summer training report of Iocl,haldia
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Transcript of summer training report of Iocl,haldia
Indian Oil Corporation LimitedHaldia Refinery, West Bengal
CONTENTS
COMPANY PROFILE
FIRE AND SAFETY DEPARTMENT
THERMAL POWER STATION
WORKSHOP AND ELECTRICAL TESTING UNIT
GAS TURBINE UNIT
LEARNING EXPERIENCE
COMPANY PROFILE
A BRIEF –HALDIA REFINARY
The fourth refinery of Indian Oil
Situated in the State of West Bengal and is about 123 km from
Kolkata city
Commissioned in January 1975 with an initial crude
processing capacity of 2.5 MTPA
The total installed capacity of the refinery is currently 7.5
MTPA.
Petroleum products are transported through various modes
like rail, road as well as environment-friendly pipelines
Caters to the high- consumption demand centers in North-
Eastern India including the States of Bihar, Bengal, Orissa,
Assam and neighboring countries Sri-Lanka, Bangladesh and
Nepal.
HALDIA REFINERY PRODUCT DISPATCH
MODE
PRODUCTS OF HALDIA REFINERY
Fuel oil products include:
LPG
Naphtha
Motor Spirit (MS)
Mineral Turbine Oil (MTO)
Superior Kerosene (SK)
Aviation Turbine Fuel (ATF)
Russian Turbine Fuel (RTF)
High Speed Diesel (HSD)
Jute Batching Oil (JBO)
Furnace Oil (FO)
Lube oil base stocks are:
Inter Neutral HVI grades
Heavy Neutral HVI grades
Bright Neutral HVI grades
Beside the above, Slack wax, carbon black feed stock (CBFS), Bitumen and Sulfur
MAIN UNITS OF HALDIA REFINERY
Fuel Oil Block (FOB)
Lube Oil Block (LOB)
Diesel Hydro De-Sulfurization Unit (DHDS)
Oil Movement & Storage Unit (OM&S)
The plot plan of the Haldia Refinery is shown in the figure:
FIR
E A
ND
SA
FE
TY
DE
PA
RT
ME
NT
1. On-site Industrial
Fire Department
comprised of full-
time career
personnel
2. Volunteer
Emergency
Response Team
members (ERT)
from within the
various work
groups
3. Operating out of
the Fire Station are
the following
Mobile response
apparatus: 2
specialized Foam
Engines,
Rescue/Hazmat
truck, 2 Foam
Tenders,3 Squads
and a utility truck.
SAFETY HAS NO HOLIDAY
THERMAL POWER STATION
(TPS)
THE RATING OF THERMAL POWER
STATION
Steam Inlet Pressure(Ata) 62 Ata
Steam Outlet Pressure(Ata) 15 Ata
Maximum Inlet temperature(degree centigrade) 480 degree centigrade
Normal Inlet Temperature(degree centigrade) 450 degree centigrade
Steam flow rate(ton/hr) 8 to 80 ton/hr
Steam Outlet Temperature(degree centigrade) 280 degree centigrade
Injection Water temperature(degree centigrade) 145 degree centigrade
Injection Water pressure(Ata) 80 Ata
Injection Water Flow Rate (ton/hr) 1.5 ton/hr
BOILER
Here are 4 boilers and each of them are oil feed type.
Among these 4 boilers 3 of them are having a capacity of
125 ton/hr (but the capacity is reducing with the
increasing age of the boilers and now the capacity is
around 100 – 105 ton/hr) and the other one has a
capacity of 150 ton/hr.
The pressure of steam in the boiler is 62 kgf/cm2 and the
temperature in the boiler is 450 degree C.
The steam that produced in the boiler is VM Steam
means high pressure steam. This steam is then supplied
into the turbine.
ELECTRICAL EQUIPMENTS OF A
THERMAL POWER STATION
Alternator
Exciter
Voltage Regulator
Reactors
Switches
Circuit Breaker
Current Transformers
Potential Transformers
Control Room or Operating Room
ALTERNATORS
The steam turbine driven generators have auxiliary
systems enabling them to work satisfactorily and
safely
Haldia refinery’s thermal power station has 4
generators. 3 of them have rating of 10.5 MW and the
other one has a capacity of 16.5 MW
Static part of the generator i.e. stator has 3 phase
double star winding from which 3 phase AC output
power is available at a rated voltage of 6.6KV
The rotating part of generator i.e. rotor has field
winding excited by controlled DC power supplied
from AVR (Automatic Voltage Regulator)
SP
EC
IF
IC
AT
IO
NS
OF
ALT
ER
NA
TO
R
Manufacture BHEL(HYDERABAD),1972
Type T G N 2202 33/2
Sr. No. TG 1,1016,TG 2 TG 3
Voltage 6600 V (+/- 5%)
Rated Speed 3000 RPM
Frequency 50C/S
Power Factor at full load 0.8
Nominal Rating 10.5 MW at 0.8 PF
Admissible overload 11.3 MW
Sub-transient reactance 11%
Transient reactance 18%
Synchronous reactance 16.18%
Negative sequence reactance 11%
Zero sequence reactance 4.5%
Neutral point earthing 3 OHM for 1250A for 10sec
Vector rotation of 3phase Anti clockwise
Insulation Class B type
Phase connection star
Cooling Air cooled
Generator terminals 6
Maximum allowed output with one of the four cooling
elements out of operation9200KVA
Moment of inertia 1.88 tgm2
Volume of cooling 11m3/sec
Critical speed of rotor 1750 rpm
No load field current 165 A
Minimum diameter of slip rings 380mm
Circuit breaker 6.6KV/1500A/500MVA
Carbon brush no 2*8
Size 25*32 mm
GRAD HM6R
EXCITER AND VOLTAGE REGULATOR
Exciter :
Main functions are:
To provide variable dc current.
Controlling the terminal
voltage by means of suitable
accuracy to ensure stable
operation with network and
other machines.
Enhance transient stability
subsequent to a fault.
Communicate with the power
plant control system and to
keep the machine within
permissible operating range.
Voltage Regulator :
Performs following functions :
Control of system voltage within
prescribed limits.
Proper division of reactive power
between the alternators operating
in parallel.
Prevention of dangerous over
voltages on the occurrence of
sudden loss of load on the system.
Increase of excitation under
system fault conditions so that
maximum synchronizing power
exists at the time of clearance of
fault, to prevent loss of
synchronism.
• Is a coil having large inductive reactance in comparison to its ohmic resistance
• Introduced in a circuit or system to limit the short circuit currents to a safer value in order to protect the electrical installation.
Reactors
• Used in an electric circuit as a device for making or breaking the electric circuit
• Classified as :
• Air Break Switches
• Oil Switches
• Isolators
Switches
• Mechanical device designed to close or open contact members
• It can be operated manually or by remote control under normal conditions and automatically under fault conditions
• EHV system, SF6, Oil, Air, Vacuum type circuit breakers have become very popular.
Circuit
Breaker
MAINTENANCE OF THE ELECTRICAL
EQUIPMENT
Preventive maintenance
A(6 month),
B(1 year),
C
Predictive maintenance
Temperature, Vibration,
IR value
Breakdown maintenance
Troubleshooting
Silica Gel Replacement.
Winding temperature &
oil temperature
monitoring
Breaker maintenance &
thermal checking
Relay testing
Tightening
Leakage Arresting
MOTOR MAINTENANCETRANSFORMER
MAINTENANCE
WORKSHOP AND ELECTRICAL
TESTING UNIT
One of the most important section of any industry
During the visit of the unit, I observed the testing of a SF6 circuit breaker with following specifications :
The analog instruments that they used for testing are :
Moving Iron Instrument
AC Voltage Frequency
Maximum Percentage of error
Installation type (perpendicular)
Line capacity (2KV)
CT Rating in primary side
Full Scale Deflection of the instrument
TYPE SF As G 12.16.40
SL NO 4811692365
RATED VOLTAGE 6.6KV
RATED FREQUENCY 1250A
RATED CURRENT 50Hz
RATED PEAK MAKING CURRENT 100KA
RATED BREAKING CURRENT 40A
RATED SHORT TIME CURRENT 40A for 3seconds
RATED PRESSURE OF SF6 3.4 bar abs
AUXILARY CIRCUIT 110V dc
MOTOR SUPPLY VOLTAGE 110V dc
TRIP/CLOSE COIL 110V dc/ac
CONNECTION DIA 5114030884
CONFORMS TO IS: 13118/IEC :56
WEIGHT 210 KG
YEAR OF MAKING 2001
RATING 2 MVA
NO LOAD VOLTAGE HV: 6.6 KV
LV: 433V
NO LOAD CURRENT HV: 17.435A
LV: 2666.75A
PHASE THREE
FREQUENCY 50
COOLING TYPE ONAN
REF IS 2026
MAXIMUM AMBIENT TEMPERATURE 45 DEGREE CENTIGRADE
MAXIMUM TEMPERATURE RISE OF OIL/WINDING 50-55 DEGREE CENTIGRADE
IMPEDENCE VOLTAGE 6.35%
CORE &WINDING WEIGHT 3600KG
OIL WEIGHT 1055KG
OIL QUANTITY 1100LTR
TOTAL WEIGHT 6455KG
DIA OF CONNECTION NO. 3RD-14096-1/a
GAS TURBINE
Have a capacity of producing a total
of 60MW power in total 3 gas
turbine plants
Gas turbine works on the Brayton
Cycle
MAJOR COMPONENTS OF GAS
TURBINE:
Starting Device : Diesel engine
Inlet System : Air filter and ducting
Compressor: Casing and balding
Turbine : Nozzle &balding
Combustion System : Igniter, Fuel
nozzle, Flame detector, Combustion
can &Liner, Transition piece
Bearings : Journal & thrust
bearings, Lubrication system
Exhaust : Exhaust plenum & Duct
Hydraulic System : Hydraulic
pump & Control
Block Diagram of Gas Turbine and HRSG
LEARNING EXPERIENCE
This Industrial tour helped us immensely in
developing key aspects of practical knowledge and
will help us substantially in the long run
The knowledge and maintenance process of entire
system in a the company is obtained
The valuable practical experience help us to clarify
our concepts