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Indian Oil Corporation Limited Mathura Ppt.pptx Ashu 11

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    Contd. Thermal Power Station (T.P.S)

    Demineralization Plant

    Boiler

    Steam Turbine

    Gas Turbine Generator

    Cooling Towers

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    UNIT PROFILE Indian Oil Corporation Limited (Indian Oil) is the largest commercial

    enterprise in India with a sales turnover of Rs.150, 677 crores and profit of

    Rs.4, 891 crores for the fiscal year 2004.

    Indian Oil is Indiasnumber one company in Fortunesprestigious listing

    of the worlds 500 largest corporations, ranked 170 based on fiscal 2004

    performance. It is also the 18th largest petroleum company in the world and

    adjudged number one in petroleum trading among the 15 national oil

    companies in the Asia-Pacific region.

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    Contd. Mathura Refinery,commissioned in 1982, current rated capacity of

    8.0 MMTPA crude processing, is meeting the product demand of

    Northwest region of the country including the National Capital

    Delhi. The Refinery processes low sulphur crude from BombayHigh, imported low sulphur crude from Nigeria, and high sulphur

    crude from Middle East Countries. In the original refinery

    configuration, there was one primary Atmospheric Vacuum unit

    coupled with Vis-breaker Unit, Fluidized Catalytic Cracking Unit,

    Bitumen unit and Sulphur Recovery unit as secondary units.

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    ENERGY CONSUMPTION Mathura Refinery consumes various types of fuels viz. Natural gas, R-LNG,

    refinery fuel gas and low Sulphur internal fuel oil (IFO) in furnaces /

    boilers. Natural gas, which is about 50% of total fuel consumed at MR issupplied by M/s GAIL whereas all others fuels are generated in the refinery

    itself. The IFO is fired as alternate fuel in old furnaces only.

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    PRODUCTS Liquefied Petroleum Gasfor domestic use

    Naphthafor fertilizer as feed

    Aviation Turbine FuelFor Civil and Defense aviation purposes

    Superior Kerosene OilFor domestic purposes

    High Speed Diesel Oil - For Transportation

    Furnace Oil and Heavy Petroleum Stock

    Petroleum

    Light Diesel OilFor agro equipments

    BitumenFor road paving PropyleneFor high polymers

    SulphurFor chemical industries

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    UNITS OLD UNIT-

    Old unit is further divided into various subunits:

    AVU(Atmospheric Vacuum Unit):

    The ADU (Atmospheric Distillation Unit) separates most of the lighter endproducts such as gas, gasoline, naphtha, kerosene, and gas oil from the

    crude oil. The bottoms of the ADU are then sent to the VDU (Vacuum

    Distillation Unit).

    Crude oil is preheated by the bottoms feed exchanger, further preheated and

    partially vaporized in the feed furnace and passed into the atmospheric towe This tower contains 20 fractionation trays, is equipped with one top pump

    around, an overhead reflux system, and three side strippers (for naphtha,

    kerosene, and gas oil products).

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    CCRU(Controlled Catalytic Regeneration Unit):

    Catalytic reforming is a chemical process used to convert petroleum refinery

    naphthas, typically having low octane ratings, into high-octane liquid

    products called reformates which are components of high-octane gasoline(also known as petrol).

    FCC(Fluidized Catalytic Cracking):

    It is the most important conversion process used in petroleumrefineries. It is widely used to convert the high-boiling, high-molecular

    weight hydrocarbon fractions of petroleum crude oils to more valuablegasoline, olefin gases and other products.

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    NEW UNITS The New Unit includes:

    OHCU(Once Through Hydrocracker Unit):

    DHDT DHDS

    HGU(Hydrogen Generation Unit)

    NHGU(New Hydrogen Generation Unit)

    PRIME-G (This unit is recently installed in Mathura refinery plant toprovide Euro4 products. It removes Sulphur from 300 ppm to 50 ppm

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    MECHANICAL WORKSHOP

    In mechanical workshop we saw the following sections

    Machine Shop

    Pump and Valve Section

    Gaskets and Grease

    Machine Shop

    In machine section we saw the various types of machines on whichoperations like threading, turning, facing, boring, drilling, etc. were being

    performed by using these machines. In machine shop all the lathes werecentre lathes. Various machines in workshop were

    Machines Name Quantity

    Lathe 8

    Boring Machine 1

    Shaper 1

    Milling 1

    Drill 3

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    Pumps

    The function of pump is to convert mechanical energy in to hydraulic

    energy. So they are used to transfer fluid from one place to another. In

    Mathura Refinery mainly two types of pumps are used

    Centrifugal Pump

    Reciprocating Pump

    Centrifugal Pumps are of two types

    Vertical

    Horizontal

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    Centrifugal Pumps -Centrifugal Pumps are used where higher head and low

    discharge is required. Centrifugal pump works on the principle of centrifugal

    force acting on the liquid. Head (pressure) is controlled is controlled by RPM,

    impeller diameter and flow rate.

    Multistage Pumps - If a larger head is required more no. of impellersare to be fitted in series so that the discharge from first impeller isguided to the inlet of second impeller. This is repeated with thirdimpeller and so on until the required head is reached. Each impeller willincrease the pressure by the same amount; a pump of this type is called amultistage pump.

    A typical boiler feed may have six to eight stages

    All the impellers are keyed to the same shaft and usually all the impellersand diffusers of the one pump are identical.

    This has the advantage of reducing the labour in manufacturing andstocking spares of maintenance.

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    Oil Seal Oil seal is used to prevent the leakage of lube oil. Bearing Two types of bearings are used Axial Bearing Which take the load along the axis of the shaft.

    Radial Bearing Which take the load acting perpendicular to theload of the shaft.

    Suction Pipe Its one end connected to outlet of pump andother end delivers the water at required height.

    Generally following types of faults are found out after the certainworking hours of pump

    Bearing Damage Damage of mechanical seal Damage of oil seal

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    THERMAL POWER PLANT Mathura Refinery has its own captive thermal power station supplied and

    erected by M/s BHEL (Bharat Heavy Electricals Limited) to meet the

    electricity requirements of Mathura Refinery as well as the township.

    There are three Boilers, three Steam Turbine Generators (S.T.G.) as wellas three Gas Turbine Generators (G.T.G.) and three Heat RecoverySteam Generators (H.R.S.G.) set as T.P.S. Normally one Steam TurbineGenerator and three Gas Turbine Generator are in service with oneboiler out of three to provide steam to them. Rest of the remaining unitstays on standby. Each boiler is capable of generating steam at a rate of150 TPH (Tonnes Per Hour) at a pressure of 64 kg/cm and temperatureof 450. Each STG is capable of generating a electric power of 12.5 MW

    with regulated steam of 0 to 105 TPH to meet

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    the process requirement in the refinery. Each GTG is capable ofgenerating an electric power of 20 MW. Nowadays not only the

    boilers but the HRGS also used to generate the steam with the helpof Gas turbine exhaust as heat source and supplementary firing (Ifneeded).

    Objectives of the Thermal Power Station

    Uninterrupted power, steam, feed water & DM water to units.

    Optimization of resources & efficiency improvement. Ensure reliability and quality of services.

    Safe practice of operations.

    Environmental safety.

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    COOLING TOWER The steam in the LP Side of the Turbine is collected in the condenser

    and has to be condensed and is re-used as a feed in the boiler. Thecooling media used for exchange of heat is water and to economize onthe use of water, water is re-circulated through a cooling tower.

    There are many types of cooling towers, the more common being theone with the induced draft cross- flow method. The scheme ofoperation is that hot water from the condenser is sprayed across thelatticed work in a rectangular cell and an induced draft fan is mountedat top of each Call. The draft fan induces a draft current from the celltowards the atmosphere and in the process carried away the water

    vapors. The cooled water collects in the sump and is again pumped intothe condenser to cool the steam in the condenser.

    These types of cooling towers are more efficient, economic in operationand occupy minimum space.

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    THANKYOU


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