Report On Summer Training At Lube Blending Plant Indian Oil Corporation Limited Paharpur Project Guide: Mr. Pujan Kumar Maity, Dy. Plant Manager Training period: 11 June, 2014 – 11 July, 2014 Submitted By Sayan Roy Department Of Mechanical Engineering (3 rd Year) Future Institute of Engineering & Management Kolkata
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Report On Summer Training
At
Lube Blending Plant
Indian Oil Corporation Limited Paharpur
Project Guide: Mr. Pujan Kumar Maity, Dy. Plant Manager
Training period: 11 June, 2014 – 11 July, 2014
Submitted By
Sayan Roy
Department Of Mechanical Engineering (3rd
Year)
Future Institute of Engineering & Management
Kolkata
2
Sl.
No. Contents Page No.
1. Introduction 3
2. Map of the plant 4
3. Lubricant-Definition & Purpose 5 - 8
4. Classifications of lubricants 9 - 10
5. Process of the plant 11 -12
6. Base oil & Base oil storage tanks 13-15
7. Additive & additive storage tanks 16-17
8. Transfer Systems 17-20
9. Lube Blending & Blending Kettles 21-23
10. Inside blending kettle
Air Spanger
Agitator
Circulation
24-25
11. Boiler 26-27
12. Air Dryer 28-29
13. Lube Despatching Section
Barrel Filling
Manual Filling
Small can filling
30-34
14. Agro Spray section 35
15. Electra Plant (Transformer Oil) 36
16. Effluent Treatment Plant (ETP) 37-38
17. Quality Control Laboratory
Crackle test
Pour point test
Flash point test
Total Acid
Number(TAN)
39-42
18. Industrial Safety in Lube Blending Plant 43-51
19. Conclusion 52
3
INTRODUCTION The Lube Blending Plant of Indian Oil Corporation Limited
Location: Paharpur, Kolkata
Area: 13.59 acres
Production Capacity: 0.1 MMT/annum
Established on: 22nd March,1963
The Kolkata plant was commissioned in 1964.In 1973 the production of
‘SERVO’ lubricants started. In 1994, the plant was certified for ISO 9002:94
quality systems and in 2001, the plant was certified for ISO 14000:96
environment management systems. In 2003, SAP had been implemented in
Kolkata plant. In 2006, the plant has been certified for ISO 9001:2000.
More than 350 grades of lubricants are manufactured in this plant.
There are 28 base oil tanks having a total capacity of 30738 KL
There are 8 bulk additive tanks having a total capacity of 1365 KL
There are 14 blending kettles having a total capacity of 1712 KL
There are 2 diesel generator of 250 KVA and 350 KVA
2 Boilers of capacity 5 tons per hour
High capacity Effluent Treatment Plant (100KL &150 KL)
Integration of plant activities with all marketing network across the
organisation through SAP
Access control system is implemented in the plant
Quality Control laboratory which is equipped with instruments of latest
state of the art technology
4
Map of the Plant
Fig: Overview of the Lube Blending Plant, IOCL, Paharpur, Kolkata
5
Lubricant: Definition & Purpose
A lubricant is a substance introduced to reduce friction between moving
surfaces. It may also have the function of transporting foreign particles. The
property of reducing friction is known as lubricity (Slipperiness).
A good lubricant possesses the following characteristics:
High boiling point
Low freezing point
High viscosity index
Thermal stability
Hydraulic Stability
Demulsibility
Corrosion prevention
High resistance to oxidation
One of the single largest applications for lubricants, in the form of motor oil,
is protecting the internal combustion engines in motor vehicles and powered
equipment.
Typically lubricants contain 90% base oil (most often petroleum fractions,
called mineral oils) and less than 10% additives. Vegetable oils or synthetic
liquids such as hydrogenated polyolefin, esters, silicones, fluorocarbons and
many others are sometimes used as base oils. Additives deliver reduced
friction and wear, increased viscosity, improved viscosity index, resistance to
corrosion and oxidation, aging or contamination, etc.
Lubricants such as 2-cycle oil are added to fuels like gasoline which has low
lubricity. Sulphur impurities in fuels also provide some lubrication properties,
which have to be taken in account when switching to a low-sulphur diesel;
biodiesel is a popular diesel fuel additive providing additional lubricity.
6
Non-liquid lubricants include grease, powders (dry graphite, PTFE,
Molybdenum disulphide, tungsten disulphide, etc.), PTFE tape used in
plumbing, air cushion and others. Dry lubricants such as graphite,
molybdenum disulphide and tungsten disulphide also offer lubrication at
temperatures (up to 350 °C) higher than liquid and oil-based lubricants are
able to operate. Limited interest has been shown in low friction properties of
compacted oxide glaze layers formed at several hundred degrees Celsius in
metallic sliding systems, however, practical use is still many years away due to
their physically unstable nature.
Another approach to reducing friction and wear is to use bearings such as ball
bearings, roller bearings or air bearings, which in turn require internal
lubrication themselves, or to use sound, in the case of acoustic lubrication.
Purpose of Lubricant:
Lubricants perform the following key functions.
• Keep moving parts apart
• Reduce friction
• Transfer heat
• Carry away contaminants & debris
• Transmit power
• Protect against wear
• Prevent corrosion
• Seal for gases
• Stop the risk of smoke and fire of objects
• Prevent rust
Keep moving parts apart:
Lubricants are typically used to separate moving parts in a system. This has the
benefit of reducing friction and surface fatigue, together with reduced heat
generation, operating noise and vibrations. Lubricants achieve this by several
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ways. The most common is by forming a physical barrier i.e., a thin layer of
lubricant separates the moving parts. This is analogous to hydroplaning, the
loss of friction observed when a car tire is separated from the road surface by
moving through standing water. This is termed hydrodynamic lubrication. In
cases of high surface pressures or temperatures, the fluid film is much thinner
and some of the forces are transmitted between the surfaces through the
lubricant.
Reduce friction:
Typically the lubricant-to-surface friction is much less than surface-to-surface
friction in a system without any lubrication. Thus use of a lubricant reduces
the overall system friction. Reduced friction has the benefit of reducing heat
generation and reduced formation of wear particles as well as improved
efficiency. Lubricants may contain additives known as friction modifiers that
chemically bind to metal surfaces to reduce surface friction even when there is
insufficient bulk lubricant present for hydrodynamic lubrication, e.g.
protecting the valve train in a car engine at start up.
Transfer heat:
Both gas and liquid lubricants can transfer heat. However, liquid lubricants are
much more effective on account of their high specific heat capacity. Typically
the liquid lubricant is constantly circulated to and from a cooler part of the
system, although lubricants may be used to warm as well as to cool when a
regulated temperature is required. This circulating flow also determines the
amount of heat that is carried away in any given unit of time. High flow
systems can carry away a lot of heat and have the additional benefit of
reducing the thermal stress on the lubricant. Thus lower cost liquid lubricants
may be used. The primary drawback is that high flows typically require larger
sumps and bigger cooling units. Turbochargers get red hot during operation
and the oil that is cooling them only survives as its residence time in the
system is very short i.e. high flow rate. If the system is shut down suddenly
(pulling into a service area after a high speed drive and stopping the engine)
the oil that is in the turbo charger immediately oxidizes and will clog the oil
ways with deposits.
8
Carry away contaminants and debris:
Lubricant circulation systems have the benefit of carrying away internally
generated debris and external contaminants that get introduced into the
system to a filter where they can be removed. Lubricants for machines that
regularly generate debris or contaminants such as automotive engines typically
contain detergent and dispersant additives to assist in debris and contaminant
transport to the filter and removal. Over time the filter will get clogged and
require cleaning or replacement, hence the recommendation to change a car's
oil filter at the same time as changing the oil. In closed systems such as gear
boxes the filter may be supplemented by a magnet to attract any iron fines that
get created.
Transmit power:
Lubricants known as hydraulic fluid are used as the working fluid in
hydrostatic power transmission. Hydraulic fluids comprise a large portion of
all lubricants produced in the world. The automatic transmission's torque
converter is another important application for power transmission with
lubricants.
Protect against wear:
Lubricants prevent wear by keeping the moving parts apart. Lubricants may
also contain anti-wear or extreme pressure additives to boost their
performance against wear and fatigue.
Prevent corrosion. Good quality lubricants are typically formulated with
additives that form chemical bonds with surfaces, or exclude moisture, to
prevent corrosion and rust.
9
Classification of Lubricant
The main types of lubricants are:
Automotive
Industrial
Specialty
Marine
Automotive Lubricants:
4 Stroke Engine Oil
2 Stroke Engine Oil
Multi-grade Engine Oil
Multi-grade Grease Oil
Transmission Fluid
Gas Engine Oil
Rail Road Oil
Industrial Lubricants:
Turbine Oil
System & Hydraulic System Oil
Knitting & Textile Oil
Circulating Oil
Vacuum Pump Oil
Steam Cylinder Oil
Heat Transfer Oil
Bearing Oil
Asphaltic Oil
Axle Oil
Gear Compound Oil etc.
10
Metal Working & Specialty Lubricants:
Soluble Cutting Oil
Neat Cutting Oil
Honing Oil
Aluminium Rolling Oil
Steel Rolling Oil
Quenching Oil
Rust Preventing Oil
Rubber Processing Oil
Agricultural Spray Oil
Glass Mould Oil etc.
Marine Lubricants:
Marine Crankshaft Oil
Marine Gear Oil
Marine Turbine Oil
Stern Tube Oil
11
Process of the plant
DISPATCHED TO REQUIRED LOCATIONS
BARGE/TANKER TRUCK WITH ADDITIVE BARREL
ADDITIVE STORAGE TANKS BASE OIL STORAGE TANKS
THROUGH MOTORS AND PUMPS
BLENDING KETTLE
TANK LORRY FILLING
SMALL CAN FILLING
BARREL FILLING
AGRO OIL BLENDING KETTLE
AGRO SPRAY
IN HDP CONTAINER
AND BUCKET
(1/5/6/7.5/10/12/20
LITRES)
BARREL (210 LITRES) TANK LORRY (2000) LITRES)
12
The base oil, also known as raw oil used for manufacturing
lubricating oil, is stored into the various storage tanks meant for
them. The base oil is brought by the tankers via sea route.
The oil is transferred to storage tanks by pipelines. The additives
which are to be mixed are brought by tank Lorries. Since the
amount of additive to be mixed to make a grade is quite small,
therefore the number of storage tanks for additives is much
smaller than the number of storage tanks. The additives and base
oil are stored in their respective storage tanks.
While making a specific grade of lubricating oil, certain amount
of base oil and additives are taken into the blending kettle. There
both are mixed by various pre-determined processes to
manufacture that specific grade of lube oil.
Now the manufactured lube oil is sent to three departments for
packaging namely small can filling, barrel filling and tank lorry
filling. In small can filling the lube oil is filled in small packages
with quantities varying from 1 to 20 litters. In barrel filing the oil
is packaged into a much larger quantity namely 210 litters. A
barrel is a large container which can contain 210 litters of oil. For
large scale dispatch tank lorry filling is used. A tank lorry with
large capacity is filled with the lube oil and dispatched to the
desired location.
In the whole process, the quality control department keeps an
eye on the quality of the oil which is dispatched. Even before the
manufacture of the lubricating oil, the quality control lab keeps a
tab on various important parameters of the oil.
The maintenance of all the machines in the plant is overseen by
the maintenance department. The maintenance department is
also responsible for overlooking the electrical system of the plant.
The finance department is responsible for allocating funds to
various vendors and repair works to be undertaken in the plant.
There is also a security department which monitors the security
in the plant. The fire security also comes under it and all the
proper equipment are kept in place.
13
Base Oil & Base Oil Storage Tanks The base oil, also known as raw oil used for manufacturing lubricating oil. The
main sources of base oil are Haldia Refinery, HPC, CRL and the rest are mainly
imported. The main types of base oil used in the plant are TOBH / TOBL /
HVI SP / LN / IN/ 500 SN HN/BN/BP/BITUMEN/PIB/PAO etc.
Mineral oil term is used to encompass lubricating base oil derived from crude oil.
The American Petroleum Institute (API) designates several types of lubricant
base oil:
Group I – Saturates <90% and/or sulphur >0.03%, and Society of
Automotive Engineers (SAE) viscosity index (VI) of 80 to 120
Manufactured by solvent extraction, solvent or catalytic dewaxing, and
hydro-finishing processes. Common Group I base oil are 150SN (solvent
neutral), 500SN, and 150BS (bright stock)
Group II – Saturates over 90% and sulphur under 0.03%, and SAE
viscosity index of 80 to 120
Manufactured by hydrocracking and solvent or catalytic dewaxing
processes. Group II base oil has superior anti-oxidation properties since
virtually all hydrocarbon molecules are saturated. It has water-white colour.
Group III – Saturates > 90%, sulphur <0.03%, and SAE viscosity
index over 120
Manufactured by special processes such as isohydromerization. Can be
manufactured from base oil or slag wax from dewaxing process.
Group IV – Polyalphaolefin (PAO)
Group V – All others not included above such as naphthenic, PAG,
esters.
In North America, Groups III, IV and V are now described as synthetic
lubricants, with group III frequently described as synthesised
hydrocarbons, or SHCs. In Europe, only Groups IV and V may be classed
as synthetics.
The lubricant industry commonly extends this group terminology to
include:
Group I+ with a Viscosity Index of 103–108
Group II+ with a Viscosity Index of 113–119
14
Group III+ with a Viscosity Index of at least 140
Can also be classified into three categories depending on the prevailing
compositions:
Paraffinic
Naphthenic
Aromatic
Lubricants for internal combustion engines contain additives to reduce
oxidation and improve lubrication. The main constituent of such lubricant
product is called the base oil, base stock. While it is advantageous to have a
high-grade base oil in a lubricant, proper selection of the lubricant additives
is equally as important. Thus some poorly selected formulation of PAO
lubricant may not last as long as more expensive formulation of Group III+
lubricant.
Currently there are 26 number of storage tanks in the plant which stores nearly
12000 KL of base oil as a whole. Storage tanks are large containers that hold
liquids or gases, in this case base oil. They work under very little or no pressure
which distinguishes them from pressure containers. These tanks are rounded in
shape, i.e. they are cylindrical in nature with either conical bottom or
hemispherical bottom. Every storage tank is equipped with heating facility.
Certain storage tanks are meant for a specific type of oil only. Oil cannot be
loaded in it, until the tank is washed three times.
The details of every storage tank with its capacity are given in the following:
STORAGE TANK CAPACITY (Litres)
1) S -1 1053488
2) S-2 1052859
3) S-3 590968
4) S-4 596715
5) S-5 1054022
6) S-6 1052685
7) S-7 264720
8) S-8 264950
9) S-9 265272
10) S-10 260263
11) S-11 262746
15
12) S-12 593059
13) S-15 1058264
14) S-16 1533231
15) S-17 1057465
16) S-18 1054337
17) S-19 1555729
18) S-20 2114736
19) S-21 2141021
20) S-22 2173390
21) S-23 250997
22) S-24 250990
23) S-25 3384459
24) S-26 3385108
25) S-27 3189609
26) S-28 3217977
16
Additives & Additives Storage Tanks
Additives are the other chemical ingredients of the Lubricant used with
proper proportions to produce desired effect. A large number of additives are used to impart performance characteristics to the
lubricants. The main families of additives are:
• Antioxidants
• Detergents
• Anti-wear
• Metal deactivators
• Corrosion inhibitors, Rust inhibitors
• Friction modifiers
• Extreme Pressure
• Anti-foaming agents
• Viscosity index improvers
• Demulsifying/Emulsifying
• Stickiness improver, provide adhesive property towards tool
surface (in metalworking)
• Complexing agent (in case of greases)
Note that many of the basic chemical compounds used as detergents (example:
calcium sulfonate) serve the purpose of the first seven items in the list as well.
Usually it is not economically or technically feasible to use a single do-it-all
additive compound. Oils for hypoid gear lubrication will contain high content of
EP additives. Grease lubricants may contain large amount of solid particle friction
modifiers, such as graphite, molybdenum sulphide.
Barrels filled with additives
17
Additives Storage Tanks
Additive oil storage tanks are also pretty much similar to base oil storage tanks.
There are 4 number of additive storage tanks in the plant. This is because the
quantity of additive required to make lubricants are very small. So as per their
requirement, their availability is also small. Some additives are also brought in
barrels (which is discussed later on). The following are the list of the additive
tanks and their capacity.
STORAGE TANK CAPACITY (In Litters)
1) A-5 251660
2) A-6 251345
3) A-7 251412
4) A-8 254680
Nearly all the additive storage tanks which are there in plant are of cylindrical type
with heating facility. Different types of additive which are kept in it are VI
improver, TBN, PIB (polyisobutylene) etc. All the tanks are located near new
filling centre.
18
Transfer Systems
The base oil and additives are stored in their respective tanks.
Then both type of oil are further transferred from storage tanks
to blending kettles. To make a certain grade of lubricating oil we
need base oil and additive in correct proportion as directed by
the Quality Control (QC) laboratory. Then both the oils are
mixed inside a blending kettle using various processes. The oil is
transferred with the help of pumps located in the blending
section. The pumps are controlled semi-automatically under the
keen observation of the persons sitting in the control room. Their
work in the section is to control the pumps through computer
system, better known as PLC.
Step 1: At first the base oil is brought from one storage tank to another
with the help of pumps. These pumps are controlled by motors. The
motors are also controlled semi-automatically. The manual part of the
process includes the attachment and detachment of pipes connecting
the pumps to various kettles. The automatic part includes the starting
of the motor. The process is that a desired quantity of base oil is to be
transferred from one tank to another. So the computer shows exactly
how much quantity of base oil should be transferred. The quantity is
fixed by the managers.
Step 2: After manually connecting the pipe to the desired output pipe
of the tank, the motor is started by the person sitting in the control
room. The weight of the base oil is shown by the unit Kg. During the
transfer process when a certain amount of oil is left to be transferred,
the system alerts the person in the control room. For example, when
600kg of oil is left to be transferred then the first siren is buzzed. The
second siren is buzzed when around 300Kg is left to be transferred.
Then the motor automatically stops after the second siren.
19
Step 3: The oil which remains stuck in the pipeline is transferred with
the help of air. Another valve is manually opened in the pipeline from
which the compressed air is supposed to pass. This air pushes the
remaining oil in the pipeline into the desired tank. A certain tolerance
is allowed regarding the quantity which is transferred. Not only base oil
but additives are also transferred using this technique.
If the additive to be transferred is very viscous, then more force
would be required to transfer it. If the force required exceeds the
force provided by the pumps, then the oil could get stuck in the
mechanism or it would take a great effort for the pump to transfer
it which means more wear and tear of the motor and the pump as
well as the pipelines. To solve this problem the additive is mixed
with a little amount of base oil to make it less viscous and easy to
flow. This does not affect the product as the mixing here is
compensated at the time of manufacturing the lubricant.
At the time when more than one type of base oil is to be
transferred, the process is extended a bit further. After the
transfer of one type of base oil is done another type of base oil is
transferred into the same tank. Since different base oils are of
different densities, therefore both the base oils floats above the
other in the tank.
Pipes through which the oil is transferred from storage tanks to blending kettles.
20
The Pumps connected at suction through storage tank and delivery to blending kettles
21
Lube Blending & Blending Kettles
The physical mixing process of blending components of a
lubricant to create a final product is called Lube Blending.
Lube oil blending and additive mixing is a fully automatic batching
process performed within four parallel lines each consisting of one
blender and one weigh hopper. Keeping the weight ratios of the lube
oil components is ensured by their precise weighing and is program-
controlled by remote opening-closing of dedicated flap valves.
Fig: Process Flow Diagram
PROCESS FLOW
DIAGRAM
BASE OIL TANKS
BULK ADDITIVES
DIRECTLY CHARGED
INTO BLENDING
KETTLE
BARREL ADDITIVES
CHARGED INTO
SUMPS
STIRRER
SUMP
STREAM COILS
FOR HEATING
AIR SPIDER
FOR AIR
PURGING
H
E
A
T
I
N
G
A
N
D
A
I
R
P
U
R
G
I
N
G
PUMP
BULK LOADING SMALL CAN FILLING BARREL FILLING
TANK LORRY FILLING
AND DISPATCH
DIRECT DISPATCH STACKING AND
STORING FOR FUTURE
DISPATCH
STACKING AND
STORING FOR FUTURE
DISPATCH
DIRECT DISPATCH
22
The blending process is the most important process in the entire plant. This
process is divided into three parts-
Mixing
Heating
Air Purging
The conical container called blending kettle is used to blend the lube. The base oil
from the tanks are put into the kettle to be blended. The bulk additives are directly
charged into the sump from where it is taken to the kettle.
The kettle is lined by heating coils along the inner walls to heat its contents during
the process of blending. The mixing is mainly done in three ways-using the stirrer,
using a pump and using air.
Step 1: A stream of air is used for air purging
Step 2: the motorized stirrer is used to mechanically stir the mixture to make it
homogeneous
Step 3: Finally a pump is present outside at the bottom of the kettle to set up a
cycle where the lube is continuously brought out of the kettle through the discharge
point at the bottom and is pumped back into the kettle. Thus, setting up a cycle to
blend the lubricant. The temperature of the mixture is measured and maintained
using a temperature gauge.
The Paharpur plant is incorporated with manual blending process. But in most
of the modern lube blending plants, modern blending techniques is used. Some
of the key parts of the modern blending techniques are-
Blending Systems
Automatic Batch Blending
In-Line Blending
Simultaneous Metered Blending
Process Automation Systems
WinBlend System Seven
Compact Blend System
e-BLEND Controller
Transfer Systems
Drum Decanting
Piggable Systems
23
Blending Kettles
A blending kettle is a small conical container or tank where the
mixing of different grades of liquids is done in correct proportion to
obtain a desired product. In this plant, base oil and additive are
mixed inside the blending kettle in a predetermined proportion to
obtain different types of lubricating oils. Unlike a storage tank, a
blending kettle not only stores the product but is also the place of
various processes which are required to make the finished product.
In Paharpur plant, there are 23 blending kettles. Some of them have
been converted into blending kettles from storage tanks.