VOCATIONAL TRAINING REPORT

INDIAN OIL CORPORATION LIMITED HALDIA OIL REFINERY

PERIOD OF TRAINING: 6TH JUNE 2011 TO 25TH JUNE 2011

SUBMITTED BY: PARIJAT MAJUMDAR ROLL NO: 08119016010 REGISTRATION NO: 081190110324 FOR THE DEGREE OF BACHELOR OF TECHNOLOGY IN ELECTRICAL ENGINEERING SILIGURI INSTITUTE OF TECHNOLOGY P.O. SUKNA, SILIGURI DT. DARJEELING PIN 734009

TRAINING SCHEDULE

TRAINING AREAS(UNITS) TPS OPERATION

GT OPERATION

TESTING AND WORKSHOP DHDS

FOB

LOB

TELECOM(REFINERY)

TPS MAINTENANCE

OHCU

OFFSITE

TRAINING PERIOD FROM 07/06/2011 TO 07/06/2011 FROM 09/06/2011 TO 09/06/2011 FROM 11/06/2011 TO 11/06/2011 FROM 14/06/2011 TO 14/06/2011 FROM 16/06/2011 TO 16/06/2011 FROM 18/06/2011 TO 18/06/2011 FROM 21/06/2011 TO 21/06/2011 FROM 21/06/2011 TO 21/06/2011 FROM 23/06/2011 TO 23/06/2011 FROM 23/06/2011 TO 23/06/2011

SIGNATURE OF CONCERNED ENGINEER WITH DESIGNATION AND SEAL

ACKNOWLEDGEMENT

For successful completion of any work, the contribution and co-operation of many persons is needed. So it is my pleasant duty to express my heartiest thanks to all the persons linked in direct or indirect manner for the successful completion of this training by giving his/her helping hand. I would like to share this opportunity to express my full heart gratitude and indebtedness to all the officials who made this training possible. I would like to thank Mr. D. Sinha(Sr. Manager, Training & Development Department Haldia refinery) for giving e the chance to undergo the training in this prestigious establishment. I would also like to thank the Principle of Siliguri Institute of Technology Mr. Goutam Das, HOD of Electrical Engineering Department of Siliguri Institute of Technology Mr. Deepak Bhattacharjee, for permitting me to undergo training in this prestigious establishment and at last I would like to thank the various officers and employees at the different departments (TPS, GT, DHDS, FOB, LOB, TELECOM, OHCU & OFFSITE) for giving me the valuable and important information about the units purpose. Lastly I would like to thank my parents for their blessings and constant support without which I would never reach here. Also my trainee-mates, who are cooperate with me very friendly and clearly. I always try to understand the matter easily by our discussions.

DATE:

PARIJAT MAJUMDAR

INDEX

SERIAL NO
1

PERTICULARS
INTRODUCTION

PAGE NO

Do S & Dont S OF HALDIA REFINERY BATTERY AREA ELECTRICAL SINGLE LINE DIAGRAM OF HALDIA REFINERY THERMAL POWER STATION OPERATION & MAINTENANCE UNIT GAS TURBINE UNIT

WORKSHOP & TESTING UNIT

DISEL HYDRO DESULPHURIRATION UNIT

FUEL OIL BLOCK UNIT

LUBE OIL BLOCK UNIT

10

TELECOM(REFINERY) UNIT

11

OXYHYDROCALAYTIC UNIT

12

OFFSITE UNIT

13

CONCLUTION

INTRODUCTION
Oil, Haldia Refinery, the fourth in the chain of seven operating refineries of Indian was commissioned in January 1975. It is situated 136 km downstream of

Kolkata in the district of East Midnapur, West Bengal, near the confluence of river Hoogly and river Haldi. The refinery had an original crude oil processing capacity of 2.5 MMTPA. Petroleum products from this Refinery are supplied mainly to eastern India through two Product Pipelines as well as through Barges, Tank Wagons and Tank Trucks. Products like MS, HSD and Bitumen are exported from this refinery. The strategic significance of this Refinery lies in its being the only coastal refinery of the Corporation and the lone lube flagship, apart from being the sole producer of Jute Batching Oil and Russian Turbine Fuel. Capacity of the Refinery was increased to 2.75 MMTPA through de-bottlenecking in 1989-90. Refining capacity was further increased to 3.75 MMTPA in 1997 with the installation/commissioning of second Crude Distillation Unit of 1.0 MMTPA capacity. Diesel Hydro Desulphurisation (DHDS) Unit was commissioned in 1999, for production of low Sulphur content (0.25% wt) High Speed Diesel (HSD). With augmentation of this unit, refinery is producing BS-II and Euro-III equivalent HSD (part quantity) at present. Reside Fluidized Catalytic Cracking Unit (RFCCU) was commissioned in 2001 in order to increase the distillate yield of the refinery as well as to meet the growing demand of LPG, MS and HSD. Refinery also produces eco friendly Bitumen emulsion and Microcrystalline Wax. In addition, a Catalytic Dewaxing Unit (CIDWU) was installed and commissioned in 2003, for production of high quality Lube Oil Base Stocks (LOBS), meeting the API Gr-II standard of LOBS. This is the only refinery in the country to produce such high quality LOBS. In order to meet the Euro-III fuel quality standards, the MS Quality Improvement Project has been incorporated for production of Euro-III equivalent MS. Currently the unit is under stabilization. At present, the Refinery is operating at a capacity of 5.5 MMTPA. Refinery expansion to 7.5 MMTPA as well as a Hydro cracker project has been approved for Haldia Refinery, commissioning of which shall enable this Refinery to supply entire Euro III HSD to the eastern region of India.

Do S and Dont S INSDE HALDIA REFINERY BATTERY AREA Dos

1. 2. 3 4 5 6 7 8

Always wear helmets & shoes while entering battery area. Always wear chin strap with helmet. Use safety shower & eye wash fountain in case of chemical spill Report any leakages, fires, accidents to fire station by telephone no 00/ 101/ 110 Break nearest manual call point in case of any emergency for informing F&S Smoking is allowed only at smoking booths. Always walk on foot path/road side inside refinery. Always run across the wind direction in case of gas leak. Donts Do not bring lighter, safety matches inside refinery Do not bring mobile phones inside refinery Do not ignore safety signs Do not block the roads. Keep the roads free for fire vehicle movement. Do not walk on pipelines Do not jump on from one platform to other Do not move in isolation. Always move with concerned supervisor Do not stand under suspended load

1. 2. 3. 4. 5. 6. 7. 8.

THERMAL POWER STATION UNIT

While visiting the Haldia refinery of IOC I have the privilege to visit the thermal power plant (Captive Power Plant 1) section of this refinery under the kind guidance of Mr. A. K. Sarkar SPUE(electrical).

EFFICINECY:
Power is energy per time. The power output or capacity of an electric plant can be expressed in units of Megawatts electric. The electric efficiency of a conventional thermal power station, considered as salable energy (in MWs) produced at the plant busbars as a percent of the heating value of the fuel consumed. This efficiency is limited as all heat engines are governed by laws of thermodynamics. The rest of the energy must leave the plant in the form of heat. This waste heat can go through a condenser and disposed of with cooling water or in cooling towers. Since efficiency of the plant is fundamentally limited by the ratio of the absolute temperatures of the steam at turbine input and output, efficiency improvements require use of higher temperature, and therefore pressure, steam.

A Thermal Power Station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which either drives an electrical

generator or does some other work, like ship population. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated: this is known as Rankine Cycle. It needs water, fuel and air mainly to generate power.The sources of water are: 1. PHE(Public Health engineering) 2. own tubules of IOC refinery 3. HFC (Haldia Fertilizer corporation) This water mainly serves the purpose of 1. Steam generating 2. Cooling The water of PHE &HFC are first taken in to the factory by certain pipes and they are then stored in to the water reservoir. The water then processed by the following methods: 1. Coagulation with chemical addition in parshall flummer 2. Flocculation 3. Clarification 4. Filtration in rapid gravity filter 5. Disinfection(pre and post chlorination) Then this water comes into the DM water plant for De Mineralization process. This process is done to give the boiler and turbine ultra pure quality of water. Its a special kind of ion exchanging process, where cautions are replaced by hydrogen and anions are replaced by hydroxyl-ion. When water is passed through a caution exchange resin in the hydrogen form and then through an anion exchange resin in the hydroxyl form it becomes de-mineralized. These ions are stored in tanks known as Bead. From this DM tank the water comes into the pump, where with the help of de-arreter the dissolve oxygen of the water is removed fully. Here to do this we do chemical dosing. There are two types of dosing are done: 1. Hydrazine Dosing 2. Tri-sodium phosphate Dosing This is done to stop produce the corrosion & surge in the boiler pipes is form due to the presence of acidic components in the feed water. Then through the feed pump this purified water goes into the boiler These boilers are water tube, bi drum, and vertical type boilers. Here are 4 boilers and each one of them are oil feed type. The two drums are 1. Mud Drum 2. Steam Drum The lower drum is known as Mud Drum and upper drum is known as Steam Drum. There are two firing point in the boiler one is in the upper section and one is in the bottom section. Among these 4 boilers 3 of them are having a capacity of 125 ton/hr (but the capacity is reducing with the increasing age of the boilers and now the capacity is around 100 105 ton/hr) and the other one has a capacity of 150 ton/hr. The pressure of steam in the boiler is 62 kgf/cm2 and the temperature in the boiler is 450 degree C. the steam that produced in the boiler is VM Steam means high pressure steam. This steam is then supplied into the turbine. The pressure of steam in the turbine is 14.5 to 15 kgf/cm2 and the temperature of the steam in the turbine is 330 degree C. Here the pressure of the steam gets reduced and known as VM steam or Medium pressure steam. Sometimes the pressure of

the steam is 40 kgf/cm2 and this steam is known as MH Steam or Medium-High Pressure Steam. This steam then goes into the Process Unit through Steam Tracing Line. With this the turbo generators have a pressure reducing station where the pressure of the steam reduces. The station has the following ratings: Steam Inlet Pressure(Ata) 62 Ata Steam Outlet Pressure(Ata) 15 Ata Maximum Inlet temperature(degree centigrade) 480 degree centigrade Normal Inlet Temperature(degree centigrade) 450 degree centigrade Steam flow rate(ton/hr) 8 to 80 ton/hr Steam Outlet Temperature(degree centigrade) 280 degree centigrade Injection Water temperature(degree centigrade) 145 degree centigrade Injection Water pressure(Ata) 80 Ata Injection Water Flow Rate (ton/hr) 1.5 ton/hr The setting of VM Safety valves are in 51 PSW.44A/B/C:17.5 to 18 kg/cm2. The steam that comes out from the boiler and goes into the turbine is of very high pressure. So it has a tendency to come out from the turbine into the atmosphere where the pressure of air is very low. So to stop this and to keep the steam in the turbine the Gladding process is used. In this process a low pressure steam (0.5 kg/m2) is injected again in the turbine inlet. The design of the turbine inlet is off Labyrinth structure so when the steam is passing through it the pressure gets reduced and in some point the pressure of both the steam gets equal and the extra injected steam known as Glad Steam prevent the main steam from getting out of the turbine.

EJECTOR:
Ejector is a chamber where air mixed steam exists and is controlled condenser vacuum. It is of 2 types: 1. Starting Ejector: It is used if the flow is higher than servicing ejector then to vacuum the condenser as early as possible. 2. Servicing Ejector: It is used to maintain the vacuum in the condenser.

BARRING MOTOR:
1. At the time of emergency stop (trip) or panned shut down: At the time of turbine stop barring motor will be on & it will rotate the turbine at 5-6 rpm. If turbine is stopped at 450 degree centigrade temperature without barring then it will get sagged due to uneven temperature distribution. Barring distributions the temperature evenly on the body of turbine. 2. At the time of starting after a long prescribed time duration: To soak the turbine so that it can withstand 450 degree centigrade temperature.

OIL SYSTEM:
The oil system is of 3 types: Auxiliary oil pump: This is used for starting and for shutdown purpose.

Emergency oil pump: This is used for emergency & when AOP is out of service. Main oil pump: This is used for normal condition. The main purpose of the oil is: 1. For lubrication purpose. 2. For cooling purpose. Oil Centrifuge: This is used to take out the water from the pipes of boiler if the lubrication system is out of order. Oil Cooler: The oil is being heated when it passes through the bearings of the turbine. The temperature is 40degree centigrade when it enters into the bearings and when it leaving the bearings the temperature is 47degree centigrade. The function of the oil cooler is to take out the extra heat from the oil by spraying water in it and make the oil temperature back as the previous.

STEAM TURBINE DRIVEN ELECTRIC GENERATOR:

The steam turbine driven generators have auxiliary systems enabling them to work satisfactorily and safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be kept in position while running. To minimize the frictional resistance to the rotation, the shaft rotates are lined with a low friction material like Babbit Metal. Oil lubrication is provided to further reduce the friction between shaft and bearing surface and to limit the heat generated. n Haldia refinerys thermal power station there are 4 generators. 3 of them have rating of 10.5 MW and the other one has a capacity of 16.5 MW. The static part of the generator is stator which is 3 phase double star winding from which is output 3 phase AC power is available at a rated voltage of 6.6KV. The rotating part of generator is rotor which has field winding excited by controlled DC power supplied from AVR (Automatic Voltage Regulator) through carbon brushes & slip rings mounted on the rotor shaft. The direction of rotation of generator rotor is anticlockwise when viewed from slip rings side. Both stator & rotor of generator is cooled by natural air cooling. The generators have the following specifications:

Generator Specifications Manufacture BHEL(HYDERABAD),1972

Type Sr. no Voltage Rated speed frequency Power factor at full load Nominal rating Admissible overload Sub transient reactance Transient reactance Synchronous reactance Negative sequence reactance Zero sequence reactance Neutral point earthing Vector rotation of 3phase Insulation Phase connection Cooling Generator terminals Maximum allowed output with one of the four cooling elements out of operation Moment of inertia Volume of cooling Critical speed of rotor No load field current Minimum diameter of slip rings Circuit breaker Carbon brush no Size GRAD

T G N 2202 33/2 TG 1,1016,TG 2 TG 3 6600 V (+/- 5%) 3000RPM 50C/S 0.8 10.5 MW at 0.8 PF 11.3 MW 11% 18% 16.18% 11% 4.5% 3 OHM for 1250A for 10sec Anti clockwise Class B type star Air cooled 6 9200KVA 1.88 tgm2 11m3/sec 1750 rpm 165 A 380mm 6.6KV/1500A/500MVA 2*8 25*32 mm HM6R

STARTING OF GENERATORS: The followings should be checked before starting the generators: 1. Ensure that the generators circuit breaker is in test position and is OFF. 2. Ensure that the field circuit breaker is open(OFF)

3. Ensure all control fuses are healthy. 4. the generators heater circuit is ON. 5. Check & ensure all protective relays are on line & reset condition except the low forward power relay. 6. Check all annunciation lamps by pressing the alarm test push button and replace in case any lamp isnt glowing. 7. Ensure field resistance & AVR potentiometer in minimum position. 8. Carry out YR test of generators. 9. Check AC oil pump, DC oil pump, barring gear & other auxiliaries of turbine. 10. Ensure electromagnetic AVR is in manual mode. 11. Keep the water valve of generator air cooler closed during rolling. 12. Check & ensure healthiness of C02 system of generator. 13. Check vibration of carbon brushes. SYNCHRONISATION OF GENERATORS : 1. Switch on the field breaker & gradually build up voltage by cutting out field resistance either from panel/manually. 2. As soon as the voltage reaches to 5.8 to 6.0kv the AVR needle starts swinging. 3. Put AVR in auto mode. 4. Further increase the voltage and check whether the AVR is controlling the voltage. 5. Adjust voltage by operating POT of AVR from panel. 6. Check the machines frequency and adjust it by increase/decrease RPM. 7. Adjust power factor by AVR POT control panel. NOMINAL OPERATION OF GENERATOR: Steam turbo generators can be operated either in considering mode or in extraction mode. The considering limitation TG 1, 2, 3 is 3.0 MW and TG 4 of 10MW. However extraction can be commissioned in TG 1, 2, 3 even at 3.0 MW load and that in TG 4 in 5 to 6 MW load. Gradually increase the load to desired value by off loading other machine. During loading of generator following points should be taken care of: 1. The system frequency is maintained. If TG 4 is running with frequency control mode, the system frequency will be automatically maintained by TG 4 by throwing away the required load. If required TG 4 load can be again increased by off loading other machine. 2. The reactive load/ power factor sharing by each machine. The power factor can be adjusted by excitation control through POT incase of TG 1, 2, 3 and through excitation lower/raise button in case of TG 4. 3. System voltage is maintained. During adjustment of power factor, system voltage may either drop or increase.

ELECTRICAL EQUIPMENTS OF A THERMAL POWER STATION:

The following equipments are mainly used in the thermal power station: Alternator: its driven by a prime mover, a steam or gas turbine. Turbo alternators have 2 pole cylindrical rotors. The rotors produce the magnetic flux. It is supplied by dc excitation from exciter which is mounted on the same turbine shaft. the stator carries the armature

winding where the emf is induced. The alternator is connected to the unit transformer through bus ducts. Circuit breakers and insulators are provided on the H.T side of the transformer to connect to the alternator to the power station bus bars. Exciter: brushless excitation systems, in which, the field winding of the alternator is supplied directly from the exciter, which inverted alternator, via rectifying bridge, all mounted on the same shaft. This eliminates the need for separate slip rings and brush system. The exciter has a static field winding and fed from a permanent magnet alternator, called pilot exciter, again mounted on the same shaft, through a thyristor bridge. The output of the bridge is controlled by an AVR. Main functions are to provide variable dc current dc controlling the terminal voltage by means of suitable accuracy to ensure stable operation with network and other machines, enhance transient stability subsequent to a fault, and communicate with the power plant control system and to keep the machine within permissible operating range. Voltage Regulator: it performs the following functions: 1. Control of system voltage within prescribed limits. 2. Proper division of reactive power between the alternators operating in parallel. 3. Prevention of dangerous over voltages on the occurrence of sudden loss of load on the system. 4. Increase of excitation under system fault conditions so that maximum synchronizing power exists at the time of clearance of fault, to prevent loss of synchronism. Reactors: it is a coil having large inductive reactance in comparison to its ohmic resistance and is introduced in a circuit or system to limit the short circuit currents to a safer value in order to protect the electrical installation. The efficiency of the system is not affected appreciably. The reactors localize the faults by limiting the current that can come into it from other healthy parts of the system. Reactors are also employed to protect the circuit breakers of inadequate rating. Switches: It is used in an electric circuit as a device for making or breaking the electric circuit in a convenient way. 1. Air Break Switches 2. Oil Switches 3. Isolators-Operates under no load condition only, i.e. it has to be closed before the associated circuit breaker is closed and opened only after the circuit breaker has opened the circuit. This requires proper interlocking to prevent wrong operations. Isolators physically show the status of the circuit, whether connected or disconnected, and is meant for isolating a circuit during the period of maintenance.

Circuit Breaker: Mechanical device designed to close or open contact members, thus closing or opening an electrical circuit under normal or abnormal operating conditions. Its designed so that it can be manually or by remote control under normal conditions and automatically under fault conditions. For switching the alternator in or out of the system a circuit breaker with an isolator on its either side is employed. It is capable of making and breaking an electrical network during normal operation. EHV system, SF6,

Oil, Air, Vacuum type circuit breakers have become very popular. Thus its functions are: 1. To carry full load current continuously 2. To open and close the circuit or no load. 3. To make and break the normal operating current 4. To make and break the short circuit currents of magnitude up to which it is designed for. Current Transformers: These are connected in ac power circuits to feed the current coils of indicating and metering instruments and protective relays. They are also used as indicating and metering instruments in high voltage installations. Current transformers are rated for rated voltage of the installation, the rated currents of primary and secondary windings and the accuracy class. Potential Transformers: These are employed for voltages above 380volts to feed the potential coils of the indicating and metering instruments and relays. Potential transformers for primary and secondary rated voltage, accuracy class, number of phases and system of cooling. Control room or Operating Room: The various controls performed from here are voltage adjustment, load control, emergency, tripping of turbines etc. and the instruments housed in a control room are synchronizing equipments, voltage regulators, relays, ammeters, voltmeters, wattmeter, temperature gauges etc.

MAINTENANCE OF THE ELECTRICAL EQUIPMENTS OF A THERMAL POWER STATION:

MOTOR MAINTENANCE: All the rotating machines are subjected to various forces like voltages, currents, centrifugal & axial forces, temperature, friction etc. during running. Even during standstill, these are subjected to ambient climatic conditions like temarature, humadity, presence of corrosive & oxidizing gases etc. Under the influence of this factors, any rotating machine is bound to deteriorate with time, increasing the probability of its failure during running or at the time of starting. This, in turn, may lead to loss of production and in extreme cases, to accidents and / or fire. The whole philosophy of maintenance of motors stems from the need to eliminate the possibility of failure as above. The major maintenance activities to achieve this objective can be broadly classified into three categories:

1. Preventive maintenance: This comprises a set of maintenance activities carried out on the motors at fixed intervals of time, irrespective of the condition of the motor. The purpose is not to allow the motor condition to deteriorate below a safe level. This greatly reduces the possibility of failure. Further, as these are planned beforehand and carried out on stand-by motors, there is little possibility of any loss production. This is of three types: 1.A Schedule maintenance-once every six months

2. B Schedule maintenance-depending on the motor condition, but normally before one year. 3. C Schedule maintenance-depending on the motor condition based on the test results. 2. Predictive maintenance: As the condition of any motor deteriorates, it starts sending out signals to this effect. The signals may be as varied as the nature & extent of deterioration, and in most cases, start coming much before the deterioration can reach the failure stage. Predictive maintenance activities comprise of a timely detection & measurement of these signals & inductors, their interpretation, and planning & execution of corrective action accordingly. This even further reduces the possibility of failure & resulting loss of production. A list of the various parameters & the instruments to measure them is as listed below 1. Temperature: High temperature indicates overloading of the motors. It happens for high temperature of cooling water, inadequate ventilation, unbalance in phase windings, loose connections, overload etc. 2. Vibration: Its caused by several factors like improper alignment, unbalanced rotor, improper foundation, bearing condition etc. 3. Breakdown maintenance: the voltage & currents are the give a sign of operating conditions. Unbalance currents indicates the unbalance in winding resistance. 4. IR value: insulation resistance value measurement is the most basic & most common means of knowing about the winding condition. 5. Dielectric loss angle (tan delta): tan delta value measurement gives an indication of dielectric strength of winding. A trend of tan delta value over a period of time helps in assessing the life of insulation. 6. On Line partial Discharge: due to non uniformities in the insulation, several microscopic pockets or voids are formed within the insulation. When voltage is applied across this insulation, these voids act tiny capacitors, concentrating charges these voids & this ultimately results in breakdown across these voids. This is known as Partial Discharge. While no insulation is completely free of voids, their concentration in the insulation determines the ability of the insulation to hold on without totally breaking down. This test, done over a period of time gives an idea about how the insulation is deteriorating. 7. Core-flux Test: this is done to assess the condition of the magnetic core. Non uniform flux density across the core may result in localized heating or hot spots, which if undetected may deteriorate, and lead to the failure of the motor. This measured by subjecting the core to a known amount of flux in the core by an induction coil. 3. Breakdown maintenance: Breakdown maintenance, as the name suggests, starts when the motor has actually failed. The activities entirely depend on the nature of the failure and normally involve a lot of cost, time & effort. This almost invariably leads to a loss in production,& in extreme cases of failure, the motor become unusable, hereby necessitating total replacement of the motor. A zero breakdown maintenance plan leaves no scope for any loss in production, and each one of us should strive to reach as near this level as possible.

4. Troubleshooting: Troubleshooting forms a very important part of maintenance activities. Listed below are the problems when the troubleshooting maintenance has to be done. 1. Bearing loose over the shaft or in the bearing housing. 2. Bearing tight over the shaft or in the bearing housing. 3. Abnormal vibration/sound. 4. Motor overheating. 5. Motor slowing down on load. 6. Motor not starting. 7. Motor humming but not rotating during starting, or motor running at low speed. 8. Spark from motor. TRANSFORMER MAINTENANCE: Just as like motor the generator also needed regular maintenance works. There are different types of maintenance operations are done. It includes 1. Silica Gel Replacement: The silica gel that is used to absorb the moisture of the cooling air have to be replaced by every 2 or 3 months. 2. Winding temperature & oil temperature monitoring: it has to be monitored every time by the scale that is in the body of the transformer and with this the oil level of conservator is also maintained. 3. Breaker maintenance & thermal checking: it has to be done when the transformer is in shutdown condition. By this the circuit breakers which are connected with the transformer are maintained. 4. Relay testing: both the protection and the auxiliary relays that are connected with the transformer are maintained in periodic time. 5. Tightening: This is done to tighten the bearings of the joints that are used in construction of a transformer. 6. Leakage Arresting: this is has to be done as per need. This is useful for find and repair any leakage in the cooling oil tank or any other part in the body of the temperature.

GENERAL DESCRIPTION OF GENERATOR TRANSFORMER:

Main constructional features are as follows: 1. Main tank with radiators 2. Windings & core 3. Conservator tank with air cell 4. H.V Bushings & L.V Bushings 5. Off load tap changer

6. Temperature indicators for winding and oil temperature measurement 7. Buchhloz relay 8. Cooling equipments for cooling of oil 9. Pressure Relief valve(PRV) 10. Oil surge relay in diverter chamber 11. Oil level indicator gauge(M.O.G) 12. Thermo-siphon filter arrangement

GAS TURBINE UNIT

During my training period I visited the Gas Turbine plant of Haldia refinery. I came to know that they have a capacity of producing a total of 60MW power in their 3 gas turbine plants. With this also I came to know about the following information about Gas turbine. Gas turbine works on the Brayton Cycle.

Air enters the compressor at ambient condition and is compressed without any external heat addition. However, temperature rises due to compression. Air leaving the compressor at higher temperature and pressure enters the combustion chamber, where the fuel is injected. Fuel can be either Distillate or Gas or both. Combustion takes place at constant pressure.

Fig: Block Diagram of Gas Turbine and HRSG MAJOR COMPONENTS OF GAS TURBINE: STARTING DEVICE: Diesel engine INLET SYSTEM: Air filter and ducting COMPRESSOR: Casing and blading TURBINE: Nozzle & blading COMBUTION SYSTEM: Igniter, Fuel nozzle, Flame detector, Combustion can &Liner, Transition piece BEARINGS: Journal & thrust bearings, Lubrication system EXHAUST: Exhaust plenum & Duct HYDRAULIC SYSTEM: Hydraulic pump & Control

WORKING PRINCIPLE OF GAS TURBINE: Very high local temperature is reached within the primary combustion zone. Combustion system is designed to provide mixing, dilution and cooling. Combustion gases leave the Combustors and enter the Turbine Section at a high temperature. In the Turbine Section, energy of the hot gases is converted to work in two stages. The gases are first made to pass through a set of nozzles where

expansion of the gases takes place and the Heat Energy is partly converted to Kinetic Energy. The high velocity hot gases are then made to pass over the turbine blades where the Kinetic Energy is converted to Mechanical Torque, which in turn, is converted into Electrical Energy in the Generator. Part of the work done by the Gas Turbine is spent in driving the Compressor. Rest is available as useful work on the coupling. Energy carried away by the exhaust gases are mostly recovered in the HRSG.

Fig: Simple Cycle Single Shaft Gas Turbine

Fig: Simple Cycle Two Shaft Gas Turbine TYPES OF LIQUID FUEL USED IN GAS TURBINE: DISTILLATES: Light distillates (<1.8 cst): Naphtha, Kerosene Heavy distillates (>1.8<25 cst): HSD, LDO ASH BEARING FUELS:

 Crude oils, Blends( 160 cst): Crude oils, Marine diesel fuel, Burner Fuel
Residual oils(900 cst): LSHS, FO, Bunker oil

GAS TURBINE SUPPORT SYSTEMS

Lubrication System Hydraulic oil System Trip oil System Fuel gas System Liquid Fuel System Atomizing air System Cooling & sealing Air System Cooling water System Hydraulic Ratchet System Starting System Inlet and Exhaust System Heating and Ventilation System Accessory Gear Box System

Operation and Maintenance:

1. Gas Turbine Operations 2. Operating Sequence 3. Gas Turbine Maintenance Program Maintenance Practices Factors affecting GT Operation & Maintenance Gas Turbine Inspections

Maintenance of Auxiliary Systems:

Torque Converter Atomizing Air Compressor Booster Compressor Fuel oil Pump Main Hydraulic oil Pump Oil Mist Eliminator Flow Divider

Gas Turbine Protection:

Vibration detection and protection is activted by abnormal turbine vibration amplitude to a pre set level. The flame detection and protection system is activated if flame is not established during start up or if flame is lost during operation.

Each protection system has redundant channels of operation, which acts independently

Protection systems are provided to prevent abnormal conditions, which could lead to damage of the turbine. The critical operating parameters monitored by the protection system are as follows: 1. Temperature 2. Speed 3. Vibration 4. Flame Over temperature are Over speed system are provided as independent back-ups for the Temperature control and Speed control systems. I also came to know that the generally the steam pressure is about 7.4 Bar and the temperature is about 331 degree centigrade. The Full Speed of the turbine at No Load or the FSNL is about 5200 rpm. The CPD or the Compress Discharge Pressure is 44 to 63. more or less than this pressure will made the circuit auto trip. There are 4 stages of the turbine rotation 1. Cracking 2. Warm up 3. Aces 4. Full Speed The two shaft turbine get declutched when the speed about 2880 rpm. The vibration level is under 12.5. They use the Mark-6 system to control the gas turbine from the control room. All the above data I have got during my visit and it was a memorable experience. .

WORKSHOP AND ELECTRICAL TESTING UNIT

Its one of the most important section of any industry because the machines which are to be repaired and installed are first brought into this section of the industry for checking and other testing works or maintenance works. In time of visiting the IOC refinery, Haldia I have the privilege to visit their electrical maintenance workshop and electrical testing

laboratory under the kind guidance of Mr. S. Banerjee, In-Charge Engineer of workshop and testing section. In this workshop section I saw a 3 phase motor with the following specification from the chemical testing laboratory had come for some necessary maintenance work. A pin has stacked in its shaft and the maintenance workers could not take it out. They first tried to heat the shaft to take it out but it stacked so deeply and so tight that they did not successful in that operation. So they decided to drill in they shaft to take that pin out and in this time they were successful. I also came to know that they done the B-Schedule operation also here that means the Bearing scheduling. They open the motor and take out its bearings and do the maintenance works. They also done the I R Value Test with the help of Motor Checker and the Meggar test in the workshop. They have one of the best refinery workshop in all over India. They are also doing the Tong testing or Balance Current testing during running condition of motor in either in loaded condition or no load condition. They told me how they are checking the fault of a motor. First of all with the help of a tester they check the junction box of the motor and also does the meggar test of the motor. If they found any short circuit then they replace that otherwise if they found any other fault they tried to found out the source of the fault and then remove it. 3 PHASE FLAMEPROOF MOTOR
VOLTAGE INSULATION CONNECTION SPEED POWER CURRENT M/C NO CMRS NO ENCL FREQUENCY EFFICIENCY DUTY A*C IC REF EX d GROUP CCE NO MAKERS NAME SPECIFICATION 415V F Y 1390rpm 0.75 KW 1.8A KHH 34-04 TC/301 1P:55 50Hz 75% S1 45 411 1S:325 11A & 11B /T3 11A & 11B R1(1)13 B- K1R-V 1-40 KIROLOSKAR ELECTRIC COMPANY PVT. LTD.

SF6 Circuit Breaker: With the combination of superior insulating and arc-quenching properties, SF6 breakers have a very wide range of application 6.6kv to 765 kv abd 20-60 KA rupturing capacity. These are becoming increasingly popular.

The properties of SF6 are such that the gas blast speeds need not to be as high as in ABCB. The gas is hermetically sealed inside the breaker body at a pressure of about 3 atm High pressure needed to generate the gas blast of sufficient speed is obtained by a puffer mechanism at the time the breaker is opened. The puffer mechanism is a piston-cylinder arrangement. While the piston remains stationary, the cylinder is moved at high speed by means of the opening mechanism, creating a high pressure inside the enclosed space. The gas moves out through a convergent-divergent muzzle at high speed into the lower pressure region blowing the arc axially and thereby quenching operation of a 145KV. It is a latest design, here combination of cross and axial blast is employed to quench the arc. In testing section I saw a SF6 circuit breaker or Sulphur Hexafluoride Circuit Breaker with following specifications TYPE SF As G 12.16.40 SL NO 4811692365 RATED VOLTAGE 6.6KV RATED CURRENT 1250A RATED FREQUENCY 50Hz RATED PEAK MAKING CURRENT 100KA RATED BREAKING CURRENT 40A RATED SHORT TIME CURRENT 40A for 3seconds RATED PRESSURE OF SF6 3.4 bar abs AUXILARY CIRCUIT 110V dc MOTOR SUPPLY VOLTAGE 110V dc TRIP/CLOSE COIL 110V dc/ac CONNECTION DIA 5114030884 CONFORMS TO IS: 13118/IEC :56 WEIGHT 210 KG YEAR OF MAKING 2001

In this section I also came to know about the analog instruments that they use for testing. They told about the sign indication of the testing instruments. : Moving Iron Instrument : AC Voltage Frequency : Maximum Percentage of error : Installation type (perpendicular) : Line capacity (2KV)

: CT Rating in primary side : Full Scale Deflection of the instrument In some of the moving coil type instrument we can see a CT ratio is given. This because when the reading is very important of the line where the instrument is installed we have to change the instruments inner circuit like the DC type instrument because we know that the DC type instrument gives us more perfect reading than the AC type instrument as in AC type instruments the scaling is Cramped, but in DC type the scaling in uniform. The followings are the signs that is given on that type of instrument : Moving Coil Instrument : Diode : Frequency (50 Hz) : Percentage of error : Installation type (perpendicular) : Line Capacity (2 KV) : CT Ratio I also come to know about the different type of tests of transformer oil. Now transformer oil is basically a type of mineral oil with dielectric strength of 1KV/mil. There are five types of tests. 1. Dielectric Strength 2. PH- Test (Acidity test) 3. Viscosity Test 4. Tan-Delta Test 5. Dissolve Gas Analysis. The Dielectric Strength test is done for checking the dielectric strength of the oil. Its the most common test of transformer oil and it is done once in a year. The dielectric strength should be about 10KV/mm. The Acidity Test or PH Test is done for checking the PH level or Acid level of the transformer oil. It is also done once in a year. The PH level should be about 6.0 to 6.8. The Viscosity Test is another important test for transformer oil by this test we can check the viscosity level of the transformer oil. It is done once in two years. TanDelta Test is also done once in two years. But the most important test is Dissolve Gas Analysis Test. With this test every test results that are mentioned above can be known. This is done once in five years. It checks the dissolve gas level of the oil to measure the data. It cant be done by the testing laboratory personals. The company, which made the transformers, sends some personals to do this test.

I also came to know about the Tong Tester device which is used to test the current and voltage of any relay. By standard IE rules the values of this test should be from 2.5 to 4. This value indicates that the relay is in perfect working condition. With that I had saw bimetallic thermal relay which is used to sense any electric fault by the thermal misbalance of the circuit and its two metallic parts disconnected automatically and it give the signal to the circuit breaker for trip the line.

I also saw a 110V/150A DC Float cum Boost Charger or Battery Charger in the testing section. This charger is used to charge the DC batteries of thermal power station specially the pilot exciter of the turbo generator. All the emergency circuits are running in DC power because if for any reason the Power Station trips then they can run the Station for some times with the help of the battery charger power till any other power supply line isnt activated. The battery charger is supplying the power to the bus coupler to run it healthily. So to run a control system of the maintenance section of a power station smoothly this is very important. The battery charger has the following rating: TYPE INPUT FCBC 415 +/- 10% 45A 3 PHASE 50Hz FLOAT=125VDC 150A BOOST=154VDC 150A LM 500AH 50A 2K901012

OUTPUT

BATTERY TYPE BATTERY CAPACITY BATTERY CURRENT SL. NO

In this section I also had seen one of the largest transformers of this refinery. This transformer is of 2MVA & 6600V/415V and it has 3*240SQ mm. the transformer has the following specification: RATING 2 MVA NO LOAD VOLTAGE HV: 6.6 KV

NO LOAD CURRENT PHASE FREQUENCY COOLING TYPE REF IS MAXIMUM AMBIENT TEMPERATURE MAXIMUM TEMPERATURE RISE OF OIL/WINDING IMPEDENCE VOLTAGE CORE &WINDING WEIGHT OIL WEIGHT OIL QUANTITY TOTAL WEIGHT DIA OF CONNECTION NO.

LV: 433V HV: 17.435A LV: 2666.75A THREE 50 ONAN 2026 45 DEGREE CENTIGRADE 50-55 DEGREE CENTIGRADE 6.35% 3600KG 1055KG 1100LTR 6455KG 3RD-14096-1/a

BASIC INSULATION LEVEL IMPULSE VOLTAGE KV PEAK HV=60 AC=20 LV=-P.F VOLTAGE KV rms HV=20 AC=3 LV=3

W.T.I CT=2670/2A CL=7.5VA +/- 5% N.C.T CORE-(1) 3200/1A, 15VA, 5P20 CORE-(2) 3200/1A, CL-PS VK>200V Imax <30mA at vk/2 RCT=8 OHMS

SWITCH POSITION 1 2 3 4 5

HV LEADS CONNECTED TO 5- 6 6-4 4-7 7-3 3-8

NO LOAD VOLTAGE & CURRENT HV AMP LV AMP 6930 6765 6600 6435 6270 166.6 170.7 433 175.0 179.4 184.2 2666.75

DIESEL HYDRO DE-SULPHURIZATION UNIT

DHDS Unit abbreviated as Diesel Hydro De-Sulphurization Unit its one of the biggest unit of this refinery. Under this unit several other units like SRU, HGU, RFCCU, and VDU are also included. The capacity of this unit is 1.32 MMTPA. I visited this unit and came to know that there over 1000 electric motors under this unit. The electrical maintenance department of this block has 5 substations 4 of them are indoor type and 1 is outdoor type. I have seen two synchronous motor of rating 2835 KW in DHDS block. These two are the largest motors of this refinery. Two separate auto-transformers is driving themselves. The rated current of each motors are 270 Ampere. Also when I was visiting in the DHDS block then the motor (TAG No-25PM02A is being preventive maintenance (A- Schedule maintenance). At first clean the motor body. Then remove the fan cover and clean the fan cover and fan. After that the terminal box is opened and terminals are inspected for any loose connections and heating. Motor and cable IR values is measured and recorded. Also earthing connections of the motor is checked. The rating of the motor is as following: TYPE DHSW-355LK-02M NR. 5130-9.52 VOLTAGE 6600V CONNECTIONS Y CURRENT 270 FREQUENCY 50Hz INSULATION F CAPACITY 2835KW POWER FACTOR 0.9 SPEED 2975 I have seen M.C.C (Motor Control Center) panel in the DHDS Units Sub Station. By this M.C.C they control the motor from the sub station. This is one type of starter of the motor. It is used for smooth running of the motor.

Operation of M.C.C panel:

Each module has 2 positions, test & service. Module can be drawn out in Test position for checking & testing. In a module apart from 3 power fuse there are 2 control fuses. Green lamp in module means the control voltage is healthy. Module has facility to close from remote (UCR) & near push button (near equipment).

Protection of M.C.C module:

Generally low rating drives are protected by thermal overload relay fitted in the module with main power conductor. If a drives trips through O/L relay, the module cant be restarted until the O/L relay is reset. It is done by a reset push button. Some high rating drives are protected by thermal O/L relay and single phase protection. If a motor trips through S.P.P relay it should be properly checked and resetting the S.P.P relay, the motor should be restarted.

Procedure of Checking a M.C.C Panel:

1. First switch OFF the module (Fuse unit) 2. Takeout the module in test position. 3. Check the control fuse. 4. Check the thermal overload relay if operated. 5. Check the single phase protection relay. 6. Close the module in test position by local push button. 7. Check interlocks if any. In the next page there is a block flow diagram of this block to have a clear idea about the production of this block.

FUEL OIL BLOCK UNIT

The crude distillation unit is designed to process 1.5 Million Metric ton/Year of 34.16 API (Sulpher content of 18%) Bonny Light Crude. The low sulpher RCO obtained from this crude distillation unit is in turn burnt in the furnaces and boilers to meet the SO2 emission level from Haldia Refinery prescribed by the Pollution Control Board. Design had envisaged 333 days of operation (8000hr/year) i.e. the hourly processing rate of 220M3/HR. it has been observed that the unit can be operated at about 400M3/HR when furnaces CIT is at desired value. This unit primarily consists of the following Pre Fractionator Crude Distilation Unit De-ethaniser De-propaniser Naphtha Stabiliser Naphtha Splitter LPG & Naphtha Caustic Treatment Form crude oil this unit produces Naphtha, Kerosene, Diesel, Jute Bleaching Oil, Recovery Oil etc. and the sediment oil from this block goes to other blocks for further regimentation. In the next page the block diagram is of HT sub station of the FOB section. All the maintenance programme of the electrical equipments are same as the DHDS Unit.

OFFSITE UNIT
HIGH PRESSURE MERCURY VAPOUR LAMP
OPERATING INSTRUCTIONS: 1. Operate lamp with proper ballast conforming to IEC specifications. 2. Lamp should be properly screwed into the lamp holder. 3. Use proper power factor corrector capacitor across mains. 4. Protect the lamp against thermal shocks and if the outer bulb is broken switch off lamp before removing. 5. Use appropriate tapping on ballast to suit relevant mains voltage of the installation.

FIG: WIRING DIAGRAM OF HIGH PRESSURE MURCURY VAPOUR LAMP

CAUTION:
The manufacturer does not assume any liability for any personal injury/damage to equipment resulting from improper use of lamp or accessories.