rated current: 1327 A
Rated frequency: 50 Hz
Power factor: 0.8 over-excited
Rated speed: 1500 rev/min
Excitation method: Brushless
Full load excitation voltage: 148.3 V
Full load excitation current: 546.5 A
Phase sequence: ABC for clockwise rotating field
Insulation class for windings: Stator-F Rotor-F
Oil pressure (maximum): 0.6 Bar
Oil inlet temperature (max): 45⁰ C
Critical speed of rotor: >1800 rpm
Ventilation in generator: Closed Circuit air cooling
Maximum continuous Stator winding Inlet air Outlet air
operating temperature: 120⁰ C 48⁰ C 78⁰ C

BRUSHLESS EXCITER:
Continuous duty 10 sec
Output rating kW: 98.1 192.0
Rated voltage V: 163 228
Rated current A: 601 842
Rated exciter voltage V: 34.5
Rated exciter current A: 12.52
Speed: 1500 rpm

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 NEW UNIT

There are 6 units present in this section. They are:

 DHDS (Diesel hydro-desulphurization unit)- Sulphur content is reduced.

 DHDT (Diesel Hydro-treating unit)-Sulphur content reduced.
 HGU-1- H2 generation with the help of natural gas takes place.
 HGU-2- H2 generation with the help of natural gas takes place.
 OHU (Once Through Hydrocracker Unit)- Cracking with the help of H2.
 HVGO (Highly Viscous Gasoline Oil)

Diesel Hydro-treating unit (DHDT) and Diesel hydro-desulfurization (DHDS) units are
involved in further processing of the products obtained after distillation of crude oil. In
DHDS/DHDT process, diesel feed is mixed with recycled Hydrogen over a catalyst bed in a
trickle bed reactor at temperature of 290-400⁰ C and pressure of 35-125 bar. The main chemical
reactions in DHDS/DHDT are Hydrosulphurization(HDS), hydrodenitrification(HDN), and
aromatic and olefin saturation. These reactions are carried on bi-functional catalysts.
Reactor effluent is separated into gas and liquid separator. Gas is recycled back to the
reactor after amine wash along with make-up Hydrogen and liquid is sent to the stripper for
removal of light gases and H2S.
In these units, 3-phase synchronous motors and 3-phase induction motors are required
for the pumping of oil and for compressors. Synchronous motors are used where pumps are to
be driven at the same speed and are to be stringently run at the same speed in all case like in
compressors. Both LT and HT motors are present here.
DHDT and DHDS units have their own substation to provide electricity to various other units
of the plant. The DHDT has an incomer bus of 11 kV voltage from bus 7A and bus 8A
connected to GT-3. From there, power is supplied to various other units like MSQU etc.
The plant has motors for the purpose of pumping oil through the pumps at different
pressures. The oil is received from one pipe at a certain pressure and the motors drive the pump
to transmit the oil to another unit after increasing/decreasing its pressure. Usually 3-phase
induction motors are employed for the process since they are self-starting. Squirrel cage
induction motors are used throughout the plant because of their ruggedness and also, wound
rotors cannot be used since the carbon brushes and slip ring system employed in wound rotor
motor may cause sparking which is highly dangerous in an oil refinery.
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