Summer Intern Report Guwahati Refinery (Mechanical Engg.)
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About This Presentation
Summer Intern Report for mechanical Engg. department IOCL Guwahati Refinery
Slide Content
1
Summer Internship Report
(01
st
July 2023 –31
th
July)
Indian Oil Corporation Ltd.
GUWAHATI REFINERY, ASSAM
A Project on Mechanical Engineering Department
Topic: Mechanical Maintenance
Submitted By:
Neeraj Jaiswal
(Rajkiya Engineering College, Azamgarh)
Branch: Mechanical Engineering
Semester: 6th Semester
Submitted To:
Mr. ABHINAVA CHOWDHURY
MANAGER (Mechanical Maintenance)
Summer Internship Report
(01
st
July 2023 –31
th
July)
Indian Oil Corporation Ltd.
GUWAHATI REFINERY, ASSAM
A Project on Mechanical Engineering Department
Topic: Mechanical Maintenance
Submitted By:
Neeraj Jaiswal
(Rajkiya Engineering College, Azamgarh)
Branch: Mechanical Engineering
Semester: 6th Semester
Submitted To:
Mr. ABHINAVA CHOWDHURY
MANAGER (Mechanical Maintenance)
2
PREFACE
Having theoretical knowledge alone is insufficient unless it can be applied in real-
world situations. Workplace training plays a vital role in the engineering
profession as it offers new perspectives on the relevant sector and bridges the
gap between theoretical understanding and practical application. We consider
ourselves fortunate to have had the opportunity to complete a 4-weeks (30 days)
of internship with Indian Oil Corporation Limited (IOCL) in Guwahati. Our
internship experience was highly beneficial for our education, and this report
serves as a culmination of the lessons and experiences we gained during that
time. The mechanical department at Guwahati Refinery sponsored our
internship, allowing us to explore the industrial application of mechanical
engineering in the field of refining processes. We also acquired knowledge about
the various units involved in the refining process. This training served as a
stepping stone towards becoming proficient engineers and enabled us to carve
out a unique niche within this industry.
PREFACE
Having theoretical knowledge alone is insufficient unless it can be applied in real-
world situations. Workplace training plays a vital role in the engineering
profession as it offers new perspectives on the relevant sector and bridges the
gap between theoretical understanding and practical application. We consider
ourselves fortunate to have had the opportunity to complete a 4-weeks (30 days)
of internship with Indian Oil Corporation Limited (IOCL) in Guwahati. Our
internship experience was highly beneficial for our education, and this report
serves as a culmination of the lessons and experiences we gained during that
time. The mechanical department at Guwahati Refinery sponsored our
internship, allowing us to explore the industrial application of mechanical
engineering in the field of refining processes. We also acquired knowledge about
the various units involved in the refining process. This training served as a
stepping stone towards becoming proficient engineers and enabled us to carve
out a unique niche within this industry.
3
ACKNOWLEDGEMENT
The success and outcome of this project were reliant on the guidance and
support of numerous individuals, and we consider ourselves fortunate to have
received assistance throughout our entire internship. It is with the help and
supervision of these individuals that we were able to successfully complete this
project. We would like to express our deep gratitude to Indian Oil Corporation
Limited, particularly the Learning and Development Cell at Guwahati Refinery,
for providing us with the opportunity to participate in the Summer Internship
program. We are immensely grateful to our Project Guide, Mr Abhinava
Chowdhury sir who equipped us with the necessary information to complete the
project and enlightened us with extensive knowledge in the field of engineering
applications.
We also extend our gratitude to the other interns from our batch, as well as the
staff and senior members, for their guidance throughout the duration of our
project. Additionally, we would like to acknowledge the Fire and Safety
department at Guwahati Refinery, IOCL, for raising our awareness about the
various risks and potential hazards within the refinery campus and providing us
with insights on the measures to mitigate them.
ACKNOWLEDGEMENT
The success and outcome of this project were reliant on the guidance and
support of numerous individuals, and we consider ourselves fortunate to have
received assistance throughout our entire internship. It is with the help and
supervision of these individuals that we were able to successfully complete this
project. We would like to express our deep gratitude to Indian Oil Corporation
Limited, particularly the Learning and Development Cell at Guwahati Refinery,
for providing us with the opportunity to participate in the Summer Internship
program. We are immensely grateful to our Project Guide, Mr Abhinava
Chowdhury sir who equipped us with the necessary information to complete the
project and enlightened us with extensive knowledge in the field of engineering
applications.
We also extend our gratitude to the other interns from our batch, as well as the
staff and senior members, for their guidance throughout the duration of our
project. Additionally, we would like to acknowledge the Fire and Safety
department at Guwahati Refinery, IOCL, for raising our awareness about the
various risks and potential hazards within the refinery campus and providing us
with insights on the measures to mitigate them.
4
CERTIFICATE OF AUTHENTICITY
This is to certify that Neeraj Jaiswal, from the Department of Mechanical
Engineering of Rajkiya Engineering College, Azamgarh has partaken in the state-
of-the-art internship course of Indian Oil Corporation Limited (IOCL), Guwahati
Refinery, for a duration of 30 (thirty) days, under my guidance. The internee has
been meticulous in completing the assignment, and has handed it on time. The
report is not a copy of any existing document, and any references taken have
been duly credited in the Bibliography portion of the report. The report is up to
standard, and I am satisfied with the authenticity and quality of the report
submitted
Abhinava Chowdhury
Maintenance Manager (Mechanical)
Guwahati Refinery
CERTIFICATE OF AUTHENTICITY
This is to certify that Neeraj Jaiswal, from the Department of Mechanical
Engineering of Rajkiya Engineering College, Azamgarh has partaken in the state-
of-the-art internship course of Indian Oil Corporation Limited (IOCL), Guwahati
Refinery, for a duration of 30 (thirty) days, under my guidance. The internee has
been meticulous in completing the assignment, and has handed it on time. The
report is not a copy of any existing document, and any references taken have
been duly credited in the Bibliography portion of the report. The report is up to
standard, and I am satisfied with the authenticity and quality of the report
submitted
Abhinava Chowdhury
Maintenance Manager (Mechanical)
Guwahati Refinery
5
CONTENTS
SI. No. Name of content Pg No.
1. Preface 02
2. Acknowledgement 03
3. Certificate of Authenticity 04
4. Abstract 06
5. Introduction to IOCL 06-09
6. Pipelines 09-10
7. IOCL Guwahati Refinery 11-13
8. Production Unit 13-14
9. Demineralization Unit (DM Plant) 14-19
10. Delayed Coking Unit 20-23
11. Introduction to Thermal Power Station (TPS) 23-29
12. TPS Cooling Tower 30-32
13. Mechanical Equipment in Guwahati Refinery 33-53
14. Mechanical Maintenance 54-55
15. References 56
CONTENTS
SI. No. Name of content Pg No.
1. Preface 02
2. Acknowledgement 03
3. Certificate of Authenticity 04
4. Abstract 06
5. Introduction to IOCL 06-09
6. Pipelines 09-10
7. IOCL Guwahati Refinery 11-13
8. Production Unit 13-14
9. Demineralization Unit (DM Plant) 14-19
10. Delayed Coking Unit 20-23
11. Introduction to Thermal Power Station (TPS) 23-29
12. TPS Cooling Tower 30-32
13. Mechanical Equipment in Guwahati Refinery 33-53
14. Mechanical Maintenance 54-55
15. References 56
6
ABSTRACT
This report is prepared by NEERAJ JAISWAL during the internship period from
01
st
July 2023 – 30
th
July 2023 at IOCL, Noonmati, Guwahati Refinery, Assam as
a industrial training it contains a brief description of the refining process
employed in the refinery.
It mainly puts focused on the daily functions on various units and specially
focused on the Mechanical Maintenance unit. The details of each unit are
described as a part along with the physical training along with the methodology
and the procedure method taken in the refinery.
ABSTRACT
This report is prepared by NEERAJ JAISWAL during the internship period from
01
st
July 2023 – 30
th
July 2023 at IOCL, Noonmati, Guwahati Refinery, Assam as
a industrial training it contains a brief description of the refining process
employed in the refinery.
It mainly puts focused on the daily functions on various units and specially
focused on the Mechanical Maintenance unit. The details of each unit are
described as a part along with the physical training along with the methodology
and the procedure method taken in the refinery.
7
Introduction to IOCL
The word ‘petroleum’ has been derived from Latin words ‘Petro’ (meaning rock)
and ‘oleum’ (meaning oil). As petroleum is obtained from sedimentary rocks of
earth; it is also called mineral oil. Petroleum is a fossil fuel which is formed when
dead plants (like sea weeds, marine algae) and lower forms of animals (like
plankton) remain buried for several hundred years. It consists of hydrocarbons
of various molecular weights (mostly alkanes, cycloalkanes, and various aromatic
hydrocarbons), organic compounds (like oxygen, nitrogen and sulphur) and trace
amounts of metals such as iron, nickel, copper and vanadium.
Petroleum is also called crude oil which is a mixture of various components.
Crude oil cannot be used directly. It has to be separated in various fractions and
that purpose is fulfilled in a refinery. Crude is the raw material for petrol, diesel,
LPG, kerosene, etc. which are major conventional fuels used all over the world.
The process of manufacture of petroleum products consists of first drilling out
of the crude oil from various sources like sea weeds, oil wells and then the
various products are separated by the process of refining and then they are
treated in different units to maintain the norms and standards.
Introduction to IOCL
The word ‘petroleum’ has been derived from Latin words ‘Petro’ (meaning rock)
and ‘oleum’ (meaning oil). As petroleum is obtained from sedimentary rocks of
earth; it is also called mineral oil. Petroleum is a fossil fuel which is formed when
dead plants (like sea weeds, marine algae) and lower forms of animals (like
plankton) remain buried for several hundred years. It consists of hydrocarbons
of various molecular weights (mostly alkanes, cycloalkanes, and various aromatic
hydrocarbons), organic compounds (like oxygen, nitrogen and sulphur) and trace
amounts of metals such as iron, nickel, copper and vanadium.
Petroleum is also called crude oil which is a mixture of various components.
Crude oil cannot be used directly. It has to be separated in various fractions and
that purpose is fulfilled in a refinery. Crude is the raw material for petrol, diesel,
LPG, kerosene, etc. which are major conventional fuels used all over the world.
The process of manufacture of petroleum products consists of first drilling out
of the crude oil from various sources like sea weeds, oil wells and then the
various products are separated by the process of refining and then they are
treated in different units to maintain the norms and standards.
8
INDIAN OIL CORPORATION LIMITED
An oil refinery or petroleum refinery is an industrial process plant where crude
oil is transformed and refined into more useful products such as petroleum
naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, liquefied
petroleum gas, jet fuel, and fuel Oils. Petrochemicals feed stock like ethylene and
propylene can also be produced directly by cracking crude oil without the need
of using refined products of crude oil such as naphtha. Oil refineries are typically
large, sprawling industrial complexes with Extensive piping running throughout,
carrying streams of fluids between large chemical processing units, such as
distillation columns. In many ways, oil refineries use much of the technology of
and can be thought of, as types of chemical plants.
The crude oil feedstock has typically been processed by an oil production plant.
There is usually an oil depot at or near an oil refinery for the storage of incoming
crude oil feedstock as well as bulk liquid products. Petroleum refineries are very
large industrial complexes that involve many different processing units and
auxiliary facilities such as utility units and storage tanks. Each refinery has its own
unique arrangement and combination of refining processes largely determined
by the refinery location, desired products, and economic considerations. An oil
refinery is considered an essential part of the downstream side of the petroleum
industry. Indian Oil Corporation Limited, established in 1959 is India’s largest
commercial enterprise. It serves mainly India, Sri Lanka, Mauritius, and the
Middle East. The main products are fuels, lubricants and petrochemicals. Indian
Oil Corporation Limited owns ten of India’s total twentytwo refineries, which are
situated Barauni, Panipat, Mathura, Koyali, Guwahati, Haldia, Digboi,
Bongaigaon, Narimanam. As India’s flagship national oil company, Indian oil
accounts for 56% petroleum products market share, 42% refining capacity, and
67% downstream pipeline throughput capacity. Guwahati refinery is the
INDIAN OIL CORPORATION LIMITED
An oil refinery or petroleum refinery is an industrial process plant where crude
oil is transformed and refined into more useful products such as petroleum
naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, liquefied
petroleum gas, jet fuel, and fuel Oils. Petrochemicals feed stock like ethylene and
propylene can also be produced directly by cracking crude oil without the need
of using refined products of crude oil such as naphtha. Oil refineries are typically
large, sprawling industrial complexes with Extensive piping running throughout,
carrying streams of fluids between large chemical processing units, such as
distillation columns. In many ways, oil refineries use much of the technology of
and can be thought of, as types of chemical plants.
The crude oil feedstock has typically been processed by an oil production plant.
There is usually an oil depot at or near an oil refinery for the storage of incoming
crude oil feedstock as well as bulk liquid products. Petroleum refineries are very
large industrial complexes that involve many different processing units and
auxiliary facilities such as utility units and storage tanks. Each refinery has its own
unique arrangement and combination of refining processes largely determined
by the refinery location, desired products, and economic considerations. An oil
refinery is considered an essential part of the downstream side of the petroleum
industry. Indian Oil Corporation Limited, established in 1959 is India’s largest
commercial enterprise. It serves mainly India, Sri Lanka, Mauritius, and the
Middle East. The main products are fuels, lubricants and petrochemicals. Indian
Oil Corporation Limited owns ten of India’s total twentytwo refineries, which are
situated Barauni, Panipat, Mathura, Koyali, Guwahati, Haldia, Digboi,
Bongaigaon, Narimanam. As India’s flagship national oil company, Indian oil
accounts for 56% petroleum products market share, 42% refining capacity, and
67% downstream pipeline throughput capacity. Guwahati refinery is the
9
country’s first public sector Refinery as well as Indian Oil’s first refinery serving
the nation since 1962. Built with Rumanian assistance, the initial crude
processing capacity at the time of commissioning of this refinery was 0.75
MMPTA, and the refinery was designed to process indigenous Assam crude. The
refining capacity was subsequently enhanced to 1 MMPTA. Due to the dwindling
supply of indigenous Assam crude, Guwahati Refinery started processing low
sulphur imported along with Assam crude. The supply of LS imported crude to
Guwahati refinery is from Barauni Refinery via Railway wagons. The Refinery
supplies various petroleum products to North-eastern India as well as beyond,
up to Siliguri end through the Guwahati-Siliguri pipeline, spanning 435KM, which
was the first pipeline of Indian oil and commissioned in 1964. Most of the
products of Guwahati Refinery are evacuated through the pipeline and some
quantity also through road transportation. LPG, Naphtha, Motor Spirit (MS),
Aviation Turbine fuel, Superior Kerosene oil, High-Speed Diesel (HSD), Raw
Petroleum Cake and sulphur are the products of this refinery. Auto Fuels MS and
HSD supplied by the refinery are of eco-friendly BS-IV grade as per statutory
guidelines of the government of India. The production of these valuable
petroleum products is through a series
PIPELINES:-
Indian Oil operates a network of more than 15,000 km long crude oil, petroleum
product and gas pipelines with a throughput capacity of 94.56 million metric
tonnes per annum of oil and 21.69 million metric standard cubic meters per day
of gas. Cross-country pipelines are globally recognized as the safest, cost-
effective, energy-efficient and environment-friendly mode for transportation of
crude oil and petroleum products. As a pioneer in oil pipelines in the country,
managing one of the world's largest oil pipeline networks, Indian Oil achieved a
throughput of 76.019 million metric tonnes during the year 2020-21
Indian Oil added 337 km of additional pipeline length during the year 2020-21,
as part of its plans to continuously expand the network in line with growth in
business. Projects currently under implementation would further increase the
length of the pipelines network to about 21,000 km, and throughput capacity to
102 million tonnes per annum
country’s first public sector Refinery as well as Indian Oil’s first refinery serving
the nation since 1962. Built with Rumanian assistance, the initial crude
processing capacity at the time of commissioning of this refinery was 0.75
MMPTA, and the refinery was designed to process indigenous Assam crude. The
refining capacity was subsequently enhanced to 1 MMPTA. Due to the dwindling
supply of indigenous Assam crude, Guwahati Refinery started processing low
sulphur imported along with Assam crude. The supply of LS imported crude to
Guwahati refinery is from Barauni Refinery via Railway wagons. The Refinery
supplies various petroleum products to North-eastern India as well as beyond,
up to Siliguri end through the Guwahati-Siliguri pipeline, spanning 435KM, which
was the first pipeline of Indian oil and commissioned in 1964. Most of the
products of Guwahati Refinery are evacuated through the pipeline and some
quantity also through road transportation. LPG, Naphtha, Motor Spirit (MS),
Aviation Turbine fuel, Superior Kerosene oil, High-Speed Diesel (HSD), Raw
Petroleum Cake and sulphur are the products of this refinery. Auto Fuels MS and
HSD supplied by the refinery are of eco-friendly BS-IV grade as per statutory
guidelines of the government of India. The production of these valuable
petroleum products is through a series
PIPELINES:-
Indian Oil operates a network of more than 15,000 km long crude oil, petroleum
product and gas pipelines with a throughput capacity of 94.56 million metric
tonnes per annum of oil and 21.69 million metric standard cubic meters per day
of gas. Cross-country pipelines are globally recognized as the safest, cost-
effective, energy-efficient and environment-friendly mode for transportation of
crude oil and petroleum products. As a pioneer in oil pipelines in the country,
managing one of the world's largest oil pipeline networks, Indian Oil achieved a
throughput of 76.019 million metric tonnes during the year 2020-21
Indian Oil added 337 km of additional pipeline length during the year 2020-21,
as part of its plans to continuously expand the network in line with growth in
business. Projects currently under implementation would further increase the
length of the pipelines network to about 21,000 km, and throughput capacity to
102 million tonnes per annum
10
11
IOCL Guwahati Refinery
Guwahati Refinery located among the picturesque surroundings near
Brahmaputra River in Guwahati city in Northeastern part of India, is the country’s
1st Public Sector Refinery as well as Indian Oil’s serving the nation since 1962.
Built with Rumanian technology available in the late 50s, the initial crude
processing capacity of the Refinery was 0.75 million Metric Tonnes Per Annum
(MMTPA). The Refinery was designed to process a mix of OIL and ONGC crude
along with Secondary processing units viz. Delayed Coker Unit (DCU) of 0.33
MMTPA capacity and Kerosene Treating Unit (KTU) of 0.23 MMTPA capacity.
Subsequently capacity of the refinery was enhanced to 1.0 MMTPA in 1986.
INDMAX Unit, a technology developed by Indian Oil R&D Centre for upgrading
heavy ends to LPG, gasoline and diesel was commissioned in June 2003.
The following units were added to meet the fuel specifications:
• To produce Euro-III quality MS Isomerisation Unit, Naphtha Hydrotreater
Unit TMTPA, Naphtha Splitter Unit, and Indmax Gasoline Unit were
commissioned in 2010.
• INDAdept-G Unit (IOC - R&D Technology based on Adsorption) was
commissioned in 2017 for treatment of Heavy Gasoline from Indmax to
comply to BS-IV MS norms.
• To produce BS-VI/Euro-VI quality MS/HSD a New indeSelectG unit ((IOC -
R&D Technology) was commissioned along with revamp of existing HDT
unit, Hydrogen unit and Isomerization Unit.
Upcoming Projects: A New Semi regenerative CRU unit along with refinery
expansion from 1 to 1.2 MMTPA has been approved and is expected to be
completed in 2023. Major products: LPG, Naphtha, MS, EBMS, HSD, SKO, ATF,
LDO and Calcined / Green needle coke.
Mode of Product Dispatch:
1. Pipeline: GSPL (Guwahati-Siliguri Product Pipeline) for MS, SKO and HSD.
The refinery supplies petroleum products to North-Eastern India and
Siliguri in West Bengal through GSPL.
2. Tanker trucks for LPG, Naphtha, EBMS and ATF.
IOCL Guwahati Refinery
Guwahati Refinery located among the picturesque surroundings near
Brahmaputra River in Guwahati city in Northeastern part of India, is the country’s
1st Public Sector Refinery as well as Indian Oil’s serving the nation since 1962.
Built with Rumanian technology available in the late 50s, the initial crude
processing capacity of the Refinery was 0.75 million Metric Tonnes Per Annum
(MMTPA). The Refinery was designed to process a mix of OIL and ONGC crude
along with Secondary processing units viz. Delayed Coker Unit (DCU) of 0.33
MMTPA capacity and Kerosene Treating Unit (KTU) of 0.23 MMTPA capacity.
Subsequently capacity of the refinery was enhanced to 1.0 MMTPA in 1986.
INDMAX Unit, a technology developed by Indian Oil R&D Centre for upgrading
heavy ends to LPG, gasoline and diesel was commissioned in June 2003.
The following units were added to meet the fuel specifications:
• To produce Euro-III quality MS Isomerisation Unit, Naphtha Hydrotreater
Unit TMTPA, Naphtha Splitter Unit, and Indmax Gasoline Unit were
commissioned in 2010.
• INDAdept-G Unit (IOC - R&D Technology based on Adsorption) was
commissioned in 2017 for treatment of Heavy Gasoline from Indmax to
comply to BS-IV MS norms.
• To produce BS-VI/Euro-VI quality MS/HSD a New indeSelectG unit ((IOC -
R&D Technology) was commissioned along with revamp of existing HDT
unit, Hydrogen unit and Isomerization Unit.
Upcoming Projects: A New Semi regenerative CRU unit along with refinery
expansion from 1 to 1.2 MMTPA has been approved and is expected to be
completed in 2023. Major products: LPG, Naphtha, MS, EBMS, HSD, SKO, ATF,
LDO and Calcined / Green needle coke.
Mode of Product Dispatch:
1. Pipeline: GSPL (Guwahati-Siliguri Product Pipeline) for MS, SKO and HSD.
The refinery supplies petroleum products to North-Eastern India and
Siliguri in West Bengal through GSPL.
2. Tanker trucks for LPG, Naphtha, EBMS and ATF.
12
Fig. Guwahati Refinery
Major products of the Guwahati refinery are as follows:
• LPG,
• Motor Spirit (Petrol),
• Aviation Turbine Fuel (ATF),
• Kerosene,
• High Speed Diesel,
• Light Diesel Oil,
• Raw Petroleum Coke
Indian Oil Corporation Limited, Guwahati Refinery comprises
of five divisions, namely:
• Marketing Division
• Refining Division
Fig. Guwahati Refinery
Major products of the Guwahati refinery are as follows:
• LPG,
• Motor Spirit (Petrol),
• Aviation Turbine Fuel (ATF),
• Kerosene,
• High Speed Diesel,
• Light Diesel Oil,
• Raw Petroleum Coke
Indian Oil Corporation Limited, Guwahati Refinery comprises
of five divisions, namely:
• Marketing Division
• Refining Division
13
• Pipeline Division
• Business & Development Division
• Research & Development Division
PRODUCTION UNIT
The production unit is the heart of the refinery. In this department, the crude is
processed and its components are extracted. The products are treated to meet
the market quality. The storage and movement of oil also comes under this
department. The production department consists of the following units:
1. Crude Distillation Unit (CDU)
2. Motor Spirit Quality Unit (MSQ)
3. Delayed Coker Unit (DCU)
4. Hydrogen Generation Unit (HGU)
5. Hydrotreater Unit (HDT)
6. INDAdeptG
7. INDMAX
8. Sulphur recovery unit (SRU)
9. Effluent treatment plant (ETP)
• Pipeline Division
• Business & Development Division
• Research & Development Division
PRODUCTION UNIT
The production unit is the heart of the refinery. In this department, the crude is
processed and its components are extracted. The products are treated to meet
the market quality. The storage and movement of oil also comes under this
department. The production department consists of the following units:
1. Crude Distillation Unit (CDU)
2. Motor Spirit Quality Unit (MSQ)
3. Delayed Coker Unit (DCU)
4. Hydrogen Generation Unit (HGU)
5. Hydrotreater Unit (HDT)
6. INDAdeptG
7. INDMAX
8. Sulphur recovery unit (SRU)
9. Effluent treatment plant (ETP)
14
10. Oil Movement & Storage (OM&S)
Demineralization Plant (DM Plant)
De-mineralization is the process of removing mineral salts from water by using
the ion exchange process. The ion exchange process is a reversible process. The
process of this plant is used for generating power and to drive machinery and it
is also used in other units for distillation and reforming. The river water from the
Brahmaputra River enters the intake plant from where the water is pumped to
the Water treatment plant in which filtration is done. The river water contains
impurities in suspended and colloidal states, it can contain muds, sand, loose
insoluble particles along with minerals. The ionic and dissolved impurities in river
water are as follows:
Cation Anion
Calcium(Ca2+) Chlorides (Cl-)
Magnesium (Mg2+) Sulphates (SO42-)
Sodium (Na+) Bicarbonates (HCO3-)
Ammonium (NH4+) Silica (SiO44-)
Iron (Fe2+) Nitrate (NO3-)
Manganese (Mn2+) Phosphate (PO43-)
Phosphate (PO43-)
The raw water is stored in a storage tank. There are 3 raw water pumps. The DM
plant has 3 chains (namely A, B and C).
10. Oil Movement & Storage (OM&S)
Demineralization Plant (DM Plant)
De-mineralization is the process of removing mineral salts from water by using
the ion exchange process. The ion exchange process is a reversible process. The
process of this plant is used for generating power and to drive machinery and it
is also used in other units for distillation and reforming. The river water from the
Brahmaputra River enters the intake plant from where the water is pumped to
the Water treatment plant in which filtration is done. The river water contains
impurities in suspended and colloidal states, it can contain muds, sand, loose
insoluble particles along with minerals. The ionic and dissolved impurities in river
water are as follows:
Cation Anion
Calcium(Ca2+) Chlorides (Cl-)
Magnesium (Mg2+) Sulphates (SO42-)
Sodium (Na+) Bicarbonates (HCO3-)
Ammonium (NH4+) Silica (SiO44-)
Iron (Fe2+) Nitrate (NO3-)
Manganese (Mn2+) Phosphate (PO43-)
Phosphate (PO43-)
The raw water is stored in a storage tank. There are 3 raw water pumps. The DM
plant has 3 chains (namely A, B and C).
15
Note: Capacity of Chain A and B =612 m3/50m3 per hour between
regenerators Capacity of Mixed Bed A and B=4200 m3
PRESSURE SAND FILTER(SPF) OR PRESSURE FILTER
For chain A and B, water is firstly pumped to Pressure Filters vessels. The
pressure filters vessels are named PF-A and PF-B. The pressure filter vessels are
similar in bed construction to rapid sand gravity filters. The pressure vessel is
packed with layers of under bed materials like pebbles of different sizes and
layers of sand. The pressure filters contain a porous medium to remove matter
(suspended slit, clay, colloidal, micro-organism etc).The pressure filter safeguard
the packing media of downstream equipment from getting fouled and
contaminated. The cation and the anion present at the outlet water of the
pressure filter are then sent to the ion exchange vessel. The ion exchange vessel
consists of two types, the first being the Strong Acid Cation and the Strong Base
Anion.
STRONG ACID CATION (SAC-A AND SAC-B)
This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion.The strong base anion exchange unit removes weakly dissociated
Note: Capacity of Chain A and B =612 m3/50m3 per hour between
regenerators Capacity of Mixed Bed A and B=4200 m3
PRESSURE SAND FILTER(SPF) OR PRESSURE FILTER
For chain A and B, water is firstly pumped to Pressure Filters vessels. The
pressure filters vessels are named PF-A and PF-B. The pressure filter vessels are
similar in bed construction to rapid sand gravity filters. The pressure vessel is
packed with layers of under bed materials like pebbles of different sizes and
layers of sand. The pressure filters contain a porous medium to remove matter
(suspended slit, clay, colloidal, micro-organism etc).The pressure filter safeguard
the packing media of downstream equipment from getting fouled and
contaminated. The cation and the anion present at the outlet water of the
pressure filter are then sent to the ion exchange vessel. The ion exchange vessel
consists of two types, the first being the Strong Acid Cation and the Strong Base
Anion.
STRONG ACID CATION (SAC-A AND SAC-B)
This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion.The strong base anion exchange unit removes weakly dissociated
16
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
pH: 7.5 to 9.5
Conductivity: less than 10µS/cm
Silica, SiO2: less than 0.15 ppm
Chemical Reactions:
Service- R
+
-OH
-
+ NaY → R-Y + NaOH
Regeneration- R-Y + NaOH → R-OH + Na-Y [here R refers to anion resins and Y
refers to the anion]
DEGASSER
The Degasser is made of acid proof material (usually wood or rubber line steel)
as it must handle acidic water of the cation exchange unit. In the degasser tower,
the acidic water from the cation exchange unit is sprayed from top by using spray
pipe or trays and diffuse with low pressure air entering from the bottom of the
tower. Air is blown at the bottom, rises counter current to the downward
trickling water. The spray tubes or tray divide water into droplets or thin film
exposing new surface to gas phase. Tray agitates the water by splashing thereby
allowing dissolved gasses to leave water readily. Agitation overcome tendency of
water to retain gas bubbles through surface tension and viscosity. The unit
removes carbonic acid and the water is then pumped using a degasser pump to
the strong base anion vessel containing anion resins.
STRONG BASE ANION (SBA-A AND SBA-B)
This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion.The strong base anion exchange unit removes weakly dissociated
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
pH: 7.5 to 9.5
Conductivity: less than 10µS/cm
Silica, SiO2: less than 0.15 ppm
Chemical Reactions:
Service- R
+
-OH
-
+ NaY → R-Y + NaOH
Regeneration- R-Y + NaOH → R-OH + Na-Y [here R refers to anion resins and Y
refers to the anion]
DEGASSER
The Degasser is made of acid proof material (usually wood or rubber line steel)
as it must handle acidic water of the cation exchange unit. In the degasser tower,
the acidic water from the cation exchange unit is sprayed from top by using spray
pipe or trays and diffuse with low pressure air entering from the bottom of the
tower. Air is blown at the bottom, rises counter current to the downward
trickling water. The spray tubes or tray divide water into droplets or thin film
exposing new surface to gas phase. Tray agitates the water by splashing thereby
allowing dissolved gasses to leave water readily. Agitation overcome tendency of
water to retain gas bubbles through surface tension and viscosity. The unit
removes carbonic acid and the water is then pumped using a degasser pump to
the strong base anion vessel containing anion resins.
STRONG BASE ANION (SBA-A AND SBA-B)
This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion.The strong base anion exchange unit removes weakly dissociated
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
17
pH: 7.5 to 9.5
Conductivity: lees than 10µS/cm
Silica, SiO2 : less than 0.15 ppm
Chemical Reactions:
Service- R
+
-OH
-
+ NaY → R-Y + NaOH
Regeneration- R-Y + NaOH → R-OH + Na-Y [here R refers to anion resins and Y
refers to the anion]
MIXED BED (MB-A and MB-B)
The mixed bed is a single pressure vessel containing a mix of cation and anion
resin. Here the ions that are further present are deionised and then stored in the
three demineralised tanks .
Capacity of Chain C = 1250m3/60m3 per hour
The water from the water treatment plant is first received in the Dual Media
Filter (DMF) tank.
pH: 7.5 to 9.5
Conductivity: lees than 10µS/cm
Silica, SiO2 : less than 0.15 ppm
Chemical Reactions:
Service- R
+
-OH
-
+ NaY → R-Y + NaOH
Regeneration- R-Y + NaOH → R-OH + Na-Y [here R refers to anion resins and Y
refers to the anion]
MIXED BED (MB-A and MB-B)
The mixed bed is a single pressure vessel containing a mix of cation and anion
resin. Here the ions that are further present are deionised and then stored in the
three demineralised tanks .
Capacity of Chain C = 1250m3/60m3 per hour
The water from the water treatment plant is first received in the Dual Media
Filter (DMF) tank.
18
MB outlet water quality
pH: 6.5 to 7.2
Conductivity: 1.0 µS/cm
Total Silica: 0.05ppm
DUAL MEDIA FILTER(DMF)
The DMF contains a porous medium to remove matter such as suspende slit,
clay, colloidal and micro-organism). The water is then stored in the filter water
tank which is then pumped (pump 1, 2).
ACTIVATED CARBON FILTER
After the pretreatment plant, the ACF removes free chlorine, oil and grease.
Water passes from an activated carbon filter bed which absorbs the above
mentioned matter. The water is then sent to the Strong Acid Cation after which
it is sent to the degasser from there to the strong base anion and then to the
mixed bed and finally stored in the demineralised tank
storage(capacity:1400m3)
NOTE:
1. The ion exchange process continues till exhausted. At this stage the unit is
isolated and regenerated.
2. Along with the above DM water storage tank, Acid and alkali handling
storage and injection and effluent disposal system are present.
3. An additional unit, i.e., the Unit condensate Recovery system is present in
the Chain #C, where the condensate from units are reused. The raw water
storage tank is present only in chain #C and approximately 110M3/day is
recovered and reused.
Regeneration Process
After working for some duration of time, the ion exchange resins present in any
of the ion-exchange vessel become exhausted and are not capable of trapping
the cations present in the raw water. The process of regaining the ion-removal
capability of the ion exchange resin is called regeneration.
MB outlet water quality
pH: 6.5 to 7.2
Conductivity: 1.0 µS/cm
Total Silica: 0.05ppm
DUAL MEDIA FILTER(DMF)
The DMF contains a porous medium to remove matter such as suspende slit,
clay, colloidal and micro-organism). The water is then stored in the filter water
tank which is then pumped (pump 1, 2).
ACTIVATED CARBON FILTER
After the pretreatment plant, the ACF removes free chlorine, oil and grease.
Water passes from an activated carbon filter bed which absorbs the above
mentioned matter. The water is then sent to the Strong Acid Cation after which
it is sent to the degasser from there to the strong base anion and then to the
mixed bed and finally stored in the demineralised tank
storage(capacity:1400m3)
NOTE:
1. The ion exchange process continues till exhausted. At this stage the unit is
isolated and regenerated.
2. Along with the above DM water storage tank, Acid and alkali handling
storage and injection and effluent disposal system are present.
3. An additional unit, i.e., the Unit condensate Recovery system is present in
the Chain #C, where the condensate from units are reused. The raw water
storage tank is present only in chain #C and approximately 110M3/day is
recovered and reused.
Regeneration Process
After working for some duration of time, the ion exchange resins present in any
of the ion-exchange vessel become exhausted and are not capable of trapping
the cations present in the raw water. The process of regaining the ion-removal
capability of the ion exchange resin is called regeneration.
19
How do we know either of the vessels is exhausted?
This can be done by checking the conductivity or the pH of the output water
from each and every vessel i.e., if the said data are not matching the required
output.
The regeneration process is completed in the following steps:
Backwash: In this process the water is pumped into either of the exhausted
vessels in the reverse direction to remove the impurities and also to break
channels of flow.
Dosing @ 5%: in this step we dose the water flowing into the exhausted with 5%
of HCl (in case of SAC) and 5% of NaOH (in case of SBA) and allow to the dosed
water the flow out of the exhausted vessel until the output water has 5%
strength of HCl or NaOH.
Rinsing: In the step since the water present in the vessel will not have a specific
gravity of 1 so we will have to allow the diluted water until the specific gravity is
found to be 1
How do we know either of the vessels is exhausted?
This can be done by checking the conductivity or the pH of the output water
from each and every vessel i.e., if the said data are not matching the required
output.
The regeneration process is completed in the following steps:
Backwash: In this process the water is pumped into either of the exhausted
vessels in the reverse direction to remove the impurities and also to break
channels of flow.
Dosing @ 5%: in this step we dose the water flowing into the exhausted with 5%
of HCl (in case of SAC) and 5% of NaOH (in case of SBA) and allow to the dosed
water the flow out of the exhausted vessel until the output water has 5%
strength of HCl or NaOH.
Rinsing: In the step since the water present in the vessel will not have a specific
gravity of 1 so we will have to allow the diluted water until the specific gravity is
found to be 1
20
DELAYED COKING UNIT (DCU)
Delayed Coking Unit is a secondary processing unit designed and installed to
process the low value heavy stock to upgrade it to more valuable lighter and
middle distillates with petroleum coke as byproduct. The feed to be processed
in the unit is Reduced Crude Oil obtained from the bottom of the fractionating
column of the CDU and the process used is Thermal Cracking.
Delayed coker unit of Guwahati Refinery is a secondary process unit to crack RCO
(Reduced Crude Oil from bottom of CDU fractionating column). The cracked RCO
is distillated into different products and coke is obtained as by product. RCO from
CDU or from OM&S tank is pumped by DCU primary feed pump (03-P-1/03-P-
1A/03-P-1B) through a series of preheat exchangers to main fractionator column
(03-CL-2). Preheat temperature obtained is around 250C. At the bottom part of
the fractionator RCO(primary feed) exchanges heat with incoming cracked
vapors coming from coke drum. A part of the cracked vapors condenses upon
contact with the primary feed and forms recycle. Exchange of heat between
primary feed and cracked vapors causes the column bottom temperature to
maintain at 365C. The column bottoms or secondary feed (fresh RCO plus
recycle) is pumped by secondary feed pump (03-9-2/03-P-2A) to DCU furnace.
The temperature of the secondary feed is increased to around 498C at the
outlet of the furnace. At this high temperature, it enters one of the coke drums
DELAYED COKING UNIT (DCU)
Delayed Coking Unit is a secondary processing unit designed and installed to
process the low value heavy stock to upgrade it to more valuable lighter and
middle distillates with petroleum coke as byproduct. The feed to be processed
in the unit is Reduced Crude Oil obtained from the bottom of the fractionating
column of the CDU and the process used is Thermal Cracking.
Delayed coker unit of Guwahati Refinery is a secondary process unit to crack RCO
(Reduced Crude Oil from bottom of CDU fractionating column). The cracked RCO
is distillated into different products and coke is obtained as by product. RCO from
CDU or from OM&S tank is pumped by DCU primary feed pump (03-P-1/03-P-
1A/03-P-1B) through a series of preheat exchangers to main fractionator column
(03-CL-2). Preheat temperature obtained is around 250C. At the bottom part of
the fractionator RCO(primary feed) exchanges heat with incoming cracked
vapors coming from coke drum. A part of the cracked vapors condenses upon
contact with the primary feed and forms recycle. Exchange of heat between
primary feed and cracked vapors causes the column bottom temperature to
maintain at 365C. The column bottoms or secondary feed (fresh RCO plus
recycle) is pumped by secondary feed pump (03-9-2/03-P-2A) to DCU furnace.
The temperature of the secondary feed is increased to around 498C at the
outlet of the furnace. At this high temperature, it enters one of the coke drums
21
which are in line alternately for 24 hours cycle. Thermal cracking of the
secondary feed takes place in the coke drum. The vapors generated by cracking
of the feed exits the coke drum at 430C and passes through a quench column
(03-CL-1) before entering the main fractionator. In the quench column, the vapor
temperature reduces to 422C and any coke fines entrained by the vapor is
washed off by the quench stream. The vapors are seperated in the main
fractionator to product streams Coker Gasoline, Coker Kerosene, Coker Gas Oil
and Coker Fuel Oil. Gases from the column overhead at 90C are cooled in
overhead condensers to 30C and enters the overhead seperator vessel (03- V-
1). A part of coker gasoline is fed to the column as top reflux while the
uncondensed gases are sent to LRU for recovery of LPG. A CGO circulating reflux
is provided from CGO chimney tray the column which maintains the overall
temperature profile of the column.
Typical cycle length of DCU coke chamber is 24rs. During 24 hours period one
chamber is in line while operations for cooling, emptying out and heating are
going on the other chamber. The feed is diverted from one coke drum to the
other at the 24th hour. The coke (RPC) which is produced in the coke drums are
emptied by coke cutting with high pressure water jet pump. RPC is dispatched as
product from the coke yard adjacent to the coke chambers.
PROCESS CHEMISTRY OF COKING
The coking process therefore involves two types of reactions.
• Primary Reaction
• Secondary reaction
PRIMARY REACTION:
In this reaction the heavier hydrocarbon molecules decomposes into smaller
ones. This reaction is known as Cracking.
SECONDARY REACTION:
In this reaction the smaller reactive molecules combine with one another to
produce heavy tarry materials. 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
which are in line alternately for 24 hours cycle. Thermal cracking of the
secondary feed takes place in the coke drum. The vapors generated by cracking
of the feed exits the coke drum at 430C and passes through a quench column
(03-CL-1) before entering the main fractionator. In the quench column, the vapor
temperature reduces to 422C and any coke fines entrained by the vapor is
washed off by the quench stream. The vapors are seperated in the main
fractionator to product streams Coker Gasoline, Coker Kerosene, Coker Gas Oil
and Coker Fuel Oil. Gases from the column overhead at 90C are cooled in
overhead condensers to 30C and enters the overhead seperator vessel (03- V-
1). A part of coker gasoline is fed to the column as top reflux while the
uncondensed gases are sent to LRU for recovery of LPG. A CGO circulating reflux
is provided from CGO chimney tray the column which maintains the overall
temperature profile of the column.
Typical cycle length of DCU coke chamber is 24rs. During 24 hours period one
chamber is in line while operations for cooling, emptying out and heating are
going on the other chamber. The feed is diverted from one coke drum to the
other at the 24th hour. The coke (RPC) which is produced in the coke drums are
emptied by coke cutting with high pressure water jet pump. RPC is dispatched as
product from the coke yard adjacent to the coke chambers.
PROCESS CHEMISTRY OF COKING
The coking process therefore involves two types of reactions.
• Primary Reaction
• Secondary reaction
PRIMARY REACTION:
In this reaction the heavier hydrocarbon molecules decomposes into smaller
ones. This reaction is known as Cracking.
SECONDARY REACTION:
In this reaction the smaller reactive molecules combine with one another to
produce heavy tarry materials. 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
22
provides residence time of 24 hours for the cracking and polymerization reaction
to take place. For this lengthening of the time of liquid phase cracking and
polymerization reaction to take place. For this lengthening of the time of liquid
phase cracking and polymerization, the whole process of cracking is known of
Delayed Coking.
The two types of chemical reactions that take place during thermal cracking
operation may be represented by the chemical reaction shown below:
DECOMPOSITION OF HEAVIER MOLECULES
CH3-CH2- CH2-CH3 = CH4 + CH3CH=CH2
N-Butane = Methane + Propene
CH3CH2CH2 CH3 = CH3CH3 + CH2=CH2
N-Butane = Ethane + Ethylene
At high temperature the first of these appears to proceeds to the extent of about
55% and second to 40%. Dehydrogenation reactions as given below appear to
represent less than 5 % of the total. The tendency to dehydrogenate, leaving an
olefin with the same number of carbon atoms as the original paraffin
hydrocarbon, rapidly diminishes as the series is ascended. Thus the production
of large amounts of hydrogen by cracking gas oil stocks should not be expected.
SECONDARY REACTION
2C2 H4 = C4 H8
3C3 H6 = C9 H18
C4 H8 + C9 H18 = C13 H26
CH3 CH2 CH=CH2=CH2 = CH3 CH2 CH2 CH2 CH2 CH=CH2
FEED AND PRODUCTS
provides residence time of 24 hours for the cracking and polymerization reaction
to take place. For this lengthening of the time of liquid phase cracking and
polymerization reaction to take place. For this lengthening of the time of liquid
phase cracking and polymerization, the whole process of cracking is known of
Delayed Coking.
The two types of chemical reactions that take place during thermal cracking
operation may be represented by the chemical reaction shown below:
DECOMPOSITION OF HEAVIER MOLECULES
CH3-CH2- CH2-CH3 = CH4 + CH3CH=CH2
N-Butane = Methane + Propene
CH3CH2CH2 CH3 = CH3CH3 + CH2=CH2
N-Butane = Ethane + Ethylene
At high temperature the first of these appears to proceeds to the extent of about
55% and second to 40%. Dehydrogenation reactions as given below appear to
represent less than 5 % of the total. The tendency to dehydrogenate, leaving an
olefin with the same number of carbon atoms as the original paraffin
hydrocarbon, rapidly diminishes as the series is ascended. Thus the production
of large amounts of hydrogen by cracking gas oil stocks should not be expected.
SECONDARY REACTION
2C2 H4 = C4 H8
3C3 H6 = C9 H18
C4 H8 + C9 H18 = C13 H26
CH3 CH2 CH=CH2=CH2 = CH3 CH2 CH2 CH2 CH2 CH=CH2
FEED AND PRODUCTS
23
Feed:
➢ Reduced Crude Oil (RCO) (Density: 950 kg/m3 & CCR: 5.5-6.0%)
➢ Clarified Oil (CLO) ex INDMAX
➢ Refinery Slop oil (as vapor line quench medium)
INTRODUCTION TO THERMAL POWER STATION (TPS)
Thermal Power Station is a power plant in which the input is heat energy and the
output is electrical energy with water (demineralized) as the working fluid. The
output electricity from TPS is supplied to the production units and it is also
supplying required steam to the production units. The whole TPS works on a
Rankine cycle (i.e., as shown in the figure below) , in this Rankine cycle there are
four processes namely:
• Process 1-2: The working fluid is pumped from low to high pressure. As
the fluid is a liquid at this stage, the pump requires little input energy.
Process 1-2 is isentropic compression.
• Process 2-3: The high-pressure liquid enters a boiler, where it is heated at
constant pressure by an external heat source to become a dry saturated
vapour. Process 2-3 is constant pressure heat addition in the boiler.
• Process 3-4: The dry saturated vapour expands through a steam turbine,
generating power. This decreases the temperature and pressure of the
vapour, and some condensation may occur. The output in this process can
be easily calculated using the chart or tables noted above. Process 3-4 is
isentropic expansion.
• Process 4-1: The wet vapour then enters the condenser, where it is
condensed at a constant pressure to become a saturated liquid. Process
4-1 is constant pressure heat rejection in the condenser.
Feed:
➢ Reduced Crude Oil (RCO) (Density: 950 kg/m3 & CCR: 5.5-6.0%)
➢ Clarified Oil (CLO) ex INDMAX
➢ Refinery Slop oil (as vapor line quench medium)
INTRODUCTION TO THERMAL POWER STATION (TPS)
Thermal Power Station is a power plant in which the input is heat energy and the
output is electrical energy with water (demineralized) as the working fluid. The
output electricity from TPS is supplied to the production units and it is also
supplying required steam to the production units. The whole TPS works on a
Rankine cycle (i.e., as shown in the figure below) , in this Rankine cycle there are
four processes namely:
• Process 1-2: The working fluid is pumped from low to high pressure. As
the fluid is a liquid at this stage, the pump requires little input energy.
Process 1-2 is isentropic compression.
• Process 2-3: The high-pressure liquid enters a boiler, where it is heated at
constant pressure by an external heat source to become a dry saturated
vapour. Process 2-3 is constant pressure heat addition in the boiler.
• Process 3-4: The dry saturated vapour expands through a steam turbine,
generating power. This decreases the temperature and pressure of the
vapour, and some condensation may occur. The output in this process can
be easily calculated using the chart or tables noted above. Process 3-4 is
isentropic expansion.
• Process 4-1: The wet vapour then enters the condenser, where it is
condensed at a constant pressure to become a saturated liquid. Process
4-1 is constant pressure heat rejection in the condenser.
24
Figure: T-S Diagram of a Rankine Cycle
TPS Process Flow Diagram
In the TPS, at first the raw water from Brahmaputra is fed into the water
treatment pump which is then pumped into Demineralising plant (a.k.a DM
plant) for removing the cations and anions as well as the minerals present in the
raw water; from the DM plant the demineralised water is sent to the deaerator
Figure: T-S Diagram of a Rankine Cycle
TPS Process Flow Diagram
In the TPS, at first the raw water from Brahmaputra is fed into the water
treatment pump which is then pumped into Demineralising plant (a.k.a DM
plant) for removing the cations and anions as well as the minerals present in the
raw water; from the DM plant the demineralised water is sent to the deaerator
25
to remove the dissolved oxygen; the output water from the deaerator is fed into
the boiler to be converted in to steam required to generate the electricity from
the Turbine, the High pressure steam from the boiler is also used for different
applications in different production units; after the turbine the high pressure
steam is converted into low pressure and medium pressure steam which is
inturned stored in the condenser to be condensed into liquid with the help of
cold water from the TPS cooling tower for reusing in the cycle.
Turbine:- A turbine is a rotary mechanical device that extracts energy from a
fluid flow and converts it into useful work or energy. The work produced by a
turbine is used in generating electrical power when the shaft of the turbine is
coupled with a generator. A turbine is a turbomachine.
The following observations were made upon study, such as:
Condensate Extraction Pump is used to pump the condensate (conversion of
steam into water in condenser) from the condenser. CEP pump then circulates
the condensate again into the deaerator tank which prevents plant from huge
loss of water.
Ejector is used for accelerating high pressure steam and converting the pressure
energy into velocity.
Auxiliary Oil Pump (AOP) supplies oil to bearings of turbine. Generally, operated
during startup and shut-down when the turbine shaft is not rotating fast enough
for the main pump to deliver the required pressure and flow.
Factors affecting the exhaust vacuum in the condensing type turbines:
• Vacuum Ejector System - Vacuum ejector system creates and maintains
the vacuum in the surface condenser by removing the air/inerts ingress.
Removal of air/inert ingress is important, as accumulation of this hampers
the performance of the surface condenser, which reduces the surface
condenser vacuum.
Motive steam condition shall be maintained as specified. Inter-after
condenser shall be cleaned in the available opportunity, as they get
choked due to foreign material coming with cooling water.
to remove the dissolved oxygen; the output water from the deaerator is fed into
the boiler to be converted in to steam required to generate the electricity from
the Turbine, the High pressure steam from the boiler is also used for different
applications in different production units; after the turbine the high pressure
steam is converted into low pressure and medium pressure steam which is
inturned stored in the condenser to be condensed into liquid with the help of
cold water from the TPS cooling tower for reusing in the cycle.
Turbine:- A turbine is a rotary mechanical device that extracts energy from a
fluid flow and converts it into useful work or energy. The work produced by a
turbine is used in generating electrical power when the shaft of the turbine is
coupled with a generator. A turbine is a turbomachine.
The following observations were made upon study, such as:
Condensate Extraction Pump is used to pump the condensate (conversion of
steam into water in condenser) from the condenser. CEP pump then circulates
the condensate again into the deaerator tank which prevents plant from huge
loss of water.
Ejector is used for accelerating high pressure steam and converting the pressure
energy into velocity.
Auxiliary Oil Pump (AOP) supplies oil to bearings of turbine. Generally, operated
during startup and shut-down when the turbine shaft is not rotating fast enough
for the main pump to deliver the required pressure and flow.
Factors affecting the exhaust vacuum in the condensing type turbines:
• Vacuum Ejector System - Vacuum ejector system creates and maintains
the vacuum in the surface condenser by removing the air/inerts ingress.
Removal of air/inert ingress is important, as accumulation of this hampers
the performance of the surface condenser, which reduces the surface
condenser vacuum.
Motive steam condition shall be maintained as specified. Inter-after
condenser shall be cleaned in the available opportunity, as they get
choked due to foreign material coming with cooling water.
26
Flange joints shall be tightened properly to avoid any ingress of air.
Exhaust side of the turbine shall be properly steam sealed to avoid any
ingress of air.
• Higher size of exhaust pipe - In many condensing turbines it is observed
that the exhaust vacuum of these turbines is much less than the vacuum
at the condenser.
Mainly, it is due to;
➢ Higher pressure drop in the exhaust pipeline from
turbine exhaust to the condenser.
➢ In order to improve the vacuum at turbine exhaust so as
to reduce steam consumption in the turbine, exhaust
pipeline of these turbines can be replaced with higher
size.
Specifications:
o Data Details on STG-3,STG-4 & STG-5
Equipment No. STG-3 STG-4 STG-5
Make BHEL BHEL BHEL
Year of
commissioning
1985 1998 2006
Type EK-1000-2 EK-1000-2 EK-1000-2
Continuous rating at
Generation Terminals
(Extraction mode)
8MW 8MW 10.5 MW
Speed 8000 RPM 8000 RPM 6500 RPM
Coupling Speed reduction gear Speed reduction gear Speed reduction
gear
Live steam Pressure 35+_1.0 ATA 35+_1.0 ATA 35+_1.0 ATA
Flange joints shall be tightened properly to avoid any ingress of air.
Exhaust side of the turbine shall be properly steam sealed to avoid any
ingress of air.
• Higher size of exhaust pipe - In many condensing turbines it is observed
that the exhaust vacuum of these turbines is much less than the vacuum
at the condenser.
Mainly, it is due to;
➢ Higher pressure drop in the exhaust pipeline from
turbine exhaust to the condenser.
➢ In order to improve the vacuum at turbine exhaust so as
to reduce steam consumption in the turbine, exhaust
pipeline of these turbines can be replaced with higher
size.
Specifications:
o Data Details on STG-3,STG-4 & STG-5
Equipment No. STG-3 STG-4 STG-5
Make BHEL BHEL BHEL
Year of
commissioning
1985 1998 2006
Type EK-1000-2 EK-1000-2 EK-1000-2
Continuous rating at
Generation Terminals
(Extraction mode)
8MW 8MW 10.5 MW
Speed 8000 RPM 8000 RPM 6500 RPM
Coupling Speed reduction gear Speed reduction gear Speed reduction
gear
Live steam Pressure 35+_1.0 ATA 35+_1.0 ATA 35+_1.0 ATA
27
Live steam
temperature
440+ -10C 440+ -10C 440+ -10C
Max. live steam flow 63MT/HR 63MT/HR 94.3MT/HR
Max. extraction-1
steam flow
30T/HR 30T/HR 50T/HR
Max. extraction-I1
steam flow
6T/HR 6T/HR 8T/HR
Extraction-1 steam Pr 13 ATA -+ 1.5/2.5 13 ATA -+ 1.5/2.5 13 ATA -+ 1.5/2.5
Extraction-I1 steam
Pr
3.5 ATA -+ 1.0/1.0 3.5 ATA -+ 1.0/1.0 3.0 ATA -+ 1.0/1.0
Speed Governor Electro-hydraulic Electro-hydraulic Electro-hydraulic
Pressure Governor Woodward 505E Woodward 505XT Woodward 505C
Main oil pump Shaft driven Shaft driven Centrifugal Elect
drive
Steam admission
valve
Lever operated servo
(5 nos. port)
Lever operated servo (5
nos. port)
Lever operated
servo (5 nos. port)
Extraction valve Lever operated servo
(3 nos. port)
Lever operated servo (3
nos. port)
Lever operated
servo (3 nos. port)
Live steam
temperature
440+ -10C 440+ -10C 440+ -10C
Max. live steam flow 63MT/HR 63MT/HR 94.3MT/HR
Max. extraction-1
steam flow
30T/HR 30T/HR 50T/HR
Max. extraction-I1
steam flow
6T/HR 6T/HR 8T/HR
Extraction-1 steam Pr 13 ATA -+ 1.5/2.5 13 ATA -+ 1.5/2.5 13 ATA -+ 1.5/2.5
Extraction-I1 steam
Pr
3.5 ATA -+ 1.0/1.0 3.5 ATA -+ 1.0/1.0 3.0 ATA -+ 1.0/1.0
Speed Governor Electro-hydraulic Electro-hydraulic Electro-hydraulic
Pressure Governor Woodward 505E Woodward 505XT Woodward 505C
Main oil pump Shaft driven Shaft driven Centrifugal Elect
drive
Steam admission
valve
Lever operated servo
(5 nos. port)
Lever operated servo (5
nos. port)
Lever operated
servo (5 nos. port)
Extraction valve Lever operated servo
(3 nos. port)
Lever operated servo (3
nos. port)
Lever operated
servo (3 nos. port)
28
BOILER:-
To cater to the demand of the power and steam in the GR , 5 boilers are present
in the refinery(namely Boiler #3, Boiler #4, Boiler#5, Boiler #6, Boiler#7) . The
boiler has been designed to confirm to Indian Boiler Regulations. The main
parameters of individual boiler are:
Maximum Net Continuous Rating
50TPH
Steam Pressure
39 kg/cm2
Superheated Steam Temperature
450
0
C
Fuel Fired
Fuel Oil, MRN & Gas
Deaerator:
The corrosive gases such as dissolved oxygen and free carbon dioxide are
removed from the DM water before being feed to the boiler. The DM water is
heated to its boiling temperature at the operating pressure by steam. The
Deaerator is of spray and tray types, it consists of a storage tank and a vapour
tank. DM water enters into the vapour tank through the topside nozzle to the
distribution ring header. Ten spray nozzles are fixed on the ring header to spray
the water into fine particles covering the entire cross section of the tank so that
easy and complete scrubbing with steam is possible.
Condenser:
A Condenser is where the exhaust steam from the turbine is condensed and
operates at a pressure lower than atmosphere.
BOILER:-
To cater to the demand of the power and steam in the GR , 5 boilers are present
in the refinery(namely Boiler #3, Boiler #4, Boiler#5, Boiler #6, Boiler#7) . The
boiler has been designed to confirm to Indian Boiler Regulations. The main
parameters of individual boiler are:
Maximum Net Continuous Rating
50TPH
Steam Pressure
39 kg/cm2
Superheated Steam Temperature
450
0
C
Fuel Fired
Fuel Oil, MRN & Gas
Deaerator:
The corrosive gases such as dissolved oxygen and free carbon dioxide are
removed from the DM water before being feed to the boiler. The DM water is
heated to its boiling temperature at the operating pressure by steam. The
Deaerator is of spray and tray types, it consists of a storage tank and a vapour
tank. DM water enters into the vapour tank through the topside nozzle to the
distribution ring header. Ten spray nozzles are fixed on the ring header to spray
the water into fine particles covering the entire cross section of the tank so that
easy and complete scrubbing with steam is possible.
Condenser:
A Condenser is where the exhaust steam from the turbine is condensed and
operates at a pressure lower than atmosphere.
29
Types:
a) Direct contact type condensers: In this type of condensers, the
condensate and cooling water directly mix and come out as a single steam.
b) Surface Condensers: In this type of condensers, shell and tube heat
exchangers are used, where two fluids do not come in direct contact and
the heat released by the condensation of steam is transferred through the
walls of the tubes into the cooling water continuously circulating inside
them.
Surface Condenser
The exhaust steam from the turbine is cooled in the condenser. One condenser
per unit has been provided with a provision of taking out half of the condenser
for cleaning purposes when operating. Cooling water is supplied to the
condenser through two pipes fitted with control valves at the condenser inlet.
The outlets of the condenser is taken through the control valve. The hot water
from the condenser is cooled in the cooling tower. The surface condenser is of a
two-part type. The condenser water boxes are divided into two independent two
way circuits by which it is possible to clean one half of the water side of the
condenser in stages, during operation of the set. The surface condenser is a shell
and tube nest arrangement with water boxes at either end. The steam side of
the surface condenser is connected to the exhaust hood of the turbine. On the
water side of the condenser is divided vertically into two independent circuits so
that the repair and maintenance on the water side can be undertaken while the
turbine is in operation.
Types:
a) Direct contact type condensers: In this type of condensers, the
condensate and cooling water directly mix and come out as a single steam.
b) Surface Condensers: In this type of condensers, shell and tube heat
exchangers are used, where two fluids do not come in direct contact and
the heat released by the condensation of steam is transferred through the
walls of the tubes into the cooling water continuously circulating inside
them.
Surface Condenser
The exhaust steam from the turbine is cooled in the condenser. One condenser
per unit has been provided with a provision of taking out half of the condenser
for cleaning purposes when operating. Cooling water is supplied to the
condenser through two pipes fitted with control valves at the condenser inlet.
The outlets of the condenser is taken through the control valve. The hot water
from the condenser is cooled in the cooling tower. The surface condenser is of a
two-part type. The condenser water boxes are divided into two independent two
way circuits by which it is possible to clean one half of the water side of the
condenser in stages, during operation of the set. The surface condenser is a shell
and tube nest arrangement with water boxes at either end. The steam side of
the surface condenser is connected to the exhaust hood of the turbine. On the
water side of the condenser is divided vertically into two independent circuits so
that the repair and maintenance on the water side can be undertaken while the
turbine is in operation.
30
TPS Cooling Tower
Cooling Towers are heat rejection devices where water and air are brought in
contact with each other to reduce the water’s temperature. The working
principle of cooling tower is to cool the hot water that gets heated up with the
help of ambient air. The small volumes of water evaporate hence lowering the
temperature of the water. Water comes out of the cooling water hot and goes
out of the cooling water cold. Water is pumped directly through pipes into the
cooling water. Cooling tower spouts are managed to diffuse the water over the
‘fills media’, that reduces the flow of water and reduces the flow of water and
reveals the maximum volume of water covering area. The water is flashed to air
as it passes throughout the cooling water. The air is pulled by a motor driven
‘cooling tower fan’. When the air and water comes into contact, a little amount
of water dissipate , producing a cooling operation and again the cold water is
pumped back to the condenser.
TPS Cooling Tower
Cooling Towers are heat rejection devices where water and air are brought in
contact with each other to reduce the water’s temperature. The working
principle of cooling tower is to cool the hot water that gets heated up with the
help of ambient air. The small volumes of water evaporate hence lowering the
temperature of the water. Water comes out of the cooling water hot and goes
out of the cooling water cold. Water is pumped directly through pipes into the
cooling water. Cooling tower spouts are managed to diffuse the water over the
‘fills media’, that reduces the flow of water and reduces the flow of water and
reveals the maximum volume of water covering area. The water is flashed to air
as it passes throughout the cooling water. The air is pulled by a motor driven
‘cooling tower fan’. When the air and water comes into contact, a little amount
of water dissipate , producing a cooling operation and again the cold water is
pumped back to the condenser.
31
Major Components and Functions of Cooling Tower:
Louvers – made of asbestos sheets and they retain the circulating water within
the tower and equalize the air flow within the fills media.
Fills Media – is a medium used to increase the surface area of the tower to allow
optimum contact surface and contact time between the air and water, while
providing minimum restriction to airflow.
Drift eliminators – These eliminators reduce the amount of water that escapes
into the discharge air in the cooling tower. They project air in multiple directions
and prevent unnecessary loss of water.
Cold Water Basin – These are located at the bottom of the cooling tower and
collect the cold water that flows through the fill.
Major Components and Functions of Cooling Tower:
Louvers – made of asbestos sheets and they retain the circulating water within
the tower and equalize the air flow within the fills media.
Fills Media – is a medium used to increase the surface area of the tower to allow
optimum contact surface and contact time between the air and water, while
providing minimum restriction to airflow.
Drift eliminators – These eliminators reduce the amount of water that escapes
into the discharge air in the cooling tower. They project air in multiple directions
and prevent unnecessary loss of water.
Cold Water Basin – These are located at the bottom of the cooling tower and
collect the cold water that flows through the fill.
32
Fans - the function of the fan is to deliver the desired air flow.
Nozzles – these allow for uniform distribution of hot water inside the cooling
water.
Drive Shaft – transmit power from the motor’s output shaft to the gear
reduction unit’s input shaft.
Casing – its function is to provide housing and to transmit loads to the tower
frame. It also acts to contain water within the cooling tower.
Fans - the function of the fan is to deliver the desired air flow.
Nozzles – these allow for uniform distribution of hot water inside the cooling
water.
Drive Shaft – transmit power from the motor’s output shaft to the gear
reduction unit’s input shaft.
Casing – its function is to provide housing and to transmit loads to the tower
frame. It also acts to contain water within the cooling tower.
33
MECHANICAL EQUIPMENTS IN GUWAHATI REFINERY
A pump is a mechanical device that transfers electrical energy into hydraulic
energy to move fluids (liquids, gases, or occasionally slurries) mechanically.
Mechanical pumps are used in a wide variety of applications, including the
pumping of water from wells, aquarium filtration, pond filtration, and aeration,
as well as fuel injection and water cooling in the automotive industry, as well as
the operation of cooling towers and other HVAC system components. Pumps are
employed in the medical sector for biochemical processes involved in creating
and producing medication as well as artificial body part replacements, including
the artificial heart and penile prosthesis.
When a pump contains two or more pump mechanisms with fluid being directed
to flow through them in series, it is called a multi-stage pump. Terms such as
two-stage or double-stage may be used to specifically describe the number of
stages. A pump that does not fit this description is simply a single-stage pump in
contrast.
In biology, many different types of chemical and biomechanical pumps have
evolved; biomimicry is sometimes used in developing new types of mechanical
pumps.
Types of Pumps:
Pumps can be broadly divided as follows:
MECHANICAL EQUIPMENTS IN GUWAHATI REFINERY
A pump is a mechanical device that transfers electrical energy into hydraulic
energy to move fluids (liquids, gases, or occasionally slurries) mechanically.
Mechanical pumps are used in a wide variety of applications, including the
pumping of water from wells, aquarium filtration, pond filtration, and aeration,
as well as fuel injection and water cooling in the automotive industry, as well as
the operation of cooling towers and other HVAC system components. Pumps are
employed in the medical sector for biochemical processes involved in creating
and producing medication as well as artificial body part replacements, including
the artificial heart and penile prosthesis.
When a pump contains two or more pump mechanisms with fluid being directed
to flow through them in series, it is called a multi-stage pump. Terms such as
two-stage or double-stage may be used to specifically describe the number of
stages. A pump that does not fit this description is simply a single-stage pump in
contrast.
In biology, many different types of chemical and biomechanical pumps have
evolved; biomimicry is sometimes used in developing new types of mechanical
pumps.
Types of Pumps:
Pumps can be broadly divided as follows:
34
Dynamic Pumps:
A dynamic pump is a type of pump that delivers kinetic energy to the working
fluid through the action of axial or centrifugal force, which then transforms that
energy into an increase in pressure or flow rate.
A dynamic pump is also known as a kinetic pump because it pumps the fluid by
providing kinetic energy. This pump most commonly uses a centrifugal force to
pump the fluid. Dynamic pumps are used for applications that require a
continuous flow rate.
These types of pumps contain an impeller, diffuser/volute casing, and housing.
Dynamic pumps are classified into different types some of them are discussed
below like Centrifugal, Vertical centrifugal, Horizontal centrifugal, Submersible,
and Fire hydrant systems.
Centrifugal Pumps:
Centrifugal pumps are widely used globally due to their simple operation, well-
described principles, and proven reliability. These pumps are robust, efficient,
and cost-effective. When in operation, the fluid pressure increases from the
pump's inlet to its outlet, driving the liquid throughout the system. Mechanical
power from an electric motor is transmitted to the fluid through a rotating
impeller, which enhances the fluid's velocity and converts kinetic energy into
pressure.
Dynamic Pumps:
A dynamic pump is a type of pump that delivers kinetic energy to the working
fluid through the action of axial or centrifugal force, which then transforms that
energy into an increase in pressure or flow rate.
A dynamic pump is also known as a kinetic pump because it pumps the fluid by
providing kinetic energy. This pump most commonly uses a centrifugal force to
pump the fluid. Dynamic pumps are used for applications that require a
continuous flow rate.
These types of pumps contain an impeller, diffuser/volute casing, and housing.
Dynamic pumps are classified into different types some of them are discussed
below like Centrifugal, Vertical centrifugal, Horizontal centrifugal, Submersible,
and Fire hydrant systems.
Centrifugal Pumps:
Centrifugal pumps are widely used globally due to their simple operation, well-
described principles, and proven reliability. These pumps are robust, efficient,
and cost-effective. When in operation, the fluid pressure increases from the
pump's inlet to its outlet, driving the liquid throughout the system. Mechanical
power from an electric motor is transmitted to the fluid through a rotating
impeller, which enhances the fluid's velocity and converts kinetic energy into
pressure.
35
Vertical Centrifugal Pumps:
Vertical centrifugal pumps, also known as cantilever pumps, have a unique
design with an external shaft and bearings. The volume falls into the pit without
the need for a filled container to cover the shaft. Instead, a throttle bushing is
used. These pumps are commonly used in applications such as parts washers.
Horizontal Centrifugal Pumps:
Horizontal centrifugal pumps consist of multiple impellers and are used in
pumping services. Each stage operates as a separate pump, with all stages
housed and mounted on the same shaft. These pumps are suitable for industries
that handle large volumes of industrial fluids. Service and maintenance of this
type of centrifugal pump are provided by various pump manufacturers.
Vertical Centrifugal Pumps:
Vertical centrifugal pumps, also known as cantilever pumps, have a unique
design with an external shaft and bearings. The volume falls into the pit without
the need for a filled container to cover the shaft. Instead, a throttle bushing is
used. These pumps are commonly used in applications such as parts washers.
Horizontal Centrifugal Pumps:
Horizontal centrifugal pumps consist of multiple impellers and are used in
pumping services. Each stage operates as a separate pump, with all stages
housed and mounted on the same shaft. These pumps are suitable for industries
that handle large volumes of industrial fluids. Service and maintenance of this
type of centrifugal pump are provided by various pump manufacturers.
36
Submersible Pumps:
Submersible pumps, also known as stormwater, sewage, and septic pumps, find
applications in building services, domestic, industrial, commercial, rural,
municipal, and rainwater recycling. They are designed for various tasks, including
transferring stormwater, subsoil water, sewage, trade waste, chemicals, bore
water, and foodstuffs. There is a wide range of submersible pump options
available for different applications, including closed impellers, contra-block
impellers, vortex impellers, multi-stage pumps, single-channel pumps, cutter
pumps, and grinder pumps. These pumps can handle high flow, low flow, low
head, or high head situations.
Fire Hydrant Systems:
Fire hydrant systems, also referred to as hydrant boosters, fire pumps, or fire
water pumps, are high-pressure water pumps designed to increase the capacity
of fire-fighting systems in buildings where the mains water pressure is
insufficient. These systems are crucial for irrigation and water transfer
applications, enhancing the firefighting capabilities of the construction.
Fig: Submersible pump Fig: Fire Hydrant Systems
Submersible Pumps:
Submersible pumps, also known as stormwater, sewage, and septic pumps, find
applications in building services, domestic, industrial, commercial, rural,
municipal, and rainwater recycling. They are designed for various tasks, including
transferring stormwater, subsoil water, sewage, trade waste, chemicals, bore
water, and foodstuffs. There is a wide range of submersible pump options
available for different applications, including closed impellers, contra-block
impellers, vortex impellers, multi-stage pumps, single-channel pumps, cutter
pumps, and grinder pumps. These pumps can handle high flow, low flow, low
head, or high head situations.
Fire Hydrant Systems:
Fire hydrant systems, also referred to as hydrant boosters, fire pumps, or fire
water pumps, are high-pressure water pumps designed to increase the capacity
of fire-fighting systems in buildings where the mains water pressure is
insufficient. These systems are crucial for irrigation and water transfer
applications, enhancing the firefighting capabilities of the construction.
Fig: Submersible pump Fig: Fire Hydrant Systems
37
Positive Displacement Pumps:
Pumps that discharge volumes of liquid separated by periods of no discharge.
The purpose of positive displacement pumps is for metering, which provides
high accuracy.
With a positive displacement pump, a certain volume of liquid is discharged due
to the thrust exerted on it by a moving member for each cycle of pump
operation.
Liquid flow into the expanding cavity and the same amount of liquid is
discharged as the cavity reduces. Therefore, a constant flow is maintained by
the pump. A positive discharge pump is a good choice, where discharge
pressures vary over a large range, but flow must remain constant.
Positive displacement pumps do not use impellers but based on rotating or
reciprocating parts transfer the flow from the suction end to the discharge
side.
In case if an outlet is completely closed or got blocked, either the unit driving a
pump will stall or something will burst. Hence, a positive displacement type
pump requires a pressure regulator or pressure relief valve in the system.
Positive displacement pumps are classified into different types some of them
are discussed below like diaphragm, gear, peristaltic, lobe, and piston pumps.
Diaphragm Pumps:
Diaphragm pumps also known as AOD pumps (Air operated diaphragms),
pneumatic, and AODD pumps. The applications of these pumps mainly include
in continuous applications like in general plants, industrial and mining. AOD
pumps are particularly employed where power is not obtainable, otherwise in
unstable and combustible regions. These pumps are also utilized for transferring
chemical, food manufacturing, underground coal mines, etc.
These pumps are responding pumps and include two diaphragms which are
driven with condensed air. The section of air by transfer valve applies air
alternately toward the two diaphragms; where every diaphragm contains a set
of ball or check valves.
Positive Displacement Pumps:
Pumps that discharge volumes of liquid separated by periods of no discharge.
The purpose of positive displacement pumps is for metering, which provides
high accuracy.
With a positive displacement pump, a certain volume of liquid is discharged due
to the thrust exerted on it by a moving member for each cycle of pump
operation.
Liquid flow into the expanding cavity and the same amount of liquid is
discharged as the cavity reduces. Therefore, a constant flow is maintained by
the pump. A positive discharge pump is a good choice, where discharge
pressures vary over a large range, but flow must remain constant.
Positive displacement pumps do not use impellers but based on rotating or
reciprocating parts transfer the flow from the suction end to the discharge
side.
In case if an outlet is completely closed or got blocked, either the unit driving a
pump will stall or something will burst. Hence, a positive displacement type
pump requires a pressure regulator or pressure relief valve in the system.
Positive displacement pumps are classified into different types some of them
are discussed below like diaphragm, gear, peristaltic, lobe, and piston pumps.
Diaphragm Pumps:
Diaphragm pumps also known as AOD pumps (Air operated diaphragms),
pneumatic, and AODD pumps. The applications of these pumps mainly include
in continuous applications like in general plants, industrial and mining. AOD
pumps are particularly employed where power is not obtainable, otherwise in
unstable and combustible regions. These pumps are also utilized for transferring
chemical, food manufacturing, underground coal mines, etc.
These pumps are responding pumps and include two diaphragms which are
driven with condensed air. The section of air by transfer valve applies air
alternately toward the two diaphragms; where every diaphragm contains a set
of ball or check valves.
38
Fig: Diaphragm Pumps
Gear Pumps:
These pumps are a kind of rotating positive dislocation pump, which means they
force a stable amount of liquid for every revolution. These pumps move liquid
with machinery coming inside and outside of mesh for making a non-exciting
pumping act. These pumps are capable of pumping on high forces & surpass at
pumping high thickness fluids efficiently.
A gear pump doesn’t contain any valves to cause losses like friction & also high
impeller velocities. So this pump is compatible for handling thick liquids like fuel
as well as grease oils. These pumps are not suitable for driving solids as well as
harsh liquids.
Peristaltic Pumps:
Peristaltic pumps are also named as tube pumps, peristaltic pumps. These are a
kind of positive displacement pumps and the applications of these pumps mainly
involve in processing of chemical, food, and water treatment industries. It makes
a stable flow for measuring & blending and also capable of pumping a variety of
liquids like toothpaste and all kinds of chemicals.
Fig: Diaphragm Pumps
Gear Pumps:
These pumps are a kind of rotating positive dislocation pump, which means they
force a stable amount of liquid for every revolution. These pumps move liquid
with machinery coming inside and outside of mesh for making a non-exciting
pumping act. These pumps are capable of pumping on high forces & surpass at
pumping high thickness fluids efficiently.
A gear pump doesn’t contain any valves to cause losses like friction & also high
impeller velocities. So this pump is compatible for handling thick liquids like fuel
as well as grease oils. These pumps are not suitable for driving solids as well as
harsh liquids.
Peristaltic Pumps:
Peristaltic pumps are also named as tube pumps, peristaltic pumps. These are a
kind of positive displacement pumps and the applications of these pumps mainly
involve in processing of chemical, food, and water treatment industries. It makes
a stable flow for measuring & blending and also capable of pumping a variety of
liquids like toothpaste and all kinds of chemicals.
39
Lobe Pumps:
These pumps offer different characteristics like an excellent high efficiency, rust
resistance, hygienic qualities, reliability, etc. These pumps can handle high
thickness fluids & solids without hurting them. The working of these pumps can
be related to gear pumps, apart from the lobes which do not approach into
contact by each other. Additionally, these pumps have superior pumping rooms
compare with gear pumps that allow them to move slurries. These are made
with stainless steel as well as extremely polished.
Piston pumps:
Piston pumps are one kind type of positive dislocation pumps wherever the high
force seal responds through the piston. These pumps are frequently used
in water irrigation, scenarios requiring high, reliable pressure and delivery
systems for transferring chocolate, pastry, paint, etc.
Fig: Gear Pump Fig: Peristaltic Pump
Lobe Pumps:
These pumps offer different characteristics like an excellent high efficiency, rust
resistance, hygienic qualities, reliability, etc. These pumps can handle high
thickness fluids & solids without hurting them. The working of these pumps can
be related to gear pumps, apart from the lobes which do not approach into
contact by each other. Additionally, these pumps have superior pumping rooms
compare with gear pumps that allow them to move slurries. These are made
with stainless steel as well as extremely polished.
Piston pumps:
Piston pumps are one kind type of positive dislocation pumps wherever the high
force seal responds through the piston. These pumps are frequently used
in water irrigation, scenarios requiring high, reliable pressure and delivery
systems for transferring chocolate, pastry, paint, etc.
Fig: Gear Pump Fig: Peristaltic Pump
40
Fig: Lobe Pump Fig: Piston Pump
Valves:
Basic Introduction:
Essentially, valves are devices used to control, regulate, or direct flow within a
system or process.
They often have a number of characteristics that help define the ideal
application.
Whether we are looking to control flow or provide safety in a system that
handles liquids, solids, gases, or anything in between, there are stainless steel
valves that can help.
Valves provide several functions, including:
• Starting or stopping flow based on the valve state
• Regulating flow and pressure within a piping system
• Controlling the direction of flow within a piping system
Fig: Lobe Pump Fig: Piston Pump
Valves:
Basic Introduction:
Essentially, valves are devices used to control, regulate, or direct flow within a
system or process.
They often have a number of characteristics that help define the ideal
application.
Whether we are looking to control flow or provide safety in a system that
handles liquids, solids, gases, or anything in between, there are stainless steel
valves that can help.
Valves provide several functions, including:
• Starting or stopping flow based on the valve state
• Regulating flow and pressure within a piping system
• Controlling the direction of flow within a piping system
41
• Throttling flow rates within a piping system
• Improving safety through relieving pressure or vacuum in a piping system
Valve Opening Methods:
While valves may have similar objectives, their mechanical operations can vary
significantly. The manner in which a valve opens and closes not only affects its
overall performance but also determines the level of control over flow and the
speed of operation.
Valves generally fall into three categories:
1. Multi-Turn Valves: These valves function similar to a screw or piston. By
turning a handle, the plug, plate, membrane, or other obstruction
moves into the pipe's path, blocking access. Depending on the valve, they
can have varying differentials, allowing for adjustable opening or closing
speeds.
2. Quarter-Turn Valves: Quarter-turn valves provide a complete range of
motion in a 90-degree turn of the handle. They are ideal for situations
where quick action and easy opening or closing are more important than
precise control.
In addition to the mechanical motion, the method of actuation should also be
considered. Valves generally fall into three actuation categories:
1. Manual Valves: These valves are typically operated by hand, using
handwheels, levers, gear wheels, or chains.
2. Actuated Valves: These valves are often connected to electric motors, air
or pneumatic systems, hydraulic systems, or solenoids. They allow for
remote control and automation, making them suitable for highprecision
or large-scale applications.
3. Automatic Valves: These valves activate based on specific flow
conditions. Examples include check valves that close during backflow or
pressure release valves that activate when over-pressure is detected.
• Throttling flow rates within a piping system
• Improving safety through relieving pressure or vacuum in a piping system
Valve Opening Methods:
While valves may have similar objectives, their mechanical operations can vary
significantly. The manner in which a valve opens and closes not only affects its
overall performance but also determines the level of control over flow and the
speed of operation.
Valves generally fall into three categories:
1. Multi-Turn Valves: These valves function similar to a screw or piston. By
turning a handle, the plug, plate, membrane, or other obstruction
moves into the pipe's path, blocking access. Depending on the valve, they
can have varying differentials, allowing for adjustable opening or closing
speeds.
2. Quarter-Turn Valves: Quarter-turn valves provide a complete range of
motion in a 90-degree turn of the handle. They are ideal for situations
where quick action and easy opening or closing are more important than
precise control.
In addition to the mechanical motion, the method of actuation should also be
considered. Valves generally fall into three actuation categories:
1. Manual Valves: These valves are typically operated by hand, using
handwheels, levers, gear wheels, or chains.
2. Actuated Valves: These valves are often connected to electric motors, air
or pneumatic systems, hydraulic systems, or solenoids. They allow for
remote control and automation, making them suitable for highprecision
or large-scale applications.
3. Automatic Valves: These valves activate based on specific flow
conditions. Examples include check valves that close during backflow or
pressure release valves that activate when over-pressure is detected.
42
Common Types of Valves and Its Applications:
Different valve types serve various applications, and their characteristics and
standards provide an understanding of their intended use and expected
performance. Some common valve types include:
Ball valve:
A ball valve is a shut-off valve that uses a rotating ball with a bore to control the
flow of liquids or gases. Rotating the ball a quarter turn (90 degrees) around its
axis allows the medium to flow or be blocked. They are characterized by a long
service life and guarantee a reliable seal throughout their service life, even if the
valve has not been used for a long time. Therefore, they are more popular as
gate valves than gate valves, etc. See our Gate and Ball Valves article for a
complete comparison. Ball valves are more resistant to contaminated media
than most other types of valves.
In a special design, ball valves are also used as control valves. This application is
less common due to the relatively limited accuracy of flow control compared to
other types of control valves. However, this valve also has some advantages. For
example, a reliable seal is guaranteed even if the medium is contaminated.
Fig: Ball Valve
Common Types of Valves and Its Applications:
Different valve types serve various applications, and their characteristics and
standards provide an understanding of their intended use and expected
performance. Some common valve types include:
Ball valve:
A ball valve is a shut-off valve that uses a rotating ball with a bore to control the
flow of liquids or gases. Rotating the ball a quarter turn (90 degrees) around its
axis allows the medium to flow or be blocked. They are characterized by a long
service life and guarantee a reliable seal throughout their service life, even if the
valve has not been used for a long time. Therefore, they are more popular as
gate valves than gate valves, etc. See our Gate and Ball Valves article for a
complete comparison. Ball valves are more resistant to contaminated media
than most other types of valves.
In a special design, ball valves are also used as control valves. This application is
less common due to the relatively limited accuracy of flow control compared to
other types of control valves. However, this valve also has some advantages. For
example, a reliable seal is guaranteed even if the medium is contaminated.
Fig: Ball Valve
43
Gate valve:
Gate valves are control valves that allow the free flow of media or stop the flow
of liquids. The main advantage of gate valves is that the continuous,
unobstructed passage minimizes the pressure drop across the valve. In contrast
to butterfly valves, gate valve bores are unobstructed, which also allows the
passage of pigs during the pipe cleaning process. However, the gate valve is
slower than his quarter-turn valve and should only be used in fully open or fully
closed positions, not for the purpose of regulating flow. Automatic gate valves
can be electric or pneumatic, but manual gate valves are less expensive because
gate valves are typically used infrequently. Gate valves are also commonly called
sluice gate valves.
Fig: Gate Valve
Globe Valve:
Globe valves are essential components in various industries, providing precise
control over fluid flow. These valves feature a movable disc or plug that regulates
the flow by raising or lowering it against a seat. With their distinct globe-shaped
design, they allow for fine adjustments in flow rate, making them
Gate valve:
Gate valves are control valves that allow the free flow of media or stop the flow
of liquids. The main advantage of gate valves is that the continuous,
unobstructed passage minimizes the pressure drop across the valve. In contrast
to butterfly valves, gate valve bores are unobstructed, which also allows the
passage of pigs during the pipe cleaning process. However, the gate valve is
slower than his quarter-turn valve and should only be used in fully open or fully
closed positions, not for the purpose of regulating flow. Automatic gate valves
can be electric or pneumatic, but manual gate valves are less expensive because
gate valves are typically used infrequently. Gate valves are also commonly called
sluice gate valves.
Fig: Gate Valve
Globe Valve:
Globe valves are essential components in various industries, providing precise
control over fluid flow. These valves feature a movable disc or plug that regulates
the flow by raising or lowering it against a seat. With their distinct globe-shaped
design, they allow for fine adjustments in flow rate, making them
44
ideal for applications requiring accurate control. Globe valves are commonly
used in systems that handle high pressures, corrosive fluids, or where flow
modulation is necessary. Their construction includes a bonnet for pressure
balance and the ability to handle flow in both directions. Overall, globe valves
play a crucial role in maintaining efficient and reliable fluid control in industrial
processes.
Pressure Valve:
Pressure valves, also known as relief valves or safety valves, are essential
components in various industries. These valves automatically release excess
pressure from systems to prevent damage or hazardous situations. Operating
based on a predetermined set point, pressure valves open when the pressure
exceeds the specified limit, allowing fluid to escape and reducing the pressure
to a safe level. They play a crucial role in maintaining system integrity, protecting
equipment, and ensuring the safety of personnel. Pressure valves are widely
used in applications such as oil and gas, chemical processing, power generation,
and water treatment. Their reliable operation and ability to regulate pressure
make them indispensable for maintaining safe and efficient operations.
ideal for applications requiring accurate control. Globe valves are commonly
used in systems that handle high pressures, corrosive fluids, or where flow
modulation is necessary. Their construction includes a bonnet for pressure
balance and the ability to handle flow in both directions. Overall, globe valves
play a crucial role in maintaining efficient and reliable fluid control in industrial
processes.
Pressure Valve:
Pressure valves, also known as relief valves or safety valves, are essential
components in various industries. These valves automatically release excess
pressure from systems to prevent damage or hazardous situations. Operating
based on a predetermined set point, pressure valves open when the pressure
exceeds the specified limit, allowing fluid to escape and reducing the pressure
to a safe level. They play a crucial role in maintaining system integrity, protecting
equipment, and ensuring the safety of personnel. Pressure valves are widely
used in applications such as oil and gas, chemical processing, power generation,
and water treatment. Their reliable operation and ability to regulate pressure
make them indispensable for maintaining safe and efficient operations.
45
Plug Valve:
Plug valves are manual valves with quarter turn rotary action. A cylindrical or
conical plug (plug-like disc) is used to allow or prevent direct flow through the
body. Plug valves pass directly through the port, allowing fluid to pass through
the port cone with minimal turbulence. Flow can be in either fully open or fully
closed direction. Plug valves are used in a variety of fluid applications. Excellent
performance in muddy water applications. They are used as on-off shut-off
valves in air bubble sealing applications. They are used in air, gas and steam
applications, natural gas and oil pipeline systems, food processing, non-abrasive
slurries, vacuum, pharmaceutical services, vacuum and high pressure
applications. They are suitable for on-off valve regulation, bypass service and
moderate throttling. Plug valves were originally developed as an alternative to
gate valves. The quarter turn design of plug valves makes them easier to open
and close against the flow than gate valves. Plug valves are generally suitable for
low pressure and low temperature applications. Plug valves with bodies lined
with materials such as polytetrafluoroethylene (PTFE) can be used in corrosive
chemical applications.
Fig: Plug Valve
Plug Valve:
Plug valves are manual valves with quarter turn rotary action. A cylindrical or
conical plug (plug-like disc) is used to allow or prevent direct flow through the
body. Plug valves pass directly through the port, allowing fluid to pass through
the port cone with minimal turbulence. Flow can be in either fully open or fully
closed direction. Plug valves are used in a variety of fluid applications. Excellent
performance in muddy water applications. They are used as on-off shut-off
valves in air bubble sealing applications. They are used in air, gas and steam
applications, natural gas and oil pipeline systems, food processing, non-abrasive
slurries, vacuum, pharmaceutical services, vacuum and high pressure
applications. They are suitable for on-off valve regulation, bypass service and
moderate throttling. Plug valves were originally developed as an alternative to
gate valves. The quarter turn design of plug valves makes them easier to open
and close against the flow than gate valves. Plug valves are generally suitable for
low pressure and low temperature applications. Plug valves with bodies lined
with materials such as polytetrafluoroethylene (PTFE) can be used in corrosive
chemical applications.
Fig: Plug Valve
46
Some other types of Valves are as follows:
Butterfly Valve:
Due to their compact design, butterfly valves are fast acting rotary motion valves
that are ideal for tight spaces due to their wafer design. Butterfly valve bodies
are offered in a variety of configurations.
Check Valve:
These valves are used to prevent backflow and are usually self-actuating. This
automatically opens the valve when the medium flows through it in the intended
direction and closes it when the flow is reversed.
Knife Gate Valve:
Knife gate valves are typically used to control the flow of media containing solids
and have a thin gate valve controlled by linear motion that can cut through the
material to form a seal. These valves are not suitable for high pressure
applications, but are ideal for use with grease, oil, paper pulp, sludge, sewage,
and other media that can interfere with other types of valve operation.
Needle valve:
Needle valves are typically used in small diameter piping systems where fine and
precise flow control is required. The name comes from the top of the conical disc
used.
Pinch valve:
Pinch valves are commonly used to handle liquids, including solid materials,
slurries and suspended solids, and utilize linear motion. Pinch valves usually have
an inner sleeve to isolate the medium.
VALVE MATERIALS : ENSURING SAFETY AND LONG-LASTING
PERFORMANCE:
Depending on the intended use, the material of manufacture of the valve can be
an important factor in ensuring safe operation and reducing maintenance and
replacement costs over the life of the operation.
Some other types of Valves are as follows:
Butterfly Valve:
Due to their compact design, butterfly valves are fast acting rotary motion valves
that are ideal for tight spaces due to their wafer design. Butterfly valve bodies
are offered in a variety of configurations.
Check Valve:
These valves are used to prevent backflow and are usually self-actuating. This
automatically opens the valve when the medium flows through it in the intended
direction and closes it when the flow is reversed.
Knife Gate Valve:
Knife gate valves are typically used to control the flow of media containing solids
and have a thin gate valve controlled by linear motion that can cut through the
material to form a seal. These valves are not suitable for high pressure
applications, but are ideal for use with grease, oil, paper pulp, sludge, sewage,
and other media that can interfere with other types of valve operation.
Needle valve:
Needle valves are typically used in small diameter piping systems where fine and
precise flow control is required. The name comes from the top of the conical disc
used.
Pinch valve:
Pinch valves are commonly used to handle liquids, including solid materials,
slurries and suspended solids, and utilize linear motion. Pinch valves usually have
an inner sleeve to isolate the medium.
VALVE MATERIALS : ENSURING SAFETY AND LONG-LASTING
PERFORMANCE:
Depending on the intended use, the material of manufacture of the valve can be
an important factor in ensuring safe operation and reducing maintenance and
replacement costs over the life of the operation.
47
Stainless steel valves are a great option for a variety of process environments,
including corrosive media (chemicals, brines, acids, etc.), environments with
strict hygiene standards (food and beverage manufacturing, pharmaceuticals,
etc.), involving high pressure or high temperature processes. However, when
dealing with solvents, fuels, or volatile organic compounds (VOCs), it is often
better to choose valve materials made from non-sparking materials such as
brass, bronze, copper, or even plastics. , would be a better option. In addition to
selecting the correct body material, interior (wet) trim panels should also be
evaluated for chemical compatibility. If the valve contains elastomers, chemical
compatibility, pressure and temperature limits should also be evaluated.
Depending on their intended use, valves may be required to meet specific
standards to meet government safety, hygiene, and other requirements.
While there are too many standard organizations and potential regulations to
cover in detail, common general standard organizations include:
• CSA Group (CSA)
• The American Society of Mechanical Engineers (ASME)
• The American National Standards Institute (ANSI)
• The American Society for Testing Materials International (ASTM International)
• The Manufacturers Standardization Society (MSS)
• The International Organization for Standardization (ISO)
• The Public Health and Safety Organization (NSF)
• NACE International (NACE)
• The American Petroleum Institute (API)
• American Water Works Association (AWWA)
Stainless steel valves are a great option for a variety of process environments,
including corrosive media (chemicals, brines, acids, etc.), environments with
strict hygiene standards (food and beverage manufacturing, pharmaceuticals,
etc.), involving high pressure or high temperature processes. However, when
dealing with solvents, fuels, or volatile organic compounds (VOCs), it is often
better to choose valve materials made from non-sparking materials such as
brass, bronze, copper, or even plastics. , would be a better option. In addition to
selecting the correct body material, interior (wet) trim panels should also be
evaluated for chemical compatibility. If the valve contains elastomers, chemical
compatibility, pressure and temperature limits should also be evaluated.
Depending on their intended use, valves may be required to meet specific
standards to meet government safety, hygiene, and other requirements.
While there are too many standard organizations and potential regulations to
cover in detail, common general standard organizations include:
• CSA Group (CSA)
• The American Society of Mechanical Engineers (ASME)
• The American National Standards Institute (ANSI)
• The American Society for Testing Materials International (ASTM International)
• The Manufacturers Standardization Society (MSS)
• The International Organization for Standardization (ISO)
• The Public Health and Safety Organization (NSF)
• NACE International (NACE)
• The American Petroleum Institute (API)
• American Water Works Association (AWWA)
48
HEAT EXCHANGER:
Heat exchangers are devices that are used to transfer thermal energy from one
fluid to another without mixing the two fluids. The fluids are usually separated
by a solid wall (with high thermal conductivity) to prevent mixing or they may
be in direct contact.
The classic example of a heat exchanger is found in an internal combustion
engine in which an engine coolant flows through radiator coils and air flows
past the coils, which cools the coolant and heats the incoming air. In power
engineering, common applications of heat exchangers include steam
generators, fan coolers, cooling water heat exchangers, and condensers. For
example, steam generator is used to convert feedwater into steam from heat
produced in a nuclear reactor core. The steam produced drives the turbine.
Heat transfer in a heat exchanger usually involves convection in each fluid and
thermal conduction through the wall separating the two fluids. In the analysis
of heat exchangers, it is often convenient to work with an overall heat transfer
coefficient, known as a U-factor. The U-factor is defined by an expression
analogous to Newton’s law of cooling.
There are several types of heat exchangers, each with its own design and
operating principles. Here are some commonly used types:
Parallel-flow arrangement:
In the parallel-flow arrangement, the hot and cold fluids enter at the same
end, flow in the same direction, and leave at the same end.
Counter-flow arrangement:
In the counter-flow arrangement, the fluids enter at opposite ends, flow in
opposite directions, and leave at opposite ends.
In the Figure shows the directions of fluid flow in the parallel and counter-flow
exchangers. Under comparable conditions, more heat is transferred in a counter-
flow arrangement than in a parallel flow heat exchanger. The temperature
profiles of the two heat exchangers indicate two major disadvantages in the
parallel-flow design.
HEAT EXCHANGER:
Heat exchangers are devices that are used to transfer thermal energy from one
fluid to another without mixing the two fluids. The fluids are usually separated
by a solid wall (with high thermal conductivity) to prevent mixing or they may
be in direct contact.
The classic example of a heat exchanger is found in an internal combustion
engine in which an engine coolant flows through radiator coils and air flows
past the coils, which cools the coolant and heats the incoming air. In power
engineering, common applications of heat exchangers include steam
generators, fan coolers, cooling water heat exchangers, and condensers. For
example, steam generator is used to convert feedwater into steam from heat
produced in a nuclear reactor core. The steam produced drives the turbine.
Heat transfer in a heat exchanger usually involves convection in each fluid and
thermal conduction through the wall separating the two fluids. In the analysis
of heat exchangers, it is often convenient to work with an overall heat transfer
coefficient, known as a U-factor. The U-factor is defined by an expression
analogous to Newton’s law of cooling.
There are several types of heat exchangers, each with its own design and
operating principles. Here are some commonly used types:
Parallel-flow arrangement:
In the parallel-flow arrangement, the hot and cold fluids enter at the same
end, flow in the same direction, and leave at the same end.
Counter-flow arrangement:
In the counter-flow arrangement, the fluids enter at opposite ends, flow in
opposite directions, and leave at opposite ends.
In the Figure shows the directions of fluid flow in the parallel and counter-flow
exchangers. Under comparable conditions, more heat is transferred in a counter-
flow arrangement than in a parallel flow heat exchanger. The temperature
profiles of the two heat exchangers indicate two major disadvantages in the
parallel-flow design.
49
• The large temperature difference at the ends causes large thermal
stresses.
• The temperature of the cold fluid exiting the heat exchanger never
exceeds the lowest temperature of the hot fluid.
The heat transfer surface in heat exchangers can be arranged in several forms.
Heat exchangers are therefore also classified as:
• Double pipe heat exchangers:
Double pipe heat exchangers are cheap for both design and maintenance,
making them a good choice for small industries. In these exchangers one
fluid flows inside the tube and the other fluid flows on the outside.
Although they are simple and cheap, their low efficiency coupled with the
high space occupied in large scales, has led modern industries to use more
efficient heat exchangers like shell and tube .
• The large temperature difference at the ends causes large thermal
stresses.
• The temperature of the cold fluid exiting the heat exchanger never
exceeds the lowest temperature of the hot fluid.
The heat transfer surface in heat exchangers can be arranged in several forms.
Heat exchangers are therefore also classified as:
• Double pipe heat exchangers:
Double pipe heat exchangers are cheap for both design and maintenance,
making them a good choice for small industries. In these exchangers one
fluid flows inside the tube and the other fluid flows on the outside.
Although they are simple and cheap, their low efficiency coupled with the
high space occupied in large scales, has led modern industries to use more
efficient heat exchangers like shell and tube .
50
• Shell and tube heat exchangers:
Shell and tube heat exchangers in their various construction modifications
are probably the most widespread and commonly used basic heat
exchanger configuration in industry. Shell-and-tube heat exchangers are
further classified according to the number of shell and tube passes
involved. Shell and tube heat exchangers are typically used for high-
pressure applications (with pressures greater than 30 bar and
temperatures greater than 260 °C). This is because the shell and tube heat
exchangers can withstand high pressures due to their shape. In this type
of heat exchanger, a number of small bore pipes are fitted between two
tube plates and primary fluid flows through these tubes. The tube bundle
is placed inside a shell and the secondary fluid flows through the shell and
over the surface of the tubes. In nuclear engineering, this design of heat
exchangers is widely used as in case of steam generator, which are used
to convert feedwater into steam from heat produced in a nuclear reactor
core. To increase the amount of heat transferred and the power
generated, the heat exchange surface must be maximized. This is
obtained by using tubes. Each steam generator can contain anywhere
from 3,000 to 16,000 tubes, each about 19mm diameter.
Fig: Shell and Tube Heat Exchanger
• Shell and tube heat exchangers:
Shell and tube heat exchangers in their various construction modifications
are probably the most widespread and commonly used basic heat
exchanger configuration in industry. Shell-and-tube heat exchangers are
further classified according to the number of shell and tube passes
involved. Shell and tube heat exchangers are typically used for high-
pressure applications (with pressures greater than 30 bar and
temperatures greater than 260 °C). This is because the shell and tube heat
exchangers can withstand high pressures due to their shape. In this type
of heat exchanger, a number of small bore pipes are fitted between two
tube plates and primary fluid flows through these tubes. The tube bundle
is placed inside a shell and the secondary fluid flows through the shell and
over the surface of the tubes. In nuclear engineering, this design of heat
exchangers is widely used as in case of steam generator, which are used
to convert feedwater into steam from heat produced in a nuclear reactor
core. To increase the amount of heat transferred and the power
generated, the heat exchange surface must be maximized. This is
obtained by using tubes. Each steam generator can contain anywhere
from 3,000 to 16,000 tubes, each about 19mm diameter.
Fig: Shell and Tube Heat Exchanger
51
• Plate heat exchangers :
A plate heat exchanger is a type of heat exchanger that uses metal plates
to transfer heat between two fluids. This arrangement is popular with
heat exchangers using air or gas as well as lower velocity fluid flow. The
classic example of a heat exchanger is found in an internal combustion
engine in which an engine coolant flows through radiator coils and air
flows past the coils, which cools the coolant and heats the incoming air.
When compared to shell and tube exchangers, the stacked-plate
arrangement typically has lower volume and cost. Another difference
between the two is that plate exchangers typically serve low to medium
pressure fluids, compared to medium and high pressures of shell and
tube.
Fig: Plate Heat Exchangers
• Plate heat exchangers :
A plate heat exchanger is a type of heat exchanger that uses metal plates
to transfer heat between two fluids. This arrangement is popular with
heat exchangers using air or gas as well as lower velocity fluid flow. The
classic example of a heat exchanger is found in an internal combustion
engine in which an engine coolant flows through radiator coils and air
flows past the coils, which cools the coolant and heats the incoming air.
When compared to shell and tube exchangers, the stacked-plate
arrangement typically has lower volume and cost. Another difference
between the two is that plate exchangers typically serve low to medium
pressure fluids, compared to medium and high pressures of shell and
tube.
Fig: Plate Heat Exchangers
52
Air Cooled Heat Exchangers:
As the name suggests, these heat exchangers use air as the cooling medium.
They are often used in applications where water availability is limited or when
the cooling fluid needs to be kept separate from the process fluid.
Fig: Air Cooled Heat Exchanger
Plate-Fin Heat Exchangers:
These heat exchangers consist of finned plates with fluid channels. The fins
increase the surface area for heat transfer and improve the efficiency of the heat
exchanger. They are commonly used in applications involving high-pressure and
high-temperature fluids.
Fig: Plate-Fin Heat Exchanger
Air Cooled Heat Exchangers:
As the name suggests, these heat exchangers use air as the cooling medium.
They are often used in applications where water availability is limited or when
the cooling fluid needs to be kept separate from the process fluid.
Fig: Air Cooled Heat Exchanger
Plate-Fin Heat Exchangers:
These heat exchangers consist of finned plates with fluid channels. The fins
increase the surface area for heat transfer and improve the efficiency of the heat
exchanger. They are commonly used in applications involving high-pressure and
high-temperature fluids.
Fig: Plate-Fin Heat Exchanger
53
Heat exchangers find extensive use in industries for various purposes:
• Heating and Cooling: Heat exchangers are used for heating or cooling process
fluids in industries such as chemical, oil and gas, power generation, and HVAC
systems.
• Refrigeration and Air Conditioning: Heat exchangers are essential components
in refrigeration and air conditioning systems. They transfer heat between the
refrigerant and the air or water, enabling cooling or heating of the surrounding
space.
• Heat Recovery: Heat exchangers are used to recover waste heat from industrial
processes and transfer it to other fluids for reuse. This helps improve energy
efficiency and reduces operating costs.
• Power Generation: Heat exchangers are critical components in power plants,
facilitating heat transfer between the steam and water in boilers, condensers,
and other systems.
The importance of heat exchangers in industries cannot be overstated. They
contribute significantly to energy conservation, cost reduction, and
environmental sustainability. By enabling efficient heat transfer, heat exchangers
help optimize process performance, reduce energy consumption, and minimize
the environmental impact of industrial operations. Proper selection, design, and
maintenance of heat exchangers are crucial for achieving optimal performance
and ensuring the smooth operation of industrial processes.
Heat exchangers find extensive use in industries for various purposes:
• Heating and Cooling: Heat exchangers are used for heating or cooling process
fluids in industries such as chemical, oil and gas, power generation, and HVAC
systems.
• Refrigeration and Air Conditioning: Heat exchangers are essential components
in refrigeration and air conditioning systems. They transfer heat between the
refrigerant and the air or water, enabling cooling or heating of the surrounding
space.
• Heat Recovery: Heat exchangers are used to recover waste heat from industrial
processes and transfer it to other fluids for reuse. This helps improve energy
efficiency and reduces operating costs.
• Power Generation: Heat exchangers are critical components in power plants,
facilitating heat transfer between the steam and water in boilers, condensers,
and other systems.
The importance of heat exchangers in industries cannot be overstated. They
contribute significantly to energy conservation, cost reduction, and
environmental sustainability. By enabling efficient heat transfer, heat exchangers
help optimize process performance, reduce energy consumption, and minimize
the environmental impact of industrial operations. Proper selection, design, and
maintenance of heat exchangers are crucial for achieving optimal performance
and ensuring the smooth operation of industrial processes.
54
MECHANICAL MAINTENANCE
Introduction:
Mechanical maintenance plays a crucial role in ensuring the efficient and reliable
functioning of mechanical systems, equipment, and machinery in various
industries. It involves a range of activities aimed at preventing failures, reducing
downtime, and extending the lifespan of mechanical assets. In this
comprehensive article, we will explore the different types of mechanical
maintenance, the types of mechanical failure, their definitions, and the
preventive measures to mitigate such failures.
Types of Mechanical Maintenance:
• Corrective or Breakdown Maintenance:
In Corrective or Breakdown maintenance repairs are made after the
equipment is out of order and it can not perform its normal function.
In that case, the maintenance department comes into action and makes
necessary repairs after checking. They do not attend to the equipment
until another breakdown occurs.
Breakdown leads to poor maintenance, excessive delays in production,
more spoilt material, and profit loss.
This type of maintenance is justified for small plants, where they do not
feel financial justification for scheduled techniques Corrective or
Breakdown maintenance needs few records and a small staff.
• Scheduled Maintenance:
Breakdown maintenance can’t be applied in the maintenance of cranes,
lifts, hoists, and pressure vassals. Scheduled maintenance must be applied
in such a condition.
The goals of the scheduled maintenance are to reduce reactive
maintenance, equipment failure, and maintenance backlog. Standard
checks help to increase the lifetime of equipment and reduce the number
MECHANICAL MAINTENANCE
Introduction:
Mechanical maintenance plays a crucial role in ensuring the efficient and reliable
functioning of mechanical systems, equipment, and machinery in various
industries. It involves a range of activities aimed at preventing failures, reducing
downtime, and extending the lifespan of mechanical assets. In this
comprehensive article, we will explore the different types of mechanical
maintenance, the types of mechanical failure, their definitions, and the
preventive measures to mitigate such failures.
Types of Mechanical Maintenance:
• Corrective or Breakdown Maintenance:
In Corrective or Breakdown maintenance repairs are made after the
equipment is out of order and it can not perform its normal function.
In that case, the maintenance department comes into action and makes
necessary repairs after checking. They do not attend to the equipment
until another breakdown occurs.
Breakdown leads to poor maintenance, excessive delays in production,
more spoilt material, and profit loss.
This type of maintenance is justified for small plants, where they do not
feel financial justification for scheduled techniques Corrective or
Breakdown maintenance needs few records and a small staff.
• Scheduled Maintenance:
Breakdown maintenance can’t be applied in the maintenance of cranes,
lifts, hoists, and pressure vassals. Scheduled maintenance must be applied
in such a condition.
The goals of the scheduled maintenance are to reduce reactive
maintenance, equipment failure, and maintenance backlog. Standard
checks help to increase the lifetime of equipment and reduce the number
55
of equipment repairs and replacements. The scheduled tasks also allow
you to better allocate resources in a cost-effective and efficient manner.
• Preventive Maintenance:
In preventive maintenance locates weak spots like bearing, part under
excessive vibration, pressure vessel, etc which needs regular inspection
and minimal repair thereby reducing the danger of breakdown.
Preventive maintenance involves periodic inspection of components and
corrects them in such conditions while they are still in the minor stage. To
make plant equipment always ready for use and achieve maximum
production.
• Predictive Maintenance:
It is newer maintenance technique uses human senses or sensing
instrument such as Audio gauge to sense machine sound, Vibration
analyzer for checking vibration, Amplitude meter, thermometer, pressure
gauge, etc, to predict trouble before breakdown .
In predictive maintenance, equipment conditions are measured
periodically to take timely action such as equipment adjustment, repair,
or overhaul.
Predictive maintenance increases the lifetime of the equipment. The
objective of predictive maintenance is the ability to first predict when
equipment failure could occur, followed by preventing the failure through
regular and timely scheduled and corrective maintenance.
of equipment repairs and replacements. The scheduled tasks also allow
you to better allocate resources in a cost-effective and efficient manner.
• Preventive Maintenance:
In preventive maintenance locates weak spots like bearing, part under
excessive vibration, pressure vessel, etc which needs regular inspection
and minimal repair thereby reducing the danger of breakdown.
Preventive maintenance involves periodic inspection of components and
corrects them in such conditions while they are still in the minor stage. To
make plant equipment always ready for use and achieve maximum
production.
• Predictive Maintenance:
It is newer maintenance technique uses human senses or sensing
instrument such as Audio gauge to sense machine sound, Vibration
analyzer for checking vibration, Amplitude meter, thermometer, pressure
gauge, etc, to predict trouble before breakdown .
In predictive maintenance, equipment conditions are measured
periodically to take timely action such as equipment adjustment, repair,
or overhaul.
Predictive maintenance increases the lifetime of the equipment. The
objective of predictive maintenance is the ability to first predict when
equipment failure could occur, followed by preventing the failure through
regular and timely scheduled and corrective maintenance.
56
REFERENCES
• Power Plant Engineering- 4 th Edition – P.K. NAG
• Power Plant Engineering (3rd Edition) – R.K. Rajput
• https://www.unifiedalloys.com/blog/valves-101
• https://tameson.com/pages/gate-valve
• https://iocl.com/pages/refining-overview
• https://iocl.com/pages/refining-overview
• https://iocl.com/download/IndianOil-Annual-Report-2019-20.pdf
• https://en.wikipedia.org/wiki/Indian_Oil_Corporation
• https://en.wikipedia.org/wiki/Indian_Oil_Corporation
• https://en.wikipedia.org/wiki/History_of_the_oil_industry_in_India#:~
:text=The%20first%20oil%20production%20started,the%20heels%20of
%20industrial%20development
REFERENCES
• Power Plant Engineering- 4 th Edition – P.K. NAG
• Power Plant Engineering (3rd Edition) – R.K. Rajput
• https://www.unifiedalloys.com/blog/valves-101
• https://tameson.com/pages/gate-valve
• https://iocl.com/pages/refining-overview
• https://iocl.com/pages/refining-overview
• https://iocl.com/download/IndianOil-Annual-Report-2019-20.pdf
• https://en.wikipedia.org/wiki/Indian_Oil_Corporation
• https://en.wikipedia.org/wiki/Indian_Oil_Corporation
• https://en.wikipedia.org/wiki/History_of_the_oil_industry_in_India#:~
:text=The%20first%20oil%20production%20started,the%20heels%20of
%20industrial%20development
57
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