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Industrial Training Report at I O C L
Industrial Training Report at I O C L
ON
VOCATIONAL TRAINING.
PREPARED BY
MIHIR G. PURABIARAO
[06BEER045]
B.E. 3RD YEAR ELECTRICAL & ELECTRONICS ENG.
INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING.
RANCHARDA, AHMEDABAD.
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GUJARAT REFINERY
P.O. JAWAHARNAGAR,BAJUWA
DIST. : VADODARA,GUJARAT-391 320.
WEBSITE : www.iocl.com
TRAINING PERIOD : [05/15/2009 TO 07/16/2009]
TRAINING TIMING : 10:30AM TO 5:30PM
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ACKNOWLEDGEMENT.
Training at INDIAN OIL CORPORATION [I.O.C.] has very
helpful to increase our skill capability & ability to understand what I
have studied so far in our engineering course. Being here I have gained
knowledge about various electrical equipments used for generation &
distribution of electrical energy to various plants running continuously.
It is pleasure and an opportunity for me to expresss my feelings of
thanks & respect to the people have at INDIAN OIL CORPORATION
LIMITED who have always helped & guided me in understanding
various concepts, which were unknown to me.
I am also thankful to Mr. Ashok Jambur from the training center
who helped in arranging my visits to various departments here. I am also
very thankful to Mr. Om Prakash (MNMEL), Mr. A. S. Patel
(SMNMEL), Mr. P.V. Ramkrishna (PUM), Mr. K S Ramarao
(MNMEL), Mr. S. Saini (MNMEL) and Mr. P.J. Shah (MNMEL), who
also helped me during my training.
- PURABIARAO MIHIR G.
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DIFFERENT PRODUCTS
REFINARY :-
OF
GUJARAT
LPG
BENZENE
TOLUENE
NAPTHA
MOTOR SPIRIT (87 OCTANE)
MOTOR SPIRIT (93 OCTANE)
AVIATION TURBINE FUEL
SUPERIOUR KEROSENE
HIGH SPEED DIESEL
LIGHT DIESEL OIL
LOW SULPHER HEAVY STOCK
FUEL OIL
BITUMEN
N-HEPTENE
ALUMINIUM ROLLING.
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ELECTRICAL SYSTEM
ENGINEERING
INTRODUCTION :Gujarat refinery is equipped with two power plants Co-Generation
Power Plant (CGP) and Thermal Power station (TPS). Complexity of
power system is due to different Generation voltage levels, Groinding
and Protection system employed. Even a small lapse while designing
for the expansion / modification of generation / distribution system may
lead to catastrophic consequence in the stability of power system.
Various equipment specification standards for selection of
equipment are available in the refinery. Expertise for engineering and
selection of equipment are also available. Need has been felt to
consolidate all good design practices gained through experience,
equipment selection dpecification etc. to serve as a guideline to the
electrical design engineers of the refinery to achieve consistency in
design on regular basis.
The role of an Eletrical engineer in Engineering Services
Department includes but not limited to study the Process scheme,
evaluate the scope of electrical jobs involved, design a suitable electrical
scheme to provide stable power supply and procurement of suitable
materials required for the same etc. Accordingly, the chapter on Design
basis is developed to provide an overview of Power Geneation,
Distribution and Maintenance of the Equipment / System is to be
designed.
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POWER GENERATION
The total Power Generation of Gujarat Refinery is 126.5 MW.
TPS (Thermal Power Station) = 12+12+12.5 = 36.5 MW.
CGP (Co-Generation Plant) = 30+30+30 = 90 MW.
Therefore the total Power Generation is 126.5 MW.
OPERATING PERAMETERS :
PROCESS IN TPS :
The TPS consist of four boilers and three turbine generators
sets. The boiler generate superheated stem by burning the fuel
obtained from other plants of the refinery itself. This
superheated steam can be utilize to supply steam yo other plants
and can also be used for generating power using steam turbines.
This steam rotates the blades which in turn produce s the
induced voltage. This voltage is then transferred to reactor.
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EQUIPMENT SPECIFICATIONS
Gas Turbine
Frame
: 6
Make
: BHEL / GE
Type
: 30 MW
Fuel
Rated Speed
Generator
Make
: BHEL
Type
: TARI 800-26P
Rating
Stator Current
: 1968 A
Voltage
: 11KV + 10%
Frequency
: 50 Hz
Power Factor
: 0.8 Lag
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: 27.77 Hz
: >83.3 Hz
: 1330 Kgm2
Weight of Stator
: 50000 Kg
Weight of Rotor
: 14500 Kg
Cooling
Cooling Air Flow
Turbine
Number of stages
: 3
Type
: Impulse
Casing
: Horizontal split
: 450 M/Sec.
: 5089 RPM
Ignition speed
: 940 RPM
: 2640 RPM
: 5737 + 50 RPM
Rotor construction
: Ductile Iron
: 2 x 18 = 36
2nd stage
: 3 x 16 = 48
3rd stage
: 4 x 16 = 64
: 92
2nd stage
: 92 (Tip shrouded)
3rd stage
: 92 (Tip shrouded)
Compressor
No. of stages
Type
Direction of rotation
: 17
: Axial flow
: CCW as seen from Inlet end.
Casing
Compressor ratio
: Horizontal split
: 1 : 11
Rated speed
: 5100 RPM
: 340 M/Sec.
Rotor construction
Blade attachment
: Dove tail
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Extraction
Blade material
Combustors
Type
No. of combustion
: 10
No. of Ignition
Firing temperature
Type
Driver
Capacity
: 1741 LPM
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Discharge pressure
: 4.57 kg/cm2
: 0.0278 kg/cm2 .
2.
3. The trip oil system which operates devices for the control,
hydraulic trip sub-system
4.
8.
9.
ELECTRICAL TESTING.
No index entries found.
MEASUREMENT OF EARTH RESISTANCE :
The earthing connection of all the machines are linked to an
underground network called as grid. The value of the earth
resistance should be minimum.
This is done using THE DIGITAL EARTH TESTER. Two
metallic rods sction as eltrodes are inserted into ground and are
connected to the tester. A third wire is connected to the body of
the machine and is connected to the tester. The voltage drop is
measured by the electrodes. Hence resistence can be found by
R = V/I.
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GREASING :
Greasing of some machine bearing is done by isolating it
from the supply, wherever online greasing facility is not
available. Greasing is also done during the working
condition also.
FINDING THE LOCATION OF UNDERGROUND
CABLE FAULT :
Whenever there is breakdown of insulation of long
underground cable, very high voltage is sent by using The
Surge generator which will burn the affected point completely
and aso detects the distance.
To measure the distance TELEFEX is used.Here
distance is measured by sending & receiving the signal and
finally location of the fault is pointed by SEISMIC
VIBRATION DETECTOR.
MEGGER :
It is an instrument used to measure the insulating
resistance of the INDUCTION MOTOR. Actually, the
value should be very high above some particular value. If
there is some damage to the insulation, the value decrease and
hence it can be detected.
ELECTRICAL WORKSHOP
Electrical workshop is a very important and very essential
unit for the primary maintenance of the electrical equipments.
Here as we reffered most of the load the industry in the form of
the INDUCTION MOTOR. So we reffered in the electrical
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workshop that here the most of the jobs are related to the
induction motors. We saw no. of induction motors of different
sizes and of different ratings.
WHY NEED FOR THE WORKSHOP ? :
In IOCL we know that its a Petroleum Industry so that
every plant contain different types of pumps, blowers,
compresser, fans of different ranges. For the operation of all
these equipments the motor is very important. Here if there is
any fault or any other constructional or operational failure arises
with any motor then it will be informed to the workshop.
MAINTENANCE AND TESTING OF MOTORS :
First of all in the workshop Earthing contacts of the motors
are tested.
Then other testing like Megger test and other Winding
tested done.
After opening the motor, it will be cleaned by the
Kerosene. Than it will be put in the Oven for removing the
moisture from the motor.
The motor needs proper insulation over the conductors
throughout the length. So the body and stator windings are
painted with Red Bectol. It improves the insulation
strength.
Then the bearing maintenance is another important job in
the workshop, here the bearings are tested and replaced (if
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