DEPARTMENT OF MECHANICAL ENGINEERING

(Session 2013-2014)

INDUSTRIAL TRAINING REPORT INDIAN OIL CORPORATION LIMITED, BONGAIGAON REFINERY

Submitted to

Submitted By DEEPJYOTI TALUKDAR Roll no.: 0177EC101023 ME (IITM),Bhopal

Mr. UMESH CH. DAS MANAGER (T&D)

INDIAN OIL CORPORATION LTD BGR,CHIRANG,ASSAM

ACKNOWLEDGEMENT
This report is a result of the concentrated effort and consistent guidance of many individuals. I take this opportunity to thank IOCL-BGR for giving me the opportunity to undergo the training. I would like to express my sincere gratitude to Mr. N.C.Deka (SMNM), Mr. Amar Boragohain (SMNM), and Mr. Aniruddha Saikia (SMNM) for their constant support and valuable guidance

I also express my profound gratitude to Mr. U.C.Das (Manager T&D) for providing the necessary correspondence with my university and helping me learn the work culture apart from sharpening the book knowledge.

DEEPJYOTI TALUKDAR B.E- ME 6th SEM IES INSTITUTE OF TECHNOLOGY AND MANAGEMENT,BHOPAL MADHYA PRADESH

Acknowledgment
Gratitude is the hardest emotions to express and often one does not find adequate words to convey ones entire feeling .We express our sincere gratitude and indebtedness to Mr. Umesh Chandra Das, Manager, T&D, IOCL, Bongaigaon Refinery for granting us the permission as summer trainee. It is our foremost duty to express our sense of gratitude and respect to Mr. N.C. Deka, SMNM, MM (REF) Department, Mr. Amar Bargohain, SMNM, MM (U&O) Department, Mr. Aniruddha saikia, SMNM, Mr. K.C. Daimary , CMNM, CWS Department . We are also very thankful to each and every technician and staffs of Bongaigaon Refinery who gave their support in their own ways. As we know that no work is possible without the help of parents and faculties so we thank our parents and teachers with our heart who motivated us to extent our reach and with their support we have able to complete this work .

Dhaligaon , 30 july 2013 Deepjyoti Talukdar

Preface
Engineering students gain theoretical knowledge only through books. Only theoretical knowledge is not sufficient for the mastery in any field .Theoretical knowledge in our book is not of much use without its practical implementation. It has been experienced that theoretical knowledge is volatile in nature; however practical knowledge imparts solid foundation in our mind. To accomplish this aspect various Engineering colleges has included training for the student of engineering. Here we have learned about various pumps, storage tanks, valves and other equipments required for refining process. This report is in fact a summary of what I have learnt and seen during my training period in IOCL, Bongaigaon Refinery and Petrochemicals Limited , Dhaligaon , Chirang.

Dhaligaon , july 2013 Deepjyoti Talukdar (IES College of Technology and Management Bhopal )

Contents-

1. Introduction 2. Supply of crude oil 3. Crude distillation unit(CDU) 4. Delayed Coker unit(DCU) 5. Utility and offset(U&O) 6. Central workshop(CWS) 7. Bibliography

Introduction
The foundation stone of IOCL Bongaigaon Refinery, then known as Bongaigaon Refinery & Petrochemicals Ltd (BRPL), was laid by late Smt. Indira Gandhi, then the Prime Minister of India on 19 January 1972 at Dhaligaon. The design processing capacity of the crude distillation unit-I commissioned on 6th February 1979 was 1.35 MTPA (million tons per annum). The first unit that came into existence was Captive Power Plant. It was commissioned on 14th January 1977. The primary units of the IOCL Bongaigaon Refinery are the crude distillation unit-I (CDU-I) which was commissioned in 1979. This was followed by the commissioning of the kerosene treating unit (KTU), the Delayed Coking Unit (DCU-I) and the coke calcinations unit (CCU) in 1981. The crude refining capacity of CDU-I was initially 1 million tons per annum. But the debottlenecking concept was a great boon to increasing its capacity thereby the crude refining capacity became 1.35 million tons per annum in 1986. In 1995, with the further and the more Delayed Coking Unit (DCU-II) the crude processing capacity of IOCL Bongaigaon Refinery was increased to 2.35 million tons per annum. Xylene was commissioned in 1985. LPG bottling plant was also commissioned in 2003.

Supply of crude oil

The crude oil from the Assam oil fields of the ONGC and the OIL located in North East India, and the Ravva crude oil from the Krishna Godavari basin off the coast of Andhra Pradesh are being Refined at IOCL Bongaigaon Refinery. A 750km long pipeline of OIL originating in Duliajan is being used to bring crude oil from Assam oil fields. Ravva crude is brought to Barauni through the Haldia-Barauni crude pipeline owned by IOCL. From Barauni the crude is brought to IOCL Bongaigaon Refinery through the pipeline owned by OIL. For the storage of the crude oil from Assam oil fields and Ravva crude, there are seven floating roof tanks at the IOCL Bongaigaon Refinery. Each of these tanks is of 20000 cubic meter capacities. Generally three tanks are allotted for Assam crude, three for Ravva crude, and one for the imported crude which is sometimes used for the Assam crude with proper procedural steps. No same storage tank is used for feeding and receiving the crude oil for reason of oil accounting. Any sort of contamination in the crude, that is mixed up of the Ravva crude oil, Assam crude and imported crude, can lead to products which might not be according to the specifications, and will ultimately not meet the EURO-II norms.

Crude distillation unit(CDU)Crude distillation unit is the mother of a refinery. Crude oil is classified by the location of its origin (e.g. West Texas Intermediate, WT, Brent, Dubai or Minas) and often by its relative weight or viscosity (light, intermediate or heavy); refineries may also refer to it as sweet, which means it contains relatively little sulphur, or as sour, which means it contains substantial amounts sulphur and requires more refining in order to meet current production specifications. The number of carbon atoms determines the oils relative weight or density. Gases generally have one to two carbon atoms, while heavy oil and waxes may have 50, asphalts hundreds.

Crude oil from an area in which the crude oils molecular characteristics have been determined and the oil has been classified are used as pricing references throughout the world. These references are known as Crude oil benchmarks. The plant capacity of any other unit depends on the capacity of main fractional column of CDU. It receives the raw crude oil from its supplier (Oil India Ltd. in case of Guwahati Refinery) and it does the required pretreatments of raw crude like Desalting, Preheating etc. The different outputs from the CDU unit of Guwahati Refinery are LPG, Light gasoline(LG), Heavy Gasoline(HG), Kero-I, Kero-II, Gas oil & Reduced Crude oil(RCO, feed to DCU).

COMPOSITION OF CRUDE OIL

Petroleum or crude oil is combustible oily liquid reddish brown or sometimes black color produced from oil wells. It is a complex mixture of various hydrocarbons and their derivatives containing sulphur, nitrogen, oxygen, metals etc. Crude oil contains 82-87% carbon, 11-15% hydrogen, and oxygen, nitrogen and other metals (Ni, V etc.) constitute the remaining. It is practically impossible to determine exactly the composition of a particular grade of petroleum, so petroleum isanalyzedusually to ascertain their group composition.

Main Constituents of Petroleum Hydrocarbons:1. Paraffinic hydrocarbons (alkanes) 2. Naphthenic hydro-carbons (cyclo-alkanes) 3. Benzene hydrocarbons (arenes) 4. Unsaturated hydrocarbons (olefins) 5. Oxygen containing compounds: (These includes naphthenic acids, phenols and tarasphaltene compounds) 6. Sulphur compounds (vary from traces to 8%)

7. Nitrogen compounds (vary from traces to 1%) 8. Mineral substances.

NEED FOR DESALTING

Crude oil carries a varying amount of water and salts (brine) mostly sodium, calcium, magnesium, potassium and iron salts. This brine is associated with crude oil both as a fine suspension of droplets and also as a more permanent emulsion. The less stable mixture can be separated by simple setting methods. The impurities in crude oil can be classified as a) oleophilic b) oleo phobic as under These impurities, if not separated from crude oil, will lead to 1. Equipment corrosion in the atmospheric distillation unit caused by HCl, which is liberated due to hydrolysis or dissociation of chloride salts. 2. Increased consumptions of ammonia to neutralize HCl. 3. Erosion of crude oil pumps, pipelines and valves by suspended matter through abrasive 1. 4. Plugging of equipments and fouling of heat transfer surfaces. 5. Product degradation like high ash content in fuel oil. 6. Trace metals in distillates which act as catalyst poisons.

MAIN PROCESS OUTLINES

1. The crude oil that is taken from the Upper Assam oil is pumped through various heat exchangers for heating the low temperature oil. 2. Then the crude oil is sent to desalter to remove the brine from the oil. In the desalter, demulsifier mixed crude I mixed with hot water through a

mixing valve. Thus the salt in crude dissolves in water and separated from the oil. The remaining salted water droplets in oil are removed in presence of electric field. The effluent water preheats the incoming wash water in E-101 before being sent to the desalter wash water vessel. 3. The crude from the desalter is pumped and divided equally into two streams for further pre-heating before entering the pre-topping column (CL1). 4. The preheated crude then enters the pre-topping column (CL-1) flash zone through a flash gallery distributor that separates the vapor and liquid. The purpose of this column is to remove the SR light gasoline (IBP to 110 degree Celsius cut point on TBP) from overhead and reduce the load on crude columnCL-2. 5. The trapped crude from CL-1 bottoms is pumped to exchanger in series, where it is heated by SR gas oil circulating reflux (SRGO CR). It then passes to S-21 where it is heated by reduced crude oil (RCO) to about 246 degree Celsius. At these temperatures pre-topped crude enters atmospheric furnace (C-1A). The purpose of theatmospheric furnace is to provide the heat of vaporisation of hydrocarbons lighter than RCO in the pretopped crude for fractionation in column CL-2. 6. Partially vaporised crude from furnace outlet is then routed to the flash zone of the main fractionating column (CL-2) at a temperature of 360 degree Celsius and pressure of 0.6kg/cm^2g. The purpose of these column is toseparate the pre-flashed crude into saleable products by distillation. From the extreme top of the column-2 SR heavy gasoline is extracted. 7. The first side draw from the top section of CK-2 IS SR KERO-I, which passes on level control of CL-3A to stripper to stripper 3L-CA.The second draw from the min fractionating column is un-stripped SR-KERO-II, which is routed through a level control valve to stripper CL-3B.The third side is unstripped straight run gas oil (SRGO), which is routed through a level control valve to stripper CL-3C. 8. The liquid portion of flashed feed from atmosphere furnace (C-1A) enters the bottom section of CL-2 along within over flash and is stream stripped. The Reduced Crude Oil (RCO) from the bottom of column-2 is pumped through various heat exchangers to Rundown tanks.

DELAYED COKING UNIT(DCU)

The delayed coking unit of Bongaigaon refinery is the first delayed Coker of IOCL, commissioned in 1962 with Rumanian technical assistance with initial capacity 0.33 MMTPA, which was revamped to 0.44 MMTPA in Sept. 2000. Delayed coking unit is a secondary processing unit which is designed and installed to process the low value heavy stock to upgrade it to more valuable lighter and middle distillates with petroleum coke as one of the products. The feed to be processed in the unit is Reduced Crude oil (RCO) obtained from the bottom of the main fractionating column ofthe Crude Distillation Unit

(CDU) and process is Thermal Cracking. DCU can process feed withhigh metal asphaltene and resin content and in DCU, metals, sulphur,
nitrogen normally end up in coke.

The unit is called Delayed coking unit as he process envisages production of coke by allowing high resistance time (24 hr) for liquid phase cracking in the reaction chamber operated in alternated days with a gap of 24 hours.

THEORY OF COKING
During processing of crude oil in CDU, hydrocarbon fractions of different boiling ranges are separated out. These fractions are LPG, gasoline, kerosene, gas oil and reduced crude obtained from the fractionating column of distillation unit. The heavier hydrocarbon fraction, obtained as reduced crude oil (also called long residue) at the bottom of the fractionating column is of less value. It is therefore required to subject the heavier hydrocarbons (reduced crude) to still higher temperature (around 495 degree Celsius)to crack the heavier ends for producing lighter ends. At this temperature, the larger hydrocarbon molecules of high boiling ranges are thermally decomposed to smaller low boiling molecules thereby producing lower boiling light and middle distillates such as gas, gasoline, kerosene, and gas oil at the same time. Some of the molecules which are reactive combine with one another giving even larger molecules than those present in original stock forming residual fuel oil and petroleum coke. The phenomena of the process under which above changes

in molecular structure of the hydrocarbons take place is known as Thermal Cracking or more precisely coking. The coking process therefore involves two types of reactions:1. Primary reaction 2. Secondary reactions.

PRIMARY REACTIONS
In these reactions the heavier hydrocarbon molecules decompose into smaller ones. This reaction is known as Cracking.

SECONDARY REACTIONS
In these reactions the smaller reactive molecules combine with one another to produce heavy tarry metals. This reaction is called polymerization. Polymerization of heavier reactive molecules takes place in reaction chambers forming coke in an alternate production time of 24 hours. The coke chamber provides residence time of 24 hour for the cracking and polymerization reaction to take place. For this lengthening of the time of liquid phase cracking and polymerisation, the whole process of cracking is known delayed coking. The two types of chemical reactions that take place during the thermal cracking operation may be represented by chemical reactions as shown:-

DECOMPOSITION OF HEAVIER MOLECULES CH3.CH2.CH2.CH3= CH4 + CH3.CH=CH2 N-BUTANE METHANE PROPENE CH3.CH2.CH2.CH3= CH3.CH3 + CH2.CH2 N-BUTANE ETHANE ETHYLENE
At high temperature the first of these appears to precede the extent of about 55% and the second to 45%. Dehydrogenation reaction as given below appears to represent less than 5% of the total. The tendency of dehydrogenate, leaving an olefin with the same number of carbonatoms as the original paraffin hydrocarbon rapidly diminishes as the series ascends. Thus the production of a large amount of hydrogen by cracking gas and stock should be expected.

CAPACITY OF DCU
Delayed coking unit commissioned in 1962 with the processing capacity of 0.33 MMTPA of RCO. Delayed coking unit revamp in Sept. 2000 to a capacity of 0.44 MMTPA of RCO.

PROCESS DESCRIPTION
The section describes the process of Delayed Coker unit of IOCL, Guwahati refinery. The process consists of the following main steps:1. Pumping and pre-heating of RCO feed. 2. Introduction of RCO feed to main fractionations (003-CL-02) control of bottom temp. 3. Introduction of fractionations bottom into heater and cracking. 4. Cracking to coke and distillates. 5. Removal of RFO. 6. Fractionation. 7. Withdrawal of side-cuts. 8. Cooling of SR 9. Coke chamber operations.

An overview on the machines available in the machine shop LatheIt is the most popular turning tool found in any workshop. Size of the lathe is specified by the swing diameter and the distance between centers; m/c tool feeds and speeds are designed in geometrical progression. The carriage of lathe may be fed along the bed by means of a lead screw for thread cutting

through a feed rod driving through a friction clutch in apron for general turning and facing operations. The lead screw is driven positively by a train of gears from the spindle. A number of attachments (contour facing, taper turning, boring) can be attached to increase utility of lathes.

Boring machineIt may be horizontal or vertical type. Horizontal boring machine is used for work not conveniently revolved for milling, slotting, drilling, tapping, boring etc. without the use of jigs and fixtures. Vertical boring mills are used for wide range of plate work that can be revolved. Work is fastened to horizontal table representing a four jaw independent chuck with extra radical T-slots.

Drilling machineThey are used for drilling holes, tapping; counter boring, reaming and general boring operations. Vertical drilling machines are designated by the diameter of the largest circle that can be drilled at its center. The size of the radial drill is designated by the length of the arm, representing the radius of the piece which can be drilled in the middle. Commonly used tool, twist drill is made in many sizes and length.

Milling machineThese use multiple teeth cutters. Milling cutters are made in a wide variety of shapes and sizes. These are broadly classified as profile cutters and formed cutters. Various types of milling machines are column and knee type, vertical and horizontal, fixed bed, rotary, drum, planetary, planer type etc. chip space should be large enough to permit a reassemble number of sharpening of the cutters and be or formed that chips may curl without heating the cutter.

Shapers machineThese are used for miscellaneous planning surfacing notching key seating and production of flat surfaces. The tool is held in a holder supported on the clapper on the end of the ram which in a holder supported on a clapper on the

end of the ram which is reciprocated in a straight line. A table carrying the vice and the work feeds transversely on each return stroke. In vertical shapes or slotter, the ram reciprocates vertically.

Grinding machineIt uses grinding wheels by fixing abrasive particles in a binder which is usually hardened be baking. Various types of grinding machines are surface grinders, center less grinders, universal grinders etc. various variants influencing type of grinding wheels are type of abrasive (A1203 and SIC), grain size or grin size, grade of hardness and type of bond. A1203 is used for grinding materials of high tensile strength. It is fast and free cutting and can be used for heavy speed on high speed steel and alloy steel. SIC is used for grinding materials of low tensile strength. Coarse grain is used for removal of stock and for ductile materials and fine grain for fine finish and hard dense and brittle materials. For short contact, wheel should be hard. Higher the work speed with relation to wheel speed, the harder the grade should be. Higher wheels are also used with machines in poor condition. Wheels subjected to bending strains should be made by the shellac, resinoid or rubber process. For rapid cutting, vitrified bond is used. The wheel should be supported on the spindle with a as close a fir as possible for safety reasons. The wheel should be sharp i.e. present newly fractured crystals to the face to act as cutting tools and for this it is trued from time to time. Grinding wheels have characteristics influenced by1. Type abrasive 2. Grain size 3. Grade 4. Structure 5. Type of bond

Rotary SectionPUMPIntroductionAlmost all rotating equipments pump is one which is most extensively and most widely used in all sorts of industries. Pump is the machine that lifts liquids, moves them from place to place pressurizes them for a number of useful tasks. ClassificationsPumps may be classified on the basis of the application they serve, the materials from which they are constructed, the liquids they handle and even their orientation in space. Pumps are basically of three types1. Reciprocating 2. Rotary 3. Centrifugal Centrifugal pumpsA centrifugal pump consists of a set of rotating vanes, enclosed with a housing of casing and is used to impart energy to a fluid through centrifugal force. In a centrifugal pump liquid is forced by atmospheric or other pressure into a set of rotating vanes, these vane constitute an impeller which discharge the liquid at its periphery at a higher velocity, the velocity is converted into pressure energy by means of a volute or by set of stationary diffuser vanes, surrounding the impeller periphery, pumps with those volute casing are generally called volute pumps while those with diffuser are called diffuser pumps.

Running clearance in pumpSuitable running clearances are maintained while manufacturing a pump to initial desired performance of the pump with the operation of the pump these clearance increases due to wear; leakage losses increase and the pump performance falls. It is considered good practice to replace or repair wear parts when the nominal clearance has doubled while establishing running clearance between rings and other moving parts, consideration should be given to pumping temperature, suction conditions, characteristics of the material etc. clearance should be sufficient to assure dependability of operation and freedom from seizure under operating conditions. For cast iron, bronze, hardened 11-13% chromium steel and materials of similar low galling tendencies, the clearances are different for each other.

Mode of operation of pumpThe fluid flows through the suction casing towards the impeller at a given pressure. Energy is transmitted to the fluid by the impeller, which is fitted with vanes. From the impeller, the fluid flows into the diffuser, where kinetic energy is converted into potential energy, increasing the pressure rise still further. The generated pressure creates an axial thrust on the pump rotor of the single and multistage centrifugal pumps. By the provision of narrow throttling gaps between the impeller necks and the casing wearing rings at either side of each impeller, equal size lateral impeller spaces, and therefore almost identical pressure conditions are created at the suction and discharge ends of each impeller. The balance holes in the discharge side impeller checks ensures a compensation of pressures between the suction and discharge sides of the impellers in the region situated between the impeller hub and the throttling gap, thus again preventing the creation of any appreciable axial thrust in this region of the impeller. Any residual axial thrust is absorbed by the fixed bearing in the discharge end bearing housing. The power absorbed by the pump does not decrease proportionately with decreasing rate of flow, remains relatively high at the pump shutoff point (capacity Q=0). This absorbed power is almost wholly converted into heat inside the pump and this heating up process can lead to rapid evaporation of the fluid inside the pump, particularly if the driving motor is powerful and the fluid pumped is hot; this happens at the pump shutoff and at very low rate of flow. In order to avoid such evaporation which might damage the pump, it is necessary to ensure a given minimum rate of flow through the pump at all times, which removes the heat generated. For this purpose, an automatic recirculation valve (combined with a non-return valve) is provided; this valve automatically opens a by-pass line when the rate of flow drops below a given preset value. If such a valve is not incorporated in the plant, the pump must not be operated below a given minimum rate of flow, nor must it be allowed to run against a closed discharge valve. If the pump handles a hot fluid or a fluid with low boiling point (highly volatile), or if it operates on suction lift, steps must be taken to ensure that the fluid at the

pump inlet nozzle has attained the pressure prescribed in the confirmation of order, in order to prevent vapors formation and the resulting damage caused by the cavitations particularly the disintegration of the first stage impeller. If the back pressure is too low, the capacity of the pump will increase unduly, and the danger than arise of overloading and overheating of the driving motor. Reciprocating pumpReciprocating pumps move the fluid using one or more oscillating pistons, plungers, or membranes (diaphragms), while valves restrict fluid motion to the desired direction. Pumps in this category range from simplex, with one cylinder, to in some cases quad (four) cylinders, or more. Many reciprocating-type pumps are duplex (two) or triplex (three) cylinder. They can be either singleacting with suction during one direction of piston motion and discharge on the other, or double-acting with suction and discharge in both directions. The pumps can be powered manually, by air or steam, or by a belt driven by an engine. This type of pump was used extensively in the 19th centuryin the early days of steam propulsionas boiler feed water pumps. Now reciprocating pumps typically pump highly viscous fluids like concrete and heavy oils, and serve in special applications that demand low flow rates against high resistance. Reciprocating hand pumps were widely used to pump water from wells. Common bicycle pumps and foot pumps for inflation use reciprocating action. These 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. Typical reciprocating pumps are:

Plungerpumps - a reciprocating plunger pushes the fluid through one or two open valves, closed by suction on the way back.

Diaphragmpumps - similar to plunger pumps, where the plunger pressurizes hydraulic oil which is used to flex a diaphragm in the pumping cylinder. Diaphragm valves are used to pump hazardous and toxic fluids. Piston displacement pumps - usually simple devices for pumping small amounts of liquid or gel manually. The common hand soap dispenser is such a pump.

Mechanical sealIf a pump is running, a great deal of leak will occur along the path between stuffing box housing and impeller because the pressure inside the impeller housing is higher than in the stuffing box. The mechanical seal is the one way to prevent this leakage.

Advantage of mechanical sealMechanical seals are preferred over soft type packing to prevent leakage because packings are forced tight against the shaft, causing wear on the shaft increased power to overcome friction. The contact area of seal faces is much less than the contact area of the packing; this reduces friction and eliminates wear on shaft and shaft sleeves. Soft packing works on the principle of the controlled leakage whereas mechanical seal tend to seal with no visible leakage. From the point of view the environment, because of the absence of visible leakage, is clean and hazard free when mechanical seals are used. Disadvantages of mechanical seal1. They are costlier. 2. The equipment requires complete dismantling for installation Seal partsA basic mechanical seal consists of two main assemblies1. Stationary part 2. Rotating part Stationary partsThe stationary part does not rotate usually and has a mating ring and some type of secondary packing like O ring gaskets etc. The stationary mating ring and the packing are fit snugly in the pump gland. Rotating partsIt clamps to the shaft. It consists of 1. Seal ring- the outer seal face 2. Spring- which holds the seal face together 3. Shell- this is a retainer for the spring 4. Set screw- to prevent leaking between the shaft and the sealing ring.

As the shaft rotates the sealing ring is hold tightly against the mating ring by action of the spring. The action seals the liquids in the wet end of the pump. It may be noted that three critical points exists in a mechanical seal assembly at which leakage may occurPacking on shaft1. Packing on gland 2. Between mating and sealing ring The leakage is eliminated by using proper packing such as elastomeric materials and by lapping mating and sealing ring faces Seal lubricationSeal faces when rubbing against each other generate heat. In order to reduce heat, wear and power loss due to the friction between the seal faces, a lubricant or coolant is used. It is sometimes pumped into the seal face itself and sometimes flushed over the faces. Fluids used for lubrication may be lubrication oil, water or fluid being pumped. Types of mechanical sealsMechanical seal may be classified in several ways of depending on how the parts are attached, where the parts are located, the way the liquid acts on the seal and the no of sealing surfaces. Another classification exists according to the location of the rotating parts of the seal. Whenever the rotating part is inside the stuffing box, in contact with the pumped liquid it is an inside seal and whenever the rotating part in outside of the stuffing box, it is an outside seal. Selection of mechanical sealNowadays, mechanical seals are widely used in various industries handling acids, alkalis and fluids at higher temperature and pressure. It is important to consider all duty parameters for selection a suitable mechanical seal.

Duly parameters for selection a mechanical seal are1. 2. 3. 4. 5. 6. Media Pressure Temperature Speed P.V factor Seal arrangement

Maintenance processesDifferent types of maintenance processes are practiced here; viz 1. Predictive maintenance 2. Preventive maintenance 3. Breakdown maintenance In predictive maintenance there is a prescribed or designed scheduled on the basis of which different machineries are checked for portable error In case of preventive maintenance different machineries are checked during running condition and the results are analyzed with the predefined patterns and signatures to check whether there is any faults or not.

One of the preventive maintenance is vibration testing of different machineries such as pumps, bearings and other rotating equipments. The apparatus used is called vibration data collector and analyzer. Thisequipments are so sophisticated that it can directly predict the bearing life to near future to avoid failure.

WeldingShielded metal arc weldingIt is manual arc welding process in which for heat for welding is generated by on arc established between a flux covered consumable electrode and the work. The electrode tip, weld puddle, arc and adjacent areas of the work piece are protected from atmospheric combination by a generous shield obtained from combustion and decomposition of the flux covering. Additional shielding is provided for molten metal in the weld puddle by a covering of molten flux (slag). Filler metal is supplied by the care of the consumable electrode and with certain electrodes from metal powder mixed with the electrode covering. This type of welding process is most widely used process due to its versatility. Moreover equipment is less complex, more portable and less costly than other welding processes.

Gas weldingIn this welding process the heating medium is air. Gas welding involves the melting of the base metal and the filler metal if used by means of flame

produced at the tip of the welding torch. The metal mixes in the common mixing pool. Properties of the gases used as fuel for welding1. The flame produced by the gas should produce high temperature near or more than that of melting temperature of the metal to be weld. 2. The rate of propagation of the flame should be high for better conduction of heat. 3. The flame should contain adequate heat. 4. There should not be or minimum chemical reaction of the flame with the base metal as well as with the filler metal. Most commonly used gas is acetylene. It contains 2.3% carbon and 7.7% hydrogen by weight. It is used because oxyacetylene flame produces the highest flame temperature than all the commonly used gases. A 1:1 mixture of oxygen and acetylene provides 5600 degree Fahrenheit approx. twice the melting temperature of steel and produce high localized heating necessary for welding. Acetylene is stored in the cylinders of high thickness. But it is not easy to store acetylene in cylinders because acetylene in cylinders because acetylene decomposes as soon as it comes in contact to air. In the cylinders to prevent the decomposition acetone is used as the filler which has capacity to absorb acetylene 25 times more than its own volume per atmosphere of pressure. To prevent explosion acetone is mixed with porous material like calcium silicate inside the cylinders. Acetylene has sweet fruity smell but inside cylinder it is something different because of the acetylene vapors present inside the cylinder.

Oxy acetylene gas weldingOne of the most widely used gas welding is oxyacetylene welding. In this welding process oxygen and acetylene is used which is indeed the fuel for welding.

Plasma arc weldingIt is an arc welding process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode and the work piece. The key difference from GTAW is that in PAW, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope. The plasma is then forced through a fine-bore copper nozzle which constricts the arc and plasma exits the orifice at high velocities and a temperature approaching 28000 degree Celsius or higher. Arc plasma is temporary state of a gas. The gas gets ionized after passage of electric current through it and it becomes a conductor of electricity. In ionized state atoms break into ve electrons and +ve ions and the system contains a mixture of ions, electrons and highly exited atoms. The degree of ionization may be between 1% and greater that 100% i.e. double and triple degrees of ionization. Such states exist as more number of electrons is pulled from their orbits. The energy of the plasma jet and thus the temperature is dependent upon the electrical power employed to create arc plasma. A typical value of temperature obtained in a plasma jet torch may be of the order of 5000 degree Fahrenheit against about 10000 degree Fahrenheit in ordinary electric welding arc. Actually all welding arcs are plasmas but, the one in plasma arc welding is constricted arc plasma.

ValvesINTRODUCTIONIn process operations, fluids and their movement and transfer from place to place, plays a large part in the process. Fluids are contained in various types of vessels and are transported in pipelines. In order to start or stop fluid flow, to control flow and to prevent back flow, various types of valves are installed in the piping. To prevent over pressure in piping and vessels, we use safety relief valves and, to isolate equipment for maintenance etc., block valves are installed.

Where fluids contain suspended solids-scale, dirts etc. which must be removed, filters and strainers of various types are installed. In steam systems, steam condensate, is a particular problem which can cause water-hammer in piping and equipment. To minimize this problem, the water must be drained from the steam lines. This is sometime accomplished by regularly blowing down- form the system. Generally, steam systems are fitted with automatic drainage mechanisms called steam-traps . Uses1. 2. 3. 4. To start and stop the flow of fluids. To regulate, throttle and control fluid flow or pressure. To prevent back-flow To relieve excess pressure/vacuum

Types of valves1. Gate valve- this is the most common type of valve in use in industry and is used to start or stop the flow of fluids. It gives a positive shut-off when closed and is often used as a BLOCK VALVE for isolating systems The gate valve may be of the RISING STEM type or a NON-RISING STEM in which the stem threads are left-hand threads set into the gate itself. The valve consists of a body which houses the valve mechanism- the stem (or spindle), the disc(s) (or gate), and the disc and body seats. Gate valves can be operated by a hand-wheel, an electric motor (MOV), or by an air diaphragm, or motor, or a piston actuator.

2. Globe valve- the globe valve is used where control of fluid flow or pressure is required and it can be operated in any position between open and closed. A globe valve may be constructed with a single or double port and plug arrangement. The double port type is generally used in a CONTROL VALVE where accurate control of fluid is required. Due to the double valve plug arrangement, the internal pressure acts on each plug in opposition to each other, giving an internal pressure balance across the plugs. This gives a much smoother operation of the valve and better control of the process. Some control valves are REVERSE ACTING. Where a valve normally opens when the plug rises, in the reverse acting valve, the valve closes on rising. The operation of the valve depends on process requirements. Also depending on requirements, a control valve may be set to open or close, on air failure to the diaphragm.

3. Needle valve- this is simply a variation of the globe valve and as its name implies consists of a narrow, tapered plug and port arrangement. The needle valve is, in itself, small in size and is used for very fine and normally manual, control of fluid flow. 4. Angle valve- another variation of the globe valve which is often used for compressor recycles systems. It is also often used for dirty fluids. In this valve, the fluid flow enters from below the plug and passes through an angle of 90 degrees to the outlet. An angle valve may be manually or automatically controlled.

5. Plug or ball valve- these valves give a more streamline flow in their operation. The valve port is about the same size as the internal pipe diameter. They are operated simply by turning a handle through 90 degrees. They can give a family tight shut-off and some degrees of control. 6. Butterfly valve- it is designed to give full flow with some control capability. Normally, this type of valve does not give positive shut-off but, present-day technology, using new polymers and higher temperature ratings, has enabled the construction of butterfly valves having a bubble-tight shut-off. 7. Check or Non-return valve- these valves will allow fluid flow in one direction only. Their pressure is to prevent backflow- for example in pump discharge lines and where back-flow is undesirable. When flow stops, the weight of the piston, ball or flapper closes the valve. If the pressure downstream of the valve is higher than the upstreamside, the valve will close firmly and back-flow cannot occur. Types1. LIFT type. (spring loaded BALL & PISTON types) 2. SWING type. (or flapper type) 8. Safety valve- these are installed on equipment to prevent over-pressure (or exercise vacuum), which could cause damage, rupture or collapse of the equipment. Where the type installed is to prevent excess vacuum, they are normally referred to as Vacuum Breakers. A safety valve will have a lifting set pressure higher (about 1.5 times) than the operating pressure of the system but well below the design maximum pressure is allowed. In the conventional type, the pressure of the valve discharge line will affect the set pressure of the valve by giving a back-pressure and therefore there is no effect on the valve setting.

Auto gears and gear lubricantsGears are the mechanical devices to transmit power or turning effect, from one shaft to another. Gears contain teeth that interlace or mesh, as the gears turn. Generally there is set pattern of relative speeds at which two driving gears-driving gear and driven gear or shafts turn. There is also set pattern of gear ratio, which denotes number of revolutions made by a driving gear as compared to number of revolutions made by a driven gear, normally of different size. There are many types of gears employed in automotive applications.

Types of gears1. Spur gears. 2. Helical gears 3. Bevel gears 4. Herring bone gears 5. Spiral gears 6. Hypoid gears 7. Worm gears 1. Spur gears- these are perhaps the simplest types of gears used in automotive and industrial applications. Spur gears are used to transmit power between parallel shafts, when the shafts are reasonably close together and when a constant velocity ratio is needed. They have straight cut teeth on a cylindrical axis, each tooth being parallel to the axis of rotation. Spur gears are generally employed, when operating speeds and loads are light to moderate. In automotive design, spur gears are commonly used for manual transmission and for transmitting torque from the starter motor to the engine fly wheel.

2. Helical gears- helical gears are a more complex variation of spur gears. As with spur gears, helical gears are also used to transmit rotary motion on parallel shafts. Unlike in spur gears, the gear teeth in helical gears are cut at an angle to the shaft axis. This gear geometry provides greater strength and smoother engagement. Helical gears by design provide a gradual transfer of load from tooth to tooth and this reduces the shock load to individual teeth. This feature of helical gear sets permits operation of higher peripheral speeds and quieter and smoother operation as compared to spur gears. Helical gear can be external, rack and pinion or internal in the same manner as spur gears.

3. Herring bone gears- the design of single set of helical gears results in an axial thrust on the gear shafts. Hence of necessity, bearing surfaces are designed into components using single helical gears to absorb the axial thrust problems, herring bone or double helical gears are made use of. These gears have all advantages of helical gears. They have two

sets of helices of opposite hands or mirror images and aligned in such a way, so that the end thrusts are compensated.

4. Bevel gears- these are most commonly used to connect non-parallel shafts which may be either intersecting or non-intersecting. The surfaces on which bevel gear teeth are cut are essentially truncated cones. While gears of this type may be used with shaft of any included angle, the most common angle is 90 degrees. Straight tooth bevel gears are used commonly in automotive axles to provide differential action i.e. in automotive differential assembly.

5. Hypoid gears- these are similar to spiral bevel gears, but they differ in design slightly from each other. In spiral bevel gears, the pinion shaft is in line with the center of the ring gear. But in case of hypoid gear, the pinion shaft is below the Centre of the ring gear.

6. Spiral bevel gears- spiral bevel gears are to straight tooth bevel gears are to spur gears. Spiral bevel gears provide smoother tooth engagement, quieter operation, greater strength and higher allowable speeds.

7. Worm gears- it is an extreme example of a hypoid gear set with maximum possible offset. The worm shaft resembles a screw. The gear or wheel is special type of helical gear designed to develop as much of the worm as possible.

BIBLIOGRAPHYBOOKS AND JOURNALS: 1. Manual for mechanical maintenance. Source: Bongaigaon refinery 2. Power plant engineering- P.K.Nag 3. Welding handbook. Source: Bongaigaon refinery References: 1. http://en.wikipedia.org/wiki/total productive maintenance 2. http://www.cheresources.com/centrifugalpumps11.gif 3. http://www.auadevice.com/english/images/J mecha-section.gif 4. http://www.cubiccapacity.com/wp-content/uploads/2008/04/garrett airesearch t3 turbocharger.thumbnail.jpg 5. Interaction with the employees of IOCL.