OBJECTIVE Indian Oil Corporation is the leading company in the field of Oil, Petroleum distribution in the country. My objective for getting internship at Indian Oil Corporation is to study in details the functioning of the company and the processes involved in supply distribution of the Oil & Petroleum products by the company. It is worth mentioning here that pumps are the very important and integral part any production and distribution system involved in the field of oil industries. The main objective of the study is to understand the selection process that is followed by IOCL for various purchases. In 1 st part of the report we shall study various types of pumps that are used in India and further study in depth the centrifugal pumps which are generally used in oil industries. Indian Oil Corporation Limited uses centrifugal pump for various processes like pumping crude oil from offshore tankers to the port, pumping crude oil to oil segregation plants , pumping final product to various location all over the country . As we move further in the report we shall discuss the main characteristics that are considered while selection of pumps. To understand the main characteristics we need to know the working of centrifugal pumps and the physical aspects that it changes (pressure , velocity , head). The main characteristics are used to plot various graphs which help us in selection pumps while keeping our costs low and efficiency high . the final selection is done via pump data sheet which is available in API-610 .
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OBJECTIVE
Indian Oil Corporation is the leading company in the field of Oil, Petroleum distribution in
the country. My objective for getting internship at Indian Oil Corporation is to study in
details the functioning of the company and the processes involved in supply distribution
of the Oil & Petroleum products by the company. It is worth mentioning here that
pumps are the very important and integral part any production and distribution system
involved in the field of oil industries. The main objective of the study is to understand
the selection process that is followed by IOCL for various purchases.
In 1st part of the report we shall study various types of pumps that are used in India
and further study in depth the centrifugal pumps which are generally used in oil
industries. Indian Oil Corporation Limited uses centrifugal pump for various processes
like pumping crude oil from offshore tankers to the port, pumping crude oil to oil
segregation plants , pumping final product to various location all over the country .
As we move further in the report we shall discuss the main characteristics that are
considered while selection of pumps. To understand the main characteristics we need
to know the working of centrifugal pumps and the physical aspects that it changes
(pressure , velocity , head). The main characteristics are used to plot various graphs
which help us in selection pumps while keeping our costs low and efficiency high . the
final selection is done via pump data sheet which is available in API-610 .
CHAPTER -1
1.0.0 INTRODUCTION TO IOCL
1.1.0 Indian Oil Corporation (IOCL) is India's largest commercial enterprise, with a sales
turnover of Rs. 4,50,756 crore and profits of Rs. 5,273 crore for the year 2014-15. It is also
the leading Indian corporate in Fortune's prestigious 'Global 500' listing of the world's
largest corporates, ranked at the 96th position for the year 2014. As India's flagship
national oil company, with a 33,000-strong workforce , Indian Oil has been meeting India’s
energy demands for over half a century. With a corporate vision to be 'The Energy of
India' and to become 'A globally admired company,' Indian Oil's business interests
straddle the entire hydrocarbon value-chain – from refining, pipeline transportation and
marketing of petroleum products to exploration & production of crude oil & gas, marketing
of natural gas and petrochemicals, besides forays into alternative energy and globalization
of downstream operations. Having set up subsidiaries in Sri Lanka, Mauritius and the UAE,
the Corporation is simultaneously scouting for new business opportunities in the energy
markets of Asia and Africa. It has also formed about 20 joint ventures with reputed
business partners from India and abroad to pursue diverse business interests.
1.1.2 BUSINESS
Indian Oil is India’s flagship Maharatna national oil company with business interests
straddling the entire hydrocarbon value chain – from refining, pipeline transportation and
marketing of petroleum products to Research & Development, Exploration & Production,
marketing of natural gas and petrochemicals. By venturing into the Renewables and the
Nuclear Energy, the company has grown and evolved itself from a pure petroleum refining
and marketing company to a full-fledged energy company.
Having set up subsidiaries in Sri Lanka, Mauritius and the United Arab Emirates, Indian
Oil is simultaneously scouting for new business opportunities in the energy markets of
Asia and Africa.
Born out of the vision of achieving self-reliance in oil refining and marketing for the nation,
Indian Oil Corporation Ltd. has the proud possession of the world’s oldest running refinery
at Digboi with a luminous legacy of more than 110 years and also the upcoming Paradip
refinery, which when commissioned would be one of the most modern and complex
refineries.
Indian Oil Group (including two refineries of its subsidiary company Chennai Petroleum
Corporation Ltd. (CPCL)) owns and operates 10 of India’s 22 refineries. The group refining
capacity of 65.7 million metric tons per annum (MMTPA) or 1.31 million barrels per day
(mb/d) is the largest among refining companies in India. It accounts for 30.5% share of
national refining capacity. On a stand-alone basis, the company owns and operates eight
refineries with a capacity of 54.2 MMTPA (1.1 mb/d).
Indian Oil Corporation Ltd.. reaches millions of people every day through an unmatched
countrywide massive and ever-expanding infrastructure network to deliver Petroleum
products. The network, comprising over 42,600 touch points as on 30.11.2014, was
strengthened from 41,640 touches. Largest and most extensive network of retail outlets,
numbering 24,403 (including 6,194 Kisan Seva Kendras), 136 depots and 6,376
consumer pumps for the convenience of large consumers, are some of the vital
components of this network, ensuring availability of products and inventory at the doorstep
of customers. The needs of domestic fuel (LPG) are fulfilled through 91 Bottling plants and
7,626 LPG distributors, serving over 86 million customers.
Continuing its thrust on reaching rural masses through Kisan Seva Kendras (KSKs) and
LPG distributorships under Rajiv Gandhi Gramin LPG Vitaran Yojana (RGGLVY), Indian
Oil Corporation Ltd. has continuously extended its reach to the rural India, with 6,194
KSKs and 1,867 RGGLVYs as on 31st November 2014. The KSKs and RGGLVs also
represent a success story for Indian Oil Corporation Ltd. in its efforts towards inclusive
development in the rural hinterlands of India. The facilities at KSKs inter-alia include
availability of seeds, pesticides, fertilizers, provisions, farm equipment, medicines, Nutan
stoves, banking help including rural ATMs, communication etc, and all under one roof.
Indian Oil Corporation Ltd. places significant thrust on knowledge and research based
growth and has a dedicated world class R&D center. The R&D center has 320 active
patents to its credit as on 30th November 2014, of which 173 are active international
patents. In the context of vagaries of the international crude oil prices and changing
domestic pricing regime, Indian Oil Corporation Ltd. R&D is viewed as a key competitive
advantage driver. Investment in proprietary research in lubricants, catalyst, refinery and
pipelines operations, and product offerings are key thrust areas for Indian Oil. Research in
new businesses, especially, petrochemicals and alternative energy is emerging a major
focus area for Indian Oil Corporation Ltd..
Indian Oil Corporation Ltd. has established itself as a key player in petrochemicals with
good market acceptability and occupies the second largest player in the domestic
petrochemical market. Under the umbrella brand PROPEL, it offers a full products slate
covering all the major segments of petrochemicals Viz. Linear Alkyl Benzene (LAB),
3.1.16 VS7 :- Double-casing volute vertically suspended pumps shall be designated pump type
VS7.
CHAPTER 4
4.1.0 PARTS Of CENTRIFUGAL PUMPS Following are the parts of the Centrifugal Pumps
4.1.1 Casing:- The casing of a centrifugal pump serves to house the impeller and
create a chamber for liquid to be pumped through. The drive pieces of a
centrifugal pump also are housed in the casing.
4.1.2 Suction and Discharge Nozzles :-Built into the casing itself, the suction and
discharge nozzles serve as ports for water to enter and exit from, respectively.
Typically, suction nozzles are placed on the end of the pump and discharge
nozzles are located on the top.
4.1.3 Seal Chamber and Stuffing Box :-Both seal chamber and stuffing box refer to
the portion of the pump between the shaft and casing where the sealing
mechanism of the pump is housed. Seal chambers utilize a mechanical seal,
whereas stuffing boxes achieve the sealing purpose through some form of
packing. Regardless of the method used, the chamber is used to prevent liquid
from exiting the pump.
4.1.4 Bearing Housing:-The bearing housing is used to enclose and protect the shaft
bearings, ensuring proper alignment. The housing will also include some type of
method for lubricating the bearings and cooling the pump.
4.1.5 Impeller :-The main moving portion of the centrifugal pump. An impeller is a
specially designed component critical for proper functioning of the pump.
Depending on the suction type and mechanical construction of the pump, the
actual design of the impeller may vary.
4.1.6 Shaft:- The shaft transfers the electrical or mechanical energy powering the pump directly to the impeller. In addition, the shaft is responsible for supporting any other moving parts on the pump. The shaft is responsible for a great deal of both energy transfer and structural support and therefore must be carefully machined.
4.1.7 Oil ring :- The bearings are most frequently oil bath or oil ring lubricated.
CHAPTER 5
5.0.0 IMPORTANT CHARACTERISTICS
Objective of understanding the characteristics of the pumps is to understand the
functioning of the pump as a whole based on following parameters:-
Working of Pumps
Head of a Pump
Importance of Head
Total Head
NPSHR
NPSHA
Volume Flow Rate
5.1.0 Working of a Pump
Centrifugal pumps are used to induce flow or raise pressure of a liquid. Its working is
simple. At the heart of the system lies impeller. It has a series of curved vanes fitted
inside the shroud plates. The impeller is always immersed in the water. When the
impeller is made to rotate, it makes the fluid surrounding it also rotate. This imparts
centrifugal force to the water particles, and water moves radially out. Since the rotational
mechanical energy is transferred to the fluid, at the discharge side of the impeller, both
the pressure and kinetic energy of the water will rise. At the suction side, water is getting
displaced, so a negative pressure will be induced at the eye. Such a low pressure helps
to suck fresh water stream into the system again, and this process continues. A
rotodynamic or centrifugal pump is a dynamic device for increasing the pressure of liquid.
In passing through the pump, the liquid receives energy from the rotating impeller. The
liquid is accelerated circumferentially in the impeller, discharging into the casing at high
velocity which is converted into pressure as effectively as possible.
5.2.0 Head of a Pump
It is assumed that a pump designed to move water clamped into a process line. There is
a suction line and a discharge line, both running horizontally. Assuming that we are able
to “move” the discharge line so it pumps straight up into the air. The pump is then turned
on. Once the pump is running, it will move the fluid to some height measured in feet.
That height to which the pump can raise the water to is its head.
5.3.0 Importance of Head
As the manufacturers do not know for what kind of fluid the purchaser requires the
pump .The pump manufacturer's want to tell you how much head their pump's will
produce but they don't know what type of water supply will be available, so how can they
get around this. Ingeniously simple, they subtract the head available at the suction from
the head produced at the discharge, they call this Total Head. Then it doesn't matter
what the suction tank level is, they are telling you only what the pump can do regardless
of the water supply pressure at the suction head is it is independent of the type of fluid
being pumped (assuming the viscosity is relatively low and similar to water). Whether
you’re pumping water or a heavy caustic solution, the head achieved will be the same.
The pressure at the discharge of the pump, however, will be higher for the heavier
solution. The relationship between head and pressure can be characterized by the
following formula.
5.4.0 Total Head
Total Dynamic Head (TDH) is the total equivalent height that a fluid is to be pumped,
taking into account friction losses in the pipe.
TDH = Static Height + Static Lift + Friction Loss
Static Height is the maximum height reached by the pipe after the pump (also known as
the 'discharge head').
Static Lift is the height the water will rise before arriving at the pump (also known as the
suction head).
Friction Loss (or Head Loss).- this depends on the length of pipes and their diameter and
the flow rate . Friction losses are different for different flow rates .
The relationship of head to pressure is expressed as
h=2.31p/SG
where
h = height of the fluid column above a reference point
p = pressure.
SG= Specific gravity
Net positive Suction head
NPSH is defined as the total suction head in feet of liquid (absolute at the pump centerline
or impeller eye) less the vapor pressure (in feet) of the liquid being pumped.
understood by the fact that the liquid's energy is a function of its velocity and the velocity
accelerates as the liquid passes through the impeller. A wider diameter impeller
accelerates the liquid to a final exit velocity greater than the proportional increase in the
diameter.
9.11.0 Maximum allowable Pressure : MAWP being the maximum pressure based on the
design codes that the weakest component of a Pressure vessel can handle. Commonly
standard wall thickness components are used in fabricating pressurized equipment, and
hence are able to withstand pressures above their design pressure.
9.12.0 Design Pressure : The most severe condition of coincident internal or external pressure
and temperature (minimum or maximum) expected during service”.
9.13.0 OTHER TERMS AND DEFINITIONS USED IN PUMP DATA SHEET
OPERATING CONDITIONS
SITE DATA
DRIVER TYPE
MOTOR DRIVER
LIQUID
MATERIAL
PERFORMANCE
UTILITY
CONSTRUCTION
SURFACE PREPARATION AND PAINT
HEATING AND COOLING
BEARINGS AND LUBRICATION
9.13.1 OPERATING CONDITIONS
PARAMETER GIVEN BY REQUIREMENTS
Flow, Rated Purchaser Rated flow is associated with rated differential head for roto-dynamic pumps, and rated outlet pressure for positive displacement pumps.
Suction pressure max. Purchaser Some factor like pump's suction flange which limits suction pressure to the given maximum value.
Suction Pressure rated Purchaser It depends on rated flow . Discharge Pressure Discharge pressure depends on the
pressure available on the suction side of the pump
Differential Pressure Determined by evaluating all pressure (or head) losses from the liquid level in the receiver through all piping and
components of the system and back to the receiver.
NPSHA Purchaser It depends on five factors 1)The absolute pressure on the surface of the liquid in the supply tank. 2)The vertical distance between the surface of the liquid in the supply tank and the centerline of the pump 3)Friction losses in the suction piping 4)Velocity head at the pump suction port 5)Absolute vapor pressure of the liquid at the pumping temperature
Purchaser The type of service depends on the requirement of the product , the cost of operation that is incurred , the eeficiency.
9.13.2 SITE DATA
PARAMETER GIVEN
Location: Purchaser Based on the application of pump and the location of the plant.
Altitude Purchaser Based on location of plant. Barometer Purchaser Based on location of plant Range of ambient temperature
Purchaser Based on location of plant
Relative Humidity Purchaser Based on location of plant Usual Conditions 1)Dust 2)Fumes
Purchaser Based on location of plant
ELECTRICAL CLASSIFICATION AREA
Class Purchaser It depends on the general nature of the explosive material . It might be 1)gas or vapour 2)Dusts 4)Fiber
Group Purchaser Depends on the type of hazardous material in the surrounding atmosphere. Groups A, B, C, and D are for gases (Class I only) while groups E, F, and G are for dusts and flyings (Class II or III).
Division Purchaser Depends on the probability of the hazardous material being able to produce an explosive or ignitable mixture based upon its presence.
9.13.3 DRIVER TYPE
PARAMETER GIVEN BY REQUIREMENT
Driver type Purchaser The types of drives that can be used are turbines , induction motor , engines etc.
9.13.4 MOTOR DRIVER
PARAMETER GIVEN BY REQUIREMENT
Power Manufacturer The power at which the motor driver operates and provides the required impeller speed , head , flow rate.
Frame Manufacturer The Frame type of the motor driver . VOLTS/PHASE/HERTZ Manufacturer The specifications of electricity supply
required by the motor. Minimum Starting Voltage Manufacturer The voltage below which the motor will
not start. Insulation Manufacturer The insulation of motor from the liquid
being used. Temperature rise manufacturer The rise in temperature in the motor due
the working of the motor driver , the friction when coupled.
Full Load AMPS Manufacturer expected performance of the motor at the rated or nameplate hp.
LOCKED rotor AMPS Manufacturer depend on the type of motor as well as the specified design voltage required for the motor
Starting Method Manufacturer The motor driver is and electrical device it is important to mention the starting method . Is it battery operated or another electrical supply is attached
Radial Bearing Type Manufacturer The type of bearings used to reduce the friction . These are lubricated .
9.13.5 LIQUID
PARAMETER GIVEN BY REQUIREMENT
Liquid type ; Hazardous/Flammable
Purchaser a flash point below 100 degrees Fahrenheit (38 degrees Celsius). Less-flammable liquids (with a flashpoint between 100 degrees and 200 degrees Fahrenheit) are defined as combustible liquids.
Pumping Temp. Purchaser The temperature at which the liquid is to be pumped.
Vapour Pressure Purchaser Vapor pressure or equilibrium vapour pressure is defined as the pressure exerted by a vapor in thermodynamic equilibrium with its condensed phases (solid or liquid) at a given temperature in a closed system. It is The property of the liquid .
Relative Density Purchaser Relative density, or specific gravity, is the ratio of the density (mass of a unit volume) of a substance to the density of a given reference material.It is the property of the liquid used
Viscosity Purchaser The viscosity of a fluid is a measure of its resistance to gradual deformation by shear stress or tensile stress. For liquids, it corresponds to the informal concept of "thickness"
Specific Heat Purchaser The specific heat is the amount of heat per unit mass required to raise the temperature by one degree Celsius. It is the property of the liquid.
Chloride Concentration Purchaser The concentration of these salts in the crude oil depends on the oil field from which the crude is extracted,
H2S concentration purchaser Total sulfur in a crude oil depends on the type of oil field and the conc with H2.
9.13.6 MATERIALS
PARAMETER GIVEN BY REQUIREMENT
ANNEX H CLASS Purchaser Materials and material specifications for pump parts
reduced hardness material required
Purchaser Annexure H
Barrel case Purchaser Annexure H Impeller Purchaser Annexure H Impeller Wear Rings Purchaser Annexure H Shaft Purchaser Annexure H Diffusers Annexure H
9.13.7 PERFORMANCE
PARAMETER GIVEN BY REQUIREMENT
Proposal Curve No. Purchaser A pump can be selected by combining the System Curve and the Pump Curve
Impeller dia (Rated/max./min)
Purchaser The calculations are based on the affinity laws which in turn are derived from a dimensionless analysis of three important parameters that describe pump performance . three things are Head , Flow and speed of impeller
Impeller type Purchaser Closed , open or semi open. Efficiency Purchaser Required efficiency that is
calculated using the pump curves and system curves
Rated Power Purchaser Power that is supplied for the impeller to produce the required efficiency
Min. continuous Flow (Thermal/Stable)
Purchaser The minimum rate of flow required to avoid problems like Cavitation
Preferred Operation Region Purchaser Range of operation where the efficiency obtained is maximum and cavitation is avoided
Max. head @rated impeller Purchaser Maximum head generated if
the impeller runs at the given parameters
9.13.8 UTILITY
PARAMETER GIVEN BY REQUIREMENT
Electricity Purchaser Electricity requirement of the driver used .
Steam Purchaser The maximum /allowable pressure of the steam used in the turbine (if a turbine is used)
Cooling water Purchaser Maximum and allowable temperature and pressure of the cooling water used in the turbine . a better cooling system provides a better efficiency of the turbine
9.13.9 CONSTRUCTION
PARAMETER
Rotation Purchaser Viewed from coupling end Pump Type Purchaser Which type of pump required . Max. Allowable working pressure
Purchaser The should be able to withstand design pressure.
Hydrotest Pressure Purchaser Pressure above the design pressure . Pipes are deformed
Nozzle Connection 1)Size Purchaser The size of the nozzle is dependent on the
head that is to be provided. 2)Flange Rating Purchaser A flange is a connection between the main
pipeline and the pump thus the pressure in the pipeline decides the flange rating. flange rating decides the flange size , the flange bolt size.
Coupling Manufacturer It includes Model , Rating , Spacer length , Type of coupling , coupling guard .
9.13.10 SURFACE PREPARATION AND PAINT
Parameter Given By Requirement
Pump Surface Preparation Purchaser Rp standard Primer Purchaser Rp standard finish coat purchaser Rp standard
9.13.11 HEATING AND COOLING Parameter Given By Requirement
Cooling water piping plan Purchaser Cooling water required for pumping volatile liquids which become flammable at room temperature
C.W.Piping Material Purchaser The material is important as it indicates the efficiency of rate of cooling.
9.13.12 BEARINGS AND LUBRICATION
Parameter Given Requirement
Oil Heater Requirement Purchaser If the liquid transported is at a particular temperature then the lubricant used should be at the same temperature so as to reduce the loss of energy .