JALPAIGURI GOVERNMENT

ENGINEERING COLLEGE

By: SHOURYASARATHI BHATTACHARYYA

Roll no: 16101103002
Reg. no: 161010110209
Department of Mechanical Engineering
7th SEMESTER

Submission Date: 19th July, 2019

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 INDUSTRIAL
TRAINING
REPORT
AT

HALDIA
PETROCHEMICA
s
LTD.
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SUMMER INTERNSHIP

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 Acknowledgement

Myself Shouryasarathi Bhattacharyya, student of Mechanical

Engineering Department, JALPAIGURI GOVERNMENT
ENGINEERING COLLEGE, have undergone a summer
industrial training at HALDIA PETROCHEMICALS
LTD., Haldia. The time spent here was quite beneficial and
enriching for gaining a vivid technical knowledge about
different aspects of the industry. A lot of field work was
involved during this training period.

I would take this opportunity to thank Mr. Shobhit Singh,

Deputy Manager NCU, Mr. Goutam Chattopadhyay, Senior
General Manager, NCU and Mr. Subhankar Banerjee,
Librarian for helping me in all sorts of ways throughout the
entire duration of my training. Also, I am thankful to my
college authorities for giving me this opportunity to visit and
enrich myself with industrial atmosphere and day to day
activities.
I feel immense pleasure and privilege to express my deep
sense of gratitude and thankfulness towards all the respected
members of Haldia Petrochemicals Ltd., Haldia who have
helped, inspired and guided me by spending a lot of precious
time with me during the entire training period.

Shouryasarathi Bhattacharyya
Date: 19th July, 2019
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Contents

1. ABOUT THE COMPANY

2. UNI TS CO MP RI S I NG I N H P L
3. MA NUFA CTURI N G P RO CE S S
4. WHA T I S NCU?
5. NCU PROCESS BLOCK DIAGRAM
6. CRACKING HEATERS
7. PROCESS FLOW FOR NCU
8. PUMPS AND TYPES
9. CENTRIFUGAL PUMP
10. COMPONENTS AND FUNCTIONS
11. ASSEMBLY DRAWING
12. SAMPLE DATA SHEET
13. CHARACTERISTIC CURVES
14. SERIES AND PARALLEL PUMP
15. CAVITAION AND RECIRCULATION
16. MECHANICAL SEALS

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ABOUT THE COMPANY
Haldia Petrochemicals Ltd (HPL) is a competitive modern naphtha
based Petrochemical Complex, located 125km from Kolkata, at
Haldia, West Bengal, India. HPL has played the role of a catalyst in
emergence of more than 500 downstream processing industries in
West Bengal. HPL is one of the largest petrochemical companies in
India with a total capacity equivalent to 6,70,000 TPA of ethylene.
Process technologies for various manufacturing plants have been
selected from internationally renowned vendors with an aim to
produce world class products with excellent safety and environment
considerations. It is a prestigious Joint Venture project having the
Government of West Bengal, The Chatterjee Group, and the TATAs
with the Indian Oil Corporation, etc. as major stakeholders with an
investment of Rs 5864 crores.

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UNITS COMPRISING IN HPL

The following Plants are in HPL Complex:

 Naphtha Cracker Unit (NCU)
 Butadiene Extraction Unit (BDEU)
 Pyrolysis Gasoline Hydrogenation Unit (PGHU)
 Benzene Extraction Unit (BEU)
 C4 Hydrogenation Unit (CHU)
 High Density Polyethylene (HDPE) Plant.
 Linear Low Density Polyethylene (LLDPE) Plant.
 Polypropylene (PP) plant.
 Integrated Offside Plant (IOP)

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 Nitrogen Plant.
 Captive Power Plant.

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 SECTION 1

OVERVIEW OF
Naphtha cracker
unit
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__________________________________________
_
What is NCU?

Naphtha Cracker Unit (NCU) is the mother plant of HPL,

where long chain of naphtha is being broken into several
short chains of mainly C1-R to C4-R. These monomers are
then separated and sent for polymerisation and sellable
products are formed.
Olefins are major building blocks for petrochemicals.
Because of their reactivity and versatility, olefins
especially the light olefins like ethylene, propylene,
butenes, butadiene, etc., there has been tremendous
growth in the demand of the olefins. Olefins are finding
wide application in the manufacture of polymers,
chemical intermediates, and synthetic rubber. Ethylene
itself is basic building block for large number of
petrochemicals and is quoted as king of chemicals.
The steam cracker remains the fundamental unit and is
the heart of any petrochemical complex and produces
large number of products and byproducts such as olefins
- ethylene, propylene, butadiene, butane and butenes,
isoprene, etc., and pyrolysis gasoline. The choice of the
feedstock for olefin production depends on the
availability of raw materials and the range of downstream
products.

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Modern ethylene plants incorporate following major
process steps : cracking compression and separation of
the cracked gas by low temperature fractionation. The
nature of the feed stock and the level of pyrolysis
severity largely determine the operating conditions in the
cracking and quenching section. Various steps involved in
the pyrolysis of naphtha and separation of the products
are discussed below.

Hot Section It consists of convection zone and radiant

zone. In the convection zone, hydrocarbon feed stock is
preheated and mixed with steam and heated to high
temperature. In the convection zone the rapid rise in
temperature takes place and pyrolysis reaction takes
place. The addition of dilution steam enhances ethylene
yield and reduces the coking tendency in the furnace
coils. The production of the pyrolysis reaction consists of
a wide range of saturated and unsaturated hydrocarbons.
Quench Section To avoid subsequent reaction the
effluent are fixed in their kinetic development by sudden
quench first by indirect quench by water to 400 – 450 C
in transfer line exchanger or quench boiler. This is a large
heat exchanger that is a bundle of metal tubes through
which the gases pass and around which is circulated
water under pressure. The hot water produced is used to

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generate steam for use in the plant. In the next step the
quench is done by heavy product of pyrolysis.
Cold Section After compression, caustic scrubbing and
drying the light effluents enter the cold section of the
unit which performs the separation of (I) hydrogen to
various concentration (ii) ethyllhene containing
99.4percent (iii) 95percent propylene (iv) A C4 cut
containing 25-50percent butadiene (v) pyrolysis gasoline
which is rich in aromatic hydrocarbons. The complexity of
the separation section of a cracker increases markedly as
the feed changes from ethane.

• PRODUCTS and PRODUCTION RATE

 760,000 MTA ETHYLENE (polymer grade)

 341,000 MTA PROPYLENE (polymer

grade)

• OPERATING HOURS

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  8000 hours/year = 333 days/yr

 91+ % On-stream Factor = 19 days down

___________________________________________________
_
NCU Process Block Diagram
The step by step process for naphtha cracking has been shown in
the following block diagram on next page. The function and
working of each stage will be discussed later.

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Cracking Heaters

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_________________________________________________________
PROCESS FLOW FOR NCU
Primary Transfer Line Exchangers (TLE’s)
 Stop Cracking Reaction
 Recover Heat from Heater Effluent
 Generate SHP Steam

Secondary Transfer Line Exchangers

 Recover additional Heat from Heater Effluent
 Preheat mixed feed to Ethane recycle heater

Gasoline Fractionators
 Separate heaviest components from Gasoline
 Remove heat from effluent (Charge Gas)
 Condense Quench Oil (QO) and provide sump for
circulation

Quench Tower
 Cool Charge Gas before compression
 Provide reflux for Gasoline Fractionator
 Condense Dilution steam for recovery
 Provide reservoir for Quench Water (QW)

Quench Water (QW) Circulation

 Remove heat from Quench Tower

Charge Gas Compressor

 Compress Charge Gas in order to separate hydrogen
and methane by products

Acid Gas Removal

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  Remove Acid gases H2S & CO2 from charge gas by
direct contact with circulating caustic (NaOH)

Charge Gas Drying

 Remove all moisture from Charge Gas before chilling

Charge Gas Chilling Train

 Provide liquid feeds for De-methanizer
 Cryogenic separation of methane product and crude
hydrogen (95%)
 Interchange heat with cold process streams
 Recover refrigeration from cold product streams
before sending to battery limits
 Recuperate cold for ethylene / propylene refrigerant
streams

De-methanizer
 Remove methane from process feeds
 Provide Deethanizer feed as bottoms product

De-ethanizer
 Fractionate C3+ components from C2’s
 Purge C2 Green Oil formed in Acetylene Converter
 Net overhead provides feed to Acetylene Converter
 Bottoms provides feed to Depropanizers

De-propanizer

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 Separate C3’s from C4+ components in Deethanizer
bottoms and Condensate Stripper bottoms
 Provide overhead C3 feed to MAPD converters
 Bottoms feeds Debutanizer
 Purge C3 Green Oil formed in MAPD converters

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Centrifugal Pumps...
Pumps are device that converts mechanical
energy into hydraulic energy (pressure energy).
Centrifugal pumps can be referred to as dynamic
machines.
machines That is to
say they use centrifugal force for pumping liquids
from one level of
pressure to a higher level of pressure. Liquid
enters the center of the
rotating impeller, which imparts energy to the
liquid. Centrifugal force
then discharges the liquid through a volute.
The centrifugal pump is one of the most widely
used fluid handling
devices in the refining and petrochemical industry.

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Different types of heads
SUCTION HEAD: It is the vertical height of the
centre line of the centrifugal pump above the water
surface in the tank or pump from which water has to
be lifted. The height is also called suction lift and is
denoted by hs.
DISCHARGE HEAD: the vertical distance between
the centre line of the pump and the water surface in
the tank to which the water is delivered is known as
discharge head. This is denoted by hd.
STATIC HEAD: the sum of suction head and delivery
head, Hs
h s + h d = Hs

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How to select a pump
for suitable
operation...
• Nature of the liquid to be pumped.
• Fresh or salt water, acid or alkali etc.
• Cold or hot, if hot then what temperature, vapour pressure of
the liquid.
• Specific gravity of the liquid.
• Clear and free from S.P.M. or dirty and gritty. If the latter, what
are the size and nature of the solids and are they abrasive?
• If the liquid is pulpy, then consistency in percentage or in
(pound per cubic foot) of liquid and the suspended material.
• Chemical analysis , pH value, etc. and variation expected in
the above analysis

 Required capacities as well as the minimum and

maximum amounts of the liquid the pump will be
called upon to deliver.
 Suction conditions. Is there a suction lift or head?
Variations expected in these conditions.

• What are the discharge conditions?

- Static head – constant or variable.
- Friction head

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 - Maximum discharge pressure against which the
pump must deliver the fluid.
• Is the service continuous or intermittent?
• Pump to be installed – horizontal or vertical
• Type of power available to drive the pump and its
characteristics.
• Space, weight or transportation limitations involved.
• Location of installation .
▫ Reference to elevation above sea level
▫ Geographic location with its effects on
recommended spare parts.
▫ Immediate surrounding that might affect
accessibility.
• Special requirements or marked preferences w.r.t.
design construction or performance of the pump.

Sample Data
Sheet for a
Centrifugal
pump
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In order to obtain the main characteristic curves of a pump, it is
operated at different speeds. For each speed, the pump
discharge (Q) is varied by means of a delivery valve and for the
different values of Q, the corresponding values of manometric
head (Hm), shaft power (SP) and overall efficiency (ho) are
measured or calculated. Thereafter, Hm vs Q; SP vs Q, and
ho vs Q curves for different speeds are plotted which represent
the main characteristics of a pump. Clearly, these curves are
useful in indicating the performance of a pump at different
speeds.

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Cavitation and Recirculation
• When the pressure inside the pump suction drops below the
vapour pressure, formation of bubble occurs. These bubbles
collapse at higher outlet pressure and generates shockwaves
through the pump. This phenomenon is called SUCTION
CAVITATION

• Sometimes due to excessive high pressure at the outlet, the

water recirculates and tends to flow back in the impeller. This
phenomenon is called DISCHARGE CAVITATION

CAUSES
• Clogs and filters in the strainer reduces flow rate, lowering the
pressure.

• Pumps operating outside the allowable limits.

• Reduction in flow rate at the source.

EFFECTS
• Noise similar to pumping gravels.

• More power consumption for the prime mover.

Physical damage/dents formation inside the pump casing

due to the shockwave generated

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REFERENCES
• http://www.haldiapetrochemicals.com/
• https://nptel.ac.in/courses/103107082/module7/lect
ure2/lecture2.pdf
• Pump Handbook by Igor Karassik.
• Process Equipment Working Guide by Norman P.
Lieberman & Elizabeth T. Lieberman.
• Pump Wisdom by Heinz P. Bloch.
• https://blog.craneengineering.net/operating-
centrifugal-pumps-in-series-or-parallel

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