***BPCL KOCHI REFINERIES LTD.***

IN- PLANT

TRAINING REPORT

An IN-PLANT TRAINING REPORT

Training code No.:-

Submitted by:-

Tony Augustine

Vishnu T V

Anu Krishnan

Basil George

Bonny Abraham

Training Period:-

19th May 2014 to 30th May 2014

CERTIFICATE :

This is to certify that Tony Augustine, Vishnu T V , Basil George, Anu Krishnan and Bonny

Abraham, third year students of National Institute of Technology, Calicut has successfully

completed in plant training from 19-05-2014 to 30-05-2014 under the guidance of

Mr.Gopu K. B. ,Senior Manager (Maintenance), with keen interest and dedication during the

course of their in-plant training.

ACKNOWLEDGEMENT:

We would like to express our gratitude to BPCL Kochi Refineries Ltd. For giving us the

opportunity to conduct an in depth study of their refining processes , the mateinance works

carried out in the plant , machinery; which has helped us to gain a thorough understanding of

theoretical concepts learned at college.

We extend sincere gratitude to our guide Mr. Gopu K. B. ,Senior Manager (Maintenance);

Mr. Prasad & Mr. Harsh (Engineers at maintenance dept.) and all the other staffs and

technicians of refinery for their cooperation, guidance, valuable suggestions , support and kind

advices during the entire course of our inplant training.

MAINTENANCE

Maintenance is the measure taken to keep the plant and facilities at prime condition or activities

undertaken to prevent equipment failure. In general better maintenance increases productivity

and improves profitability of organization.

Objectives of maintenance

To keep facilities and equipment in the best operating conditions.

To operate facilities and equipment to optimum percentage of time. To obtain minimum

operating cost.

To ensure maximum safety to operating personnel.

To prevent production loss due to equipment failure.

To provide maximum availability of equipment and facilities for operation.

In BPCL ‘Owner-Service Group’ relation is maintained between other departments and

maintenance department.

There are four types of maintenance:-

1. Preventive Maintenance

2. Predictive Maintenance

3. Breakdown Maintenance

4. Turn around Maintenance

The mechanical components in the refinery are broadly classified as:

1. Static

2. Rotary

STATIC EQUIPMENTS

1) Heat Exchanger:

Heat exchangers are devices used to transfer heat energy from one fluid to another. Heat

exchangers are commonly used in practice in a wide range of applications, from heating

and air conditioning systems in a household, to chemical

processing and power production in large plants.

Types of heat exchangers:

a) Shell and tube heat exchanger:

A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type

of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-

pressure applications. As its name implies, this type of heat exchanger consists of a shell with a

bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes

(through the shell) to transfer heat between the two fluids. The set of tubes is called a tube

bundle, and may be composed of several types of tubes: plain, longitudinally finned, etc.

Description of parts:

Tube: Tubing may be seamless or welded. Seamless tubing is produced in an extrusion process;

welded tubing is produced by rolling a strip into a cylinder and welding the seam. Welded

tubing is usually more economical. Normal tube diameters are 5/8 inch, 3/4 inch and 1

inch. Tubes of smaller diameter can be used but they are more difficult to clean

mechanically. Tubes of larger diameter are sometimes used either to facilitate mechanical

cleaning or to achieve lower pressure drop. Tubing may be finned to provide more heat transfer

surface

Tube Sheet: Tube sheets are plates or forgings drilled to provide holes through which tubes are

inserted. Tubes are appropriately secured to the tube sheet so that the fluid on the shell side is

prevented from mixing with the fluid on the tube side. Holes are drilled in the tube sheet

normally in either of two patterns, triangular or square. The tubes are inserted through the holes

in the tube sheets and are held firmly in place either by welding or by mechanical or hydraulic

expansion. A rolled joint is the common term for a tube-to-tube sheet joint resulting from a

mechanical expansion of the tube against the tube sheet. This joint is most often achieved using

roller expanders; hence the term rolled joint. Less frequently, tubes are expanded by hydraulic

processes to affect a mechanical bond. Tubes can also be welded to the front or inboard face of

the tube sheet.

Baffles: Baffles serve three functions:

1) Support the tube

2) Maintain the tube spacing

3) Direct the flow of fluid in the desired pattern through the shell side.

A segment, called the baffle cut, is cut away to permit the fluid to flow parallel to the tube axis as

it flows from one baffle space to another. Segmental cuts with the height of the segment

approximately 25 percent of the shell diameter are normally the optimum.

Tie Rods and Spacers

Tie rods and spacers are used for two reasons:

1) Hold the baffle assembly together

2) Maintain the selected baffle spacing.

The tie rods are secured at one end to the tube sheet and at the other end to the last baffle. They

hold the baffle assembly together. The spacers are placed over the tie rods between each baffle

to maintain the selected baffle pitch. The minimum number of tie rod and spacers depends on the

diameter of the shell and the size of the tie rod and spacers.

Channels (Heads)

Channels or heads are required for shell-and-tube heat exchangers to contain the tube side fluid

and to provide the desired flow path.

Other types of heat exchangers are:

b) Plate heat exchanger

c) Plate fin heat exchanger

d) Adiabatic wheel heat exchanger

2) Boiler

A boiler is a device used to create steam by applying heat energy to water.

The different types of boilers are:

a) Water Tube Boiler:

A water tube boiler is a type of boiler in which water circulates in tubes heated externally

by the fire. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-

generating tubes. In smaller boilers, additional generating tubes are separate in the furnace, while

larger utility boilers rely on the water-filled tubes that make up the walls of the furnace to

generate steam.

The heated water then rises into the steam drum. Here, saturated steam is drawn off the top of the

drum. In some services, the steam will reenter the furnace through a superheater to become

superheated. Superheated steam is a dry gas and therefore used to drive turbines, since water

droplets can severely damage turbine blades.

Cool water at the bottom of the steam drum returns to the feed water drum via large-bore 'down

comer tubes', where it pre-heats the feed water supply. To increase economy of the boiler,

exhaust gases are also used to pre-heat the air blown into the furnace and warm the feed water

supply.

b) Fire Tube Boiler

c) Flash Boiler

d) Sectional Boiler

VALVES

A valve is a device that regulates, directs or controls the flow of a fluid by opening, closing, or

partially obstructing various passageways.

Different types of valves are:

1) Gate Valve :

The gate valve, also known as a sluice valve, is a valve that opens by lifting a round or

rectangular gate/wedge out of the path of the fluid. Gate valves are designed to completely open

the line to flow, or to completely stop the flow. They are therefore, used wide open or fully

closed, and are not intended for throttling service.

2) 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. It can be used

wide open, fully closed, or with the disk in an intermediate position for regulating the flow. The

character of the fluid and the degree of control desired determine the particular design of globe

valve that should be used.

3) 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.

4) 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 favored because they are lower in cost

to other valve designs as well as being lighter in weight, meaning less support is required. The

disc is positioned in the center 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

5) Relief Valve :

The relief valve (RV) is a type of valve used to control or limit the pressure in a system

or vessel which can build up by a process upset, instrument or equipment failure, or fire.

STORAGE TANKS

Storage tanks containing organic liquids, non organic liquids, vapors and can be found

in many industries. Most storage tanks are designed and built to the American Petroleum

Institute API-650 specification. These tanks can have different sizes, ranging from 2 to 60 m

diameter or more. They are generally installed inside containment basins in order to contain

spills in case of rupture of the tank. Industries where storage tanks can be found are: petroleum

producing and refining, petrochemical and chemical manufacturing, bulk storage and transfer

operations, other industries consuming or producing liquids and vapors.

There are fixed roof tanks and floating roof tanks.Fixed roof tanks are meant for liquids

with very high flash points, (e.g. fuel oil, water, bitumen etc.) Cone roofs, dome roofs and

umbrella roofs are usual. These are insulated to prevent the clogging of certain materials,

wherein the heat is provided by steam coils within the tanks. Dome roof tanks are meant for

tanks having slightly higher storage pressure than that of atmosphere (e.g. slop oil).Floating roof

tanks are broadly divided into external floating roof tanks (usually called as floating roof

tanks:FR Tanks) and internal floating roof types(IFR Tanks).IFR tanks are used for liquids with

low flash-points(e.g. ATF, MS. gasoline, ethanol). These tanks are nothing but cone roof tanks

with a floating roof inside which travels up and down along with the liquid level. This floating

roof traps the vapor from low flash-point fuels. Floating roofs are supported with legs or cables

on which they rest. FR tanks do not have a fixed roof (it is open in the top) and has a floating

roof only. Medium flash point liquids such as naphtha, kerosene, diesel, crude oil etc. are stored

in these tanks.

As flash point of liquid go very low tanks are usually spherical and are used for storage

of LPG, Hydrogen etc.

PIPING

Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one

location to another. The engineering discipline of piping design studies the efficient transport of

fluid.

Industrial process piping (and accompanying in-line components) can be manufactured from

wood, fiberglass, glass, steel, aluminum, plastic, copper, and concrete. The in-line components,

known as fittings, valves, and other devices, typically sense and control the pressure, flow rate

and temperature of the transmitted fluid, and usually are included in the field of Piping Design

(or Piping Engineering). Piping systems are documented in piping and instrumentation diagrams

(P&IDs). If necessary, pipes can be cleaned by the tube cleaning process.

"Piping" sometimes refers to Piping Design, the detailed specification of the physical piping

layout within a process plant or commercial building. In earlier days, this was sometimes called

Drafting, Technical drawing, Engineering Drawing, and Design but is today commonly

performed by Designers who have learned to use automated Computer Aided Drawing /

Computer Aided Design (CAD) software.

Plumbing is a piping system with which most people are familiar, as it constitutes the form of

fluid transportation that is used to provide potable water and fuels to their homes and businesses.

Plumbing pipes also remove waste in the form of sewage, and allow venting of sewage gases to

the outdoors. Fire sprinkler systems also use piping, and may transport nonpotable or potable

water, or other fire-suppression fluids.

Piping also has many other industrial applications, which are crucial for moving raw and semi-

processed fluids for refining into more useful products. Some of the more exotic materials of

construction are Inconel, titanium, chrome-moly and various other steel alloys

ROTORY TYPE

AIR COMPRESSOR

An air compressor is a device that converts power (usually from an electric motor, a diesel engine or a

gasoline engine) into kinetic energy by compressing and pressurizing air, which, on command, can be

released in quick bursts.

There are three basic types of air compressors:

Reciprocating

Rotary Screw

Rotary Centrifugal

a) Reciprocating

Reciprocating air compressors are positive displacement compressors. This means they are

taking in successive volumes of air which is confined within a closed space and elevating this air

to a higher pressure. The reciprocating air compressor accomplishes this by using a piston within

a cylinder as the compressing and displacing element. The reciprocating air compressor is

considered single acting when the compressing is accomplished using only one side of the

piston. A compressor using both sides of the piston is considered double acting. The

reciprocating air compressor uses a number of automatic spring loaded valves in each cylinder

that open only when the proper differential pressure exists across the valve. Inlet valves open

when the pressure in the cylinder is slightly below the intake pressure. Discharge valves open

when the pressure in the cylinder is slightly above the discharge pressure. A compressor is

considered to be single stage when the entire compression is accomplished with a single cylinder

or a group of cylinders in parallel. Many applications involve conditions beyond t

he practical capability of a single compression stage. Too great a compression ration (absolute

discharge pressure/absolute intake pressure) may cause excessive discharge temperature or other

design problems. For practical purposes most plant air reciprocating air compressors over 100

horsepower are built as multi-stage units in which two or more steps of compression are grouped

in series. The air is normally cooled between the stages to reduce the temperature and volume

entering the following stage.

b) Rotary Centrifugal

In a centrifugal compressor, energy is transferred from a set of rotating impeller blades to the

gas. The designation “centrifugal” implies that the gas flow is radial, and the energy transfer is

caused from a change in the centrifugal forces acting on the gas. Centrifugal compressors deliver

high flow capacity per unit of installed space and weight, have good reliability, and require

significantly less maintenance than reciprocating compressors. However, the performance

characteristic of centrifugal compressors is more easily affected by changes in gas conditions

than is the performance of reciprocating compressors.

The API has produced an industry standard, API Standard 617, which is frequently used to

govern the design and manufacture of centrifugal compressors.

Major components

Case (casing or housing)

The case (casing or housing) is the pressure-containing component of the compressor. The case

houses the stationary internal components and the compressor rotor. Bearings are attached to the

case to provide both radial and axial support of the rotor. The case also contains nozzles with

inlet and discharge flange connections to introduce flow into and extract flow from the

compressor.

Rotor assembly

The compressor rotor is fundamentally an assembly of impellers mounted on a steel shaft.

Additional rotor components include miscellaneous hardware, such as:

A thrust balance drum (balance piston)

Impeller spacers

Seal sleeves

A thrust disc

One or two couplings

For most applications, high-strength alloy steel is selected for the impeller material. Stainless

steel is often the material of choice for use in corrosive environments.

Bearings and seals

Centrifugal compressors are equipped with two radial (journal) bearings to support the rotor

weight and position the rotor concentrically within the stationary elements of the compressor.

One thrust bearing also is used to ensure that the compressor rotor is maintained in its desired

axial position.

wo distinct categories of compressor seals are used:

Internal seals

Shaft seals

Internal seals minimize internal recirculation losses between stages and across the thrust balance

drum. Labyrinth type seals are customarily used for this purpose to maximize operating

efficiency. Shaft seals are required to seal the gas inside the compressor at the point where the

compressor rotor shaft penetrates the case. This vital sealing function is necessary to prevent

escape of process gas to the environment surrounding the compressor. Dry gas seals are the most

commonly used type of shaft seal.

PUMPS

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical

action. The main types of pump used in Kochi Refinery are :

1) Centrifugal Pump

Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing

turbomachinery.Centrifugal pumps are used to transport fluids by the conversion of rotational

kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically

comes from an engine or electric motor. The fluid enters the pump impeller along or near to the

rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser or volute

chamber (casing), from where it exits.

Components :

Impeller : The impeller is mounted on a shaft with bearings so that it can be rotated insidethe

casing. Where the rotating shaft enters the casing, it must besealed against leakage of liquid.

Shafts : Pump shafts are designed to support the impeller on one end, overhung from the

bearings or between the bearings. The overhung design allows straight liquid flow into the

impeller, but results in greater radial load on the bearings. The overhung design eliminates one

seal around the shaft and simplifies the construction of the casing.

Bearings : Rolling element bearings are most commonly used to support centrifugal pumpshafts.

Single row or double row ballbearings are good for carrying radial andaxial loads.

Seals and Packing : In order to sealrotating shaftsagainst leakageof the pumpedliquid, soft

packing is often used. Such packing is usually made of braided fibers impregnated with graphite

or other lubricating material.The packing is retained by a gland whichcan be tightened to squeeze

the packingclose to the shaft.

Casing : Pump casings collect the liquid from the pump impeller, convert the velocity energy to

pressure energy, and guide the liquid to the pump discharge nozzle.

2) Positive Displacement Pump

A positive displacement pump causes a fluid to move by trapping a fixed amount of it then

forcing (displacing) that trapped volume into the discharge pipe.

The positive displacement pumps can be divided in two main classes

reciprocating

rotary

Reciprocating pumps move the fluid using one or more oscillating pistons, plungers, or

membranes (diaphragms), while valves restrict fluid motion to the desired direction.

Typical rotary pumps are

gear pumps

lobe pumps

vane pumps

progressive cavity pumps

peripheral pumps

screw pumps

a) Screw Pump

A screw pump is a positive displacement pump that use one or several screws to move fluids or

solids along the screw(s) axis. Development of the screw pump has led to a variety of multiple-

axis technologies where carefully crafted screws rotate in opposite directions or remains

stationary within a cavity. The cavity can be profiled, thereby creating cavities where the

pumped material is "trapped".In offshore and marine installations, a three spindle screw pump is

often used to pump high pressure viscous fluids. Three screws drive the pumped liquid forth in a

closed chamber. As the screws rotate in opposite directions, the pumped liquid moves along the

screws spindles.Three-Spindle screw pumps are used for transport of viscous fluids with

lubricating properties. Compared to centrifugal pumps, positive displacements (PD) pumps have

several advantages. The pumped fluid is moving axially without turbulence which eliminates

foaming that would otherwise occur in viscous fluids. They are also able to pump fluids of

higher viscosity without losing flow rate.

TURBINE

A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful

work.

a) GAS TURBINE

The gas turbine is an internal combustion engine that uses air as the working fluid.

The engine extracts chemical energy from fuel and converts it to mechanical energy .

The combustion (gas) turbines being installed in many of today's natural-gas-fueled power plants

are complex machines, but they basically involve three main sections:

The compressor, which draws air into the engine, pressurizes it, and feeds it to the

combustion chamber at speeds of hundreds of miles per hour.

The combustion system, typically made up of a ring of fuel injectors that inject a steady

stream of fuel into combustion chambers where it mixes with the air. The mixture is

burned at temperatures of more than 2000 degrees F. The combustion produces a high

temperature, high pressure gas stream that enters and expands through the turbine section.

The turbine is an intricate array of alternate stationary and rotating aerofoil-section

blades. As hot combustion gas expands through the turbine, it spins the rotating blades.

The rotating blades perform a dual function: they drive the compressor to draw more

pressurized air into the combustion section, and they spin a generator to produce

electricity.

A simple cycle gas turbine can achieve energy conversion efficiencies ranging between 20 and

35 percent.

There are two gas turbines in Kochi Refinery . They have 17 stage compressor and is supplied by

BHEL. Initially it is started using a diesel Engine.

b) STEAM TURBINE

A steam turbine is a mechanical device that, as the result of the thermal energy of the steam,

produces rotary motion. It’s modern day manifestation was first conceived by Sir Charles

Parsons in the year 1884.

It has almost completely replaced the reciprocating piston steam engine primarily because of

it’s greater thermal efficiency and higher power-to –weight ratio. Because the turbine generates

rotary motion, it is suited to drive an electrical generator. About 80% of all electricity generation

in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives

much of it’s improvements in thermal efficiency through the use of multiple stages in the

expansion of the steam as it traverses the blades, which results in a closer approach to the ideal

reversible process.

Principle of Operation and Design

The expansion of steam in a steam turbine is considered to be an isentropic process i.e. constant

entropy at the inlet and outlet of the steam turbine. But practically no steam turbine is truly

isentropic due to the presence of thermodynamic irreversibilities. However, typical isentropic

efficiencies range from 20%-90% base on the application of the turbine.

The periphery of the turbine consists of a set of blades. One set of stationary blades is connected

to the casing and one set of rotating blades is connected to the shaft. The sets intermesh with

certain clearances which are handled during the manufacturing process, with the size and

configuration of sets varying to effectively exploit the expansion of the steam at each stage.

CONCLUSION :

BPCL-Kochi Refineries is one of the leading refineries in India. The plant consists of various

units meant for the refining and manufacturing of a variety of chemical products.The plants

are equipped with standard and reliable mechanical equipment required for each and every

stage of the manufacturing process. Also the company is looking forwards to expand its

capacity and the project associated with it , the IREP is undergoing on its way.

We had undergone training in the maintenance department, and it has helped us to realise

various working environments of mechanical engineers and also apply all our theoretical

knowledge into practical applications. The training also helped us to get an insight about the

refining process and the working of machines constituting the same.