Contd. Thermal Power Station (T.P.S) Demineralization Plant Boiler Steam Turbine Gas Turbine Generator Cooling Towers
UNIT PROFILE Indian Oil Corporation Limited (Indian Oil) is the largest commercial enterprise in India with a sales turnover of Rs.150, 677 crores and profit of Rs.4, 891 crores for the fiscal year 2004.
Indian Oil is Indias number one company in Fortunes prestigious listing of the worlds 500 largest corporations, ranked 170 based on fiscal 2004 performance. It is also the 18 th largest petroleum company in the world and adjudged number one in petroleum trading among the 15 national oil companies in the Asia-Pacific region.
Contd. Mathura Refinery, commissioned in 1982, current rated capacity of 8.0 MMTPA crude processing, is meeting the product demand of Northwest region of the country including the National Capital Delhi. The Refinery processes low sulphur crude from Bombay High, imported low sulphur crude from Nigeria, and high sulphur crude from Middle East Countries. In the original refinery configuration, there was one primary Atmospheric Vacuum unit coupled with Vis-breaker Unit, Fluidized Catalytic Cracking Unit, Bitumen unit and Sulphur Recovery unit as secondary units. ENERGY CONSUMPTION
Mathura Refinery consumes various types of fuels viz. Natural gas, R-LNG, refinery fuel gas and low Sulphur internal fuel oil (IFO) in furnaces / boilers. Natural gas, which is about 50% of total fuel consumed at MR is supplied by M/s GAIL whereas all others fuels are generated in the refinery itself. The IFO is fired as alternate fuel in old furnaces only.
PRODUCTS
Liquefied Petroleum Gas for domestic use Naphtha for fertilizer as feed Aviation Turbine Fuel For Civil and Defense aviation purposes Superior Kerosene Oil For domestic purposes High Speed Diesel Oil - For Transportation Furnace Oil and Heavy Petroleum Stock Petroleum Light Diesel Oil For agro equipments Bitumen For road paving Propylene For high polymers Sulphur For chemical industries
UNITS OLD UNIT- Old unit is further divided into various subunits: AVU(Atmospheric Vacuum Unit): The ADU (Atmospheric Distillation Unit) separates most of the lighter end products such as gas, gasoline, naphtha, kerosene, and gas oil from the crude oil. The bottoms of the ADU are then sent to the VDU (Vacuum Distillation Unit). Crude oil is preheated by the bottoms feed exchanger, further preheated and partially vaporized in the feed furnace and passed into the atmospheric towe This tower contains 20 fractionation trays, is equipped with one top pump around, an overhead reflux system, and three side strippers (for naphtha, kerosene, and gas oil products).
CONTD. The VDU (Vacuum Distillation Unit) takes the residual from the ADU (Atmospheric Distillation Unit) and separates the heavier end products such as vacuum gas oil, vacuum distillate, slop wax, and residue.
VBU(Viscosity Breaker Unit):
A visbreaker is a processing unit in oil refinery whose purpose is to reduce the quantity of residual oil produced in the distillation of crude oil and to increase the yield of more valuable middle distillates by the refinery. A visbreaker thermally cracks large hydrocarbon molecules in the oil by heating in a furnace to reduce its viscosity and to produce small quantities of light hydrocarbons (LPG and gasoline). The process name of "visbreaker" refers to the fact that the process reduces the viscosity of the residual oil.
CCRU(Controlled Catalytic Regeneration Unit): Catalytic reforming is a chemical process used to convert petroleum refinery naphthas, typically having low octane ratings, into high-octane liquid products called reformates which are components of high-octane gasoline (also known as petrol). FCC(Fluidized Catalytic Cracking): It is the most important conversion process used in petroleum refineries. It is widely used to convert the high-boiling, high-molecular weight hydrocarbon fractions of petroleum crude oils to more valuable gasoline, olefin gases and other products. NEW UNITS
The New Unit includes: OHCU(Once Through Hydrocracker Unit): DHDT DHDS HGU(Hydrogen Generation Unit) NHGU(New Hydrogen Generation Unit) PRIME-G (This unit is recently installed in Mathura refinery plant to provide Euro4 products. It removes Sulphur from 300 ppm to 50 ppm
MECHANICAL WORKSHOP
In mechanical workshop we saw the following sections Machine Shop Pump and Valve Section Gaskets and Grease
Machine Shop In machine section we saw the various types of machines on which operations like threading, turning, facing, boring, drilling, etc. were being performed by using these machines. In machine shop all the lathes were centre lathes. Various machines in workshop were Machines Name Quantity Lathe 8 Boring Machine 1 Shaper 1 Milling 1 Drill 3
Pumps The function of pump is to convert mechanical energy in to hydraulic energy. So they are used to transfer fluid from one place to another. In Mathura Refinery mainly two types of pumps are used
Centrifugal Pump Reciprocating Pump
Centrifugal Pumps are of two types Vertical Horizontal
Centrifugal Pumps - Centrifugal Pumps are used where higher head and low discharge is required. Centrifugal pump works on the principle of centrifugal force acting on the liquid. Head (pressure) is controlled is controlled by RPM, impeller diameter and flow rate.
Multistage Pumps - If a larger head is required more no. of impellers are to be fitted in series so that the discharge from first impeller is guided to the inlet of second impeller. This is repeated with third impeller and so on until the required head is reached. Each impeller will increase the pressure by the same amount; a pump of this type is called a multistage pump. A typical boiler feed may have six to eight stages All the impellers are keyed to the same shaft and usually all the impellers and diffusers of the one pump are identical. This has the advantage of reducing the labour in manufacturing and stocking spares of maintenance.
Main parts of circumferential pump are Impeller Suction Pipe Delivery pipe Casing Mechanical Seal Oil Seal Shaft Bearing Bearing house
Impeller It is rotating part of centrifugal pump. It consists of series of backward curved vanes. I is mounted on shaft which is connected to the shaft of an electric motor.
Mechanical Seal Mechanical seal is used to prevent the leakage of product. IT has two parts. a ) Rotary part Which rotates with the shaft. b) Stationary part Which does not rotate with the shaft.
Oil Seal Oil seal is used to prevent the leakage of lube oil. Bearing Two types of bearings are used Axial Bearing Which take the load along the axis of the shaft. Radial Bearing Which take the load acting perpendicular to the load of the shaft.
Suction Pipe Its one end connected to outlet of pump and other end delivers the water at required height. Generally following types of faults are found out after the certain working hours of pump Bearing Damage Damage of mechanical seal Damage of oil seal
THERMAL POWER PLANT Mathura Refinery has its own captive thermal power station supplied and erected by M/s BHEL (Bharat Heavy Electricals Limited) to meet the electricity requirements of Mathura Refinery as well as the township.
There are three Boilers, three Steam Turbine Generators (S.T.G.) as well as three Gas Turbine Generators (G.T.G.) and three Heat Recovery Steam Generators (H.R.S.G.) set as T.P.S. Normally one Steam Turbine Generator and three Gas Turbine Generator are in service with one boiler out of three to provide steam to them. Rest of the remaining unit stays on standby. Each boiler is capable of generating steam at a rate of 150 TPH (Tonnes Per Hour) at a pressure of 64 kg/cm and temperature of 450. Each STG is capable of generating a electric power of 12.5 MW with regulated steam of 0 to 105 TPH to meet
the process requirement in the refinery. Each GTG is capable of generating an electric power of 20 MW. Nowadays not only the boilers but the HRGS also used to generate the steam with the help of Gas turbine exhaust as heat source and supplementary firing (If needed).
Objectives of the Thermal Power Station Uninterrupted power, steam, feed water & DM water to units. Optimization of resources & efficiency improvement. Ensure reliability and quality of services. Safe practice of operations. Environmental safety.
COOLING TOWER The steam in the LP Side of the Turbine is collected in the condenser and has to be condensed and is re-used as a feed in the boiler. The cooling media used for exchange of heat is water and to economize on the use of water, water is re-circulated through a cooling tower.
There are many types of cooling towers, the more common being the one with the induced draft cross- flow method. The scheme of operation is that hot water from the condenser is sprayed across the latticed work in a rectangular cell and an induced draft fan is mounted at top of each Call. The draft fan induces a draft current from the cell towards the atmosphere and in the process carried away the water vapors. The cooled water collects in the sump and is again pumped into the condenser to cool the steam in the condenser.
These types of cooling towers are more efficient, economic in operation and occupy minimum space.