Submitted BY: Submitted TO:

VINEET KUMAR GUPTA Mr.VK DWIVEDI

B.Tech. 4th Year Mr.KUWAR MAUSAM

PROJECT STUDY REPORT
On
VARIOUS MECHANICAL DEVICES

CONTENTS
Introduction -- Mathura Refinery Unit Profile
Energy Consumption
Products of Mathura Refinery
Units of Mathura refinery

Mechanical Workshop
Machine Shop
Pumps
Pressure Relief Devices
Heat Exchanger Shop


Contd.
Thermal Power Station (T.P.S)
Demineralization Plant
Boiler
Steam Turbine
Gas Turbine Generator
Cooling Towers

UNIT PROFILE
Indian Oil Corporation Limited (Indian Oil) is the largest commercial
enterprise in India with a sales turnover of Rs.150, 677 crores and profit of
Rs.4, 891 crores for the fiscal year 2004.

Indian Oil is Indias number one company in Fortunes prestigious listing
of the worlds 500 largest corporations, ranked 170 based on fiscal 2004
performance. It is also the 18
th
largest petroleum company in the world and
adjudged number one in petroleum trading among the 15 national oil
companies in the Asia-Pacific region.


Contd.
Mathura Refinery, commissioned in 1982, current rated capacity of
8.0 MMTPA crude processing, is meeting the product demand of
Northwest region of the country including the National Capital
Delhi. The Refinery processes low sulphur crude from Bombay
High, imported low sulphur crude from Nigeria, and high sulphur
crude from Middle East Countries. In the original refinery
configuration, there was one primary Atmospheric Vacuum unit
coupled with Vis-breaker Unit, Fluidized Catalytic Cracking Unit,
Bitumen unit and Sulphur Recovery unit as secondary units.
ENERGY CONSUMPTION

Mathura Refinery consumes various types of fuels viz. Natural gas, R-LNG,
refinery fuel gas and low Sulphur internal fuel oil (IFO) in furnaces /
boilers. Natural gas, which is about 50% of total fuel consumed at MR is
supplied by M/s GAIL whereas all others fuels are generated in the refinery
itself. The IFO is fired as alternate fuel in old furnaces only.

PRODUCTS

Liquefied Petroleum Gas for domestic use
Naphtha for fertilizer as feed
Aviation Turbine Fuel For Civil and Defense aviation purposes
Superior Kerosene Oil For domestic purposes
High Speed Diesel Oil - For Transportation
Furnace Oil and Heavy Petroleum Stock
Petroleum
Light Diesel Oil For agro equipments
Bitumen For road paving
Propylene For high polymers
Sulphur For chemical industries


UNITS
OLD UNIT-
Old unit is further divided into various subunits:
AVU(Atmospheric Vacuum Unit):
The ADU (Atmospheric Distillation Unit) separates most of the lighter end
products such as gas, gasoline, naphtha, kerosene, and gas oil from the
crude oil. The bottoms of the ADU are then sent to the VDU (Vacuum
Distillation Unit).
Crude oil is preheated by the bottoms feed exchanger, further preheated and
partially vaporized in the feed furnace and passed into the atmospheric towe
This tower contains 20 fractionation trays, is equipped with one top pump
around, an overhead reflux system, and three side strippers (for naphtha,
kerosene, and gas oil products).

CONTD.
The VDU (Vacuum Distillation Unit) takes the residual from the ADU
(Atmospheric Distillation Unit) and separates the heavier end products such
as vacuum gas oil, vacuum distillate, slop wax, and residue.

VBU(Viscosity Breaker Unit):

A visbreaker is a processing unit in oil refinery whose purpose is to
reduce the quantity of residual oil produced in the distillation of crude
oil and to increase the yield of more valuable middle distillates by the
refinery. A visbreaker thermally cracks large hydrocarbon molecules in
the oil by heating in a furnace to reduce its viscosity and to produce
small quantities of light hydrocarbons (LPG and gasoline). The process
name of "visbreaker" refers to the fact that the process reduces the
viscosity of the residual oil.



CCRU(Controlled Catalytic Regeneration Unit):
Catalytic reforming is a chemical process used to convert petroleum refinery
naphthas, typically having low octane ratings, into high-octane liquid
products called reformates which are components of high-octane gasoline
(also known as petrol).
FCC(Fluidized Catalytic Cracking):
It is the most important conversion process used in petroleum
refineries. It is widely used to convert the high-boiling, high-molecular
weight hydrocarbon fractions of petroleum crude oils to more valuable
gasoline, olefin gases and other products.
NEW UNITS

The New Unit includes:
OHCU(Once Through Hydrocracker Unit):
DHDT
DHDS
HGU(Hydrogen Generation Unit)
NHGU(New Hydrogen Generation Unit)
PRIME-G (This unit is recently installed in Mathura refinery plant to
provide Euro4 products. It removes Sulphur from 300 ppm to 50 ppm

MECHANICAL WORKSHOP


In mechanical workshop we saw the following sections
Machine Shop
Pump and Valve Section
Gaskets and Grease

Machine Shop
In machine section we saw the various types of machines on which
operations like threading, turning, facing, boring, drilling, etc. were being
performed by using these machines. In machine shop all the lathes were
centre lathes. Various machines in workshop were
Machines Name Quantity
Lathe 8
Boring Machine 1
Shaper 1
Milling 1
Drill 3





Pumps
The function of pump is to convert mechanical energy in to hydraulic
energy. So they are used to transfer fluid from one place to another. In
Mathura Refinery mainly two types of pumps are used

Centrifugal Pump
Reciprocating Pump

Centrifugal Pumps are of two types
Vertical
Horizontal


Centrifugal Pumps - Centrifugal Pumps are used where higher head and low
discharge is required. Centrifugal pump works on the principle of centrifugal
force acting on the liquid. Head (pressure) is controlled is controlled by RPM,
impeller diameter and flow rate.

Multistage Pumps - If a larger head is required more no. of impellers
are to be fitted in series so that the discharge from first impeller is
guided to the inlet of second impeller. This is repeated with third
impeller and so on until the required head is reached. Each impeller will
increase the pressure by the same amount; a pump of this type is called a
multistage pump.
A typical boiler feed may have six to eight stages
All the impellers are keyed to the same shaft and usually all the impellers
and diffusers of the one pump are identical.
This has the advantage of reducing the labour in manufacturing and
stocking spares of maintenance.




Main parts of circumferential pump are
Impeller
Suction Pipe
Delivery pipe
Casing
Mechanical Seal
Oil Seal
Shaft
Bearing
Bearing house

Impeller It is rotating part of centrifugal pump. It consists of series of
backward curved vanes. I is mounted on shaft which is connected to the shaft
of an electric motor.

Mechanical Seal Mechanical seal is used to prevent the leakage of product.
IT has two parts.
a ) Rotary part Which rotates with the shaft.
b) Stationary part Which does not rotate with the shaft.



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

Suction Pipe Its one end connected to outlet of pump and
other end delivers the water at required height.
Generally following types of faults are found out after the certain
working hours of pump
Bearing Damage
Damage of mechanical seal
Damage of oil seal


THERMAL POWER PLANT
Mathura Refinery has its own captive thermal power station supplied and
erected by M/s BHEL (Bharat Heavy Electricals Limited) to meet the
electricity requirements of Mathura Refinery as well as the township.

There are three Boilers, three Steam Turbine Generators (S.T.G.) as well
as three Gas Turbine Generators (G.T.G.) and three Heat Recovery
Steam Generators (H.R.S.G.) set as T.P.S. Normally one Steam Turbine
Generator and three Gas Turbine Generator are in service with one
boiler out of three to provide steam to them. Rest of the remaining unit
stays on standby. Each boiler is capable of generating steam at a rate of
150 TPH (Tonnes Per Hour) at a pressure of 64 kg/cm and temperature
of 450. Each STG is capable of generating a electric power of 12.5 MW
with regulated steam of 0 to 105 TPH to meet



the process requirement in the refinery. Each GTG is capable of
generating an electric power of 20 MW. Nowadays not only the
boilers but the HRGS also used to generate the steam with the help
of Gas turbine exhaust as heat source and supplementary firing (If
needed).

Objectives of the Thermal Power Station
Uninterrupted power, steam, feed water & DM water to units.
Optimization of resources & efficiency improvement.
Ensure reliability and quality of services.
Safe practice of operations.
Environmental safety.

COOLING TOWER
The steam in the LP Side of the Turbine is collected in the condenser
and has to be condensed and is re-used as a feed in the boiler. The
cooling media used for exchange of heat is water and to economize on
the use of water, water is re-circulated through a cooling tower.

There are many types of cooling towers, the more common being the
one with the induced draft cross- flow method. The scheme of
operation is that hot water from the condenser is sprayed across the
latticed work in a rectangular cell and an induced draft fan is mounted
at top of each Call. The draft fan induces a draft current from the cell
towards the atmosphere and in the process carried away the water
vapors. The cooled water collects in the sump and is again pumped into
the condenser to cool the steam in the condenser.

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


THANKYOU