HALDIA PETROCHEMICALS Ltd.

(HIGH DENSITY POLYETHYLENE) 2012

PRESENTED BY :
NAME: SHUBHAM KISHORE MISHRA

ROLL:

09103007044

REG. NO. 091030110508

TRAINEE: HALDIA PETROCHEMICALS LTD.

COLLEGE: HALDIA INSTITUTE OF TECHNOLOGY DEPTT: MECHANICAL ENGINEERING

HALDIA PETROCHEMICALS LTD.

ACKNOWLEDGEMENT
I express my sincere gratitude to Mr. G K SINHA (HOD MECH.) and Mr. CHAYON MONDOL for having permitted me to carry out summer trainee in HALDIA PETROCHEMICALS LTD. Under HIGH DENSITY POLYETHYLENE department. I wish to express my deep sense of gratitude to my Internal Guide Mr. DEBASISH MAJEE (Sr. MANAGER HDPE) for his able guidance and useful suggestions, which helped me in completing the summer trainee in time. I want to thank Mr.RANJIT GHOSH Mr. TONMOY SARKAR Mr. MINTU MONDAL and Mr. ARNAB SAMANTA who had been a source of inspiration and for his timely guidance in the conduct of summer trainee. I would also like to thank Mr. AJAY CHAKRABORTY and Mr. SHYAM SUNDAR KUITI for all their valuable assistance. I would also like to thanks Ms SHALINI SINGH of HR DEPARTMENT with her effective management. Words are inadequate in offering my thanks to the working staffs and Assistants, for their encouragement and cooperation in carrying out the summer trainee. I feel pleasure to being the part of this HALDIA PETROCHEMICALS LTD. Which gave as the vast knowledge about Mechanical components different parts etc. It was such a great experience for me. I want to give the vast appreciation to the working staff of the plant for giving me this new life of experience.

CONTENTS
Page no.

ACKNOLEDGEMENT CONTENTS PLANT OVERVIEW MECHANICAL COMPONENTS

1. Pump 2. Centrifuge 3. 4. 5. 6. 7. Steam Dryer Plate Type Heat Exchanger Compressor Blower Control Valves

2 3 4

06 14 15 16 17 19 20

CONCLUSION BIBILIOGRAPHY

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Haldia Petrochemicals Ltd- Overview

Haldia Petrochemicals Ltd is a modern naphtha based Petrochemical Complex located 125 kms from Kolkata, at Haldia, West Bengal, India. We are a customer focused organization, recognized as a leading supplier of quality products and services. A symbol of industrial resurgence in West Bengal, HPL has led the economic growth of the region by propelling significant investments in downstream processing industries, which generate huge employment opportunities for skilled and unskilled workers. Through strategic market focus, innovative product application development and excellent customer support services, HPL has played the role of a catalyst in emergence of more than 500 downstream processing industries in West Bengal with a capacity to process more than 3,50,000 TPA of polymers and generating more than 1,50,000 employment opportunities in the process. With dedicated efforts, HPL truly symbolizes its motto :-

"Come Grow With Us".

MANUFACTURING PROCESS

The Haldia Petrochemical Complex is primarily engaged in the production of Polyethylene (High Density & Linear Low Density) & Polypropylene. The complex has a capacity of generation 210 kilotons of Polypropylene (PP), 225 kilotons of Linear Low Density Polyethylene (LLDPE) and 200 kilotons of High Density Polyethylene (HDPE), per annum. The basic feedstock for producing Ethylene and Propylene is Low Aromatic Naphtha that will be procured partly from IOCL Haldia and partly imported. Along with these polymer products, the complex will also produce chemicals like Benzene, Butadiene, Cyclo-pentane, Carbon Black Feed stock, Hydrogenated Pyrolysis Gasoline and C6 Raffinate. The following plants are there in the complex: 1. Naphtha Cracker Unit (NCU) 2. Butadiene Extraction Unit (BDEU) 3. Pyrolysis Gasoline Hydrogenation Unit (PGHU) 4. Benzene Extraction Unit (BEU) 5. C4 Hydrogenation Unit (CHU) 6. High Density Polyethylene Plant (HDPE) 7. Linear Low Density/ High Density Polyethylene Plant (LLDPE/HDPE) 8. Polypropylene Plant (PP) 9. Integrated Off sites Plant (IOP) 10. Captive Power Plant

Mechanical Components:
1.PUMP
DEFINITION: Pump is a mechanical device to increase the pressure energy of a liquid with the help of a prime mover to enable it to impart energy to the liquid. Principal purpose: Pump is used for raising liquid from a lower to a higher level. This is achieved by creating a low pressure at the suction end and high pressure at the delivery end of the pump. Vast numbers of processes require liquid to move from one location to another. These processes can be seen in nuclear and non-nuclear power generation, oil pipelines, petrochemical refineries, municipal wastewater and domestic water treatment facilities, both large and small buildings, on ships and offshore oil platforms. In virtually all of these processes, pumps play the essential role of providing the propulsion necessary to move the liquid. Pumps are critical machines in many processes because their loss can create serious or even catastrophic results. Process industries such as petrochemical refineries are also vulnerable to similar Financial consequences. The processing of liquid product employs large numbers of pumps. A failed pump can shut down an entire process resulting in revenue losses on the order of tens or even hundreds of thousands of dollars a day. In order to avoid such losses, many process industries find it necessary to devote large portions of their maintenance budgets to pumps. Safety is an even greater concern, pump handle radioactive or toxic liquids. If a malfunction causes vibration, temperature, or pressure to change radically or to move outside of normal Operating ranges, these seals may leak and expose plant workers and the surrounding public to the adverse effects of hazardous liquids.

Positive Displacement : It exert a force directly on the liquid. Dynamic Action: It adds energy by passing the liquid through an impeller which speeds up the liquid thereby increasing its kinetic energy. Reciprocating pump: It is a positive displacement mechanism with liquid displacement pressure being limited only by the strength of the structural parts. i) Piston Pump: The piston is driven by a crank mechanism. The forward and backward (in case of double acting) travel of the piston displaces the liquid. Plunger pump: is similar to piston pump except for the packing design and installation. As the plunger reciprocates within the pump a dynamic seal is made between the outside diameter of the plunger and the inside diameter of the packing. Hydraulic Diaphragm Pump : The piston or plunger reciprocates within a precise cylinder at an established stroke length, displacing a volume of hydraulic liquid which moves the diaphragm
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ii)

iii)

forward and backward and there by displaces the product liquid through discharge check valve. Zero leakage is ensured.

Centrifugal Pump
A centrifugal pump converts energy of a prime mover (a electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two main parts of the pump - the impeller and the volute or diffuser. The impeller is the rotating part that converts driver energy into the kinetic energy. The volute or diffuser is the stationary part that converts the kinetic energy into pressure energy.

THREE FUNDAMENTAL WAYS CENTRIFUGAL PUMPS ADD ENERGY:

All centrifugal pumps use an impeller to add velocity head to a liquid. However, not all impellers accomplish this in exactly the same manner. Depending on the method used, impeller designs are grouped into three general types. The difference between them is the direction in which each type forces the high velocity liquid to flow. 1. Radial flow impellers increase liquid velocity in a direction perpendicular (or radial) to the pump axis. 2. Mixed flow impellers increase liquid velocity in a direction that is a mixture of perpendicular and parallel flow with respect to the pump axis.

3. Axial flow impellers increase liquid velocity in a direction parallel (or axial) to the pump axis.

Parts of a Centrifugal Pump

A centrifugal pump has rotating and stationery components viz. (a) Rotating components: comprising an impeller and a shaft. (b) Stationary components: comprising of a Casing, Casing cover and Bearings. The impellers are fitted inside the casings.

Impellers
The impeller, or more specifically, the impeller vanes, is that part of the pump where the rotating shaft energy from the driver is converted into kinetic energy in the pumped liquid. Radial and axial flow impellers perform this conversion using different mechanisms while mixed flow impellers combine the two methods.

Open, Semi-Open, and Enclosed Impellers

Single versus Double Suction

Impellers can be designed with suction inlets, or eyes, on one or both sides. Single and double suction impellers. Double suction impellers have several advantages over single suction impellers. First, their design provides a better balance of the axial forces that occur when pumps are operated off of design capacity (see section entitled Thrust Balancing). Second, double suction Impellers have a larger suction area than single suction pumps for a given flow which means that less energy is required to push flow into the suction. In other words, double suction pumps have a lower Net Positive Suction Head Required (NPSHR) than single suction pumps (NPSHR is explained below in Net Positive Suction Head). Single suction impellers are usually preferred because they are less expensive. Single suction pumps are easier to manufacture and less likely to clog when handling suspended matter such as sewage.

Shaft Sleeve :
Pump shafts are usually protected from erosion, corrosion, and wear at the seal chambers, leakage joints, internal bearings, and in the waterways by renewable sleeves. Unless otherwise
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specified, a shaft sleeve of wear, corrosion, and erosionresistant material shall be provided to protect the shaft. The sleeve shall be sealed at one end. The shaft sleeve assembly shall extend beyond the outer face of the seal gland plate. (Leakage between the shaft and the sleeve should not be confused with leakage through the mechanical seal).

Casing:
It is apparent that the liquid and impeller must be contained in some kind of vessel which directs the flow toward the discharge. The pump case has another equally important role it must convert some of the velocity head into pressure head. the discharge side of the case. The conversion process follows the principle of conservation of energy as stated by Bernoullis law. Since total amount of energy must remain constant (assuming not losses or gains), pressure head must Increase as velocity head is reduced. The way to reduce velocity is by increasing the cross-sectional area of the flow through the process of diffusion. Simply, diffusion occurs when flow area is expanded. The expansion causes a reduction in velocity and an accompanying increase in pressure.

Single volute casing:

It is the most common type of casing design. The volute provides the expanding flow passage necessary for diffusion to occur. The smallest point of flow area where the volute begins is called the cutwater.
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The clearance between the cutwater and the periphery of the impeller is a critical design dimension because it must be sized to strike a compromise between efficiency and pressure pulsations. Pump efficiency increases as the clearance between cutwater and impeller is reduced. However, if the clearance is too small, then large pressure pulsations resulting in pump failure can occur. Volutes have an additional drawback which has been the cause for many broken pump shafts and failed seals and bearings. The pressure of the liquid in the volute acts on the projected area of the impeller to produce a radial force. These radial forces are generally balanced when the pump is operated at its Best Efficiency Point (BEP). However, when operated above or below BEP, the forces become unbalanced which can result in a significant net radial force F. The direction and magnitude of this net radial force will vary depending on operating point relative to design capacity. The net radial force can be as much as fifteen times the force at design capacity.

Double Volutes
Double volute casings have two opposing volutes positioned 180 degree opposite of each other. This feature makes the double volute more effective than the single volute at minimizing the radial loads produced by operation away from the BEP.

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Bearings
All rotating machines, including centrifugal pumps, require bearings to support and position the rotor axially and radially. These bearings must maintain relatively constant rotor position under loads that fluctuate. The most common types of bearings used in centrifugal pumps are either fluid-film bearings or rolling element bearings.

Fluid-film bearings
Most fluid-film bearings are oil lubricated. The simplicity and load-carrying capacity of plain, cylindrical bearings (also referred to as sleeve bearings) make it the most commonly used type of fluid-film bearing. However, since sleeve bearings sometimes experience the malfunction of fluid-induced instability (whirl and whip), other designs are also used. Figure 3.33 in the section Fluid-Induced Instability shows some of these designs and describes how they reduce the potential for fluid-instability.

Rolling element bearings.

Rolling element bearings are very commonly used in smaller centrifugal pumps. They include ball, roller, and tapered rolling element bearings. Generally, ball bearings have the greatest application in centrifugal pumps because they are capable of carrying both radial and axial loads.

Maintenance of Centrifugal Pumps:

Hence, the first step towards maintenance is proper understanding of the working principle of centrifugal pumps and identification of the major components of such a pump.

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There are three types of problems mostly encountered with centrifugal pumps : Design errors Poor operation Poor maintenance practices Centrifugal pumps are the ultimate in simplicity. In general there are two basic requirements that have to be met at all the times for a trouble free operation and longer service life of centrifugal pumps. The first requirement is that no cavitations of the pump occurs throughout the broad operating range, and second requirement is that a certain minimum continuous flow is always maintained during operation.

2.

Centrifuge

A centrifuge is a piece of equipment, generally driven by an electric motor (some older models were spun by hand), that puts an object in rotation around a fixed axis, applying a force perpendicular to the axis. The centrifuge works using the sedimentation principle, where the centripetal acceleration causes denser substances to separate out along the radial direction (the bottom of the tube). By the same token lighter objects will tend to move to the top (of the tube; in the rotating picture, move to the centre). Centrifuge is applying centrifugal force to separate the useful component in mixtures of liquids and solids or liquids and liquids. Centrifuge is mainly used to separate solids from liquids in suspension or separate two liquids with different density and non-homogenous liquids, for example, separate cream form milk; and also it can be used to remove liquids existed in solids, such as special speeding tubular centrifuges can separate the mixed gas content with different density, depending different density and particle size of solid particles in the liquid and different characteristics of the subsiding speed centrifuge, the sedimentation centrifuge also can classified solids according to different density and particle size.
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Centrifuge is widely used in chemical, oil, food, pharmaceutical, beneficiation, coal, water treatment and shipping etc. Centrifuge has a drum rotating its axle called bowl, generally derived by motor. Suspension or emulsion is introduced to the bowl and rotate with bowl with the same speed, eject separately under the centrifugal force. Usually, high separation speed, high separation ratio. The principle of centrifuge is divided to centrifugal filtering and centrifugal sedimentation. Centrifugal filtering is made suspension become filtrate under the centrifugal force. and the centrifugal sedimentation is applied different density to separate suspension and emulsion and realize liquid-solid or liquid-liquid separation.

3.Steam Dryer

Steam tube dryer is one of the indirect heated rotary dryers, which contains rotating shell, rows of steam tubes arranged in concentric circles and extended throughout the length of the dryer. Steam tubes are designed to transfer heat from steam to the material being dried. This is one of the most energy

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efficient dryers. The tubes and radial fights together serve to agitate the material and to provide required residence time.

4.Plate Type Heat Exchanger

A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids spread out over the plates. This facilitates the transfer of heat, and greatly increases the speed of the temperature change. Plate heat exchangers are now common and very small brazed versions are used in the hot-water sections of millions of combination boilers. The high heat transfer efficiency for such a small physical size has increased the domestic hot water (DHW) flow rate of combination boilers. The small plate heat exchanger has made a great impact in domestic heating and hot-water. Larger commercial versions use gaskets between the plates, smaller version tend to be brazed. The concept behind a heat exchanger is the use of pipes or other containment vessels to heat or cool one fluid by transferring heat between it and another fluid. In most cases, the exchanger consists of a coiled pipe containing one fluid that passes through a chamber containing another fluid. The walls of the pipe are usually made of metal, or another substance with a high thermal conductivity, to facilitate the interchange, whereas the outer casing of the larger chamber is made of a plastic or coated with thermal insulation, to discourage heat from escaping from the exchanger.

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5.Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids.

Classification Of Compressor

Centrifugal compressors

A single stage centrifugal compressor

Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section converts the velocity energy to pressure energy. They are primarily used for continuous, stationary service in industries such as oil refineries, chemical and petrochemical plants and natural gas processing plants. Their application can
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be from 100 horsepower (75 kW) to thousands of horsepower. With multiple staging, they can achieve extremely high output pressures greater than 10,000 psi (69 MPa). Many large snowmaking operations (like ski resorts) use this type of compressor. They are also used in internal combustion engines as superchargers and turbochargers. Centrifugal compressors are used in small gas turbine engines or as the final compression stage of medium sized gas turbines. Sometimes the capacity of the compressors is written in NM3/hr. Here 'N' stands for normal temperature pressure (20C and 1 atm ) for example 5500 NM3/hr.

Reciprocating compressors

A motor-driven six-cylinder reciprocating compressor that can operate with two, four or six cylinders.

Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial and petroleum applications. Discharge pressures can range from low pressure to very high pressure (>18000 psi or 180 MPa). In certain applications, such as air compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, and more costly than comparable rotary units. Another type of reciprocating compressor is the swash plate compressor, which uses pistons which are moved by a swash plate mounted on a shaft - see Axial Piston Pump. Household, home workshop, and smaller job site compressors are typically reciprocating compressors 1 hp or less with an attached receiver tank.
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6. BLOWER
Types of blowers
Blowers can achieve much higher pressures than fans, as high as 1.20 kg/cm2. They are also used to produce negative pressures for industrial vacuum systems. The centrifugal blower and the positive displacement blower are two main types of blowers:-

Centrifugal blowers

Centrifugal blowers look more like centrifugal pumps than fans. The impeller is typically gear-driven and rotates as fast as 15,000 rpm. In multi-stage blowers, air is accelerated as it passes through each impeller. In single-stage blower, air does not take many turns, and hence it is more efficient. Centrifugal blowers typically operate against pressures of 0.35 to 0.70 kg/cm2, but can achieve higher pressures. One characteristic is that airflow tends to drop drastically as system pressure increases, which can be a disadvantage in material conveying systems that depend on a steady air volume. Because of this, they are most often used in applications that are not prone to clogging.

Positive-displacement blowers
Positive displacement blowers have rotors, which "trap" air and push it through housing. These blowers provide a constant volume of air even if the system pressure varies. They are especially suitable for applications prone to clogging, since they can produce enough pressure (typically up to 1.25 kg/cm2) to blow clogged materials free.
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They turn much slower than centrifugal blowers (e.g. 3,600 rpm) and are often belt driven to facilitate speed changes.

7. CONTROL VALVE
Flow rate in process control is usually expressed in volume/unit time. If a mass Flow rate is decided it can be calculated from particular fluid density. If a given fluid is delivered through a pipe then the volume Flow rate is:

Types of control valve

A different type of control valve is classified by a relationship between the valve stem position and the flow rate through the valve. The control valve characteristics are assigned with the assumption that the stem position indicates the extent of the valve opening and the pressure difference is determined by the valve alone. There are three basic types of control valve those relationship between position (as percentage of full range) and flow rate (as percentage of maximum).

General classifications of valve

Valve are generally classified as : 1. 2. 3. 4. 5. 6. Gate valve Globe valve Plug Valve Ball Valve Butterfly Valve Check Valve.

Gate valve:
In this valve the diameter of the opening through which the fluid passes is nearly same as that of the pipe and direction of the flow does not change as a results wide open gate valve is not used for controlling flow and usually left as fully open or closed.

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Globe valve:
Globe valve is widely used for controlling flow. The opening increases almost linearly with stem position and wear is evenly distributed around the disk. The fluid passes to restricted opening and change direction several times. As a result pressure drop is large the glob valve.

Ball valve:
The ball valve consist of a spherical ball as sealing element it is an on off valve. It has occasional application in flow control. Ball valve also capable of higher flow rate capacity of globe valve.

BUTTERFLY VALVE:
A butterfly valve is a valve which can be used for isolating or regulating flow. The closing mechanism takes the form of a disk. Operation is similar to that of a ball valve, which allows for quick shut off. Butterfly valves are generally favoured because they are lower in cost to other valve designs as well as being lighter in weight, meaning less support is required. The
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disc is positioned in the centre of the pipe, passing through the disc is a rod connected to an actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow; therefore a pressure drop is always induced in the flow, regardless of valve position

Check Valve :

A check valve, clack valve, non-return valve or one-way valve is a mechanical device, a valve, which normally allows fluid (liquid or gas) to flow through it in only one direction. Check valves are twoport valves, meaning they have two openings in the body, one for fluid to enter and the other for fluid to leave. There are various types of check valves used in a wide variety of applications. Check valves are often part of common household items. Although they are available in a wide range of sizes and costs, check valves generally are very small, simple, and/or inexpensive. Check valves work automatically and most are not controlled by a person or any external control; accordingly, most do not have any valve handle or stem. The bodies (external shells) of most check valves are made of plastic or metal. An important concept in check valves is the cracking pressure which is the minimum upstream pressure at which the valve will operate. Typically the check valve is designed for and can therefore be specified for a specific cracking pressure.

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CONCLUSION
It was a great experience of mine that i got an opportunity to undergo my training in Haldia Petrochemicals Ltd. This Training was really helpful for me to understand the working of various mechanical components e.g pumps, Compressors, Blowers, Heat Exchangers, control valves etc. Practical knowledge and exposure was helpful for me to correlate my theoretical concepts in practical field. I had seen behaviour among the engineers and others staffs and the time management that would really be helpful for my personal as well as professional life.

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BIBLIOGRAPHY

www.wikipedia.com http://en.wikipedia.org/wiki / supercharger Trainee%20Project/Industrial%20Report.htm Encyclopaedia Britannica ready reference 2010 http://www.haldiapetrochemicals.com/
http://en.wikipedia.org/wiki

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