Indian Oil Corporation LimitedHaldia Refinery, West Bengal

CONTENTS

COMPANY PROFILE

FIRE AND SAFETY DEPARTMENT

THERMAL POWER STATION

WORKSHOP AND ELECTRICAL TESTING UNIT

GAS TURBINE UNIT

LEARNING EXPERIENCE

COMPANY PROFILE

A BRIEF –HALDIA REFINARY

The fourth refinery of Indian Oil

Situated in the State of West Bengal and is about 123 km from

Kolkata city

Commissioned in January 1975 with an initial crude

processing capacity of 2.5 MTPA

The total installed capacity of the refinery is currently 7.5

MTPA.

Petroleum products are transported through various modes

like rail, road as well as environment-friendly pipelines

Caters to the high- consumption demand centers in North-

Eastern India including the States of Bihar, Bengal, Orissa,

Assam and neighboring countries Sri-Lanka, Bangladesh and

Nepal.

HALDIA REFINERY PRODUCT DISPATCH

MODE

PRODUCTS OF HALDIA REFINERY

Fuel oil products include:

LPG

Naphtha

Motor Spirit (MS)

Mineral Turbine Oil (MTO)

Superior Kerosene (SK)

Aviation Turbine Fuel (ATF)

Russian Turbine Fuel (RTF)

High Speed Diesel (HSD)

Jute Batching Oil (JBO)

Furnace Oil (FO)

Lube oil base stocks are:

Inter Neutral HVI grades

Heavy Neutral HVI grades

Bright Neutral HVI grades

Beside the above, Slack wax, carbon black feed stock (CBFS), Bitumen and Sulfur

MAIN UNITS OF HALDIA REFINERY

Fuel Oil Block (FOB)

Lube Oil Block (LOB)

Diesel Hydro De-Sulfurization Unit (DHDS)

Oil Movement & Storage Unit (OM&S)

The plot plan of the Haldia Refinery is shown in the figure:

FIR

E A

ND

SA

FE

TY

DE

PA

RT

ME

NT

1. On-site Industrial

Fire Department

comprised of full-

time career

personnel

2. Volunteer

Emergency

Response Team

members (ERT)

from within the

various work

groups

3. Operating out of

the Fire Station are

the following

Mobile response

apparatus: 2

specialized Foam

Engines,

Rescue/Hazmat

truck, 2 Foam

Tenders,3 Squads

and a utility truck.

SAFETY HAS NO HOLIDAY

THERMAL POWER STATION

(TPS)

THE RATING OF THERMAL POWER

STATION

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

BOILER

Here are 4 boilers and each of them are oil feed type.

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.

ELECTRICAL EQUIPMENTS OF A

THERMAL POWER STATION

Alternator

Exciter

Voltage Regulator

Reactors

Switches

Circuit Breaker

Current Transformers

Potential Transformers

Control Room or Operating Room

ALTERNATORS

The steam turbine driven generators have auxiliary

systems enabling them to work satisfactorily and

safely

Haldia refinery’s thermal power station has 4

generators. 3 of them have rating of 10.5 MW and the

other one has a capacity of 16.5 MW

Static part of the generator i.e. stator has 3 phase

double star winding from which 3 phase AC output

power is available at a rated voltage of 6.6KV

The rotating part of generator i.e. rotor has field

winding excited by controlled DC power supplied

from AVR (Automatic Voltage Regulator)

SP

EC

IF

IC

AT

IO

NS

OF

ALT

ER

NA

TO

R

Manufacture BHEL(HYDERABAD),1972

Type T G N 2202 33/2

Sr. No. TG 1,1016,TG 2 TG 3

Voltage 6600 V (+/- 5%)

Rated Speed 3000 RPM

Frequency 50C/S

Power Factor at full load 0.8

Nominal Rating 10.5 MW at 0.8 PF

Admissible overload 11.3 MW

Sub-transient reactance 11%

Transient reactance 18%

Synchronous reactance 16.18%

Negative sequence reactance 11%

Zero sequence reactance 4.5%

Neutral point earthing 3 OHM for 1250A for 10sec

Vector rotation of 3phase Anti clockwise

Insulation Class B type

Phase connection star

Cooling Air cooled

Generator terminals 6

Maximum allowed output with one of the four cooling

elements out of operation9200KVA

Moment of inertia 1.88 tgm2

Volume of cooling 11m3/sec

Critical speed of rotor 1750 rpm

No load field current 165 A

Minimum diameter of slip rings 380mm

Circuit breaker 6.6KV/1500A/500MVA

Carbon brush no 2*8

Size 25*32 mm

GRAD HM6R

EXCITER AND VOLTAGE REGULATOR

Exciter :

Main functions are:

To provide variable dc current.

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.

Communicate with the power

plant control system and to

keep the machine within

permissible operating range.

Voltage Regulator :

Performs following functions :

Control of system voltage within

prescribed limits.

Proper division of reactive power

between the alternators operating

in parallel.

Prevention of dangerous over

voltages on the occurrence of

sudden loss of load on the system.

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.

• Is a coil having large inductive reactance in comparison to its ohmic resistance

• Introduced in a circuit or system to limit the short circuit currents to a safer value in order to protect the electrical installation.

Reactors

• Used in an electric circuit as a device for making or breaking the electric circuit

• Classified as :

• Air Break Switches

• Oil Switches

• Isolators

Switches

• Mechanical device designed to close or open contact members

• It can be operated manually or by remote control under normal conditions and automatically under fault conditions

• EHV system, SF6, Oil, Air, Vacuum type circuit breakers have become very popular.

Circuit

Breaker

MAINTENANCE OF THE ELECTRICAL

EQUIPMENT

Preventive maintenance

A(6 month),

B(1 year),

C

Predictive maintenance

Temperature, Vibration,

IR value

Breakdown maintenance

Troubleshooting

Silica Gel Replacement.

Winding temperature &

oil temperature

monitoring

Breaker maintenance &

thermal checking

Relay testing

Tightening

Leakage Arresting

MOTOR MAINTENANCETRANSFORMER

MAINTENANCE

WORKSHOP AND ELECTRICAL

TESTING UNIT

One of the most important section of any industry

During the visit of the unit, I observed the testing of a SF6 circuit breaker with following specifications :

The analog instruments that they used for testing are :

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

TYPE SF As G 12.16.40

SL NO 4811692365

RATED VOLTAGE 6.6KV

RATED FREQUENCY 1250A

RATED CURRENT 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

RATING 2 MVA

NO LOAD VOLTAGE HV: 6.6 KV

LV: 433V

NO LOAD CURRENT HV: 17.435A

LV: 2666.75A

PHASE THREE

FREQUENCY 50

COOLING TYPE ONAN

REF IS 2026

MAXIMUM AMBIENT TEMPERATURE 45 DEGREE CENTIGRADE

MAXIMUM TEMPERATURE RISE OF OIL/WINDING 50-55 DEGREE CENTIGRADE

IMPEDENCE VOLTAGE 6.35%

CORE &WINDING WEIGHT 3600KG

OIL WEIGHT 1055KG

OIL QUANTITY 1100LTR

TOTAL WEIGHT 6455KG

DIA OF CONNECTION NO. 3RD-14096-1/a

GAS TURBINE

Have a capacity of producing a total

of 60MW power in total 3 gas

turbine plants

Gas turbine works on the Brayton

Cycle

MAJOR COMPONENTS OF GAS

TURBINE:

Starting Device : Diesel engine

Inlet System : Air filter and ducting

Compressor: Casing and balding

Turbine : Nozzle &balding

Combustion 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

Block Diagram of Gas Turbine and HRSG

LEARNING EXPERIENCE

This Industrial tour helped us immensely in

developing key aspects of practical knowledge and

will help us substantially in the long run

The knowledge and maintenance process of entire

system in a the company is obtained

The valuable practical experience help us to clarify

our concepts