2011

BPCL-----KOCHI REFINERY LIMITED

IN-PLANT TRAINING REPORT

TRAINING No: P : 2039

MAINTENANCE DEPARTMENT SUBMITTED BY :-

DEPARTMENT OF MECHANICAL ENGINEERING

Toc H INSTITUTE OF SCIENCE AND TECHNOLOGY

GUIDE NAME : SIGNATURE :

ACKNOWLEDGEMENT

We take this opportunity to express our deep sense of gratitude and sincere thanks to all who helped us to complete this training successfully. Our first and foremost thanks go to God almighty that showered his immense blessing on our effort. We are deeply indebted to our guide Mr. Ravi.K, Senior Manager(Maintenance) , Mr. Sasi Prakash, Deputy Manager(Maintenance) and Mr. G. Shankar for their excellent guidance and support. We also thank Dr. K.K. Jayan , Deputy General manager L&D centre and Ms. G.Shobana for giving the opportunity to undergo the in -plant training. Finally big thanks to all the staff of Kochi Refinery Limited who directly contributed to completion of this training successfully.

OVERVIEW
Kochi Refinery, a unit of Bharat Petroleum Corporation Limited (BPCL), embarked on its journey in 1966 with a capacity of 50,000 barrels per day. Formerly known as Cochin Refineries Limited and later renamed as Kochi Refineries Limited, the refinery was originally established as a joint venture in collaboration with Phillips Petroleum Corporation, USA. Today it is a frontline entity as a unit of the Fortune 500 company, BPCL. Kochi Refinery, located at Ambalmugal near the city of Kochi in Kerala, is one of the two Refineries of BPCL, presently having a crude oil refining capacity of 9.5 Million Metric Tonnes per Annum (MMTPA). The product portfolio of the 190,000 barrels per day refinery today includes petrochemical feedstocks and specialty products in addit ion to its range of quality fuels. Fuel products of this fuel based refinery includes Liquefied Petroleum Gas, Naphtha, Motor Spirit, Kerosene, Aviation Turbine Fuel, High Speed Diesel, Fuel Oils and Asphalt. Specialty products for the domestic markets include Benzene, Toluene, Propylene, Special Boiling Point Spirit, Poly Iso Butene and S ulphur. The refinery has implemented world class technology and systems for operations and enterprise resource planning. It is an ISO 14001 Environmental Management Systems (EMS) and ISO 9001:2000 Quality Management System (QMS) accredited company and has also obtained the ISO 17025 (Testing Methods in Quality Control) certification from NABL (National Accreditation Board for testing & Calibration of Laboratories). The refinery has successfully implemented the Occupational Health and Safety Management System (OHSAS) 18001:2007 in the year 2009. With the prestigious Crude Oil receipt facilities consisting of the Single Point Mooring (SPM) and the associated shore tank farm in place since December 2007, the refinery is equipped to receive crude oil in Very Large Crude Carriers (VLCCs). This facility helps Kochi refinery in reducing the freight charges to a great extent, over and above increasing flexibility in crude oil selection. This, thereby, is a major infrastructure facility to accelerate the future growth of Kochi Refinery. The refinery has facilities to evacuate products to the consuming centres through road, rail, ships and through pipelines. All the major industries in the area are connected to the refinery for product receipt. The BPCL installation at Irumpanam, to which the refinery is connected by pipelines, is the major product distribution centre of the refinery. Petronet CCK, a joint venture company of BPCL looks after the 300 km long pipeline that connects the refinery to various consumption point s in Tamil Nadu such as Coimbatore and Karur. Of the two-part Capacity Expansion cum Modernisation Project (PhaseII), the capacity expansion to 9.5 MMTPA has been successfully completed and refinery modernisation slated for completion in August 2010 would equip the refinery to produce auto-fuels conforming to Euro-III and partly Euro-IV specifications. The refinerys foray into direct marketing began since 1993 through marketing of its aromatic products - Benzene and Toluene. The entry into the international petroleum

business stream began with its first parcel of Fuel Oil exported in January 2001. Since then the refinery, has earned the reputation as a reliable player in the international trade, by virtue of superior product quality and customer service. Moreover, the Fuel Oil has been benchmarked in the Singapore and Dubai Fuel Oil markets. Kochi Refinery is situated in Kochi, the most happening city in Kerala that is rightly called Gods own country. The refinery has a unique bond with its environment which is evident in the green blanket so carefully nourished right around it. The refinery has been blessed with a fine topography and the entire complex, spreading across over thousand two hundred acres has been so constructed as to blend naturally with it. Upcoming expansions and developments would also adhere to this philosophy of blending with nature. The most recent addition to the refinery architecture is the rainwater harvesting pond and eco-park that has been converted to a must-see spot with sprawling landscaped lawns and thatched canopies for conferences and get-togethers. Year after year the refinery has been bagging accolades for its commitment to the environment; for the all round care for the environment, the judicious storage, use and reuse of water, the efficiency in managing solid wastes and effluents and the care taken to keep the atmosphere clean. The recent achievement of 18 million accident free man-hours stands testimony to the fact that the prime focus of Kochi Refinery is on safety in everything we do. From training to retraining, and adhering to international standards in safety practices, both, offsite and onsite, Kochi Refinery has taken it as a mission to make safe living and working a natural mantra of its employees, contract workers, customers and the general public. Several awareness programmes have been successfully conducted to this effect with the results for all to see. As a socially responsible corporate citizen, the community welfare initiatives of the refinery concentrate on developing the weaker sections of society, particularly, the scheduled castes and scheduled tribes and people below the poverty line in important sectors like health, education, housing and women empowerment. Most of the programmes falling under the categories of medical and educational assistance turned out to be poverty alleviation measures also. This is since the programmes like universal health insurance, scholarship to SC/ST students and medical camps for poor have helped the poor villagers in the refinery vicinity to save money over their medical expenses and educational expenses of children. Various people intensive small-scheme community development programmes have brought new life for many; be it poor villagers in need of medical treatment; poor students in government schools or differently abled children! Thus, apart from maintaining its world class standards in operational excellence, the singular objective of Kochi Refinery is to uphold the BPCL vision of energizing lives by continued excellence in all round performance with new ideas, added vigour and sustained commitment to its social, cultural, organizational and natural environment.

CRUDE OIL
Petroleum or crude oil is a naturally occurring, flammable liquid consisting of a complex mixture of hydrocarbons of various molecular weights and other liquid organic compounds that are found in geologic formations beneath the Earth's surface. Petroleum is recovered mostly through oil drilling. This latter stage comes after studies of structural geology (at the reservoir scale), sedimentary basin analysis, reservoir characterization (mainly in terms of porosity and permeable structures). It is refined and separated, most easily by boiling point, into a large number of consumer products, from gasoline and kerosene to asphalt and chemical reagents used to make plastics and pharmaceuticals Petroleum is often attributed as the "Mother of all Commodities" because of its importance in the manufacture of a wide variety of materials. Petroleum includes only crude oil, but in common usage it includes all liquid, gaseous, and solid hydrocarbons. Under surface pressure and temperature conditions, lighter hydrocarbons methane, ethane, propane and butane occur as gases, while pentane and heavier ones are in the form of liquids or solids. However, in an underground oil reservoir the proportions of gas, liquid, and solid depend on subsurface conditions and on the phase diagram of the petroleum mixture. An oil well produces predominantly crude oil, with some natural gas dissolved in it. Because the pressure is lower at the surface than underground, some of the gas will come out of solution and be recovered (or burned) as associated gas or solution gas. A gas well produces predominantly natural gas. However, because the underground temperature and pressure are higher than at the surface, the gas may contain heavier hydrocarbons such as pentane, hexane, and heptane in the gaseous state. At surface conditions these will condense out of the gas to form natural gas condensate, often shortened to condensate. Condensate resembles petrol in appearance and is similar in composition to some volatile light crude oils. The proportion of light hydrocarbons in the petroleum mixture varies greatly among different oil fields, ranging from as much as 97% by weight in the lighter oils to as little as 50% in the heavier oils and bitumens. The hydrocarbons in crude oil are mostly alkanes, cycloalkanes and various aromatic hydrocarbons while the other organic compounds contain nitrogen, oxygen and sulfur, and trace amounts of metals such as iron, nickel, copper and vanadium. The exact molecular composition varies widely from formation to formation but the proportion of chemical elements vary over fairly narrow limits as follows:

Carbon

83 to 87%

Hydrogen

10 to 14%

Nitrogen Oxygen

0.1 to 2% 0.05 to 1.5%

Sulfur

0.05 to 6.0%

Metals

< 0.1%

PRODUCTS
Kochi Refinery is a petroleum based refinery, producing a variety of petroleum-based products such as: Liquefied Petroleum Gas (LPG) and Superior Kerosene Oil (SKO) for household and industrial uses Motor Spirit (MS/ Petrol) and Hi-speed Diesel (HSD) for automobiles Naphtha, the major raw material for fertilizer and petrochemical industries Furnace Oil (FO), Light Diesel Oil (LDO) and Low Sulphur Heavy Stock (LSHS) as fuel for industries Aviation Turbine Fuel (ATF) for aircrafts SPECIALTY PRODUCTS Benzene for manufacture of caprolactum, phenol, insecticides and other chemicals Special Boiling Point Spirit (SBPS) used as solvent in tyre industry Toluene for manufacture of solvents and insecticides, pharmaceuticals and paint Mineral Turpentine Oil (MTO) for use in textile and paint industry Sulphur for use in fertilizer, sugar, chemicals and tyre industry Poly Isobutene (PIB) for manufacture of lubricants and cable jelly Propylene as a feedstock for various petrochemicals EXCLUSIVE PRODUCTS Natural Rubber Modified Bitumen or Rubberised Bitumen: Natural Rubber Modified Bitumen (NRMB) is one of Kochi Refinerys premium products that revolutionized road development. NRMB has been on a fast track since its introduction in 1999.Bitumen, which is derived from petroleum, is a critical component in road building. Polymer added to Bitumen enhances both quality and longevity of roads. Kochi Refinery in association with leading research institutes made an in-depth study on feasibility of using natural rubber available in abundance in Kerala, to develop the premium product, NRMB.NRMB has improved many roads throughout the region. Its success track is evident from the smooth Seaport-Airport road in Cochin.NRMB is a superior mix of bitumen and natural rubber latex. It is superior in quality to ordinary bitumen.

PROCESS
Kochi Refinery presently has a crude oil processing capacity of 9.5 MMTPA (Million Tons per Annum) in its two Crude Distillation units (CDU-1 and CDU-2). The refinery currently processes about 30% of Indigenous and 70% Imported crude oils. Crude oil is transported in ships from the point of origin to Kochi and is received through a Single Point Mooring (SPM) facility. Kochi SPM, located approximately 20 kms off the shore of Puthuvypeen, is capable of handling Very large Crude Carriers (VLCC) with crude oil carrying capacities upto 3.0 Lakh Tons. Crude oil from SPM is received in offshore tanks in Puthuvypeen and is then pumped to the refinery. Apart from the Crude Distillation Units, major processing facilities in the refinery include a Fluidized Catalytic Cracking (FCC) unit, Diesel Hydro Desulphurization (DHDS) unit, Kerosene Hydro Desulphurization (KHDS) unit, Sulphur Recovery Unit (SRU) and an Aromatics Block consisting of a Naphtha Splitter Unit (NSU), Naphtha Hydro Desulphurization (NDHS), Catalytic Reformer Unit (CRU) and Aromatics Recovery Unit (ARU). Crude oil is first processed in the Crude Distillation Unit where it is heated up to around 360 to 380 oC depending on the type of crude oil after removing impurities such as sodium and magnesium salts, water and other sediments. Crude oil is then fractionated in a distillation column where lighter fractions such as LPG, Naphtha, Kerosene and Diesel are separated. The products are routed to respective storage locations after cooling to atmospheric temperature. LPG is treated using Di-Ethanol Amine (DEA) to remove the impurities before being stored as product LPG. Part of the Naphtha is processed in the Aromatics Block to produce Benzene, Toluene and a solvent SBPS (Special Boiling Point Spirit). Part of the Kerosene is treated either in a MEROX unit or in KHDS to produce Aviation Turbine Fuel (ATF) and Mineral Turpentine Oil(MTO). Diesel from the CDU is processed in DHDS unit to produce BS-II/ Euro-III grade Diesel. Remaining heavier portion of the crude oil is further distilled under vacuum in a Vacuum Distillation Unit (VDU) to separate Vacuum Gas Oil (VGO) and Vacuum Residue (VR) as major fractions. The VGO is processed in FCC unit where the heavier molecules are broken down to produce LPG, Gasoline (also called Motor Spirit or Petrol) and Diesel. Refinery is currently capable of producing both BS -II and Euro-III grade Petrol. With the commissioning of Continuous Catalyst Regeneration (CCR) Reformer and VGO Hydro Desulphurization Unit (VGO HDS), the refinery will be capable of producing nearly 70% MS (Motor Spirit) and HSD (High Speed Diesel) meeting Euro -III specifications and 30% MS and HSD meeting Euro-IV specifications. Vacuum Residue (VR) from VDU is routed to a Biturox Unit to produce Bitumen or to a Vis-Breaker Unit (VBU) to produce Furnace Oil (FO). VR can also be directly routed to LSHS (Low Sulphur Heavy Stock fuel used in Boilers, Power Plants, etc.) pool if the crude oil processed in CDU is of low sulphur content (less than 0.5 wt%). A state of the art Sulphur Recovery Unit (SRU) recovers sulphur from the gases produced within the refinery before it is consumed as fuel gas.

Kochi Refinery operates a Gas Turbine (GT) with a rated capacity of 22.0 MW, a Steam Turbine Generator (STG) of 17.8 MW and a Turbo Generator (TG) of 2.5 MW to meet its power requirements. The steam requirement of the refinery is met from 8 boilers and 2 Waste Heat Boilers (HRSG), apart from small HRSGs installed in process units. A new GT of 34 MW capacity has been commissioned to cater to the additional power requirement of CCR and VGO HDS units and the associated facilities which being installed. Effluent Treatment Plants (ETP) takes care of the liquid effluent from the process units and other off site areas. The treated effluent after meeting the MINAS (Minimum National Standards) is discharged to inland rivers. Other Utilities and Off-site facilities such as tankages, flare system and connected pipelines are installed in the refinery to match with the requirements of processing, storage and products dispatch.

AREA WISE DIVISION

Area 1 :CDU 1 - Crude Distillation Unit 1 FCCU - Fluidized Catalytic Cracking Unit PIB - Poly Iso Butylene unit NHDS - Naftha Hydro Desulphurization unit

Area 2 :CDU 2 ARU AAU RPU VDU - Crude Distillation Unit 2 - Aromatic Recovery Unit - Amine Absorption Unit - Raffinate Purification Unit - Vaccum Distillation Unit

Area 3 :DHDS - Diesel Hydro HGU - Hydrogen Generation Unit SRU - Sulphur Recovery Unit

Area 4 :Maintenance

MAINTENANCE
Maintenance is defined as a set of activities performed on plant and machineries to maintain the same prime condition, in economic ways for smooth running of the plant for achievement of organizational objectives. Prime conditions refer to that the plant and the machinery shall be in good condition for efficient and effective utilization of the same function for which it is designed and installed for. Maintenance is to ensure the maximum availability and reliability of plant and machinery at an optimum cost uninterrupted operation of all unit s for achievement of organizational goals with respect to reaching targets and to meet standard conditions.

There are 4 types of maintenance:1. Preventive maintenance:It refers to the set of activities that are performed periodically to improve any possible failures. They include checking of lubricating oil condition, seal quenching, seal cooling system checking operating parameters like suction pressure, temperature, discharge pressure etc and also checking for any abnormal noises if any observed. If abnormalities is of critical nature, stand by equipment is put into operation and abnormality is attended to. 2. Predictive or condition monitoring:This type refers to constant monitoring or functioning of equipment. The collected data is then analysed and possible abnormalities are derived and correctional remedies are prescribed. Vibration analysis forms the basis of condition monitoring. To cover all equipments of the plant, equipment is grouped based on the critically and a schedule is jotted to cover all equipments and condition monitoring is performed on these equipments as per schedule. 3. Breakdown maintenance:It is the maintenance carried out on equipments after they breakdown. This is performed on certain equipments which are not in the production line, which are not easily approachable in hostile atmosphere like high temperature zones, highly corrosive or radioactive zones etc. 4. Turn around maintenance:It is maintenance of plant and machinery carried out during turn around of the plants. In this type, those functions which were not possible to carry out during running of the plants are listed and taken up during plant turnarounds. This type of maintenance activities comprise of internals, seals, complete over hauling, any modifications for improving performance.

MAINTENANCE WORKSHOP

1. Workshop :A workshop comprises of basis repairing of mechanical parts. The machines used include lathe machines, milling machines, grinding machines, drilling machines ,a 10 tonne capacity crane for heavy load movement. 2. Welding shop Broken pipes, machine parts are welded. Types of welding used are electric arc, plasma arc welding, gas welding etc. 3. Instrument shop In the instrument shop repair of various instrument used for taking reading are done. These include pressure gauges, speed meters, vibration transducers etc. 4. Electrical shop Repair of electrical parts of the machine or prime movers like motors and generators are carried out.

The mechanical components in the maintenance department are classified as:1. Rotary type 2. Static type

1. ROTORY TYPE
a. AIR COMPRESSOR

An air compressor is a device that convert power( usually from an electrical or diesel or gasoline engine) into kinetic energy by pressurizing and compressing air, which is then released in quick bursts. There are numerous method of air compression, divided into either positive-displacement or negative-displacement types. Positive-displacement air compressors work by forcing air into a chamber whose volume is reduced to effort the compression. Piston-type air compressors use this

principle by pumping air into an air chamber through the use of the constant motion of the pistons. They use unidirectional valves to guide air into a chamber, where the air is compressed. Rotary screw compressors also use positive-displacement compression by matching 2 helical screws that, when turned, guide air into a chamber, the volume of which is reduced as the screws turn. Vane compressors use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. Negative-displacement air compressor include centrifugal compressors. These device use centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes it. The air compressors seen by the public are used in5 main applications:
y To supply a high-pressure clean air to fill gas cylinders. y To supply a moderate-pressure clean air to supply air to a submerged

surface supplied diver.

y To supply a large amount of moderate-pressure air to power pneumatic tools. y For filling tires.

To produce large volumes of moderate-pressure air for macroscopic industrial processes ( such as oxidation for petroleum coking or cement plant bag house purge systems).

Single Stage Air Compressor

A single stage air compressor works using the force of a piston and pressure sensitive valve. IT is designed to house one cylinder that compresses air with a single piston stroke. This cylinder is connected to a power supply that provides the force

needed to compress the air. It is different from double and multiple stage air compressors because it operates with just the one cylinder and valve. Operation:At rest, the single stage air compressor cylinder is open. The piston is at the top of the cylinder and there is air inside. When turned on, the piston slides down the cylinder compressing the air to a certain level. Once this pressure level is achieved, a release valve opens and the compressed air is released into a chamber. This same action occurs on the resulting upwards stroke of the piston. Air is again compressed and released through a valve.

Intake:The single stroke compressor actually has another stage. This is called the suction or clean air intake stage. Air is forced into the cylinder to make up for the loss of pressure on one side. Each time the piston slides to one end, this occurs on the opposite end.

b. PUMPS

A pump is a device used to move fluids, such as liquids, gases or slurries.

 CENTRIFUGAL PUMPS

A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the pressure and flow rate of a fluid. Centrifugal pumps are the most common type of pump used to move liquids through a piping system. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward or axially into a diffuser or volute chamber, from where it exits into the downstream piping system. Centrifugal pumps are typically used for large discharge through smaller heads.

Centrifugal pumps are most often associated with the radial flow type. However, the term "centrifugal pump" can be used to describe all impeller type rotodynamic pumps including the radial, axial and mixed flow variations.

General Components Of Centrifugal Pump

 Stationary Components:1. Casing:Casings are generally of 2 types: volute and circular. The impellers are fitted inside the casings. 2. Suction and discharge nozzle:The suction and discharge nozzles are part of casings itself. 3. Gland:The gland is a very important part of the seal chamber or the stuffing box. It gives the packing or the mechanical seal the desired fit on the shaft sleeve. It can be easily

adjusted in axial direction. The gland comprises of the seal flush, quench, cooling, drain and vent. Connection ports as per the standard codes like API 682. 4. Throat bushing:The bottom or inside end of the chamber is provided with a stationary device called throat bushing that forms a restrictive close clearance around the sleeve between the seal and the impeller. 5. Throttle bushing:It refers to a device that forms a restrictive close clearance around the sleeve at the out board end of the mechanical seal gland. 6. Internal circulating device:It refers to device located in the sleeve chamber fluid through cooler or barrier fluid reservoir. Usually it is referred to as a pumping . 7. Bearing housing:The bearing housing encloses the bearings mounted on the shaft. The bearings keep the shaft or rotor in correct alignment with the stationary parts under the action of radial and transverse loads. The bearing house also includes an oil reservoir for lubrication, constant level oiler, jacket for cooling by circulating cooling water.

 Rotating Components:1. Impeller The impeller is the main rotating part that provides the centrifugal acceleration to the fluid.
y Based on major direction of flow in reference to axis of rotation:-

Radial flow pumps: Often simply referred to as centrifugal pumps. The fluid enters along the axial plane, is accelerated by the impeller and exits at right angles to the shaft (radially). Radial flow pumps operate at higher pressures and lower flow rates than axial and mixed flow pumps.

Axial flow pumps: Axial flow pumps differ from radial flow in that the fluid enters and exits along the same direction parallel to the rotating shaft. The fluid is not accelerated but instead "lifted" by the action of the impeller. They may be likened to a propeller spinning in a length of tube. Axial flow pumps operate at much lower pressures and higher flow rates than radial flow pumps. Mixed flow pumps: Mixed flow pumps, as the name suggests, function as a compromise between radial and axial flow pumps, the fluid experiences both radial acceleration and lift and exits the impeller somewhere between 090 degrees from the axial direction. As a consequence mixed flow pumps operate at higher pressures than axial flow pumps while delivering higher discharges than radial flow pumps. The exit angle of the flow dictates the pressure head-discharge characteristic in relation to radial and mixed flow.

y Based on suction type:Single suction : liquid inlet on one side Double suction : liquid inlet to the impeller symmetrically from both sides. y Based on mechanical construction:Closed : shrouds or sidewall enclosing the vanes. Open : no shrouds or wall to enclose the vanes. Semi open or vortex:

2. Wear rings Wear ring provides an easily and economically renewable leakage joint between the impeller and the casing. Clearance becomes too large the pump efficiency will be lowered causing heat and vibration problems. Most manufactures require that you disassemble the pump to check the wear ring clearance and replace the rings when this clearance doubles. 3. Shaft:The basic purpose of centrifugal shaft is to transmit the torques encountered when starting and during operation while supporting the impeller and other rotating parts. It must do this job with a deflection less than the minimum clearance between the rotating and stationary parts.

4. Shaft sleeve:Pump shafts are usually protected from erosion, corrosion and wear at the seal chambers, leakage joints, internal bearings and in the waterways by renewable sleeves. Unless otherwise specified, a shaft sleeve of wear, corrosion and erosion resistant material shall be provided to protect the shaft. The sleeve shall be sealed at one end. The shaft sleeve assembly shall extend beyond the outer face of the seal gland plate. 5. Coupling:Coupling can compensate for axial growth of shaft and transmit torque to the impeller. Shaft couplings can be broadly classified into 2 groups: rigid and flexible. Rigid couplings are used in applications where there is absolutely no possibility or room for any misalignment. Flexible shaft couplings are more prone to selection and maintenance errors. Flexible shaft couplings can be divided into 2 basic groups: elastomeric and non elastomeric.

 Auxiliary Components:Auxiliary components generally include the following piping systems for the following services:
y y y y y

Seal flushing, cooling, quenching systems Seal drains and vents Bearing lubrication, cooling systems Seal chamber or stuffing box cooling, heating systems Pump pedestal cooling systems

Auxiliary piping systems include tubing, piping, isolating valves, control valves, relief valves, temperature gauges and thermocouples, pressure gauges, sight flow indicators, seal flush coolers, dual seal barrier/ buffer fluid reservoirs and all related vents and drains.
PRIMING:

Most centrifugal pumps are not self-priming. In other words, the pump casing must be filled with liquid before the pump is started, or the pump will not be able to function. If the pump casing becomes filled with vapors or gases, the pump impeller becomes gas-bound and incapable of pumping. To ensure that a centrifugal pump remains primed and does not become gas-bound, most centrifugal pumps are located below the

level of the source from which the pump is to take its suction. The same effect can be gained by supplying liquid to the pump suction under pressure supplied by another pump placed in the suction line.

 POSITIVE DISPLACEMENT PUMP

A positive displacement pump causes a fluid to move by trapping a fixed amount of it then forcing (displacing) that trapped volume into the discharge pipe. Or A positive displacement pump has an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation. A positive displacement pump can be further classified according to the mechanism used to move the fluid:
y Rotary-type

Internal gear, screw, shuttle block, flexible vane or sliding vane, circumferential piston, helical twisted roots (e.g. the Wendelkolben pump) or liquid ring vacuum pumps. Positive displacement rotary pumps are pumps that move fluid using the principles of rotation. The vacuum created by the rotation of the pump captures and draws in the liquid. Rotary pumps are very efficient because they naturally remove air from the lines, eliminating the need to bleed the air from the lines manually. Positive displacement rotary pumps also have their weaknesses. Because of the nature of the pump, the clearance between the rotating pump and the outer edge must be very close, requiring that the pumps rotate at a slow, steady speed. If rotary pumps are operated at high speeds, the fluids will cause erosion. Rotary pumps that experience such erosion eventually show signs of enlarged clearances, which allow liquid to slip through and detract from the efficiency of the pump. Positive displacement rotary pumps can be grouped into three main types. Gear pumps are the simplest type of rotary pumps, consisting of two gears laid out side-by-side with their teeth enmeshed. The gears turn away from each other, creating a current that traps fluid between the teeth on the gears and the outer casing, eventually releasing the fluid on the discharge side of the pump as the teeth mesh and go around again. Many small

teeth maintain a constant flow of fluid, while fewer, larger teeth create a tendency for the pump to discharge fluids in short, pulsing gushes.


Reciprocating-type:

For example diaphragm pumps. Positive displacement pumps have an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation.

 SCREW PUMP

A screw pump is a positive displacement pump that use one or several screws to move fluids or solids along the screw(s) axis. In its simplest form (the Archimedes' screw pump), a single screw rotates in a cylindrical cavity, thereby moving the material along the screw's spindle. This ancient construction is still used in many low-tech applications, such as irrigation systems and in agricultural machinery for transporting grain and other solids. Development of the screw pump has led to a variety of multi-axis technologies where carefully crafted screws rotate in opposite directions or remains stationary within a cavity. The cavity can be profiled, thereby creating cavities where the pumped material is "trapped". In offshore and marine installations, a three spindle screw pump is often used to pump high pressure viscous fluids. Three screws drive the pumped liquid forth in a closed

chamber. As the screws rotate in opposite directions, the pumped liquid moves along the screws spindles. Three-Spindle screw pumps are used for transport of viscous fluids with lubricating properties. They are suited for a variety of applications such as fuel-injection, oil burners, boosting, hydraulics, fuel, lubrication, circulating, feed and so on. Compared to centrifugal pumps, positive displacements (PD) pumps have several advantages. The pumped fluid is moving axially without turbulence which el iminates foaming that would otherwise occur in viscous fluids. They are also able to pump fluids of higher viscosity without losing flow rate. Also, changes in the pressure difference have little impact on PD pumps compared to centrifugal pumps.

 GEAR PUMP

A gear pump uses the meshing of gears to pump fluid by displacement. They are one of the most common types of pumps for hydraulic fluid power applications. Gear pumps are also widely used in chemical installations to pump fluid with a certain viscosity. There are two main variations; external gear pumps which use two external spur gears, and internal gear pumps which use an external and an internal spur gear. Gear pumps are positive displacement (or fixed displacement), meaning they pump a constant amount of fluid for each revolution. Some gear pumps are designed to function as either a motor or a pump.

3. TURBINE
A turbine is a rotary engine that converts the pressure energy of a fluid and converts it into useful mechanical energy. The simplest turbines have one moving part, a rotor assembly which is a shaft or drum with blades attached onto the periphery. The movement of the fluid over the blades of the turbine causes its displacement, and a result the shaft will rotate. Examples of these kinds of simple turbines are windmills and water-wheels.

 STEAM TURBINE

A steam turbine is a mechanical device that, as the result of the thermal energy of the steam, produces rotary motion. Its modern day manifestation was first conceived by Sir Charles Parsons in the year 1884. It has almost completely replaced the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is suited to drive an electrical generator. About 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvements in thermal efficiency through the use of multiple stages in the expansion of the steam as it traverses the blades, which results in a closer approach to the ideal reversible process.  Principle of Operation and Design The expansion of steam in a steam turbine is cons idered to be and isentropic process i.e. constant entropy at the inlet and outlet of the steam turbine. But practically no

steam turbine is truly isentropic due to the presence of thermodynamic irreversibilities. However, typical isentropic efficiencies range from 20%-90% based on the application of the turbine. The periphery of the turbine consists of a set of blades. One set of stationary blades in connected to the the casing and one set of rotating blades is connected to the shaft. The sets intermesh with certain clearances which are handled during the manufacturing process, with the size and configuration of sets varying to effectively exploit the expansion of the steam at each stage.

 GAS TURBINE

A gas 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. Energy is added to the gas stream in the combustor where fuel is mixed with air and ignited. In this high pressure environment off the combustor, combustion of the fuel also increases the temperature. The products of the combustion are forced into the turbine section. There the high velocity and volume of the of the gas flow is directed through a nozzle over the turbines blades, spinning the turbine and providing the required mechanical output. Energy can be extracted in the form of shaft power, compressed air, thrust or any combination of these and used to power aircrafts, trains, ships, tanks etc.

Uses of Turbines 1. It is used in the generation of electricity. 2. Jet engines use turbines to produce the required mechanical output.

3. Turbines are often part of a larger machine. For example, a gas turbine consists of the following principle parts, a compressor, a combustion chamber and a multistage turbine. 4. I.C. engines can use a turbine powered by the exhaust to drive an intake -air compressor- a configuration known as a turbocharger.

STATIC EQUIPMENTS

a. HEAT EXCHANGER
A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall so that they never mix. They are widely used in space heating, refrigeration, air conditioning, power plants, petroleum refineries etc. Types of Heat Exchangers 1. Plate Heat Exchanger It comprises of multiple thin, slightly separated plates that have very large surface areas for effective heat transfer and fluid flow passages. This stacked-plate arrangement can be more effective in a given space than the shell and tube heat

exchanger. Advances in gasket and brazing technologies have made the plate-type heat exchanger increasingly practical. In HVAC applications large heat exchangers of this type are called plate and frame.

2. Shell and Tube Heat Exchanger

This heat exchanger consists of a series of tubes. One set of these tubes contain the fluid that must be either heated or cooled. The second fluid runs over the tubes that are being heated or cooled so that it can either provide the heat or absorb the required heat. A set of tubes called the tube bundle can be made of several types of tubes:- plain, longitudinally finned etc. Shell and tube heat exchangers are typically used for high-pressure applications( with pressures greater than 30 bar and temperatures greater than 260 degrees Celsius.) owing to the fact that they are robust in construction.

b. BOILER
A boiler is a closed vessel in which water or some other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications.

Materials used for construction of Boilers: The pressure vessel in a boiler is usually made of steel (or alloy steel) or historically of wroght iron. Stainless steel is prohibited ( by the ASME Boiler Code) for use in wetted parts of modern boilers, but is used often in super-heated sections that will not be exposed to liquid boiler water. In live steam models , copper or brass is often used because it is easier to fabricate. For much of the Victorian age, the only material used for boiler-making was the highest grade of wrought iron, with assembly by riveting. This sort of iron was obtained from specialist ironworks noted for their high quality and high -reliability. In the 20th century, design practise was moved instead to the use of steel which is stronger and cheaper, with welded construction which was quicker and required less labour. Also cast iron may be used for the heating vessel of domestic water heaters. Although such heaters are usually termed boilers, their actual purpose is usually to produce hot water, not steam. The brittleness of steam makes it a poor choice for high pressure boiler applications.

Fuel : The source of heat for a boiler is combustion of any of several fuels such as wood, coal, oil, natural gas etc. Electric steam boilers use resistance or immersion type heating elements. Nuclear fission is also used as a heat source for generating steam. Heat recovery steam generators (HRSGs) use the heat rejected from other processes such as gas turbines. Steam Trap : A steam trap is a device used to discharge condensate and non-condensable gases with a negligible consumption or loss of live steam. Most steam traps are nothing more than automatic valves. They open, close or modulate automatically. Others, like venturi traps are based on turbulent 2-phase flows to obstruct the steam flow. The three important functions of steam traps are:1. Discharge condensate as soon as it is formed. 2. Have negligible steam consumption. 3. Have the capacity of discharging air and other non-condensable gases. Types of Steam Traps There are 4 types of steam traps:1. Mechanical Traps:They have a float that rises and falls in relation to condensate level and this usually has a mechanical linkage attached that opens and closes the valve. Mechanical traps operate in direct relationship to condensate levels present in the body of the steam trap. 2. Temperature Traps:They have a valve that is driven on or off the seat by either expansion or contraction caused by temperature change. They differ from mechanical traps in that their design requires them to hold back some condensate waiting for it to cool sufficiently to allow the valve to open. In most circumstances this is not desirable as condensate needs to be removed as soon as it is formed.

3. Thermodynamic Traps :These traps work on the difference in dynamic response to velocity change in flow of compressible and incompressible fluids. As steam enters, static pressure above the disk forces it against the valve seat. The static pressure over a large area overcomes the high inlet pressure of the steam. As the steam starts to condense, the pressure against the disk lessens and the trap cycles. This essentially makes it a time cycle device i.e. itll open even if there is only steam present which can cause premature wear. If non-condensable gas is trapped on top of the disc, it can cause the trap to be locked shut. 4. Venturi Traps:This type works in a turbulent two-phase flow regime. Internally it consists of a venture type valve with a certain shape. Condensate is fully discharged while eventual steam also tries to pass the venture. But while traversing the venture towards the low pressure zone the steam expands and chokes through-hole together with the slow condensate. Because of this, the amount of live steam escaping the orifice in negligible.

HOT TAPPING

Hot tapping consists of tapping saddle, gate valve and hot tapping machine. Before hot tapping a stub is welded onto the location. Use:1. 2. 3. 4. 5. 6. Product sampling points. Pressure control switches installation. Flow meter installation. Inspection of pipe lines. Draining of pipe lines. Air relief points.

STORAGE TANKS

It is a container usually for holding liquids and compressed gases. The term can be used for reservoirs (artificial lake and ponds), and for manufactured containers. Tanks for a particular fluid are chosen according to the flash-point of that substance. Generally in refineries and especially for liquid fuels there are fixed roof tanks and floating-type roof tanks. The type of roofing used for a tank depends on the type of fuel being stored in it. Fixed roof tanks are meant for liquids with very high flash points (ex: fueal oil, bitumen). Cone roofs and umbrella roofs are usual. There are installed to prevent the clogging of certain materials wherein the heat is provided by steam coils within the tanks. Dome roof tanks are meant for tanks having slightly higher storage pressure than that of the atmosphere. Floating roof tanks are broadly divided into external floating roof tanks (FR) and internal floating roof tanks (IFR). IFR tanks are used for liquids with low flash points (ex: ATF, MS etc). These tanks are nothing but cone roof tanks with a floating roof inside which travels up and down along with the liquid level. This floating roof traps the vapour from low flash-point fuels. Floating roofs are supported with legs on which they rest. FR tanks do not have a fixed roof, but are open at the top, and only has a floating roof. Medium flash-point liquids such as naptha, kerosene, diesel etc are stored in these tanks. As flash-points of fuels go very low the tanks are usually spherical and are used in the storage of LPG, hydrogen, hexane, oxygen etc.

VALVE
A valve is a device that regulates the flow of a fluid (gases, liquids, slurries etc) by opening, closing or partially obstructing various passageways. Valves are technically pipe fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a direction from higher pressure to lower pressure. Valves are used in a variety of contexts, including industrial, commercial, residential, military and transport. The industries in which the majority of valves are used are oil and gas, power generation, mining and chemical manufacturing. Valves can be categorized into the following types:-

1. Ball valve:This type of valve is used for on or off control without pressure drop, and ideal for quick shutoff since a 45 degree turn offers complete shutoff angle compared to multiple turns required on most manual valves. 2. Butterfly Valve:This is used for flow regulation in large diameter pipes. 3. Check Valve:This a non-return valve that allows only a uni-directional flow of fluid.

4. Pl

Sli fluid.

valve for on or off control but will lead to drop of pressure of t e

BE

A bearing is a device t at allows constrained relative motion between two or more parts t picall rotation or linear movement. Bearings may be classified broadly according to t e motions t ey allow and according to t eir principle of operation as well as by t e directions of applied loads t ey can handle. The different types of bearings used in the industrial scene are: 1. Pl i beari also known by the specific styles namely journal bearings sleeve bearings rifle bearings. 2. Rolli element bearings such as ball bearings and roller bearings. in these bearings the load is carried by rolling the axle slightly off 3. Jewel beari center. 4. Fl i beari in this type of bearing the load is carried by a gas or a li uid. 5. Magneti bearings-in this type of bearing the load is carried by a magnetic field. 6. Flexure bearings-the motion is supported by a load element which can be subjected to bends.

ENVIRONMENT PROTECTION
Right from the initial stages, the Company has always given utmost attention to environmental care and protection. Extensive anti-pollution measures have been incorporated in the design of the units. BPCL-KR is an ISO 14001 company, which confirms that KRs Environment Management Systems conform to international standards. Kochi Refinery is the first organization in Kerala to receive the ISO 14001 certification. The design of the effluent water treatment system is such that the water discharged from the treatment unit is well within the quality levels prescribed by the State Pollution Control Board and the national standards. In fact, Kochi Refinery is the first industrial unit in Kerala permitted by the State Pollution Control Board, to discharge treated water into inland rivers. BPCL-KR has installed Sulphur Recovery units to minimise the SO2 emissions from the Refinery. KR has also installed three fully automatic, on-line and computerised Ambient Air Quality Monitoring Stations for regular monitoring of ambient air quality at company boundary. In addition, three ambient air quality monitoring stations have been set up at the shore tank farm area also, for continuous monitoring of ambient air quality. To reduce particulate matter emission from the Fluid Catalytic Cracking (FCC) unit, an electrostatic precipitator was commissioned in 1985. KR is the first Refinery in India to install this facility. KR produces auto fuels (MS & HSD) conforming to Bharat Stage-II norms from January 2005, well ahead of the implementation of new fuel quality norms in the region. The Diesel Hydro-Desulphurization unit (DHDS) enables to reduce the sulphur content in diesel to 0.05 wt. %, thereby minimizing the sulphur emissions from vehicle exhausts. Presently a refinery modernisation project is underway to make auto-fuels conforming to Euro-III specifications. An ecological park has been developed within the company premises in 2004-05 by planting 4000 saplings of different species of trees, flowering plants, herbal trees, etc. Now the ecological park and the treated effluent waterbed attract different birds including seasonal migratory birds. Implementation of rain water harvesting schemes inside the refinery is another project for environmental protection. Water collected from this facility is routed to cooling towers as make up water. In recognition of the measures taken up by KR in the field of pollution control & environmental management, various awards have been conferred on Kochi Refinery

CONCLUSION

BPCL-Kochi Refineries is one of the leading refineries in India. The plant consists of various units meant for the refining and manufacturing of a variety of chemical products. The plants are equipped with standard and reliable mechanical equipment required for each and every stage of the manufacturing process. Also the company in looking to expand its present base by bringing in sophisticated machinery from outside India, all in the hopes of increasing their petroleum refining capabilities and to bring out a better rate of production year after year to be able to compete with other petroleum refining companies in the world, and to stand out as one among the best. During our 2 week period of training, we were able to apply all of our theoretical jargon into practical foresight with the help of a number of the working staff. We also got an insight as to how to crude oil is refined and manufactured and the various products BPCL-KR produces and markets.