Vocational

Training Presentation

WRPL-CHAKSU, JAIPUR
Presented By:
Sarthak Sharma
11EJCEE057
EE, 7th Sem
JECRC

Brief Coverage:
1. Introduction to WRPL and SMPL
2. Mainline Components and Engine auxiliaries
3. Electrical Department and Electrical Assets
4. Pipeline Corrosion and Cathode Protection
5. Observations during Training Period

Western Region Pipelines

(WRPL)
1. Crude Oil Pipelines:
SMPL (Salaya-Mathura Pipeline)
MPPL (Mundra Panipat Pipeline)

2.Product Oil Pipelines:

KSPL (Koyali-Sanganer)
KRPL (Koyali-Ratlam)
KAPL (Koyali-Ahmedabad)
KDPL (Koyali-Dahej)

Headquarters: Rajkot (Gujarat)

Salaya-Mathura Pipeline (SMPL)

Construction Progressively Commissioned by IOCL during 1978-1981.
Section
Salaya-Viramgam
Viramgam-Koyali
Viramgam-Chaksu
Chaksu-Mathura
Chaksu-Panipat

28
28
28
24
24
24
24

Outer Diameter x Length

x 275 km. mainline.
x 159.7 km. loop line (in sections)
x 148.3 km
x 606 km mainline
x 110 km loop line (in sections)
x 197 km
x 349 km

Chaksu Base Pump Station

T point
Two Sections: Chaksu-Mathura and Chaksu Panipat
Capacity
1. CM Section- 7.5 MMTPA
2. CP Section- 7.0 MMTPA

6 Storage tanks with 60,000 KL capacity

Mainline Components and

Engine Auxiliaries
1. Mainline Engines
1787 BHP (CM section) & 1592 BHP (CP section), 600 RPM, WH-Allen UK make, total
(3+3)

2. Mainline Pumps

Diff. head 314 m (CM) & 208 m (CP), capacity-1462 Kl/hr, BPCL make, total (3+3)

3. ITCL Pump Motors

1.1 KW, 2.4 A, 415 V, 2890 RPM, Brook Crompton make, total (3+3)

4. Crude and Diesel Pump Motors

0.75 HP (~ 560 W), 415 V, 1.4 A, 1440 RPM, total (6+6)

5. Air, Water and Oil Radiator Motor

10.5 Kw, 19 A, 415 V, 1440 RPM, total (6+6)

6. Booster Pumps
160 KW, 260 A, 415 V, 1480 RPM, make CG, total 3

7. Firefighting Motors
160 KW, 276 A, 415 V, 1480 RPM , make Kirloskar, total 1

8. Jockey Pump Motors

18.5 Kw & 30 Kw, 31 & 53 A resp. , 415 V, make CG, total 2

9. Sump Pump Motors

45 Kw & 5.5 Kw, 80 & 11 A resp. , 415 V, make CG, total 2

10. Other Motors:

Centrifuge Motors
Stirrer Motors
O/W Motors
Foam motors

Electrical Department and

Electrical Assets
1.

Diesel Generator Set / Emergency Generator 1

750 KVA, 433 V, 1043 A, make Kirloskar, total 2 (1 spare)

2.

3.

4.

5.

Diesel Generator Set / Emergency Generator 2

500 KVA, 433 V, 667 A , make KEL, total 1

Transformer
1250 KVA, HT side 11 KV, LT side 433 V

Minimum Oil Circuit Breaker (MOCB)

630 Fault MVA, 12 KV, 800 A, make Jyothi Elec.

Compressor Motors

make Kirloskar Electric (1,2) and Bharat Bijli Ltd (3,4)

11kw & 15 kw resp, 20.5 & 28.3 A resp

Pipeline Corrosion
1. What is Corrosion?
Degradation of a material through environmental interaction.
Thermodynamically Instability.
A redox reaction (metal or anode oxidizes, moist water etc. are reduced as
cathode)

2. Corrosion in pipelines?
Exposure to differential Oxygen Concentration
Also, Moist soil act as a conductive electrolyte.

3. How we detect Corrosion?

By means of Potential measurements.

Copper Sulphate Electrode (CSE) is a common reference electrode for soil
potential measurements.
More positive the potential is, more the substance resistant towards the corrosion.

4. How do we mitigate corrosion?

a)

Pipeline Coatings
Isolation of metal surface from the surrounding electrolyte.
Coatings are self subjected to the corrosion.
Regardless overall quality, coatings have holes, voids called Holidays.
A corrosion at a Holiday, can lead to rupturing of pipeline.

b) Cathode Protection

Cathode Protection
Basic Idea: Corrosion occurs at Anode(metal surfaces)? Make it cathode!
At the anodic areas, current ows from the pipeline steel into the
surrounding electrolyte (soil or water) and the pipeline corrodes.
If every bit of exposed metal on the surface of a pipeline could be made to
collect current, rate of corrosion could be drastically reduced. This is what a
CP unit does.
Current is forced to ow onto the pipe at areas that were previously
discharging current, the driving voltage of the CP system must be greater
than the driving voltage of the corrosion cells that are being overcome.
For the CP system to work, current must be discharged from an earth
connection (ground bed)

There are generally two methods for Cathode Protection

1. Cathode Protection with Sacrificial Anode (Galvanic Anode)
Purposely establish dissimilar metal cell strong enough to counteract corrosion
cells.
This is accomplished by connecting a very active metal to the pipeline.
By this method Corrosion is not eliminated, It is just bypassed.
Limited driving voltage, non controllable.
Sacrificial anodes are used in low resistivity soils.

2. Cathode Protection with Impressed Currents

No limiting voltage as in sacrificial anode.
Current from some outside power source is impressed on the pipeline by using a
ground bed and a power source.
A TRU (Transformer Rectifying Unit) is heart of CP Unit.
Operation range: 10-50 V

Observations
1. Monthly maintenance of Transformer

General Cleaning
Position of valves, leakage check, silica gel in breather check.
Oil in conservator tank and thermometer pockets were checked.
Winding temperature and Oil temperature readings are noted.

2. Defective Capacitor from Capacitor bank

Bank of 6 cylindrical capacitors, rating 58.4 mf, 440 VAC

3. Maintenance of CT-06 (Crude Storage Tank)

60,000 KL storage capacity, stores BH and MI type of crude in it.

60 yard diameter, oating roof tank with MS oor at 5.5-6 feet minimum height.
Total height 15 meters
Steam Abrasive Blasting

4. Levelling of Junction Boxes (JB) at CT-06 field

Raise the height of JBs to minimum height of periphery boundary wall.
Reduces the risk of any mishappening.
1 out of 3 JBs could not be raised, because of the absence of the wire loop.

5. Heat shrink Cable joint at CT-06 site

Kit includes shrink tubes for conductors, lugs, copper wire mesh, cage installation
tube, outer jacket tube, XLPE insulation layer.

6. Auto Power Factor Control Panels (APFC)

A transducer in APFC continuously checks the phase angle between Voltage and
Current.
Depending on the phase angle, the APFC controller Automatically switches
capacitors from Capacitor banks, the desired equivalent capacitor from series
parallel connection of Capacitor banks provides equivalent Reactive power balance
thereby improving p.f almost to unity.
APFC now consists of Thyristor Switching Modules.
At IOCL chaksu, net saving of Rs 11 Lacs per annum has been done.

7.Contactors

Electrical controlling switch in Power circuits, with very high current ratings.

8. Visit to the New Pump Shed

Under construction.
Will replace Mainline Engines with Electrical Motors for Pumping.
The new HT motors has ratings (1550 KW CM Section x3, 1255 KW CP Section x3, 11 KV)
Will have higher efficiency,
Overall electricity would cost much less than crude/diesel consumption.
Noise level (120-150 dB) would reduce to significant level with operating on HT motors.
New 33 kV HT line has been given by RSEB already and establishment of Transformer (33 kV : 11
kV) and cabling is being done.
The new pump shed will be in working state within 5-6 following months.

9.Emergency Mock Drill

Conducted Every month.

2 persons has to remain inside the Control Room for Operational Purpose.
Rescue Response time was 7 minutes.
Overall response time was around 12 minutes including fire fighting operation, foam producing
etc.
Each department representative had a walkie-talkie having 2 private radio frequency channels.
There was a slight disturbance and the siren could not be heard around the mainline engine area
due to the working of mainline engines.
Overall Response was satisfactory.

Thank You
References:
IOCL Apex manual
IOCL Cathode Protection manual
IOCL Operations manual
Peabodys Control of Pipeline Corrosion by A.W Peabody.