Summer Training - Mechanical

Maintenance and Planning of

IOCL Refinery Guwahati

Presented By
Dhrubajyoti Das (MEB10002)
Department Of Mechanical Engineering
Tezpur University

IOCL (An overview)

Indian Oil Corporation is an Indian state-owned oil and gas company head
quartered at New Delhi.

It is the 18th largest petroleum country in the world.

It own and operates 10 of Indias 19 refineries.

Largest public corporation in India when ranked by revenue.

It has a combined refining capacity of 65.7 million metric tonns per year.

Guwahati Refinery

Established with Romanian collaboration in 1st January 1962

Annual refining capacity is 1.0 million metric tonnes per year

Processes crude oil from oil fields in upper Assam and caters to
the need of petroleum products in the North Eastern Regions.

PRODUCTS: Motor spirit (Petrol),Aviation Turbine

Fuel,LPG,Kerosene,Light Speed Diesel and raw petroleum coke

UNITS

FIRE AND SAFETY DEPARTMENT

MECHANICAL WORKSHOP

THERMAL POWER STATION (TPS)

CRUDE DISTILLATION UNIT (CDU)

DELAYED COKER UNIT (DCU)

HYDROGEN GENERATION UNIT (HGU)

HYDROTREATER UNIT (HDT)

OIL MOVEMENT AND STORAGE (OM&S)

FIRE AND SAFETY

DEPARTMENT
The responsibility of ensuring the safety of the entire refinery and keeping it
accident free.
Elements for causing fire:
Oxygen
Fuel
Heat

Fire can be extinguished by removing any

one of them.

Fire triangle

Protection
Fir extinguishers:

Soda-acid.
Foam type.
Dry chemical: this is an all-purpose fire extinguisher.
Carbon-dioxide: this type is mostly found at homes.

Personal Protection Equipment

Helmet
Shoes
Gas-masks
Gloves

SOME KEY COMPONENTS OF

THE REFINERY
1. PUMP-transfers fluid from one point to another by virtue of change of pressure
They are of two types:
.

Rotodynamic (or centrifugal) : These are a type of pump that operate by using centrifugal force to
pull liquid away from the centre of the container, where it can then be sent through an outlet

Reciprocating pump:

.These are those which cause the fluid to move

using pistons.

.These pumps are being used for pumping highly

viscous fluid

Centrifugal Pumps
PRINCIPLE:

Kinetic energy is imparted to the fluid by the rotating impeller

The potential energy

of the fluid is increased
by decreasing the
value of velocity as it
tends to leave through the impeller casing.

COMPONENTS OF THE PUMP

Impeller
Pump eye
Casing
Shaft

Mechanical seal-A mechanical seal is a device which helps join systems or

mechanisms together by preventing leakage .
Mechanical Seals may be of following types:
STATIC SEALS:
These are employed where no movement occurs at the juncture to be sealed.
Typical examples being gaskets & O rings.
DYNAMIC SEALS:
These are employed where surfaces have relative motion. Typical examples
being a reciprocating shaft or a rotating shaft

Pump bearings: Used to attain free frictionless movement at the ends so that the losses in

the machines are reduced.

It is of two types:
1) Roller:
In this type, the outer as well inner parts are separate which has the cage holding the roller and
the outer ring moving independently.
This can take more load than ball bearings under
normal conditions.

2)Journal bearings:
It consist of a shaft or journal which rotates freely in a supporting metal sleeve or shell.
There are no rolling elements in these bearings.

2. MECHANICAL VALVES
A valve is a device that regulates, directs or controls the flow of a fluid by opening,
closing, or partially obstructing various passageways.
Many different types of valves are used in a refinery:
Gate Valve :

These valves are ones which open by lifting

a round or rectangular gate/wedge out of the path of the
fluid
. a gate valve is the sealing surfaces between
the gate and seats are planar, so gate valves are often
used when a straight-line flow of fluid and minimum
restriction is desired.
For extremely thick fluids, a specialty valve often
known as a knife valve is used to cut through the
liquid.

Butterfly Valve :

This a valve can be used for regulating

flow.

Flow can also be completely isolated.

Globe valve :

A globe valve is a type of valve used for regulating flow in a pipeline, consisting
of a movable disk-type element and a stationary ring seat in a generally
spherical body.

 Ball valve :
A ball valve is a valve with a
spherical disc, the part of the valve
which controls the flow through it

The sphere has a hole, or port,

through the middle so that when the
port is in line with both ends of the valve, flow will occur.

When the valve is closed, the hole is perpendicular to the ends of the valve,
and flow is blocked.

 Non-Return Valve :
A check valve or a non-return valve is a mechanical device, a valve, which
normally allows fluid to flow through it in only one direction. The check valves
are two-port valves with the two openings in the body, one for fluid to enter and
the other for fluid to leave.

 Pressure relief valve :

A safety valve is a valve mechanism for the automatic
release of a substance from a boiler, pressure vessel,
or other system when the pressure or temperature
exceeds preset limits .

3.HEAT EXCHANGER
An equipment built for efficient heat transfer from one medium to another.

The various application of a heat exchangers in a refinery are :

As Intercoolers and as Preheaters
As condensers and as Boilers
As Evaporators
As Regenerators
As Oil coolers
Kinds of heat exchanger:
1) Counter flow Heat Exchanger:
2) Parallel Flow Heat Exchanger
3) Cross flow Heat Exchanger

4. Furnace
Main components of a furnace are:

Heating coils
Enclose or box
Combustion equipment or burner
Air pre heater (APH)

Problems in furnace:

High excess air operation

Failed connections sections
Over firing
Bad flames /flame impingement

THERMAL POWER STATION

A thermal power station is a power plant in which the prime mover is steam driven.
It operates on Rankine cycle.

Sub-units :

5 boilers Nos. 3,4,5,6,7

3 turbines Nos. 3,4 ( 8 MW) No. 5 ( 12MW )

Generators are coupled to turbines by geared coupling

De-aerator

Boiler Feed pumps

Heat Exchanger

Cooling towers ( 2 Nos.)

De-mineralization plant

SALIENT FEATURES

Fuel used to generate steam is Low Sulphur Heavy Stock(LSHS).

Pressure of the boiler is 37 kg/cm2

Various capacities of the boilers are 20 metric tonnes per hour ,40
metric tonnes per hour , maximum capacity being 60 metric tonnes
per hour

Super-heated steam which is generated is at a temperature of 400500C

Readings from TG 5

Low Pressure Steam

Speed A ( from probe
1) : 6561.75 rpm
Speed B ( from probe 2) Pressure : 2.59 kg / cm 2
: 6563.29 rpm
Temperature : 274.60 deg C
Power : 6.63 Mw
Frequency : 50.04 Hz
Flow rate : 6.44 Tonne / hr

Main Steam

Pressure : 36.63 kg / cm

Medium Pressure Steam

Pressure : 11.37

Temperature : 439.51 deg C Temperature : 330 deg C

Flow rate : 50.15 Tonne / hr Flow rate : 18.40

Exit Steam
Pressure : 675.38 mm Hg
FX Hood Temperature : 38.16 deg C

FLOW DIAGRAM OF THE

PLANT

Demineralization
plant

Feed water
pump

D
De-aerator
52.98 0C

29.64
0
C

economize
r

Steam
Drum

Water
Drum

52.98 0C
52.98 0C

Turbine
52.98 C
0

Secondary
super
heater

52.98 0C

Primary
super heater
52.98 0C

LP Steam

MP Steam
Desuperheater
52.98 0C

52.98 0C

CRUDE DISTILLATION
UNIT(CDU)

Crude distillation unit is the mother unit of a refinery.

It receives the raw crude oil from its supplier (Oil India Ltd. In case of Guwahati refinery)
and it does the required pre-treatments of raw crude like Desalting, Preheating etc.
The different outputs from the CDU unit of Guwahati Refinery are LPG, Light gasoline(LG),
Heavy Gasoline(HG), Kero-l, Kero-ll, Gas oil & Reduced Crude oil(RCO feed to DCU).

Composition of crude oil:

Crude oil contains around 82-87% carbon, 11-15% hydrogen, and oxygen, nitrogen and other
metals (Ni, V etc.) constitute the remaining.
Main Constituents of Petroleum hydrocarbons:1. Paraffinic hydrocarbons(alkanes)
2. Naphthenic hydro-carbons(cyclo-alkanes)
3. Benzene hydrocarbons( arenes)
4. Unsaturated hydrocarbons(olefins)
5. Oxygen containing compounds:
6. Sulphur compounds (vary from traces to 8%)
7. Nitrogen compounds (vary from traces to 1%)

FLOW DIAGRAM

condenser

113 deg

HX

desalter
210 deg

Crude
oil
storage
tank

Col.
1

liquid

Series of HX

pump
260 deg

Stabilized feed foe LPG

furnace
HX

364 deg

Heavy gasoline

140 deg

Kerosene 1
Col.
2

Kerosene 2
Gas oil

RCO ( to DCU)

DELAYED COKER UNIT(DCU)

The feed to be processed in the unit is Reduced Crude oil (RCU) .
The process by which heavy residual oil is converted into lower molecular weight
hydrocarbon is known as Theory of coking.
The process thermally cracks the long chain hydrocarbon
molecules in the residual oil feed into shorter chain molecules.
At a temperature of 415 0 C temperature, the larger hydrocarbon
molecules of high boiling ranges are thermally decomposed to smaller
low boiling molecules thereby producing lower boiling light and middle
distillates such as gasoline, kerosene, and gas oil at the same time.
Some of the molecules which are reactive combine with one another
giving even larger molecules than those present in the original stock
forming residual fuel oil and petroleum coke.
On completion of 24 hours of filling, the coke chamber is isolated
&Coke from the filled coke chamber is cut and cleared by hydraulic
jets operating at a pressure of about 115kg/cm2

HYDROGEN GENERATOR UNIT

( HGU)

Used for the generation of hydrogen

Divided into six main sections-

Feed treatment

Pre-reforming
Reforming
Heat recovery
Shift
Product recovery

Feed:
Straight run naptha
LRU off gas

Hydrotreater Unit (HDT)

The purpose is to meet Bharath stage III specification of diesel and to produce
kerosene of high smoke pint.
It receives its hydrogen requirements from the HGU.
The plant deals with following fuels:
Crude oil
Motor spirit
Straight run naphtha (SRN)
Aviation turbine fuel (ATF)
Superior kerosene (SKO)
High speed diesel (HSD)
Light diesel oil (LDO)
Low sulphur heavy stock (LSHS)
Input feed: Diesel in the form of SRK II, SRGO, CK-I, CGO.
Products: MSP, Superior kerosene, Aviation Turbine Fuel.

ISOM

It is a unit where the octane number of petrol is increased and where normal
paraffins are separated from a mixed stream of normal paraffins and non-normal
hydrocarbons.
FEED
:
PRODUCT :

NEPTHA, HYDROGEN.
ISONEPTHA PRODUCTS.

The ISOM Unit is divided into four sections:

Fresh feed circuit.
Adsorber section circuit.
Make up and recycle gas circuit.
Stabilizer section circuit.

OIL MOVEMENT & STORAGE

This is the unit of the refinery where the storage and movement of the products
are controlled.

There are three kinds of tanks for storing liquids in the refinery these are:
Fixed roof tank
Floating roof tank
Fixed and floating roof tank.
Uses of tank
Heavier hydrocarbons like HSD,
Petrol are stored in fixed roof tanks.
While smaller hydrocarbons like
ATF, Naptha, fuel gas etc while are
more likely to vaporise are stored in floating roof tanks.
Crude Oil is stored in floating roof tank.
LPG is stored in a specially designed spherical tank called Horton Sphere

PLANNING AND MAINTENENCE

In refineries planning is required due to the following reasons To increase the run length of various mechanical or other equipments.
To prevent breakdown of equipments.
To avoid unplanned shut down.
To increase the amount of profit.
Objective od maintenance :
To provide maintenance services at right time with right quality and with
minimum expenditure of resources and time for supplying the right quality of
products in time
Adherence to the Safety, Health & Environment friendly practices
Types of maintenence:
Shutdown or Turn around maintenance.
Predictive or Condition Based maintenance .
Preventive or Time Based maintenance

CONCLUSION
I got a wonderful opportunity to do my
vocational training at IOCL Guwahati
refinery. It had bridged the gap between
theory and practice. I had the experience
to see the industrial process practically,
which I have known only theoretically.