Industrial Training 2012

7/31/2019 Industrial Training 2012

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Presented by:Amar Karam Chandani(091405)Ankit Shrivastava(091407)Himanshu Jha(091411)Aman Chaturvedi(091440)


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Cost estimation is a specialised subject and aprofession in its own right. The design Engineer,however, needs to be able to make quick, rough, costestimates to decide between alternative designs and

for project evaluation. Chemical plants are built tomake a profit, and an estimate of the investmentrequired and the cost of production are needed beforethe profitability of a project can be assessed.


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ESTIMATION AT IOCL

Preliminary cost estimate at IOCL is done manually using excel,where all the data is fed into the excel sheet and a X-Y scatterplot is generated then all the points which are distorting thecurve heavily are neglected as they will decrease the accuracy ofthe estimation. After generation of the plot a equation isobtained on excel and the preliminary new cost is estimatedusing the obtained equation. To this cost various factors areadded and the final cost is obtained.

Problems with approach are following: -Arranging the massive amount of data present is a tedious job.Huge input of time is required.Wastage of valuable time is there and if the cost is requiredimmediately it will mean a lot of work.


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Working steps of the program are following: -Takes input data from the user like size of heat exchanger, tagnumber etc.Then the program connects to the database and searches for allavailable data points.After obtaining the required data like base cost, base area.Then using the six tenth formulae it does capacity correctionand brings all the data into the required area.Then upgrades it to current time by using CEPCI index.The obtained cost is then multiplied with factors to take intoaccount MOC.


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Bharat Oman Refineries has set up 6 million tonne per annumcapacity grass root refinery at Bina, Madhya Pradesh. It is dividedinto 3 major facilities as given below:

Crude Import and Handling facilityCrude transfer and receiving facility through crosscountrypipelines and terminals

Refining and related facilities.

A 935 km pipeline from dispatch terminal of COT Vadinar, Gujaratbrings crude to the Receipt Terminal at Bina.


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1.Primary Processing facilities:Crude Distillation Unit(CDU)

Vacuum Distillation Unit(VDU)

2. Secondary Processing Facilities.Motor Spirit Block(MSB)

Hydrocracker Unit(HCU)

Delayed Coker Unit(DCU)

3. Treating Units:

LPG Treating unit

ATF Merox

Diesel Hydrotreater


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4.Sulphur Recovery Block(SRB)5.Hydrogen Generation Unit(HGU)

6.Captive Power Plant(CPP)

7.Utilities systems:Raw Water intake system

Raw water treatment plant

Cooling Tower and Cooling water treatment plantReverse Osmosis based Demineralization (RODM)

Nitrogen plant and Effluent Water TreatmentPlant(ETP)


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Fuel GasLiquefied Petroleum Gas(LPG)

Naphtha

Euro III Motor Spirit (MS)

Euro IV Motor Spirit (MS)

Aviation Turbine Fuel(ATF)

Euro III HSD

Euro IV HSDSulphur

Pet Coke


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The Delayed Coker Unit (DCU) is designed to process1,360,000 MT of Vacuum Residue based on Arab MixCrude

This Unit is based on CB&I Lummus technology.

Delayed Coking Process is a thermal cracking processfor upgrading heavy petroleum residues into lightergaseous & liquid products and solid Coke .

The thermal cracking reaction starts in heater coils and

provided residence time or Delayed for an extendedperiod in the Coke Drum for Polymerisation andCracking reactions to take place


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For heating feed from 170oC to 200oC,we require a Shell & Tube Heat

Exchanger of overall heat transfer areaof 1.77 m2


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Coker gas

LPG

Coker Naphtha (C5-140C)

Light Coker Gas Oil(140C-370C)

Heavy Coker Gas Oil(370C plus)

Coker Fuel Oil

Pet Coke


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DELAYED COKER

UNIT (1.36

MMTPA)

Vacuum

Residue fromCDU/VDU or

Storage Tanks

Coker Gas

LPG (CDU)

Coker Naphtha

(HCU/DHT)

Light Coker Gas Oil

(HCU/DHT)

Heavy Coker Gas Oil

(HCU/DHT)

Pet Coke to CPP


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DCU HEATER(14-FF-00-101 A/B) CONFIGURATIONBalanced Draft, Twin Cell, Cabin Type,Horizontal Tubes Double Fired.

Heat Absorption :- 17.2 MMKcal/HrNo of Tubes in Radiation Zone:- Total-64 (32 /Cell)

No of Tubes in Convection Zone:-56

No of Soot Blowers:-16/heater

No of Burners:-32/heater


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The following measurements are to be made fordoing the energy balance in oil fired reheatingfurnaces (e.g. Heating Furnace)

i) Weight of stock / Number of billets heated

ii) Temperature of furnace walls, roof etc

iii) Flue gas temperature

iv) Flue gas analysis

v) Fuel Oil consumption


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USING APPROXIMATE METHOD:1.) WITH AIR PREHEATER: 89.55%

2.) WITHOUT AIR PREHEATER: 82.05%

B.)USING INDIRECT METHOD:

1.) SENSIBLE HEAT LOSS DUE TO FLUE GAS: 6.45%

2.)LOSSES DUE TO SKIN TEMPERATURE AND RADIATION: 3.01%OVERALL EFFICIENCY OF THE FURNACE: 90.5251%


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KCFL began its operation in 1987 at Nimrani near Indore, WestMadhya Pradesh and has earned cash profits each and everyyear, since its inception, even though SSP Industry has gonethrough tumultuous times. Today KCFL has earned the

distinction of being the largest manufacturer ofSSP in IndiaSSP manufactured and sold by Khaitan Chemicals & FertilizersLimited under the brand name "Khaitan Khad is amongst themost sought after brands in Western Madhya Pradesh andsurrounding areas. Being a straight fertilizer with easy

application, low cost per bag and unique 12% sulphur contentmakes it very popular with the farmers. It is extensively used incrops like Oil Seeds, Groundnut, Potato etc. SSP is alsomanufactured in granulated form called GSSP


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The Wet Gas compressor is a steam turbinedriven, 2-stage centrifugal compressor withvertically split casing supplied by M/s BHEL,Hyderabad.

The wet gas compressor boosts the pressure ofCoker fractionator column overhead receivergas from 1.13 Kg/cm2 and is delivered to the

absorber at a pressure of 15.92 Kg/cm2

. Thefunction of the Wet Gas Compressor is tocompress Coker Fractionator overhead gases toa higher pressure for enhancing C3, C4 recovery.


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The major components of WGC are:1. Casing

2. Diaphragm

3. Rotor4. Balancing Drum

5. Bearings

6. Internal Seal


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n/(n-1) = EFp. k/(k-1)0.695 x 1.4 /(1.4-1) = 2.432


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With number of impeller = 8 and 2 dimShrouded impeller, uncorrected efficiency =0.72

Corrected efficiency become

EFp = 0.72 x Co = 0.72 x 0.915 = 0.66 or 66% .


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Industrial Training 2012

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