PETROLEUM DISPENING PUMPS AND SYSTEMS&FABRICATION OF

HORIZONTAL 20 KL UNDER GROUND TANKS

Submitted to INDIAN OIL CORPORATION

LIMITED as TRAINEE

RAJAT ABHINAV EKKA

&

PRADEEP KUMAR

BECHLOR OF TECHNOLOGY, UG (3rd year)

DEPARTMENT OF MECHANICAL ENGINEERING,BUDGE BUDGE INSTITUTE OF TECHNOLOGY

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SL NO. TOPIC PAGE NO.

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1 ACKNOWLEDGEMENT

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CHAPTER:-1 DISPENSING PUMPS AND

SYSTEM

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1.1 INTRODUCTION 51.2 MACHINERY

PARTS6

A) SUCTION UNIT 6B) METERING UNIT 7C) HOSE 8D) NOZZLE 91.3 ELECTRONIC

PARTS9

A) SMPS 9B) CPU 9C) DISPLAY CARD 10D) BLOCK DIAGRAM

OF ELECTRONIC PARTS

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3.1 SEALING AND AUTOMATION

PROCESS

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A) SEALING PROCESS

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B) AUTOMATION PROCESS

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3.2 INSTALLATION DIAGRAM

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4.1 WORKING PRINCIPLE

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4.2 CONCLUSION 15SL NO. TOPIC PAGE NO.

2 CHAPTER-2FABRICATION OF

20KL UNDERGROUND

TANK

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2.1 INTRODUCTION 162.2 HORIZONTAL

TANK FABRICATION

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A) KEY FEATURES 17B) ORDER PROCESS 18C) FABRICATION

PROCESS18

D) CUTTING PROCESS

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3.1 SOME IMPORTANT PARTS

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A) STIFFNER 21B) MAN HOLE 21C) TURNBUCKLE 22D) BOX 22E) HYDRAULIC TEST 244.1 DELIVERY

PROCESS25

4.2 CONCLUSION 25

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ACKNOWLEDGEMENT:This assignment was made under guidance of Mr. Krishnendu Datta, Assistant Manager (Engg), Kolkata Divisional Office. We thank Indian Oil Corp. Ltd who provided insight and expertise that greatly assisted the assignment

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CHAPTER 1:- DESPENSING PUMPS AND SYSTEMS

1.1 INTRODUCTION:A fuel dispenser is a machine at a filling station that is used to pump gasoline, diesel, CNG, CGH2, HCNG, LPG, LH2, ethanol fuel, biofuels like biodiesel, kerosene, or other types of fuel into vehicles. Fuel dispensers are also known as bowsers (in Australia),petrol pumps (in Commonwealth countries), or gas pumps (in North America)Pump operates by rotary mechanism and consumes energy to perform mechanical work by moving the fluid. After installation of Horizontal tank at Retail Outlet the major work is to supply petrol or Diesel to the customers. This part of work is done by pump.

MPD fuel dispenser

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Fuel Dispenser are classified into 2 types :a)Multi Product Pump (MPP)b)Multi Product Dispenser (MPD)

1.2 MACHINERY PARTSDispensary unit has two parts, one Electronics part and another Hydraulic part. First considering the Electronics part,MECHANICAL PARTS:-

Pumping unit is under beneath the fuel dispenser above the tank

A) Suction Unit:-

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Pulser

Metering unit

Solenoid Valve

When a dispenser is switched on, the electric motor is activated, and begins draw fuel from its outlet. This displacement of the liquid creates a partial vacuum at the pump inlet. When the discharge nozzle remains closed, the vacuum is relieved byfuel circulating continuously through the unit. But when the nozzle is opened, suction pressure is transferred instantaneously from the pump inlet to the storage tank through the pipe line. There, atmospheric pressure forces the fuel to flow through a check valve toward the dispenser.Before entering the pumping unit, it passes through a strainer or filter, which removes any solid particles. Small quantities of trapped air and fuel vapor are also removed from the fuel through an air separator chamber.Then the fuel, free of air and vapor, passes to the automatic control valve which permits fuel to flow only in the direction of the meter, never back to the pump. Now-a-days, the control valve is replaced by a solenoid and pilot valve.

B) Metering Unit:-

A mechanical metering Unit

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Metering devices mostly use piston meters and are positive-displacement. A piston moving through a cylinder filled with liquid will displace a quantity of liquid which will be determined by the bore of the cylinder and the stroke of the piston. Usually four cylinders are used. The pistons operate may operate in a horizontal plane or in a vertical plane and convert to reciprocating action to a rotary shaft output to drive either a sensor or a mechanical computer (gear box).PERFORMANCE

Accuracy: Between 4LPM to full flow :- +/- 0.25% Range of calibration (in 20 litre):- +100 ml or more

& -500 ml or less. Working pressure : 35psi (2.5 bars) Volume per outlet drive shaft revolution: 250 ml.

(litre version) Mechanical adjusting increment : 5cc in 20 litres

Every meter is hydrostatically tested and calibrated to meet stringent performance standardsC) Hose:-Double Braided, Anti-static, Petrol Resistant Pipe is used for Hose in D.U.

3/4" is used for Standard duty and 1" is used for Heavy duty.

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Typical Nozzle and Hose assembly in above figure

D) Nozzle:-Nozzle is used to control fuel which comes out from Hose pipe.Spout size 13/16" for Standard duty and 1" for Heavy duty.

Typical Nozzle

1.3 ELECTRONIC PARTS:-

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A)SMPS:- Switched Mode Power Supply is known as a SMPS. It is most important thing of the Electronic Parts. It provides supply voltage to the CPU.

B)CPU:- CPU is the main equipment of Electronic Part. It collects power from the SMPS and supplies power to the other parts like Relay card, Pulsar etc. as their requirement.

C)Display Card:- Display Card is used to show the amount of fuel and price of it and density of the fuel to the customers.

Display card in above figureD) BLOCK DIAGRAM OF ELECTRONIC PARTS :-

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CPU inside a dispenser unit

3.1 SEALING AND AUTOMATION PROCESS:-

a) Sealing Process:-A metering unit is Tested by the by measuring the amount of oil of a 5litre standard can and after that test is passed the officials certifies it and seals it so that no fraud can be found and the customers are not cheated.

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Sealing process of a typical DUb) Automation Process:-Another process to protect our customers to be cheated is Automaton process. It is basically a process which records the amount of fuel has been dispatch or decantation and amount of price according to the dispatching fuel automatically. At the R.O., There are two things that can be automated.

1)FCC ( Fort Court Control )2)ATG ( Automatic Tank Gauge )1)FCC:- Fort Court Control is known as a FCC. It is

basically deals with Fort Court. Fort Court is a place where Dispensing unit is installed and the way of the vehicles after and before fueling. Dispensing unit is connected CAT-5 (2 pairs of cables) wire to the DOMS and in DOMS LAN cable is connected to the computer through the 4 no. of RS-485 in DOMS. Signals are transferred by those wire and shown in computers. In this way FCC system works.

FCC panelFCC display in computer2) ATG :- ATG deals with undergrounded tank. How much fuel is dispatched and how much fuel will decanted, that will measured by ATG system automatically. 2 pair of

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cable is connected with TANK which is undergrounded. Other port of the cable is connected with DOMS. 3 of them are connected with RS-232 and one is connected with ATG display device.

ATG Console showing all tanksATG Console showing details of 1 tank

3.2 INSTALLATION DIAGRAM:-

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Installation diagram of underground tank with dispenser unit

4.1 Working Principle:-

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Flow diagram of working principleFirst Nozzle is supposed to lift for provide Petrol or Diesel at the desire level of the Customers. At that time Relay card is sending a signal to SMPS to control the Dispensary unit. First Suction Pump is controlled by Signal which comes from SMPS. Rotary motion of the Suction Pumps creates pressure difference which pulls out the petrol or diesel from the tank to Chamber. In this Chamber Fuel is supposed to be filtered to remove the foreign particles by some arrangements.When this Chamber is filled by fuel then the pressure is

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increased, This increasing pressure helps to open the Spring valve. The reserved fuel follows the desire path as the valve is opened. Then fuel goes to the Sump unit for removing those air bubbles. After removing foreign particles and air bubbles Fuel goes to the Metering unit. This metering unit has Photo sensor, Rotor with slots and shaft. This unit is used to measure the amount of the fuel pass. This unit also connected with display board to show the amount to the Customer

4.2CONCLUSION:- Since fuel dispensers are the focal point of distributing fuel to the general public, and fuel is a hazardous substance, they are subject to stringent requirements regarding safety, accuracy and security. The exact details differ between countries and can depend to some extent on politics. Proper maintenance must be maintained for proper distribution to general public by the company on regular basis beside attention on technical importance to man power must be inculcated by owner of filling station as a policy.

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CHAPTER -2:- FABRICATION OF 20 KL UNDERGROUND TANK 2.1 INTRODUCTION:-

20 Kl horizontal tank is made of mild steel of length 6250mm and shell diameter 2100mm which is installed underground in a filling station. There are other tanks of size 15KL, 50KL, 70Kl depending upon on requirement for filling station. Proper safety precaution and maintenance of tanks must be ensured in filling station to ensure proper functioning of station and smooth distribution to general public. Various specification will be discussed ahead in the reports as follows.

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2.2 Horizontal Tank Fabrication:-1. Key Features2. Order Process3. Fabrication Process4. Delivery Process

A)Key Features

a) Fabrication as per IS standard and PESO Rules.b) Using MS quality plates Grade B of 6,8mm thickness. For

Horizontal storage tanks.c) Welding as per IS-814:1991 Grade 6012-14d) Tanks will be tested pneumatically at a pressure of

0.75kg/cm2

e) Radiography test will be conducted for weld joints on customer request.

f) All Ball Valves, Flow Meters, Non Return Valves, Strainers, Pressure relief Valves, Pressure switches, Foot Valves, Float Valves, Pressure gauges, Solenoid valves Level probes for DG day tanks, Level Transmitters for Bulk storage tanks, Pumps, FLP motors, DOL Starters, Emergency Stop switches and Leak detectors with alarm are standard as per IS specifications.

B)Order Process

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IOCL informs to the CIP, Mourigram, Dist-Howrah to provide MS Plates (5/6/8/10 mm) to the fabricator as per requirement of HORIZONTAL TANK FABRICATION (20KL).

a) The MS Plates will be supplied free of cost by CIP, Mourigram, Dist-Howrah. The fabricator should make their own arrangement fortransporting from above mentioned place to their fabricating shop including loading and unloading. The cost of transportation should be beard by Fabricator.

b) The Fabricator issued MS Plates for fabrication of tanks as per the drawing enclosed in the tender

c) Finally, Horizontal Tank shipped to the location where it is to be installed.

C)Fabrication Process In this process Fabricator has to make Horizontal Tank from

MS Plates by cutting as per the instructed measurement and welding. Let, Fabricator is supposed to make 5 Horizontal tanks of 20KL capacity.The required MS Plate as per Standard Chart:-

As per IOCL Standard

Quantity Thickness (mm) Length x Width (mm2)

5 8 1500 x 630022 6 1500 x 6300

D) Cutting Process : The Diameter and Length of Horizontal Tank will be 2100 mm and 6250 mm respectively. Fabricator has to use MS Plate, having

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thickness of 6 mm for Shell construction and 8 mm in case of End Plate construction.

SKETCH DIAGRAM OF 20 KL TANK

First considering 20 plates among 22 plates (1500 x 6300) having thickness of 6 mm to make shell of 5 Horizontal Tanks. 4 Plates with 1500 x 6300 dimension (standard plates) are required for each shell. In this way welding of 4 Plates result a length of shell would be 6000 mm but required length is 6250 mm. By welding a plate having 300 x 6300 dimension at the middle of 4 standard Plates. So, here the no. of requirement of 300 x 6300 dimension plate is 1 for each shell. 5 Tanks needed 5 number of plates which are getting from one no. of 1500 x 6300 plate remaining of 2 plates. Then the length of each shell 6250 mm is achieved. Now bother about to achieve the shell diameter 2100 mm. The circumference of the each shell πx (Diameter) = 6594 mm. The width of each plate is 6300 mm. Now to get required circumference of shell have to add 1500 x 300 dimensional plates which obtained the last remaining plate having dimension 1500 x 6300 with 1,2,3,4 no. plates as shown in fig. 1. At last 300 x 300 plate from remaining plate is added with 300 x 6300 plate (Ref. fig. 1).

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This is a 20KL unfinished tank

3.1SOME IMPORTANT PARTS:-A) STIFFNER:-Stiffner is attached with End Plate inside the tank to resist End plate to bend during the pressure of the liquid inside it and it is used to minimize the error of calibration part.

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Stiffner

Stiffner for a 20KL unfinished tank

B) MANHOLE:-Manholes are situated at the top of the shell. Two types of Manholes are there. One is for cleaning and another is for suction filling and measuring of liquid. The outside and inside diameter of manhole are 740 mm and 640 mm respectively. The other Manhole except cleaning manhole having Suction Pipe, Filling Pipe, Dip pipe, Bend Pipe with Bush Socket in every pipe. To attach the cover of Manholes having 40 holes with 0.5 inch.

Unfinished Man Hole for 20KL tankC) TURNBUCKLE:-Turnbuckle is device used to fastened the tank in the excavation pit which is installed in RCC slab to keep it in a fixed position

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Unfinished turnbuckle for 20KL tankD) BOX: - The Box is very important part for installation of horizontal tank. By using box floating of tank is restricted and situated at zero level. 4 no. of boxes are used at each side of the tank. Each box attached at the center of the tank. Turn buckle is a device to lock the box. One side of the turn buckle is connected with box and other part of the turn buckle is grounded with chair inside concreted part. 8 no. of turn buckles are used for each box on the tank.

The important parts of the tank are described above. Some parts are there except those, mentioned earlier. Those are Earth boss, Lifting hook, Dip plate, Earth boss is a mandatory part of the tank. Lifting hook is used in case of uppering and lowering of the rank. Dip plate is another mandatory part which protects tank from corrosion when calibration scale strikes at tanks inside surface to measure the amount of liquid. Following fittings should be supplied with the tank by the fabricator and rate of same shall be included in the fabrication rates:

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Item Description Qty.

unit

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no

1 70x70x8 thick, angle stiffner,1660 long 2 number & 1330 long 4 number 6 NO.

2 4ox40x6 thick ,angle stiffners,6100 long 2 NO.

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80 diameter fill pipe, 1940 long pipe, & 500 long outside. the tank(in two pieces) inside pipe to be threaded at one end ,outside pipe to be threaded at both ends. Bottom end of the fill pipe to be chamfered at 45 degree 1

NO.

5 50 mm diameter suction pipe,2300 long inside 3 NO.

6 15 thick MS hexagonal bushing to suit 80 diameter fill pipe (110 O.D.) 1 NO.

7 80x50 MS hexagonal bushing threaded on both sides(80 O.D.) to suit 50 diameter pipe 3 NO.

8 Brass cap with locking arrangement for 50 diameter dip pipe(as per details) 1 NO.

9 Standard lifting eyes 40 internal diameter (as per details) 2 NO.

10 Holding down brackets(as per drawing/sketch) 8 NO.

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25 diameter bolt with hexagonal heads,520 long with RH threads 8 NO.

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25 diameter bolt with hexagonal heads,200 long with LHthreads 8 NO.

13 225 long turn buckles as per details 8 NO.

SL

Item Description Qty.

unit

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no14

75x50x8 thk,200 long(used) in holding down arrangement 8 NO.

15 6 thick MS plate for manhole neck , size 340x1885 2 NO.

16 10 thk,742 diameter MS plate for manhole cover 2 NO.

17 65x65x8 angle rings 610 ID(for manhole) 2 NO.

18 EARTHING BOSS CONNECTION AS PER DRAWING 2 NO.

19 6 mm thick M.S pad plate manhole size- 50x2040 2 NO.

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5 mm thick M.S pad plate for dip rod to be welded inside the shell plate 1 NO.

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80 mm diameter automatic level/temperature pipe 2300 long inside,300 mm long outside the tanks.(inclusive of socket & bush)

1 Set.

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80 mm diameter automatic density pipe 2300 mm long inside,300 mm long outside the tanks(inclusive of socket & bush)

1 Set.

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12 sq.mm aluminum dip rod 2750 long graduated on side in cm and 1/5 cm 1 NO.

E) Hydraulic Test:-A very important test for horizontal tank. Those tanks are disputed or not which is known by this hydraulic test. First tank is filled with water by help of pump. After that applied pressure by compression pump and hammered at welded joint, this pressure is maintained at 0.75kg/cm 2 . If there is found no leakage then tank is ready to install.

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4.1 DELIVERY PROCESS a) After fabrication process is done fabricator supposed to

deliver those tanks at installation place to install the Horizontal tank.

b) Verified tanks are lifted by crane on transportable vehicles.

c) These vehicles (Trailer, truck, etc.) are used to transport the tank from fabricating shop to customer. This arrangement cost should be bear by fabricator.

4.2 CONCLUSION:-Therefore 20KL horizontal tank is an underground tank installed in the filling station. Since fuel dispensers are the focal point of distributing fuel to the general public, and fuel is a hazardous substance, they are subject to stringent requirements regarding safety, accuracy and security. The exact details differ between countries and can depend to some extent on politics. Proper maintenance must be maintained for proper distribution to general public by the company on regular basis beside attention on technical importance to man power must be inculcated by owner of filling station as a policy.

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