VOCATIONAL TRAINING PROJECT REPORT

INDIAN OIL CORPORATION LIMITED

(An ISO 9002:14001 Certified Company)
BARAUNI REFINERY

Period of Training: - 1 June 2016 TO 30 June2016

Branch: Electrical Engineering

Submitted To: - Submitted By: -

Mrs. Krishna Kumari PERWEZ ALAM
Assistant Manager T&D CTAE/2013/155
IOCL Barauni Refinery College of Tech. and Engg.
Udaipur (Rajasthan)
 ACKNOWLEDGEMENT

It’s a great pleasure to be part of Indian Oil Corporation Limited as a Vocational

Training which is the world’s 96th largest public corporation according to the
fortune Global 500 list and top companies in the India by fortune India 500
in2014.
This acknowledgement is way by which I am getting the opportunity to show
the deep sense of gratitude and obligation to all the people who provided me
with inspiration and guidance during the preparation of this training report.

My special thanks to Mr. K.K Majumdar, CM(MS, T&D) , Ms Krishna Kumari,

AM(T&D) , Mr. Rajeev Acharya Officer (T&D) and all staff members of training
department , fire & safety & CISF personnel’s for the supervision and support
the have given which truly helped the progression and smoothness of the
vocational training .

My grateful thanks also goes to *names of reporting coordinators for their

invaluable guidance kind cooperation and inspiration during entire course of
this training.

I would like to thanks technicians for helping me during the training and for
shedding light on the practical aspects of Electrical Engineering in Barauni
Refinery.

Last but not the least I would like to thank my friends and employees of
Barauni Refinery for their wise ideas throughout the training period.
 TABLE OF CONTENTS

INTRODUCTION TO THE COMPANY

 OIL REFINERY
 OPREATION
 MAJOR PRODUCTS

FIRE AND SAFETY

 SOME COMMON CAUSES OF FIRE

 PREPARATION

THERMAL POWER STATION

 FUNCTIONING
 ORGANIZATIONAL STRUCTURE OF POWER PLANT
 OVERVIEW OF CAPTIVE POWER PLANT
 BOILER OPERATION
 DETAILED PROCESS OF POWER GENERATION IN A THERMAL
POWER PLANT
 ROLE AND IMPORTANCE OF POWER PLANT
 GAS TURBINE
 STEAM TURBINE GENERATOR
 WATER TREATMENT PLANT AND STORAGE

ELECTRICAL WORKSHOP

 ELECTRIC MOTORS
 AC MOTORS
 SYNCHRONOUS MOTORS
 INDUCTION MOTORS

ELECTRICAL TESTING

 TRANSFORMER
 ELECTRICAL MAINTENANCE AND TESTING
 SAFETY GENERATOR PROTECTIVE FUNCTION
INTRODUCTION TO THE COMPANY

Barauni refinery in the Bihar state of India was built in collaboration with the
Soviet Union at a cost of Rs. 49.4 crores and went on stream in July, 1964. The
initial capacity of 2 MMTPA was expanded to the 3 MMTPA by 1969.The
present capacity of this refinery is 6 MMTPA. A Catalyst Reformer Unit (CRU)
was also added to the refinery in 1997 for production of unleaded motor spirit.
Projects are also planned for meeting future fuel quality requirements.
Barauni Refinery was built in collaboration with Russia and Romania, situated
125 kilometers (78miles) from Patna. It was built with an initial cost of Rs 49.40
crores. Barauni Refinery was commissioned in 1964 with a refining capacity of
2 million metric tonnes per annum(MMTPA) and it was dedicated to the Nation
by the then Union Minister for Petroleum, professor Humayun Kabir in January
1965.After de-bottlenecking, revamping and expansion project, its capacity
today is 6 MMTPA. Matching secondary processing facilities such as Residue
Fluidized Catalytic Cracker (RFCC), Diesel Hydro Treating (DHDT), Sulphur
Recovery Unit (SRU) have been added. These state of the art eco-friendly
technologies have enabled the refinery to produce environment friendly green
fuels complying with international standards.
Barauni Refinery was initially designed to process low sulphur crude oil (sweet
crude) of Assam. After establishment of other refineries in the Northeast,
mainly Assam crude is unavailable for Barauni. Hence, sweet crude is being
sourced from African, South East Asian and Middle East countries like Nigeria,
Iraq and Malaysia. The refinery receives crude oil by pipeline from Paradip on
the East Coast via Haldia. With various revamps and expansion projects at
Barauni Refinery, capability for processing high- sulphur crude has been added.
High sulphur crude oil (sour crude) is cheaper than low-sulphur crudes, thereby
increasing not only the capacity but also the profitability of the refinery.

OIL REFINERY

An oil refinery or petroleum refinery is an industrial process plant where crude

oil is processed and refined into more useful products such as petroleum
naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied
petroleum gas. Oil refineries are typically large, sprawling industrial complexes
with extensive piping running throughout carrying streams of fluids between
large chemical processing units. In many ways, oil refineries use much of the
technology and can be thought of as types of chemical plants.
The crude oil feedstock has typically been processed by an oil production plant.
There is usually an oil depot (tank farm) at or near an oil refinery for the
storage of incoming crude oil feedstock as well as bulk liquid products.
An oil refinery is considered an essential part of the downstream side of the
petroleum industry.

OPERATION

Raw or unprocessed crude oil is not generally useful in industrial applications,

although “light sweet” (low viscosity, low sulphur) crude oil has been used
directly as a burner fuel to produce steam for the propulsion of seagoing
vessels. The lighter elements, however, from explosive vapours in the fuel tank
are therefore hazardous, especially in warships. Instead, the hundreds of
different hydrocarbons molecules in crude oil are separated in a refinery into
components which can be used as fuels, lubricants, and as feedstock in
petrochemical processes that manufacture such products as plastics,
detergents, solvents, elastomers and fibres such as nylon and polyesters.
Petroleum fossil fuels are burned in internal combustion engines to provide
power for ships, automobiles, aircrafts engines, lawn mowers, chainsaws and
other machines. Different boiling points allow the hydrocarbons to be
separated by distillation. Since the lighter liquid products are in great demand
for use in internal combustion engines, a modern refinery will convert heavy
hydrocarbons and lighter gaseous elements into these higher value products.
Oil can be in a variety of ways because it contains hydrocarbons of varying
molecular masses, forms and lengths such as paraffin’s, aromatics, naphthenic
(or cycloalkanes), alkenes, dines and alkynes. While the molecules in crude oil
include different atoms such as sulphur and nitrogen, the hydrocarbons are the
most common form of molecules, which are molecules of varying lengths and
complexity made of hydrogen and carbon atoms and a small number of oxygen
atoms. The differences in the structure of these molecules account for their
varying physical and chemical properties and it is this variety that makes crude
oil useful in a broad range of applications.
Once separated and purified of any contaminants and impurities, the fuel or
lubricant can be sold without further processing. Smaller molecules such as
isobutene and propylene or butylenes can be recombined to meet specific
octane requirements by processes such as alkylation, or less commonly,
demonization. Octane grade of gasoline can also be improved by catalytic
reforming which involves removing hydrogen from hydrocarbons producing
compounds with higher octane ratings such as aromatics. Intermediate
products such as gasoline can even be reprocessed to break heavy, long-
chained oil into a lighter short- chained one, by various forms of cracking such
as fluid catalytic cracking, thermal cracking and hydro cracking. The final step
in gasoline production is the blending of fuels with different octane ratings,
vapour pressures and other properties to meet product specifications.
Oil refineries are large scale plants processing about a hundred thousand to
several hundred thousand barrels of crude oil a day. Because of high capacity,
many of the units operate continuously, as opposed to processing in batches,
at steady state or nearly steady state for months to years. The high capacity
also makes process optimization and advanced process control very desirable.

MAJOR PRODUCTS

Petroleum products are usually grouped into three categories: -

 Light Distillates (LPG, Gasoline, Naphtha)
 Middle Distillates(Kerosene, Diesel)
 Heavy Distillates and residuum (Heavy Fuel Oil, Lubricating Oils, Wax,
Asphalt).

This classification is based on the way crude oil is distilled and separated into
fractions (called distilled and residuum) as in the above
 Liquefied Petroleum Gas(LPG)
 Gasoline(also known as petrol)
 Kerosene and related Jet Aircraft Fuels
 Naphtha
 Kerosene and related Jet Aircraft Fuels
 Diesel Fuel
 Lubricating Oils
 Paraffin Wax
 Asphalt and Tar
 Petroleum Coke
 Sulphur

Oil refineries also produce various intermediate products such as Hydrogen,

Light Hydrocarbons, Reformate and Pyrolysis Gasoline. These are not usually
transported but instead are blended or processed further on- site. Chemical
plants are thus often adjacent to oil refineries. For example, Light
Hydrocarbons are steam-cracked in an Ethylene plant and the produced
Ethylene is polymerized to produce polythene.

FIRE AND SAFETY

FIRE PREVENTION IN THE WORKPLACE

It is your responsibility to be aware of the causes of fire and to prevent fires

from occurring in the workplace.

SOME COMMON CAUSES OF FIRE

 Arson or Deliberate Ignition

Poor housekeeping leading to excessive storage of combustible
materials or the accumulation of waste.
 Electrical
Misuse of electrical equipment such as: Overloading Sockets and
Adaptors obstructing vents on electrical equipment. Using equipments
for the purposes for which it was not designed, using faulty and
defective equipments. Leaving appliances switched on when not in use.
 Smoking
Smoking in unauthorized areas and the careless disposal of smoking
materials.

The Fire Safety will ask the following when they arrive

 Is everyone accounted for

 Where is the fire
 What is the nature of the fire
 How does we get to the fire(are there any locked doors etc)
 Are there any hazards in the vicinity of the fire
PREPARATION

Installers, maintenance personnel and any other contractors or persons

required to work on roofs should ensure the workplace and access to the
egress to the workplace are safe before work starts, including

 Assessment of wind and weather

 Organization of:
 Fall prevention equipment
 Crane placement schedule
 Access/egress
 Personal protective equipment on site
 Specific instructions for the workers
 Protection of portable electrical plant by Residual Current Devices
(RCD’s)
 Means of rescuing persons from safety harnesses following Arrested
falls.
 Inspection of existing roofs for
 Integrity of existing safety mesh
 Structural soundness, including inspection from below
 Fragile roofs or fragile panels in solid sheet roofs (including identifying
and highlighting them

THERMAL POWER PLANT OVERVIEW

The power plant is heart of the refinery, any interruption in the plant will affect
the operation of the production units resulting in huge losses.

The basic function of the power plant is

 To ensure uninterrupted power generation and distribution as per

requirement
 To ensure uninterrupted steam generation and distribution as per
requirement
 To ensure uninterrupted generation and distribution of utilities like DM
Water, Instrument Air and Industrial Air as per requirement.
ORGANISATIONAL STRUCTURE OF POWER PLANT

 Chief Power & Utilities Manager

 Senior Power & Utilities Manager
 Power & Utilities Manager/(Shift Incharge)
 Shift Engineer-Boiler
 Shift Engineer- Electrical
 Shift Engineer - Turbine
 Boiler and its Aux. Operators
 Control Room Operators & Asst. Control Room Operators
 Turbine & its Aux. Operators

DETAILED PROCESS OF POWER GENERATION IN A THERMAL POWER PLANT

Water intake: Firstly, water is taken into the boiler through a water source. If
water is available in a plenty in the region, then the source is an open pond or
river. If water is scarce, then it is recycled and the same water is used over and
over again.

Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A
furnace issued to heat the fuel and supply the heat produced to the boiler. The
increase in temperature helps in the transformation of water into steam.

Steam Turbine: The steam generated in the boiler is sent through a steam
turbine. The turbine has blades that rotate when high velocity flows across
them. This rotation of turbine blades is used to generate electricity.

Generator: A generator is connected to the steam turbine. When the turbine

rotates, the generator produces electricity which is then passed on to the
power distribution system.

Special mountings: There is some other equipments like the economizer and
air preheater. An economizer uses the heat from the exhaust gases to heat the
feed water. An air preheater heats the air sent into the combustion chamber
to improve the efficiency of the combustion process.
Ash collection system: There is a separate residue and ash collection system in
place to collect all the waste materials from the combustion process and to
prevent them from escaping into the atmosphere.

Apart from this, there are various other monitoring systems and instruments in
place to keep track of the functioning of all the devices. This prevents any
hazards from taking place in the plant.

BOILER OPERATION

The boiler is a rectangular furnace about 50 feet (15m) on a side and 130 feet
(40m) tall. Its walls are made of a web of high pressure steel tubes about 2.3
inches (58mm) in diameter.

There are 6 boilers in the IOCL Barauni Refinery

1-4 are Russian boilers – capacity 75 TPH

5TH boiler is IJT manufactured boiler – capacity 75 TPH

6TH boiler is BHEL manufactured boiler –capacity 150 TPH

Furnace oil (FO) the at last product of the refining is used as a fuel to ignite the
furnace. It is blown into the furnace through burners located at the four
corners, or along one wall, or two opposite walls, and it is ignited to rapidly
burn, forming a large fireball at the centre. The thermal radiation of the fireball
heats the water that circulates through the boiler tubes near the boiler
perimeter. The water circulation rate in the boiler is three to four times the
throughput. As the water in the boiler circulates it absorbs heat and changes
into steam. The working pressure is 40kg/cm2. The temperature of the steam
is 4400c. The boiler has cast steel water inlets at the boiler and furnace at the
centre. There is a steam separator to remove moisture from the steam.

BOILER FURNACE AND STEAM DRUM

The water enters the boiler through a section in the convection pass called the
economizer. From the economizer it passes to the steam drum and from the
there it goes through down comers to inlet headers at the bottom of the water
walls. From these headers the water rises through the water walls of the
furnace where some of it turned into steam and the mixture of water and
steam then re-enters the steam drum. This process may be driven purely by
natural circulation (because the water in the down comers is denser than the
water/steam mixture in the water walls) or assisted by pumps. In the steam
drum, the water is returned to the down comers and the steam is passed
through a series of steam separators and dryers that remove water droplets
from the steam. The dry steam then flows into the super heater coils.

The boiler furnace auxiliary equipment includes coal feed nozzles and igniter
guns, soot blowers, water lancing and observation ports (in the furnace walls)
for observation of the furnace interior. Furnace explosions due to any
accumulation of combustible gases after a trip-out are avoided by flushing out
such gases from the combustion zone before igniting the fuel.

The steam drum (as well as the super heater coils and headers) have air vents
and drains needed for initial start up.
SUPERHEATER

The steam passes through drying equipment inside the steam drum on to the
super heater, asset of tubes in the furnace. The steam picks up more energy
from hot flue gases outside the tubing and temperature is now superheated
above the saturation temperature. The superheated steam is then piped
through the main stream lines to the valves before the high pressure turbine.

GAZE GLASS

The gaze glass checks the level of water (steam) in the boiler.

ID (INDUCED DRAFT) FAN AND FD (FORCED DRAFT) FAN

As the furnace requires air to ignite, it is given by the FD fans to the boiler.

The extraction of air (flue part) is done by ID fans.

Boiler 5&6 have no ID Fans requirement due to natural extraction of flue air.

External fans are provided to give sufficient air for combustion. The primary air
fan takes air from the atmosphere and, first warming it in the air preheater for
better combustion, injects it via the air nozzles on the furnace wall.

The induced draft fan assists the FD fan by drawing out combustible gases from
the furnace, maintaining a slightly negative pressure in the furnace to avoid
backfiring through any closing.

SAFETY VALVE

It is required to control the pressure of the steam in boiler if the pressure is

rises the safety valve is open to release high pressure.

STEAM CONDENSING

The condenser condenses the steam from the exhaust of the turbine into the
liquid to allow it to be pumped. If the condenser can be made cooler, the
pressure of the exhaust steam is reduced and efficiency of the cycle increases.
The surface condenser is a shell and tube heat exchanger in which cooling
water is circulated through the tubes. The exhaust steam from the low
pressure turbine enters the shell where it is cooled and converted to
condensate (water) by flowing over the tubes .Such condensers use steam
ejectors or rotary motor-driven exhausters for continuous removal of air and
gases from the steam side to maintain vacuum.

For best efficiency, the temperature in the condenser must be kept as low as
practical in order to achieve the lowest possible pressure in the condensing
steam. Since the condenser temperature can almost always be kept
significantly below 1000c where the vapour pressure of water is much less
than atmospheric pressure, the condenser generally works under vacuum.
Thus leaks of non- condensable air into the closed loop must be prevented.

Typically the cooling water causes the steam to condense at a temperature of

about 350c (950F) and that creates an absolute pressure in the condenser of
about 2-7 kPa (0.59-2.07 in Hg), i.e. a vacuum of about -95Pa(-28 in Hg) relative
to atmospheric pressure. The large decrease in volume that occurs when water
vapour condenses to liquid creates low vacuum that helps pull steam through
and increase the efficiency of the turbines

The limiting factor is the temperature of the cooling water and that, in turn, is
limited by the prevailing average climatic conditions at the power plant’s
location (it may be possible to lower the temperature beyond the turbine
limits during winter, causing excessive condensation in the turbine).Plants
operating in hot climates may have to reduce output if their source of
condenser cooling water becomes warmer; unfortunately this usually coincides
with periods of high electrical demand for air conditioning.

The condenser generally uses either circulating cooling water from a cooling
tower to reject waste heat to the atmosphere or once through water from a
river like a ocean.

The heat absorbed by the circulating cooling water in the condenser tubes
must also be removed to maintain the ability of the water to cool as it
circulates. This is done by pumping the warm water from the condenser,
through either natural draft, forced draft or induced draft.
The condenser tubes are made of brass or stainless steel to resist corrosion
from either side. Nevertheless they may become internally fouled during
operation by bacteria or algae in the cooling water or by mineral scaling, all of
which inhibit heat transfer and reduce thermodynamic efficiency. Many plants
include an automatic cleaning system that circulates sponge rubber balls
through the tubes to scrub them clean without the need to take the system
off-line.

The cooling water used to condense steam in the condenser returns to its
source without having been changed other than having warmed. If the water
returns to a local water body (rather than a circulating cooling tower), it is
temperate with cool ‘raw’ water to prevent thermal shock when discharge into
that body of water.

Another form of condensing system is the air- cooled condenser. The process is
similar to that of a radiator and fan. Exhaust heat from the low pressure
section of a steam turbine runs through the condensing tubes, the tubes are
usually finned and ambient air is pushed through the fins with the help of a
large fan. The steam condenses to water to be reused in the water steam
cycle. Air- cooled condensers typically operate at a higher temperature than
water- cooled versions. While saving water, the efficiency of the cycle is
reduced (resulting in more carbon dioxide per megawatt of electricity).

From the bottom of the condenser, powerful condensate pumps and recycles
the condensed steam (water) back to the water/steam cycle.

PREHEATER

The preheater section containing tubes heated by hot flue gases outside the
tubes. Exhaust steam from the high pressure turbine is passed through these
heated tubes to collect more energy before driving the intermediate and then
low pressure turbine.

STEAM TURBINE GENERATOR

The turbine generator consists of a series of steam turbines interconnected to

each other and a generator on a common shaft. There is a high pressure
turbine at one end, followed by an intermediate pressure turbine, two low
pressure turbines, and the generator. As steam moves through the system and
losses pressure and thermal energy. It expands in volume, requiring increasing
diameter and longer blades at each succeeding stage to extract the remaining
energy. The entire rotating mass may be over 200 metric tons and 100 feet
(30m) long. It is so heavy that it must be kept turning slowly even when shut
down (at 3 rpm) so that the shaft will not bow even slightly and become
unbalanced. This is so important that it is one of only five functions of blackout
emergency power batteries on site. Other functions are emergency lighting,
communication, station alarms and turbo generator lube oil.

Superheated steam from the boiler is delivered through 14-16 inch (360-410
mm) diameter piping to the high pressure turbine where it falls in pressure to
600 psi (4.1 MPa) and to 6000F (3200C) in temperature through the stage. It
exits via 24-26 inch (610-660mm) diameter cold reheat lines and passes back
into the boiler where the steam is reheated in special reheat pendant tubes
back to 1,0000F (5400C). The hot reheat steam is conducted to the
intermediate pressure turbine where it falls in both temperature and pressure
and exits directly to the long bladed low pressure turbines and finally exits to
the condenser.

The generator, 30 feet (9m) long and 12 feet (3.7m) in diameter, contains a
stationary stator and a spinning rotor, each containing miles of heavy copper
conductor- no permanent magnets here. In operation it generates up to 21,000
amperes at 24,000 volts AC (504 MW) and it spins at either 3,000 rpm,
synchronized to the power grid. The rotor spins in a sealed chamber cooled
with hydrogen gas, selected because it has the highest known heat transfer
coefficient of any gas and for its low viscosity which reduces windage losses.
This system requires special handling during startup, with air in the chamber
first displaced by carbon dioxide before filling with hydrogen. This ensures that
the highly explosive hydrogen-oxygen environment is not created.

The power grid frequency is 60 Hz across North America and 50 Hz in Europe,

Oceania, Asia (Korea and parts of Japan are not notable exceptions) and parts
of Africa. The desired frequency affects the design of large turbines since they
are highly optimized for one particular speed.

The electricity flows to a distribution yard where transformers increase the

voltage for transmission to its destination.

The steam turbine- driven generators have auxiliary systems enabling them to
work satisfactorily and safely. The steam turbine generator being rotating
equipment generally has a heavy, large diameter shaft. The shaft therefore
requires not only supports but also has to be kept in position while running. To
minimize the frictional resistance to the rotation, the shaft has a number of
bearings. The bearings shells, in which the shaft rotates, are lined with a low
friction material like Babbitt metal. Oil lubrication is provided to further reduce
the friction between the shaft and bearing surface and to limit the heat
generated.

GAS TURBINE

A gas turbine, also called a combustion turbine, is a type of internal

combustion engine. It has an upstream rotating compressor coupled to a
downstream turbine, and a combustion chamber in- between.

The basic operation of the gas turbine is similar to that of the steam power
plant except that air is used instead of water. Fresh atmospheric air flows
through a compressor that brings it to higher pressure. Energy is then added
by spraying fuel into the air and igniting it so the combustion generates a high-
temperature flow. This high- temperature high- pressure gas enters a turbine,
where it expands down to the exhaust pressure, producing a shaft work output
in the process. The turbine shaft work is used to drive the compressor and
other devices such as an electric generator that may be coupled to the shaft.
The energy that is not used for shaft work comes out in the exhaust gases, so
these have either a high temperature or a high velocity. The purpose of the gas
turbine determines the design so that the most desirable energy form is
maximized. Gas turbines are used to power aircraft, trains, ships, electrical
generators, or even tanks.

Number of GTs- 2

Supplier- BHEL

Capacity of each- 48.5 TPH

Rating- 40Kg/cm2, 4400c.

Fuel Used- Naphtha.

COOLING TOWER

A Cooling Tower is a heat rejection unit which rejects waste heat to the
atmosphere through the cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or, in the
case of closed circuit dry cooling towers, rely solely on air to cool the working
fluid to near the dry- bulb air temperature.

 Fan – 3
 Speed in RPM – 100
 Motor -75MW, 0.4 KV, 1480 RP

COOLING TOWER FAN AND MOTOR

MOTOR MAKER: CROMPTON GEARERS

 V=0.4KV
 FULL ROAD CURRENT FOR FAN 1&2
 FAN RPM =10
CHEMICAL DOSING AND ACID DOSING

Dosing is done to prevent corrosion, scaling, and microbiological growth. Rate

of corrosion depends on Ph, due to evaporation of water TDS of cooling water
increases, which increases pH of water and corrosion is severe in acidic
medium. CaCO3 decreases pH, alkaline pH increases scaling, the pH of cooling
water is maintain from 7.5 to 8 by H2SO4

CORROCIL-132B

For corrosion control in copper alloy, total quantity dozed/day-45.4kg.

SCACIL -121B

Prevents scaling, total quantity dozed/day- 70.6kg.

SCACIL-451B

Its prevents bacteria, algae formation, total quantity dozed/day- 70.6kg.

BIONIL-2130B & 3140B

Total quantity dozed/month-120kg.

Sodium hypo chloride is dozed everyday in morning.

Concentration of FRC (Free Residue Chloride) is maintained in cooling tower is

0.2 to 0.5 ppm.

Quantity- 468kg/day.

For ClO2 generation following are dozed in combination

BIONIL 231B – 104.5Kg/day

SODIUM HYPO CHLORIDE – 107.3 Kg/day

H2SO4 – 33Kg/day.
TECHNICAL DATA OF COOLING TOWER

 Type of tower- Cross flow, induced draft

 Number of cells- 4
 Re- circulating rate- 9750 M3/Hr
 System volume- 2400 M3
 Blow down- 105 M3/Hr.
 Make up water- ground water
 Cooling water supply pressure- 2.5
 Cooling water supply return temperature - 32/40
 Wet bulb temperature (deg 0c)- 29
 Cooling range- 8
 Approach- 3
 COC Level – 2

DBT (DRY BULB TEMPERATURE): Dry bulb temperature is the temperature of

the air measured by thermometer whose bulb is dry.

WBT (WET BULB TEMPERATURE): The WBT is measured by passing the air over
the bulb of a thermometer that is covered by a cloth wick saturated with
water.

DEW POINT: Dew point is the temperature at which a given mixture of air and
water vapour is saturated with water vapour.

COOLING RANGE: maximum 8

It is the difference between the inlet hot water temperature and outlet water
temperature.

APPROACH: It is the difference between the supply cold water leaving and wet
bulb temperature of air entering.

HEAT LOAD: The amount of heat dissipated in cooling tower in BTU ( in

calorie)/minute= weight of water circulating per second multiplied by cooling
range.
FIVE WAYS TO INCREASE CAPACITY OF COOLING TOWER

 Increase velocity of air over exposed water surface.

 Increase surface area of water being exposed to passing atmosphere.
 Lower the atmospheric pressure (increase altitude above sea level).
 Raise entering water temperature.
 Reduce vapour content (humidity of inlet air)

BLOWDOWN: The continuous or innermost (mittant) wasting of a portion of

circulation water to minimize built up of harmful concentration of dissolved
solids in hydrochloric acid.

PERCENTAGE BLOWDOWN: It is equal to the ratio of percentage of ppm

chlorides in makeup water to the ppm chloride in circulating water.

COC (CYCLE OF CONCENTRATION): It is equal to the ratio of ppm chloride in

circulating water to the ppm chloride in makeup water.

EVAPORATION RATE: Rate of water evaporation to cool the circulating water.

MAKE-UP WATER: The water volume per minute required to replace that
evaporated and lost to blow down.

CAPACITY: Average amount of circulating water volume in cooling system at

any given time.

WATER CONCENTRATION: Rate at which water falling through cooling tower

expressed as volume per unit time per unit area of tower.

RETENTION TIME: The time required for water to fall from distribution header
to cooling tower basin.

WATER TREATMENT PLANT AND STORAGE:

Since there is continuous withdrawal of steam and continuous return of
condensate to the boiler, losses due to blow down and leakages have to be
making- up to maintain a desired water level in the boiler steam drum. For this,
continuous make-up water is added to the boiler water system. Impurities in
the raw water input to the plant generally consist of calcium and magnesium
salts which impart hardness to the water. Hardness in the make-up water to
the boiler will form deposits on the tube water surfaces which will lead to
overheating and failure of the tubes. Thus, the salts have to be removed from
the water, and that is done by a water demineralising treatment plant and
reverse osmosis treatment plant (DM & RO PLANT).

DM PLANT

A DM plant generally consists of cation and anion and mixed bed exchangers.
Any ions in the final water from this process consist essentially of hydrogen
ions and hydroxide ions, which recombine to form pure water. Very pure DM
water becomes highly corrosive once it absorbs oxygen from the atmosphere
because of its very high affinity of oxygen.

The capacity of the DM plant is dictated by the type and quantity of salts in the
raw water input. However, some storage is essential as the DM plant may be
down for maintenance. For this purposes, a storage tank is installed from
which DM water is continuously withdrawn for boiler make- up. The storage
tank for DM water is made from materials not affected by corrosive water,
such as PVC. The piping and valves are generally of stainless steel. Sometimes,
a steam blanketing arrangement or stainless steel doughnut float is provided
on top of the water in the tank to avoid contact with air. DM water make-up is
generally added at the steam surface of the surface condenser (i.e., the
vacuum side). This arrangement not only sprays the water but also DM water
gets defecated, with the dissolved gases being removed by a de- aerator
through an ejector attached to the condenser.

RO PLANT

A reverse osmosis is a manufacturing plant where the process of reverse

osmosis takes place. An average modern reverse osmosis plant needs six
kilowatt- hours of electricity to desalinate one cubic metric of water. The
process also results in an amount of salty- briny waste. The challenge for these
plants is to find ways to reduce energy consumption.

In the RO process cellophane like membranes separate purified water from

contaminated water. RO is when pressure is applied to the concentrated side
of the membrane forcing purified water into the dilute side, the rejected
impurities from the concentrated side being washed away in the rejected
water.

RO can also act as an ultra- filter removing particles such as some micro-
organisms that may too large to pass through the pores of the membrane.

CIRCULATING WATER SYSTEM:

 Circulating water capacity (m3/hr) – 3200x3

 Number of CW pumps – 3
 Capacity of each pump- (m3/hr) – 3600
 Head in m – 32
 Speed in RPM – 596
 Motor- 420MW, 6.6 KV
 Number of cells – 3
 Reduction gear ratio- 14:84:1

FURNACE OIL

Furnace oil is used to ignite to make steam from water and having several
steps:

After refining of crude oil the remaining portion left is the furnace oil which
goes filtration and stored in tank. The fuel from tank is suctioned from the tank
by the pump and through tank goes to header to another filter for fine
filtration of the furnace oil and discharge to the boiler via screw pump. An
essential part of FO unit is BPC (Back Pressure Controller) use to pressurize the
FO to the pump symmetrically.

MONITORING AND ALARM SYSTEM

Most of the power plant’s operational controls are automatic. However, at

times, manual intervention may be required. Thus, the plant is provided with
monitors and alarm systems that alert the plant operators when certain
operating parameters are seriously deviating from their normal range.
 ELECTRICAL WORKSHOP
ELECTRIC MOTORS

An electric motor uses electrical energy to produce mechanical energy. The

reverse process that of using mechanical energy to produce electrical energy is
accomplished by a generator or dynamo. Traction motors used on locomotives
and some electric and hybrid automobiles often performs both tasks if the
vehicle is equipped with dynamic brakes.

A High Power Electric Motor

AC MOTOR

An AC motor is an electric motor that is driven by an alternating current. It

consists of two basic parts, an outside stationary stator having coils supplied
with AC current to produce a rotating magnetic field, and an inside rotor
attached to the output shaft that is given a torque by the rotating field.

There are two types of AC motors, depending on the type of rotor used. The
first is the synchronous motor, which rotates exactly at the supply frequency or
a sub multiple of the supply frequency. The magnetic field on the rotor is
either generated by current delivered through slip rings or by a permanent
magnet.
The second type is the induction motor which turns slightly slower than the
supply frequency. The magnetic field on the rotor of this motor is created by
induced current.

SYNCHRONOUS MOTOR

A synchronous electric motor is an AC motor distinguished by a rotor spinning

with coils passing magnets at the same rate as the alternating current and
resulting magnetic field which drives it. Another way of saying this is that is has
zero slip in order to produce torque.

Sometimes a synchronous motor is used, not to drive a load but to improve the
power factor on the local grid it’s connected to. It does this by providing
reactive power to or consuming reactive power from the grid. In this case the
synchronous motor is called a synchronous condenser.
Electrical power plants almost always use synchronous generator because it’s
very important to keep the frequency constant at which the generator is
connected.

ADVANTAGES

Synchronous motors have the following advantages over non-synchronous

motors:

 Speed is independent of the load, provided an adequate field current is

applied.
 Accurate control in speed and position using open loop controls, e.g.
Stepper motor
 They will hold their position when a DC current is applied to both the
stator and the rotor windings.
 Their power factor can be adjusted to unity by using a proper field
current relative to the load. Also, a “capacitive” power factor (current
phase leads voltage phase) can be obtained by increasing this current
slightly, which can help achieve a better power factor correction for the
whole installation.
 Their construction allows for increased electrical efficiency when low
speed is required (as in ball mills and similar apparatus).
 EXAMPLES- Brushless permanent magnet DC motor, Stepper motor,
slow speed AC synchronous motor, Switched reluctance motor.
INDUCTION MOTOR

An induction motor (IM) is a type of a asynchronous AC motor where power is

supplied to the rotating device by means of electromagnetic induction. Three
Phase Induction Motors an electric motors converts electrical power to
mechanical power in its rotor (rotating part .There are several ways to supply
power to the rotor. In a DC motor this power is supplied to the armature
directly from a DC source, while in an AC motor this power is induced in the
rotating device. An induction motor is sometimes called a rotating transformer
because the stator (stationary part) is essentially the primary side of the
transformer and the rotor (rotating part) is the secondary side. Induction
motors are widely used, especially polyphase induction motors, which are
frequently used in industrial drives. Induction motors are now the preferred
choice for industrial motors due to their rugged construction, lack of brushes
(which are needed in most DC motors) and thanks to modern power
electronics – the ability to control the speed of the motor.

CONSTRUCTION

The stator consists of wound poles that carry the supply current that induces a
magnetic field in the conductor. The number of poles can vary between motor
types but the poles are always in pairs (i.e. 2,4,6 etc). There are two types of
rotor:

 Squirrel Cage Rotor

 Slip Ring Rotor

The most common rotor is a squirrel cage rotor. It is made up of bars of either
solid copper (most common) or aluminium that span the length of the rotor
and are connected through a ring at each end. The rotor bars in squirrel cage
induction motor are not straight but have some skew to reduce noise and
harmonics.

The motor’s phase type is one of two types:

 Single phase induction motor

 Three phase induction motor

PRINCIPLE OFOPERATION

The basic difference between an induction motor and a synchronous AC motor

is that in the latter a current is supplied onto the rotor. This then creates a
magnetic field which through magnetic interaction, links to the rotating
magnetic field in the stator which in turn causes the rotor to turn. It is called
synchronous because at steady state the sped of the rotor is the same as the
speed of the rotating magnetic field in the stator.

By way of contrast, the induction motor does not have any direct supply onto
the rotor; instead, a secondary current is induced in the rotor. To achieve this,
stator windings are arranged around the rotor so that when energised with a
polyphase supply they create a rotating magnetic field pattern which swifts
past the rotor. This changing magnetic field pattern can induce currents in the
rotor conductors. These currents interact with the rotating magnetic field
created by the stator and the rotor will turn.

However, for these currents to be induced, the speed of the physical rotor and
the speed of the rotating magnetic field in the stator must be different, or else
the magnetic field will not be moving relative to the rotor conductors and no
currents will be induced. If by some chance this happens, the rotor typically
slows slightly until a current is re- induced and then the rotor continues as
before. This difference between the speed of the rotor and speed of the
rotating magnetic field in the stator is called slip. It has no unit and the ratio
between the relative speeds of the magnetic field as seen by the rotor to the
speed of the rotating field. Due to this an induction motor is sometimes
referred to as an asynchronous machine.
TYPES:

 Single phase induction motor (not self starting)

 Three phase induction motor (self starting in nature)

OTHER

 Squirrel cage induction motor

 Slip ring induction motor

ALTERNATOR (SYNOCHRONOUS GENERATOR)

Alternator is an AC machine used to convert mechanical energy into electrical

energy. The alternators are generally used in power generation in power
plants. For reasons of cost and simplicity, most alternators use a rotating
magnetic field with a stationary armature. The generation capacity is 76.5 MW.

PRINCIPLE OF OPERATION

A conductor moving relative to a magnetic field develops an EMF in it .This

EMF (Faraday’s Law) reverses its polarity when it moves under magnetic poles
of opposite polarity. Typically, a rotating magnet called the rotor turns within a
stationary set of conductors wound in coils on an iron core, called the stator.
The field cuts across the conductors wound in coils on an iron core, called the
stator. The field cuts across the conductors generating an induced EMF, as the
mechanical input causes the rotor to turn.

The rotating magnetic field may be produced by permanent magnets, or by

field coils electromagnets. Automotive alternators use a rotor winding which
allows control of the alternator’s generated voltage by varying the current in
the rotor field winding. Permanent magnet machines avoid the loss due to
magnetizing current in the rotor, but are restricted in size, due to the cost of
the magnet material. Since the permanent magnet field is constant, the
terminal voltage varies directly with the speed of the generator.

EXCITATION

An electric generator or electric motor consists of a rotor spinning in a

magnetic field. The magnetic field may be produced by permanent magnets or
by field coils. In the case of a machine with field coils, a current must flow in
the coils to generate the field, otherwise no power is transferred to or from
the rotor. The process of generating a magnetic field by means of an electric
current is called excitation.

Rated O/P- 105 MW

Rated voltage- 220V

Rated current- 475A

Rated speed- 3000rpm (separately excited)

Min. diameter of commutator- 238mm

EXCITATION IN GENERATORS

For a machine using field coils, which are most large generators, the field
current must be supplied otherwise the generator will be useless. Thus it is
important to have a reliable supply. Although the output of a generator can be
used once it starts up, it is also critical to be able to start the generators
reliably. In any case, it is important to be able to control the field since this will
maintain the system voltage.

SEPARATE EXCITATION

For large, or older, generators, it is usual for a separate exciter dynamo to be

operated in conjunction with the main power generator. This is a small
permanent magnet or battery excited dynamo that produces the field current
for the large generator.
SELF EXCITATION

Modern generators with field coils are self-excited, where some of the power
output from the rotor is used to power the field coils. The rotor iron retains
magnetism when the generator is started with no load connected; the initial
weak field creates a weak voltage in the stator coils, which in turn increases
the field current, until the machine “builds up” to full voltage.

STARTING

Self- excited generators must b started without any external load attached. An
external load will continuously drain off the buildup voltage and prevent the
generator from its proper operating voltage.

FIELD FLASHING

If the machine does not have enough residual magnetism to build up to full
voltage, usually a provision is made to inject current into the rotor from
another source. This may be a battery, a house unit providing DC or rectified
current from a source of alternating current power. Since this initial current is
required for a very short time, it is called “field flashing”. Even small portable
generator sets may occasionally need field flashing to restart.

SWITCHGEAR

The apparatus including its associated auxiliary’s employs for switching,

controlling and protecting the electrical circuits and equipments is known as
switchgear.

A switch which is an ordinary fuse is the simplest form of switchgear and is

generally used to control and protect the domestic and commercial appliances
and equipments. For high rating circuits, high rupturing circuits (HRC) fuse in
conduction with switch may serve the purpose. However, the switchgear
cannot be applied to power system operating at high voltages i.e., more than
11 KV due to following reasons:
  When fuse blows, it takes sometimes to replace it and consequently
there is interruption of power supply.
 On high voltage system, a fuse cannot be successfully interrupt large
fault current.

Therefore due to above reasons protected lines, generators and other

electrical equipments needs automatic protective switchgear systems to
mainly relay and circuit breakers are used.

SWITCH

It makes and breaks the circuit under full load or no load condition but cannot
be operated under fault condition. It generally operated manually.

ISOLATOR

It is only operated under no load condition. Its main purpose is to isolate a

portion of the circuit from the other. Isolators are place on both the sides of a
circuit breaker from the other in order to make repairs and maintenance on
the circuit breaker without any danger. There are two types of isolator:

 Single pole isolator

 Double pole isolator

FUSES

A fuse is a short piece of metal, insert in series with the circuit, which melts
and excessive currents flows and it breaks the circuit. The material used in the
formation of the fuse element should have following properties:

 Low melting point

 High conductivity
 Free from oxidation

CIRCUIT BREAKER

The IOCL Barauni Refinery has three types of circuit breaker in the control
room for operation.
Circuit breaker is an on/off switch operating in an electric circuit in normal as
well abnormal condition. During normal condition the current flows in the
circuit breaker normally but at abnormal condition the circuit breaker trips to
isolate the faulty part.

OPERATING PRINCIPLE OF CIRCUIT BREAKER

A circuit breaker consists of fixed and moving contacts, called electrodes.

When fault occurs on the power system, the trip coil of circuit breaker is
energized which pulls apart the moving contact from the fixed contacts. When
the moving contacts are separated from the fixed contacts, an arc is struck
between them. This arc delays the current interruption and generates
enormous heat which may damage the equipment and hence needs to be
extinguished.

TYPES OF CIRCUIT BREAKER

OIL CIRCUIT BREAKER

In this circuit breaker the current carrying contacts are immersed in

transformer oil. When the contacts are separated, arc is struck between them
under faulty condition. The heat of the arc dissociates the oil. Hydrogen gas is
used to quench the arc.
VACUUM CIRCUIT BREAKER

A vacuum circuit breaker is such kind of circuit breaker where the arc
quenching takes place in vacuum. The technology is suitable for mainly for low
power generation from 3 kV to 38 kV. In vacuum circuit breaker the arc
interruption takes place in vacuum in the interrupter. For opening the circuit
breaker, the operating mechanisms separate the moving contacts from the
fixed contact inside the interrupter.

OPERATING PRINCIPLE

At the point of contact separation a very small amount of metal vaporizes from
contact tip and arc is drawn between the contacts. Current flows between the
contacts through this arc. The vacuum condensing shield is used so that the
metallic vapour condenses on the glass. In the absence of the shield the
metallic vapour condenses on the glass and gradually the glass becomes
conducting, so that the insulation between moving and fixed contacts is lost in
open or abnormal condition of breaker.
AIR CIRCUIT BREAKER

Air circuit breaker employs a high pressure air blast as an arc quenching
medium under abnormal condition. Under normal condition the contacts are
closed.

OPERATING PRINCIPLE

When fault occurs contacts are opened and an arc is struck between them. The
openings of contacts are done by a flow of air blast established by the opening
of blast valve between air reservoir and arching. The air blast cools the arc and
quenches it.

RELAY

Relay is a sensing device that senses the abnormal condition or the faults
occurs and indicates it to the circuit breaker to trip the circuit breaker and
isolate the fault.
BUS BARS

This term is used for main bar on conductor carrying electric current through
which many connections are made for connecting switches and the
equipments like bus bars made of aluminium because it has higher
conductivity, corrosion resistant and lower cost as compared to copper.

FEEDER LINES

A feeder line is a type of transmission line that is used to transmit supply

voltage.

DC SUPPLY SYSTEM

DC Supply is the brain of the plant. Each unit has its own 220 volts DC system
located and comprises of following

 Storage battery
 Battery Charger
 Distribution and sub distribution system

SWITCHYARD

The electricity generated at 11kV by turbo generator sets it step up by power

transformer up to 132kV in case of stage -1 and 220 kV in case of stage -2. For
further transmission it is step up and step down into substations:

 Indoor sub station

 Outdoor sub station
INDOOR SUBSTATION

In these substation the equipments are installed within the building of

substation and hence the name indoor substation.

OUTDOOR SUBSTATION

In this substation the equipments are installed in the open and hence the
name is suggested outdoor substation.

The generation capacity of IOCL Barauni Refinery is 20MW which exceeds up to

40 MW.

Low voltage transmission is 415 -440V.

High voltage transmission is 6.6-6.9 kV.

REACTORS

Reactors can reduce the short- circuit current to levels that can be adquetly
handled by existing distribution equipment. They can also be used in high
voltage electric power transmission grids for a similar purpose.

OPERATING PRINCIPLE

Where the prospective short circuit current in a distribution or transmission

system is calculated to exceed the interrupting rating of the associated
switchgear, a current limiting reactor may be selected. The inductive reactance
is chosen to be low enough for an acceptable voltage drop during normal
operation, but high enough to restrict a short circuit to the rating of
switchgear. The amount of protection that a current limiting reactor offers
depends upon the percentage increase in impedance that it provides for the
system.

CONSTRUCTION

It is desirable that the reactor does not go into magnetic saturation during a
short circuit, so generally an air core coil is used. At low and medium voltages,
air insulated coils are practical, for high transmission voltages, the coils may be
immersed in transformer oil.
CURRENT AND POTENTIAL TRANSFORMER

CT’s and PT’s are used as protecting as well as instrumental device. It is used to
detect and measure current and voltage by stepping down and stepping up the
current and voltage respectively.

ELECTRICAL TESTING

TRANSFORMER

This article is about the electrical device. Pole mounted distribution

transformer with centre-tapped secondary winding used to provide split-
phase power for residential and light commercial service, which in North
America is typically rated 120/240 volt.

A transformer is a device that transforms an alternating current (AC) input

voltage into a lower or higher AC output voltage. Transformers are not
designed to raise or lower direct current (DC) voltages. A transformer is
composed of electrical equipment designed to transfer energy by inductive
coupling between its winding circuits. A typical transformer has two or more
coils that share a common laminated iron core. One of the coils is referred to
as the primary (containing Np turns), while the other coil is called the
secondary (containing NS turns). A varying current in the primary winding
creates a varying magnetic flux in the transformer’s core and thus a varying
magnetic flux through the secondary winding. This varying magnetic flux
induces a varying electromotive flux or voltage in the secondary winding.
Transformers can be used to vary the relative voltage of circuits or isolate
them, or both.

Transformers range in size from thumbnail- sized used in microphones to units

weighing hundreds of tons interconnecting the power grid. A wide range of
transformer designs are used in electronic and electric power applications.
Transformers are essential for the transmission, distribution and utilization of
electrical energy.

MAINTENANCE AND TESTING

Heat and contamination are the two greatest enemies to the transformer’s
operation. Heat will break down the solid insulation and accelerate the
chemical reactions that take place when the oil is contaminated. All
transformers require a cooling method and it is important to ensure that the
transformer has proper cooling. Proper cooling usually involves cleaning the
cooling surfaces, maximizing ventilation and monitoring loads to ensure the
transformer is not producing excess heat.

Contamination is detrimental to the transformer both inside and outside. The

importance of basic cleanliness and general housekeeping becomes evident.
When long term service life is considered. Dirt builds up and grease deposits
severely limit the cooling abilities of radiators and tank surfaces. The oil in the
transformer should be kept as pure as possible. Dirt and moisture will start
chemical reactions in the oil that lower both its electrical strength and its
cooling capability. Contamination should be the primary concern any time the
transformer must be opened. Most transformer oil is contaminated to some
degree before it leaves the refinery. Although maintenance and work practices
are designed to extend the transformer’s life, it is inevitable that the
transformer will eventually deteriorate to the point that it fails or must be
replaced.

SAFETY

Safety is of primary concern when working around a transformer. The

substation transformer is usually the highest voltage item in a facility’s
distribution system. The higher voltages found at the transformer deserve the
respect and complete attention of anyone working in the area. A 6.6 kV system
will arc to ground over 1.5 to 2.5 in. However, to extinguish that same arc will
require a separation of 15 in. Therefore, working around energized conductors
is not recommended for anyone but the qualified professional. The best way to
ensure safety when working around high voltage apparatus is to make
absolutely certain that it is de-energized.

 Although inspections and sampling can usually be performed while the

transformer is in service, all other service testing functions will require
that the transformer is de energized and locked out. This means that a
thorough understanding of the transformer’s circuit and the
disconnecting methods should be reviewed before any work is
performed.
 A properly installed transformer will usually have a means for
disconnecting both the primary and the secondary sides: ensure that
they are opened before any work is performed. Both disconnects should
be opened because it is possible for generator or induced power to back
feed into the secondary and step up into the primary. After verifying
that the circuit is de- energised at the source, the area where the work is
to be performed should be checked for voltage with a “hot stick” or
some other voltage indicating device.