INTERNSHIP REPORT

UMAR SIDDIQUE
SERVICE NO: 361949

UNIVERSITY OF THE PUNJAB (LAHORE)

 EXECUTIVE SUMMARY
The objective of this report is to explain the experience of whole electrical
network in attock oil refinery limited. In ARL there are basically 4 distillation plant
and one refining plant. Some up gradation project are also on the way...

Many auxiliary plants like power plant, boiler house, PMS, ETP and CMS are also
present.

The E&I is the sub department of the maintenance department and it is

responsible for all onsite and offsite maintenance.

The load of whole ARL plants are dependent on a power plant of capacity 7.5MW
and a grid is also there as a backup all auxiliaries installed on grid for protection
and measurement are running by this grid supply coming from WAPDA.
 Abbreviation and Acronyms

ARL attock refinery limited

HBU Howe baker unit

HCU heavy crude unit

NDU new distillation unit

HSEQ health safety environment quality

HSRN heavy straight run naphtha

LSRN light straight run naphtha

DHDS diesel hydro desulphurization

CCTV close circuit television

AITSL attock information technology service limited

CMS crude metering system

ETP effluent treatment plant

PMS product metering system

ATG auto tank gauging

GDS gas detection system

CCR central control room

CT current transformer

PT potential transformer

E&I electrical and instrumentation

 ARL overview

Attock refinery limited is a member of attock group of companies, a group that

covers all segment of oil and gas sector from exploration production and refining
to marketing of wide variety of petroleum Products.

Attock group a renowned group of country also providing medical facilities to

employees and local communities of morgah region in Rawalpindi.

Attock Refinery limited was established as a private limited company in

November, 1978 to take over the business of attack Oil Company relating to
refining of crude oil and supplying of refined petroleum products. It was
subsequently converted in to public limited company in June, 1979 and is listed
on the three stock exchanges of the country.

it is one of the oldest companies of Pakistan, it is refining crude oil since 1922.
With such a rich experience of successful operations of 90 years of ARL has been
gradually upgraded to meet the new challenges requirements and to provide eco-
friendly energy solutions.
 MAIN PLANTS
The main plants for distillation and refining of petroleum products are:

LUMMUS PLANT
This is the oldest plant with a capacity of 5500 bpd. It
consists of two towers one is atmos tower and 2nd one is vacuum tower. Both are
use for refining of heavy and light crude.

HBU
In 1981 two new distillation units of capacity 20000 and 5000 bpd were
installed with name HBU1 and HBU2 respectively. They are also named as NDU1
AND NDU2.

HCU
Heavy crude unit is also a distillation plant with two distillation towers and its
capacity is 10000bpd.This plant was installed in 1999.

Reformer
This plant consists of two splitter to separate the LSRN and
HSRN and is also use to increase octane no of naphtha by catalytic process.
Auxiliary System
There are many auxiliary units use to fulfill the
operation of distillation to sustain the supply change of crude oil and products to
reduce the environment pollution and to ensure the safety measures....

The main auxiliary systems are

 PMS
 CMS
 Boiler house
 ETP (effluent treatment plant )
 power plant
 Fire Alarm System
 CCR (central control system)
 GDS (gas detection system)
 ATG (auto gauging )
 storage tank

ARL Products
Wide range of product produce in ARL liquefied petroleum
Gas Unleaded Petroleum Solvent Grade

 Naphtha
 Motor gasoline
 JP-1
 JP-8
 Kerosene oil
 High Speed Diesel
 Light Diesel Oil
 Furnace Oil
 Low Sulphur fuel oil
Our main concern is on the ELECTRICAL UTILITIES of ARL plants
for this we divide it in to two categories.
1. power plant
2. Grid station

GRID STATION
A grid station is a point in the chain of electricity distribution
which takes supply from WAPDA and will be utilized as a backup to power plant in
case of any fault and also supplying power to some areas like bungalow shahpur
colony etc.

In ARL 132kv line is coming from the WAPDA (NTDC) and is step down to 11kv by
a power transformer of rating 25KVA.

There are different components of grid station like PT CT circuit breaker, isolator,
transformer, lightning arrestor protection devices. Their brief description is as
follow

Potential Transformer
Potential transformer or voltage transformer gets used in
electrical power system for stepping down the system voltage to a safe value
which can be fed to low ratings meters and relays. Commercially available relays
and meters used for protection and metering, are designed for low voltage.
PTs are used for
 Metering
 Protection
ISOLATOR
It is essentially a knife switch and is designed to open a circuit under no
load. The insulator plays a vital role in electrical system. Electrical Insulator is a
very high resistive path through which practically no current can flow. In
transmission and distribution system, the overhead conductors are generally
supported by supporting towers or poles. The towers and poles both are properly
grounded. So there must be insulator between tower or pole body and current
carrying conductors to prevent the flow of current from conductor to earth
through the grounded supporting towers or poles.
There are 2 types of isolators depending upon its position.
Line Isolator
This type of isolator is attached on both sides of equipment. It is always
accompanied with earthling switch. It is used to separate any equipment from
circuit for maintenance or Repair.
Bus-Bar Isolator
It is used to connect any circuit with bus bar. It separates any circuit from bus bar
for Repair of maintenance.

CURRENT TRANSFORMER
A current transformer in essentially a step-up
transformer which steps down the current to a known ratio. The primary of this
transformer consists of one or more turns of thick wire connected in series with
the line. The secondary consists of a large number of turns of fine wire.
Current transformers, together with voltage (or potential) transformers (VT or
PT), are known as instrument transformers. When current in a circuit is too high
to apply directly to measuring instruments, a current transformer produces a
reduced current accurately proportional to the current in the circuit, which can be
conveniently connected to measuring and recording instruments
CIRCUIT BREAKER
Circuit breaker is a switching device which can be operated
manually as well as automatically for controlling and protection of electrical
power system respectively. It does all the required switching operations during
current carrying condition.

Types of circuit breaker:

According to their arc quenching media the circuit breakers can be divided as-

1. Oil circuit breaker.

2. Air circuit breaker.
3. SF6 circuit breaker.
4. Vacuum circuit breaker

SF6 BREAKER
In ARL three SF6 breakers are installed on HV side of 132 KV. SF6 circuit
breaker is such type of breaker in which current carrying contacts operate in
sulphur hexafluoride .the reason is gas has high dielectric strength

And is non toxic and harmless for the metal under the normal conditions. It is also
non flammable so there is no risk of fire hazard due to all these properties SF6
breaker is used for high voltage levels.

VACCUM CIRCUIT BREAKER (VCB)

A vacuum circuit breaker is a circuit breaker in which the arc
quenching takes place in vacuum these circuit breakers are suitable for medium
level voltage applications.
OIL CIRCUIT BREAKER
The oil circuit breaker is one of the oldest technologies and has
less use in today’s application. Basically OCB is a High voltage CB arc is drawn in
oil dissipate the heat and to extinguish the arc .The main disadvantage of using
OCB is the inflammability of the oil that may cause the fire hazard.

MINIATURE CIRCUIT BREAKER

It is used in low level electrical network instead of fuse it
automatically switch off the circuit during the abnormal condition it is much more
sensitive than fuse .For MCB the rated current is no more than 100A.

MOLDED CASE CIRCUIR BREAKER

This circuit breaker is also use in electrical
circuits where current rating is more than 100A 800A.moreover trip characteristic
may also be adjustable

LIGHTNING ARRESTOR

“A lightning arrester or a surge diverter is a protective device

which protect electrical equipment from over-voltage transients
caused by external (lightning) or internal (switching) events.”

It is the first equipment in a substation. It is basically a protective device. The

reliable continuous operation of the facility requires detailed attention to
preventing surges (over voltages) from entering the substation facility.
There are several types such as
Low-voltage surge arrester
Apply in Low-voltage distribution system, exchange
of electrical appliances protector, low-voltage distribution transformer windings
Distribution arrester
Apply in 3KV, 6KV, 10KV AC power distribution system to
protect distribution transformers, cables and power station equipment

TRANSFORMER
This is the most important part of grid station in ARL the
transformer use is a step down transformer and it step-down the value of voltage
from 132kv to 11kv.the rating of transformer is 7.5MVAmany safety devices are
attached to detect and control the fault in transformer .

Nameplate
The national electrical manufacture association (NEMA) specifies
the nameplate that should be present on the nameplate. It includes…

 KVA rating
 Serial number
 Year of manufacture
 Number of phases
 KVA or MVA rating
 Frequency
 Voltage rating
 Tap voltages
 Connection diagram
 Cooling class
 Rated temperature in C
 Vector diagram
 % impedances
 Conductor material of each winding
 Type of insulation liquid
VECTOR GROUP OF TRANSFORMER
This is a method proposed by IEC
(International electro technical commission) which is used to categorize the
primary secondary winding and also to find the phase difference between HV and
LV winding. How to symbolize??

It is symbolized as for example Ydn11 here 1st written Y which showing primary of
transformer is HV and connected as star connection. D showing the secondary in
delta configuration .the symbol (0, 1, and 11) relate to phase displacement
between HV and LV winding using a clock face notation. We relate it with watch
yd11 mean 11 o clock take 12 as reference the phase angle is 30 degree.

There are 4 main vector groups:

Group 1 0 o clock,0 delta/delta star /star

Group 2 6 o clock,180 delta/delta, star/star

Group 3 1 o clock ,-30 start/delta, delta/star

Group 4 11 o clock ,+30 star/delta, delta/star

Power plant
The power plant that is present in ARL has three generator of 2.5 MW each and
the total capacity is 7.5 MW. The power plant’s sections are
 Generating units
 Control units
 Maintenance

Generation unit
There are three generators and total capacity is 7.5MW there are 12
cylinder diesel engines in each generator. Each generator start on diesel engine
when its load reaches to 25% it is shifted to furnace oil. Each generator has 8
poles and run on frequency of 50Hz. usually two generators are work at a time
and one is at backup. The load requirement of ARL is 4-5MW.We run our
generator on furnace oil as it is heavy than diesel cost effective and best for heavy
load.

Generators
An electric generator is a device that converts mechanical energy obtained
from an external source into electrical energy as the output. The modern-day
generator works on the principle of electromagnetic induction discovered by
Michael Faraday in 1831-32. Faraday discovered that the above flow of electric
charges could be induced by moving an electrical conductor, such as a wire that
contains electric charges, in a magnetic field. This movement creates a voltage
difference between the two ends of the wire or electrical conductor, which in turn
causes the electric charges to flow, thus generating electric current.
Main components of a generator
The main components of an electric
generator can be broadly classified as follows

 Engine
 Alternator

 Fuel System
 Voltage Regulator Cooling and Exhaust Systems

 Lubrication System

 Battery Charger

 Control Panel

 Main Assembly / Frame

CONTROL UNIT
All control of power plant utilities including generator motors pumps protective
devices is done in the control room. Outgoing feeder’s protective relays breakers all
metering system is control in this unit. Moreover all this control is attached to a PLC
(programmable logic controller). On HMI display whole data including generator load,
power factor indication of faults etc are displaying on it.

GENERATOR TESTING & MAINTENANCE

The following is a comprehensive list of the generator tests.

o Insulation Resistance / Polarization Index

o DC Winding Resistance
o DC Step Voltage
o Visual Inspection
o AC High Potential
Motors
A electromechanically device which convert electrical energy to mechanical
energy .there are several type of motors Like DC motors AC motors AC motors
are further classified as induction and synchronous motors.

Induction motor
Most of the motors use in ARL is squirrel cage induction motors. One of the most
common electrical motor used in most applications which is known as induction
motor. This motor is also called as asynchronous motor because it runs at a speed
less than synchronous speed. Synchronous speed is the speed of rotation of the
magnetic field in a rotary machine and it depends upon the frequency and
number poles of the machine. An induction motor always runs at a speed less
than synchronous speed because the rotating magnetic field which is produced in
the stator will generate flux in the rotor which will make the rotor to rotate, but
due to the lagging of flux current in the rotor with flux current in the stator, the
rotor will never reach to its rotating magnetic field speed i.e. the synchronous
speed.

Synchronous motors
When a 3 phase electric conductors are placed in a certain
geometrical positions (In certain angle from one another) there is an electrical
field generate. Now the rotating magnetic field rotates at a certain speed, that
speed is called synchronous speed. Now if an electromagnet is present in this
rotating magnetic field the electromagnet is magnetically locked with this rotating
magnetic field and rotates with same speed of rotating field. Synchronous motors
are called so because the speed of the rotor of this motor is same as the rotating
magnetic field. It is basically a fixed speed motor because it has only one speed,
which is synchronous speed, and therefore no intermediate speed is there or in
other words it’s in synchronism with the supply frequency. Synchronous speed is
given by
Motor nameplate
The NEC states that the motor nameplate must show the following
information:

 Rated voltage or voltages

 Rated full-load amps for each voltage level
 Frequency
 Phase
 Rated full-load speed
 Insulation class and rated ambient temperature
 Rated horsepower
 Time rating
 Locked-rotor code letter
 Manufacturer's name and address

Motor starting techniques

There are two main starting techniques which are using in ARL for three phase
induction motor which are …

 Direct online starter (DOL)

 Star delta starter

Direct online starter (DOL)

It is the most simplest and inexpensive technique it is usually used for squirrel
cage induction motor it directly connect to the contact of the motor to the full
supply voltage the starting current is very large normally 6 to 8 time than the
rating current.
Star delta starter
It is very common type of starter which is extensively used. This method is
use in low starting current by 1st connecting the stator winding in star and then
after the motor reaches the 25% speed it automatically shifted to delta
configuration. Since the torque develop by the induction motor is directly
proportional to the square of the applied voltage star delta reduce the starting
torque to 1 3rd that obtained by DOL.

Electrical cables
There are different type of electrical cables use in ARL different factor which
decide the which cable use in order to calculate the voltage drop across the cables
we use the following formula

%Voltage drop= (mV /amp/Meter) I*L/1000

L=LENGTH OF WIRE

I=CURRENT

V=VOLTAGE DROP

There are two types use in ARL

 PVC
 XLPE

PVC CABLES
These are for LT line. These cables are basically use in home appliances wiring
house internal and external wiring the PVC cables are used for rating of 1.1kv
XLPE CABLES
These cables are used for HT and LT lines they can withstand high
temperature as compared to PVC

The characteristic of this cable are follow as

 XLPE cables work for voltage 240V to 500 KV

 Conductor material can either be aluminum or copper
 XLPE cables can either be single core or multicore