 The demineralized water shall then be stored in the DM water

storage tank(approx. 130mts away in tankage area). This tank shall be

provided with water seal arrangement and polypropylene balls etc. as
required avoiding air ingress.

COOLING TOWER:

A cooling water is equipment used to reduce the temperature of water

steam by extracting heat from water and emitting it to the atmosphere.
Cooling towers make use of evaporation whereby some of the water is
evaporated into a moving air stream and subsequently discharged into
the atmosphere. As a result, the remainder of the water is cooled down
significantly. Cooling towers are able to lower the temperature of
water more significantly than devices that uses only air to reject it.
There are two types:

Natural Draft Cooling Tower-makes use of difference in temperature

between ambient air and hotter air inside tower.

Mechanical Draft Cooling Water- have large fans to force or draw air
through circulated water. It depends upon fan diameter and speed of
operation.

PAGE 26
 MECHANICAL WORKSHOP(MEWS)

Workshop may be a room or building which provides the area, tools

and machinery that may be required for the manufacture or repair of
manufactured goods. In this report, we shall discuss about the
machines used in the workshop and will also study about different
kind of valves and pumps used in the refinery.

VALVES
A valve is a mechanical device which regulates either the flow or the
pressure of the fluid. Its function can be stopping and starting the flow,
controlling flow rate, diverting flow, preventing back flow, controlling
pressure or relieving pressure. Basically, the valve is an assembly of a
body with connection to the pipe and some elements with a sealing
functionality that are operated by an actuator. The valve can be also
complemented with several devices such as position testers,
transducers, pressure regulators etc.

Types of Valve used in Oil Industry:

(i) Ball Valve
(ii) Gate Valve
(iii) Butterfly Valve
(iv) Globe Valve
(v) Plug Valve

(i) BALL VALVE:

The ball valve has a spherical plug as a closure

member. Seal on the ball valves are excellent,

PAGE 27
the ball contact circumferentially uniform the seat, which is generally
made of soft materials.

Depending on the type of the body the ball valve can be more or
less easily maintained. Drop pressure relative to its hole size is
low.

• Applications in Refinery:
They are used in steam, water, corrosive fluids, air, gas and
also handles slurries and dusty dry fluids. Abrasive and
fibrous material can damage the ball of valve.
The balls are generally made out of several metallic whilst.
The seat are made of soft material like Teflon. The
combination of materials means the ball valve can operate
at temperature as low as -200 deg C and as high as 500 deg
C.
• Limitations:
Lack of throttling properties available.
They’re not recommended to be used in partly open
position for a long time under conditions of high pressure
drop across the valve, thus the soft seat could tend to flow
through the orifice and block the valve movement.

(ii) GATE VALVE:

Gate valves are primarily designed to start or stop a flow when a

straight line flow of fluid and minimum flow restriction is
needed.

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Gate valves are primarily designed to start or stop a flow when a
straight line flow of fluid and minimum flow restriction is
needed.

• Limitations:
This valve is not recommended to regulate or throttling service.
Partly opened valve can vibrate. Opening and closing operations
are slow and the valve requires big actuators.

(iii) BUTTERFLY VALVE:

The development of this type of valve has been more

recent than the other ones. A major conviction on
saving energy was an advantage for its introduction,
due to which head loss is small.

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Application in Refinery:
A quarter- turn rotational motion valve, the butterfly
valves is used to stop, start and regulate flow.

Easy and fast to open, the valve usually comes

equipped with a gearbox where the hand wheel by gear
is connected to the stem.

As well as being lightweight, and quick to use, the

butterfly valves are available in large sizes and can cope
with lowpressure drop and high pressure recovery.

Limitations:
One disadvantage of butterfly valves is that some
portion of the disc is always presented to the flow, even
when they are fully opened. The use of a butterfly valve
therefore always results in a pressure switch across the
valve, regardless of the settings.

PAGE 30
(iv) GLOBE VALVE:
A globe valve may be constructed with a single or
diuble port and plug arrangement. The double port
type is generally used in a Control Valve where
accurate control of flow is required. Due to the double
valve plug arrangement, the internal pressure acts on
each plug in opposition to each other, giving an
internal pressure balance across plugs.

• Application in Refinery:
Typically, used for cooling water systems,
transporting fuel oil and turbine lube oil systems, a
globe valve is a linear motion used to stop, start and
regulate flow.

• Limitations:
The slight disadvantages of globe valve are that they
perform unfavourably when high pressure drops, and
require greater force or throttling flow under the seat
to shut off valve.

(v) PLUG VALVE:

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 Plug valves have a plug as a closure member. Plug can
be cylindrical or conical. Ball valves are considered as
another group despite that they are some kind of plug
valve. They are used in on/off services and flow
diverting, as they can be multiport configured.

• Advantages:
They can handle fluids with solids in suspension.

Lift plug valve type are designed to rise the plug at start valve
operation, in order to separate and protect plug-seat sealing
surfaces from abrasion.
• Limitations:
It requires high maintenance cost.

Requires more time for maintenance.

SAFETY VALVES

A safety valve is a valve mechanism which automatically releases

a substance from a boiler, pressure vessel, or other system when
the pressure or temperature exceeds preset limits.

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It is one of a set of Pressure Safety Valve(PSV) or Pressure Relief
Valves(PRV), which also includes relief valves, safety relief
valves, pilot operated relief valves, low pressure safety valves
and vacuum pressure safety valves.

PRESSURE SAFETY VALVE OR 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.
The pressure is relieved by allowing the pressurized fluid to flow
from an auxiliary passage out of the system.

PAGE 33
The RV is designed or set to open at a predetermined set pressure to
protect pressure vessel and other equipment from being subjected to
pressures that exceeds their design limits. When the set pressure is
exceeded, the RV becomes the “path of least resistance” as the valve is
forced open and a portion of the fluid is diverted through the auxiliary
route. The diverted fluid is usually routed through a piping system
known as flare header or relief header to a central, elevated flare where
it is usually burned and the resulting combustion gases are released in
te atmosphere.

It should be noted that PRVs and PSVs are not same thing, despite
what many people think; the difference is that PSVs have a manual
lever to open the valve in case of emergency.

TEMPERATURE SAFETY VALVE

Water heaters have thermostatically controlled devices that keep them

from overheating. Both gas and electric water heaters have
temperature limiting devices that shut off the energy source when
their regular thermostat fails. Thermostatically controlled gas valves
found on most residential gas water heaters have a safety shutoff built
into the gas valve itself. When they react to excessive temperature, the
gas flow to the burner is stopped.

PAGE 34
 PUMPS

A Pump is a device that moves fluids(liquids or gases) or

sometimes slurries, by mechanical action. Pumps can be classified
into three major groups according to the method they use to move
the fluid: direct lift, displacement and gravity pumps. Common
types of pumps used in IOCL:

(i) Centrifugal Pump

(ii) Screw Pump
(iii) Vertical Cantilever Pump
(iv) Split Case Pump

(i) CENTRIFUGAL PUMP:

A centrifugal pump is a pump that consists of a fixed impeller
on a rotating shaft that is enclosed in a casing, with an inlet
and a discharge connection. As the rotating impeller swirls
the liquid around, centrifugal force builds up enough pressure
to force the water through the discharge outlet. This type of
pump operates on the basis of an energy transfer, and has
certain definite characteristics which makes it unique. The
amount of energy which can be transferred to the liquid is
limited by the type and size of the impeller, the type of
material being pumped and the total head of the system
through which the liquid is moving.

➢ Specifications of Centrifugal Pump in Refinery:

Offered capacity : 317LPM
RPM : 1450

Efficiency : 93%

Mounting : Horizontal

PAGE 35
 Sealing : Mechanical Seal

Power Rating : 7KW

Centrifugal pumps are designed to be used as a portable pump, and

are often referred to as a trash pump. It is named so because the water
that is being pumped is not clean water. It is most often water
containing soap or detergents, grease and oil, and also solids of
various sizes that are suspended in the water.

➢ Application of Centrifugal pump in Barauni

Refinery:
• For circulation of cooling water
• For pumping the fluid in reactors, coulombs etc.
• In liquid storage tanks.

(ii) SCREW PUMP:

§ Main elements of Screw Pump design :
The pumping element of a two screw pump consists of two
intermeshing screws rotating within a stationary bore/housing that is
shaped like a figure eight.

PAGE 36
The rotor and housing/body are metal and the pumping element is
supported by the bearings in this design.

The clearances between the individual areas of the pumping screws are
maintained by the timing gears.

When a two screw pump is properly timed and assembled there is no

metal-to-metal contact within the pump screws.

The pumping screws and body/ housing can be made from virtually
any machinable alloy. This allows the pump to be applied for the most
severe applications in aggressive fluid handling. Hard coatings can
also be applied for wear resistance.
The stages of the screw are sealed by the thin film of fluid that moves
through the clearances separating them.

Finally, in a two screw design, the bearings are completely outside of

the pumped fluid. This allows them to have a supply of clean
lubricating oil and be independent of the pumped fluid characteristics.
The external housings also allows for cooling which means the quality
of the lube oil can be maintained in high temperature or horsepower
applications.

➢ WORKING:
These pumps are based on the basic principle where a rotating
cavity or chamber within a close fitting housing is filled with
process fluid, the cavity or chamber closes due to the rotary action
of the pump shaft, the fluid is transported to the discharge or
displaced, this action being accomplished without the need for
inlet or outlet check valves.

➢ Specifications of a Screw Pump:

PAGE 37
 Name : Emergency Lube Oil Pump

Driver : Electric Motor

Liquid Handled : Lube Oil

Pumping Temperature : 65℃

Specific Gravity : 0.88

Rated Capacity : 237LPM

Suction Pressure : Atmospheric

Discharge Pressure : 10kg/𝑐𝑚2

NPSH available : 10m

➢ Applications:
Mostly used for high viscous fluid.

Used where high pressure is needed.

(iii) VERTICAL CANTILEVER PUMP:

It is a specialized type of vertical pump designed to be
installed in a tank or sump but with no bearing located in the
lower part of the pump. Thus, the impeller is cantilevered
from the motor, rather than supported by the lower bearings.

➢ A cantilever pump is considered a centrifugal pump configured

with the impeller submerged in the fluid to be pumped. But
unlike a traditional vertical column sump pump, there are no
bearings below the motor supporting the impeller and shaft.
➢ The Cantilever pump has a much larger diameter shaft, since it
has no lower sleeve bearings that act to support the impeller and
shaft.

PAGE 38
 ➢ In general, cantilever pumps are best for relatively shallow
sumps, usually around 8 to 10 feet maximum. This is because the
deeper the sump, the larger the shaft diameter that is required to
cantilever the impeller.

(iv) SPLIT CASE PUMP:

➢ This type of pump has a split casing at the suction side.
It prevents the turbulence and formation of eddies at
the inlet.
➢ Split Case Pumps are designed to pump clean water or
low viscosity clean liquids at moderate heads more
economically, which is widely used for liquid transfer
and circulation of clean or slightly polluted water. And
the typical applications are Municipal water supply,
Power plants, Industrial plants, Boiler feed and
condensate systems, irrigation and dewatering and
marine service.

NET POSITIVE SUCTION HEAD(NPSH)

OVERVIEW:

Net Positive Suction Head(NPSH) available is a function of the

system in which the pump operates. It is excess pressure of the
liquid in feet absolute over its vapour pressure as it arrives at the
pump section. In an existing system, the NPSH available can be
determined by a gauge on the pump suction.

The Hydraulic institute defines NPSH as the total suction head

in feet absolute, determined at the suction nozzle and corrected
to datum, less than vapor pressure of liquid in feet absolute.
The pressure which a liquid exerts on its surrounding is

PAGE 39
dependent upon its temperature. This pressure, called vapor
pressure is a unique characteristics of every fluid and increased
with increasing temperature.

It is obvious from the above that if we are to pump a fluid

effectively, we must keep it in liquid form. NPSH is simply a
measure of the amount of suction head present to prevent this
vaporization at the lowest pressure point in the pump.

LATHE

Lathe is a machine, which removes the metal from a workpiece

to the required shape and size.

Ø
Common types of Lathes:

(i) Engine Lathe: The most common type of lathe, motor

driven and comes in large variety of shapes and sizes.
(ii) Bench Lathe: A bench top model usually of low power
used to make precision machine small work pieces.
(iii) Tracer Lathe: A lathe that has the ability to follow a
template to copy shape or contour.
(iv) Automatic Lathe: The lathe in which the workpiece is
automatically fed and removed without the use of an
operator. Cutting operations are automatically
controlled by a sequencer of some form.
(v) Turret Lathe: The lathes which have multiple tools
mounted on turret either attached to the tailstock or
the cross slide, which allows for quick changes in
tooling and cutting operations.

PAGE 40
(vi) Computer Controlled Lathe: Highly automated
lathes, where cutting, loading, tool changing and part
unloading are automatically controlled by computer
coding.

Photographic view of Engine Lathe showing various parts:-

Ø Components of Lathe:

(i) Bed: It is the base of the lathe and supports all major
components of the lathe.
It is made of grey cast iron, to resist deflection and
absorb vibrations during cutting.

(ii) Carriage: Slides along the ways and consists of the

cross slide, tool post and apron.
For Longitudinal feed- Tool is fed along the work.
For Cross Feed- Tool is fed across the work.

PAGE 41
 (iii) Headstock: Holds the jaws for the workpiece, supplies
power to the jaws and has various drive speeds.
(iv) Tailstock: Supports the other end of the work piece. It
is like a stationary drill press which is centered with
your workpiece. To remove the workpiece turn the
tailstock back to zero and the chuck should pop out.
(v) Feed Rod and Lead Screw: Feed rod is powered by a
set of gears from headstock.

Ø Various Lathe Operations:

(i) Turning: Produces straight, conical, curved or grooved
workpieces.
(ii) Facing: Produces a flat surface at the end of that part.
(iii) Boring: To enlarge a hole.
(iv) Drilling: To produce a hole.
(v) Cutting off: To cut off a workpiece.
(vi) Threading: To produce threads.
(vii) Knurling: Produces a regularly shaped roughness.

DRILLING

Drilling is the operation of producing circular hole in the

workpiece by using a rotating cutter called DRILL.

▪ The machine used for drilling is called drilling

machine.
▪ The drilling operation can also be accomplished
in Lathe, in which the drill is held in tailstock
and the workpiece is held by the chuck.
▪ Common used drill is Twist Drill.

PAGE 42
Ø Types:
There are two types of drilling machines used by
maintenance personnel for repairing and fabricating
needed parts: Hand-feed and Power-feed.
(i) Hand-feed: The hand feed drilling machines are the
simplest and most common type of drilling machines
used today. These are light duty machines that are
hand-fed by the operator, using a feed handle so that
the operator is able to ”feel” the action of the cutting
tool as it cuts through the workpiece.
(ii) Power-feed: The power feed drilling machines are
usually larger and heavier than the hand feed. They are
equipped with the ability to feed the cutting tool into
the work automatically, at the preset depth of cut per
revolution of the spindle, usually in thousandths of an
inch per revolution.

Bench Drilling Machine

Ø Uses: A drilling machine called a drill press, is used to cut
holes into or through metal, wood or other materials.
Drilling machines uses a drilling tool that has cutting
edges at its point. This cutting tool is held in the drill

PAGE 43
 press by a chuck and is rotated and fed into the work at
variable speeds.

Drilling machines may be used to perform other

operations.

They can perform countersinking, boring, counterboring

etc. The size or capacity of the drilling machine is
determined usually by the largest piece of stock that can
be center-drilled.

MILLING MACHINE

Milling is a machining process of using rotary cutters to remove

material from a workpiece by advancing in a direction at an
angle with the axis of the tool. It covers a wide variety of
different operations and machines, on a scale from small
individual parts to large, heavy-duty gang milling operations. It
is one of the most commonly used processes in the industry.

➢ Types: Mill orientation is the primary classification for

milling machines. The two basic configurations are
vertical and horizontal.
♦ Vertical Mill: In vertical mill, the spindle axis is vertically
oriented. Milling cutters are held in the spindle and rotate
on its axis. The spindle can generally be extended allowing
plunge cuts and drilling. There are two sub-categories: the
bed mill and the turret mill.

♦ Horizontal Mill: A horizontal mill has the same sort but

the cutters are mounted on a horizontal spindle across the
table. Many horizontal mills also feature a built-in rotary

PAGE 44
 table that allows milling at various angles, this feature is
called universal table.

➢ Processes:
Milling is a cutting process that uses a milling cutter to
remove material from the surface of a workpiece. The
milling cutter is a rotary cutting tool often with multiple
cutting points. As opposed to drilling, where the tool is
advanced along its rotation axis, the cutter in milling is
usually moved perpendicular to its axis so that cutting
occurs on the circumference of the cutter. As the milling
cutter enters the workpiece, the cutting edges of the tool
repeatedly cut into and exit from the material, shaving off
chips from the workpiece with each pass. This makes
metal somewhat different from slicing other softer
materials with a blade. The milling process removes
materials by performing many separate small cuts. This is
accomplished by using cutter with many teeth, spinning
the cutter at high speed, or advancing the material
through the cutter slowly. The speed and feed used are
varied to suit the combination of variables.

There are two major classes of milling process:

♦ In face milling, the cutting action occurs primarily

at the end corners of the milling cutters. Face
milling is used to cut flat surfaces into the
workpiece.

♦ In peripheral milling, the cutting action occurs

primarily along the circumference of the cutter, so
that the cross section of the milled surfaces ends
up receiving the shape of the cutter.

PAGE 45
Uses:
They are usually used to machine flat surfaces, but can also
produce irregular surfaces. They can also be used to drill, bore,
cut gears and produce slots.

BARAUNI EXPANSION PROJECT(BXP)

It consists of following units:

(i) Residue Fluidized Catalytic Cracking Unit (RFCCU)

(ii) Catalytic Reforming Unit (CRU)
(iii) Diesel Hydrotreating Unit (DHDT)
(iv) Hydrogen Generation Unit (HGU)

PAGE 46