PUNJAB COLLEGE OF ENGINEERING & TECHNOLOGY TRAINING REPORT OF SIX MONTHS PRACTICAL TRAINING UNDERTAKEN, AT HORIBA INDIAN PVT. LTD. on Project Assigned SUBMITTED IN PARTIAL FULFILLMENTOF THE DEGREE Of BACHELOR OF TECHNOLOGY In Mechanical Engineering Submitted To :- Submitted by : 1
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PUNJAB COLLEGE OF ENGINEERING &
TECHNOLOGY
TRAINING REPORTOF
SIX MONTHS PRACTICAL TRAINING UNDERTAKEN,
AT
HORIBA INDIAN PVT. LTD.on
Project Assigned
SUBMITTED IN PARTIAL FULFILLMENTOF THE DEGREEOf
BACHELOR OF TECHNOLOGY
In
Mechanical Engineering
Submitted To :- Submitted by :
Er. BEANT SINGH(H.O.D) Ashish Ranjan
Department Mechanical Engineering Roll no:100531131272
1
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ACKNOWLEDGMENT
It would be my sacred duty to first express my deep gratitude to Er. Ranjit
Kumar who was not my internal training guide but also incharge of ME Deptt. I am
thankful for their kind co-operation in given shape to this training.
I express my humble thanks to respected Mr. Divesh Jha for spacing every
moment out of his busy schedule for me, who has not only guided me properly but
also gave me an encouraging help to make this training successful one. Without his
able guidance, I would not have been able to complete this training report.
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DECLARATION
I hereby declare that the project work entitled “PUC” is an authentic record of my
own work carried out at “HORIBA INDIA” as requirements of Industry Internship
project for the award of degree of B.Tech- (ME), Punjab College Of Engg. &
Technology, under the guidance of Er. Ranjit Kumar and Mr. Divesh Jha during
January to June, 2014.
(Signature of student)
Name: Ashutosh Kumar Singh
Roll no. - 100531131273
Date: ___________________
Certified that the above statement made by the student is correct to the best of our
knowledge and belief.
Mr.Divesh Jha Er. Ranjit Kumar
Faculty Coordinator Industry Coord.
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ABSTRACT
This report is aimed at explaining key areas of my training under the Student
Industrial Work Experience Scheme undertaken at The Horiba India Pvt. Ltd. It
gives a brief introduction about HORIBA, an indigenous design company relevant in
the oil & gas industry. It also gives a good representation of the organizational
structure and the interconnectivity of the various Engineering and Services
Departments.
Effort was made to explain the role of the Mechanical Engineering Department,
bearing in mind the various electrical facilities and relevant softwares. Adequate
coverage has been given to the operations and maintenance training I received, as
well as the specific type of work I was engaged in.
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TABLE OF CONTENTS
CONTENTS PAGE
Title Page.......................................................................................................................i
- Datasheets: pipe support datasheet and pipe material datasheet.
Mechanical/Vessel Group:
The activities carried out by this group are:
- Selection and Specification of process equipment like: -
Pumps, turbines, fired heaters, heat exchangers, air coolers, and pressure
vessels.
- Heating, Ventilation and Air Conditioning System (HVAC) design.
Electrical Group:
Activities carried out by this group include:
- Develop Design Criteria.
- Formulate Power Generation and Distribution Philosophy.
- Carry out load shedding/sharing studies.
- Transient and earth fault condition analysis.
- Electrical Equipment sizing specification and selection.
- Lighting design.
- Hazardous Area classification.
- Single line drawing.
- Electrical layout drawing.
Control Systems/ Instrumentation Group:
Instruments are used in process plants.
Some of the deliverables produced by this group are:
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- Instrument Index.
- Instrument installation schedule.
- Instrument Data sheets.
- Instrument Installation details.
- Instrument location diagrams.
- Loop and Logic diagrams.
- Interconnection diagram.
- Alarm and shut-down matrix.
- Material requisition.
- Cable schedule.
They also update the Process Engineering flow scheme (PEFS).
During any particular project, the Document Control Centre (DCC) works with the
Engineering discipline groups to control receipt and despatch of project documents.
Through the DCC, project documents are accurately tracked.
All the discipline groups produce their deliverables with the aid of computer
applications and softwares. Some of the applications are: -
AutoCAD, AutoPLANT.
MicroStation.
PDMS.
ISOGEN.
HYSYS, HYSIM.
FLARENET.
FOUNDS, FASTRUDL, STRUCAD, STAAD PRO,
INTOOLS.
PRIMAVERA P3.
MS OFFICE PROFESSIONAL.
PRO/II
During the training, I was attached to the Electrical discipline group which is under
the Engineering department.
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CHAPTER FOUR
4.0 THE ELECTRICAL GROUP
4.1 INTRODUCTION
Usually, a typical project begins in the process group with the conceptual or basic design. The
process group develops the initial block diagrams, evaluates all the options, and proposes the
best alternative for the project. Other disciplines (Electrical group inclusive) will then work
on what the process group has put down.
4.2 ROLES OF THE ELECTRICAL GROUP
On any project, the Electrical group is concerned with the following:
To design a system that delivers energy or electricity to utilization points.
To design a system that is reliable, economical and operationally flexible.
To ensure that the system designed is safe for both personnel and equipment.
4.3 ELECTRICAL GROUP ACTIVITIES
To achieve the above objectives, the following activities are usually carried out by the
electrical group:
Develop design criteria.
Formulate power generation/distribution philosophy.
Carry out load shedding and/or sharing duties.
Carry out transient and earth fault condition analysis.
Develop electrical equipment specifications.
Carry out electrical equipment sizing and selection.
Prepare material requisition(MR) and Bill of Quantities(BOQ) for electrical
equipment.
Technical bid analysis.
Produce electrical deliverables.
4.4 ELECTRICAL GROUP DELIVERABLES
Deliverables are documents produced by a group with respect to the scope of the project. The
deliverables produced by the electrical group are: -
One line diagrams
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Electrical layout drawings
- Earthing
- Cable
- Lighting
Hazardous area classification
Material Requisition (MR)
Supplementary Drawing
- Data sheets
- Cable schedules
- Schematic and interconnection drawings
- Installation details
- Specifications
COMPUTER SOFTWARES used by the Electrical group are: -
AutoCAD
Plant Design Management System (PDMS)
Microsoft Excel
Microsoft Word
Chalmlite
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CHAPTER FIVE
5.0 SKILLS AND PRACTICES ACQUIRED AS AN INDUSTRIAL TRAINEE
As a student under the SIWES at HORIBA, I was exposed to standard
Engineering design practices. The projects executed at HORIBA ensured that
Engineers worked in teams, hence, I was taught to be a team player, and a good
one at that.
I received training in the following areas of electrical engineering practice:
1. Computation of Load list:
This is one of the starting point for the electrical group activities. For any given
project, it is important to know the specific number of electrical loads on site. This
is to ensure adequate sizing of power sources, cables, distribution boards etc. I
learnt how to compute a load list, which is usually a Microsoft Excel document
showing all intended loads, their tag numbers, current, voltage and power ratings,
efficiencies, power factors, and service duty.
Table 1 below shows a sample load list which I developed for a given offshore
platform.
ELECTRICAL LOAD SUMMARY FOR THE FOR THE OFFSHORE PLATFORM
CONSUMED
LOADS EQUIPMENT SERVICE DESCRIPTION
DUTY
EFF
PF KW KVA REMARK
TAG NOS.
AREA 1 BANK 1: 6.6KV WATER INJECTION PUMP C 0.92 0.85 300 383.63 WATER INJECTION PUMP S 0.92 0.85 300 383.63 AIR COMPRESSOR I 0.92 0.85 500 639.39 AIR COMPRESSOR C 0.92 0.85 500 639.39 DEMULSIFIER PUMP I 0.92 0.85 200 255.75 DEMULSIFIER PUMP S 0.92 0.85 200 255.75 BANK 2: 415V LIGHTING D.B C 0.98 1.00 1.50 1.53 CHEMICAL INJECTION SKID PUMP C 0.92 0.85 1.00 1.28 CHEMICAL INJECTION SKID PUMP S 0.92 0.85 1.00 1.28 CHEMICAL INJECTION SKID PUMP C 0.92 0.85 2.00 2.56 CHEMICAL INJECTION SKID PUMP S 0.92 0.85 2.00 2.56
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CONDENSATE HEATER C 0.98 1.00 1.00 1.02 CONDENSATE HEATER S 0.98 1.00 1.00 1.02 CONDENSATE HEATER I 0.98 1.00 1.00 1.02 CONDENSATE HEATER C 0.98 1.00 0.50 0.51 CONDENSATE HEATER I 0.98 1.00 0.50 0.51 CONDENSATE HEATER S 0.98 1.00 0.50 0.51
HEATING, VENTILATION AND AIR CONDITIONING PANEL C 0.92 0.85 1.50 1.92
HEATING, VENTILATION AND AIR CONDITIONING PANEL C 0.92 0.85 1.50 1.92
AREA 2 BANK 1: 6.6KV BOIL-OFF GAS COMPRESSORS C 0.92 0.85 2500 3196.93 BOIL-OFF GAS COMPRESSORS C 0.92 0.85 2500 3196.93 BANK 2: 415V LIGHTING D.B C 0.98 1.00 1.50 1.53 FIRE WATER PUMP S 0.92 0.85 30 38.36 JOCKEY PUMP I 0.92 0.85 30 38.36 CONDENSATE HEATER C 0.98 1.00 1.00 1.02 CONDENSATE HEATER C 0.98 1.00 0.50 0.51
HEATING, VENTILATION AND AIR CONDITIONING PANEL C 0.92 0.85 1.00 1.28
HEATING, VENTILATION AND AIR CONDITIONING PANEL C 0.92 0.85 1.00 1.28
AREA 3 EMERGENCY PANEL (DUAL SUPPLY) 6.6KV START-UP MOTOR I 0.92 0.85 300 383.63 START-UP MOTOR I 0.92 0.85 300 383.63 FIRE WATER PUMP S 0.92 0.85 200 255.75 FIRE WATER PUMP S 0.92 0.85 200 255.75 GENERATOR COOLING WATER PUMP I 0.92 0.85 200 255.75 GENERATOR COOLING WATER PUMP S 0.92 0.85 200 255.75 GENERATOR COOLING WATER PUMP S 0.92 0.85 200 255.75 EMERGENCY PANEL(DUAL SUPPLY) 415V UNINTERUPTED POWER SUPPLY C 0.98 1.00 29.40 30 LIGHTING DB C 0.98 1.00 1.50 1.53 LIGHTING DB C 0.98 1.00 1.50 1.53 INSTRUMENT DB I 0.98 1.00 9.80 10 INSTRUMENT DB I 0.98 1.00 9.80 10 CONTROL ROOM DB C 0.98 1.00 4.90 5
Table 1: Load List for an Offshore Platform.
2. Generation of single line diagrams:
There were many instances where I was required to develop one or single line
diagrams. The electrical load list came in very handy in such instances. A single
line diagram is a schematic drawing that uses graphical symbols and standard
nomenclature to illustrate the overall configuration of an electrical system. The
single line diagram shows diagrammatically the conceptual/detailed design for
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power generation and distribution on a site, interconnections between various
loads, Generation philosophies, load layouts, busbars and their respective voltage
levels, system protection devices, amongst others. These are well shown on single
line diagrams with standard electrical symbols. I received extensive training on
the use of autoCAD, which is the software used by the electrical group to draw
one line diagrams. Figure 3 below shows the single line diagram which I drew
with the aid of autoCAD for the offshore platform whose load summary is shown
in Table 1.
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Fig.3 – Single line digram for the Offshore Platform.
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3. Equipment sizing and Cable sizing:
Areas covered here includes Generator sizing, Transformer sizing, circuit breaker
sizing, and cable sizing calculations. I also learnt about the relevant standards and
codes as regards equipment sizing and cable selection, such as the National
Electric Code (NEC), and the National Electric Manucfacturers
Association(NEMA) codes.
As part of my training, I was given an assignment on equipment and cable sizing
in the Bechtel project. The calculations I carried out are shown below:
CALCULATIONSSIZING OF EQUIPMENT IN THE BECHTEL PROJECT.
SIZING OF TRANSFORMERS AND GENERATORS.FORMULA USED:GEN. SIZING:RUNNING LOAD (RL) = TOTAL CONTINUOS LOAD +30% INTERMITTENT LOAD.PEAK LOAD (PL) = RUNNING LOAD +20% STANDBY LOAD.TRANSFORMER SIZE ≥ I.25 *PEAK LOAD.ASSUMPTION: USING N+1 PHILOSOPHY.
TRANSFORMER SIZING GENERATOR SIZING.
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BUS SUMMARY
BUS IDENTITY
CONTINUOUSLOADS -C
(KVA)
INTERMITTENTLOADS –I
(KVA)
STANDBY LOADS –S
(KVA)
BUS A, 33KV 30,0000 ---- -----
BUS B, 6.6KV ---- 1380 ----
BUS C ,400V 217.5 55 ----
BUS D ,400V 118.75 ---- -----
BUS E,4OOV 60 22.5 -----
BUS F,400V 295.4 66.68 352.98
TOTAL 30691.65 1524.18 352.98
Table 2: Bus Summary.
GENERATOR SIZING (USING N+1 PHILOSOPHY)RL = 30691.65 + (0.3*1524.18) = 31148.90 KVAPL = 31148.90 +70.60 = 31219.56 KVAFUTURE EXPANSION = 25%PL = 1.25*31219.56 = 39024.45 KVAFOR N + 1 GEN.; WHERE N = 2 PL/2 = 19512.25 KVA
4. Electrical Layout drawings (Earthing, Cable, and Lighting layout):
An electrical layout drawing gives a plan view of an area (e.g a flowstation), and
shows by means of appropriate sign conventions, such features as the earthing
grid(earthing layout), electrical cable route(cable routing layout), location of
lighting towers/fixtures(lighting layout) etc. I was trained on how to draw layout
drawings using autoCAD. I learnt about the various factors to be considered
before layout drawings/designs are produced.
5. Hazardous Area classification/drawings:
I was also trained on how to produce hazardous area drawings using autoCAD. A
hazardous area is a three-dimensional space in which a flammable atmosphere
may be expected to be present at such frequencies as requires special precautions
for the construction and use of all electrical apparatus.
The purpose of these drawings is to provide assistance in selecting the correct
certified equipment for hazardous zones (as will be clearly noted on the drawing)
such as petrochemical plants, refineries, gas plants, oil terminals, etc.
6. Supplementary drawings (Cable schedules, Distribution board schedules,
Schematics and Interconnection drawings, Installation details,
Specifications):
These drawings are also produced at later electrical design stages for a project. I
was also opportuned to see how these drawings were produced and their relevance
to the project.
The training I received involved the use of the following computer aided
design/application softwares:
AutoCAD
Chalmlite ( a software for lighting design and calculations).
Plant design Management system (PDMS).
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AutoCAD
It is a computer aided drawing software. It is used by the electrical group to draw
single line diagrams, electrical layout drawings, hazardous area drawings, distribution
board schedules, schematics and interconnection diagrams, power layouts etc.
The AutoCAD design package is a general purpose software. It is an extremely
powerful tool. The speed and ease at which a drawing can be prepared and modified
using a computer offers a phenomenal advantage over hand preparation. There is
virtually no limit to the kind of drawings that can be prepared using the software.
AutoCAD provides a set of entities for use in constructing a drawing. An entity is a
drawing element such as a line, circle, or text string annotations. The effect of every
change appears immediately, thus enabling the designer to take immediate decisions
concerning size, aesthetics and taste of the designer.
Other AutoCAD functions allow modifications of the drawing in a variety of ways
e.g. erasing or moving entities or copying them from repeated patterns. The view of
the drawing displayed on the screen can be changed, or information about the drawing
can be displayed. The use of layers and assigning colours to the different layers
enhances the appearance of the end product and aids in detecting errors in the drawing
that would otherwise have gone undetected. The final drawing can then be plotted
with a pen plotter or printer plotter.
The importance of this software can be more appreciated in that is saves time and cost
in the production of drawings, by providing the engineer with a mature tool to work,
thus, ensuring a more professional and accurate output.
The activities of the electrical group to which to which I was attached, involved the
extensive use of autoCAD.
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Chalmlite:
It is a computer aided lighting design software. It is used by the electrical group to
carry out lighting design/calculations (general lighting, fence lighting, interior lighting
etc). With the aid of this software, an area could be lit to any required illumination
level, with appropriate fixtures/lighting towers positioned at appropriate locations.
Illumination levels at various locations are automatically calculated and displayed.
Design specifications such as maintenance factor, mounting height, aiming point, type
of fixtures, etc are usually supplied by the client. Design is thus based on client
specifications, with allowance made for suggestions to the client from the electrical
group.
The activities of the electrical group to which to which I was attached, also involved
the extensive use of chalmlite.
The lighting calculation results as computed by the Chalmlite Lighting Design
Program indicating the illumination level at different points in the defined
area(Tuomo flowstation) and target grid summaries are as shown below as Fig 4 and
Table 3 respectively. The lighting towers are shown on the figure as FT-1 to FT-17
respectively. This design is for general lighting of the area under consideration.
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Fig.4: Lighting calculation result showing illumination levels.
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TARGET GRID SUMMARIES
Grid is x-y plane at z= 0.0 Horizontal Lux Limits: from x = -690.0 to x= -330.0, from y =201 to y= 621Average = 27.4 lux Minimum / Average = 0.0Maximum = 171.0 lux Minimum / Maximum=0.0Minimum = 0.0 Number Points = 418
FLOODLIGHT / LUMINAIRE SUMMARYEVOLUTION 400W SON-T MEDIUM BEAM Ex DE ATEXCat.Ref. EVOD / 400 / MS / M Lumens per Lamp = 55000.0 MF= 0.80Beam is not RotatedNumber Luminaires = 170Total Number Luminaires = 170LUMINAIRE LOCATIONS AND ORIENTATION ANGLES
LIGHTING TOWERNO.
CAT.REF SEQUENCE NO.
LOCATION AIMING POINT
AIMING ANGLES
FT-01
X Y Z X Y Z HORIZ. VERT.EVOD/400/MS/M 1 -598 231 25 -586 240 0 54 30