VOCATIONAL TRAINING REPORT

INDIAN OIL CORPORATION LTD

GUJARAT REFINERY
Submitted byKaran N Shah
B-Tech., Electrical Engineering, 4th year
School of Technology
Pandit Deendayal Petroleum University, Gandhinagar

INDIAN OIL CORPORATION LTD

GUJARAT REFINERY
P.O. JAWAHAR NAGAR, BAJWA,
VADODARA-391320.
WEBSITE- www.iocl.com
TRAINING PERIOD: [13/6/2016 TO 27/6/2016]
TRAINING TIME: 9:30AM TO 5:30PM

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ACKNOWLEDMENTS
Training at IOCL has been immense source of technical as
well as industrial knowledge for me.
I have been able to appreciate the courses that I have so far
learned in the field of electrical engineering.
The training has imparted me knowledge about various
electrical equipments used for generation and distribution
of power to the various plants of the refinery.
I would like to sincerely thank IOCL for providing me this
vital opportunity of vocational training.
I would like to thank Mr. J.K Shersia, Mr. Rohit Singh, Mr.
R.V Sinha, Mr. Vinod Pargi, Mr. Mohit Tyagi, and
Mr. A. M Datir for all their guidance and help during my
training.
A special thanks to Mr. A.C Shekhar and Mr. B.C Patel
Without whom this training would have not been possible
for me.
Lastly, I would like to extend my sincere thanks to the
entire IOCL Staff involved with me during my training.
I believe my vocational training at IOCL was a vivid and
once in a lifetime Experience

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-KARAN N SHAH

Table of Contents
About IOCL

Products and Services 4

Refineries

Employees

Competitors

Profile of Gujarat Refinery

Electrical System Engineering 7

Introduction

Power Generation

CGP-2(Co-Generation Plant) 8
Gas Turbine Operation Principle
Starting Means

10

Stages Of Gas Turbine 11

Support System of Gas Turbine 12
Equipment Specifications

14

TPS(Thermal Power Station)

20

Specifications of Russian/BHEL Boilers 21

Process in TPS

22

SRU(Sulphur Recovery Unit) 23

Electrical Maintenance in SRU 24

LAB/MSQ Plant

25

Electrical Maintennance in LAB/MSQ

Preventive Maintenance
C-Schedule

25

25

26

Result/Findings27
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ABOUT IOCL
Indian Oil Corporation (IndianOil) is India's largest commercial
enterprise, with a sales turnover of Rs. 3,50,603 crore (US$ 53,560
million) and profits of Rs. 10,399 crore (US$ 1,589 million) for the
year 2015-16. IndianOil is ranked 119th among the world's largest
corporates (and first among Indian enterprises) in the prestigious
Fortune Global 500 listing for the year 2015.
As India's flagship national oil company, with a 33,000-strong
work-force currently, IndianOil has been meeting Indias energy
demands for over half a century. With a corporate vision to be 'The
Energy of India' and to become 'A globally admired company,'
IndianOil'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 globalisation 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.
Corporate office

Corporate Logo

Indian Oil Corporation Ltd,

3079/3, J B Tito Marg,
Sadiq Nagar, New Delhi - 110049
Phone No : 011 26260000

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Products and Services

The main products of Indian Oil are petrol, diesel, LPG, auto LPG,
aviation turbine fuel, lubricants and petrochemicals: naphtha,
bitumen, kerosene etc.

Refineries
IOCL has following refineries across India

Digboi Refinery

Guwahati Refinery

Bongaigaon Refinery

Barauni Refinery

Gujarat Refinery

Haldia Refinery

Mathura Refinery

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Panipat Refinery

Paradip Refinery - The 15 million tonnes per annum refinery

in Paradip in Coastal Odisha has been inaugurated by PM
Narendra Modi on 7 February 2016.

Employees
As of 31 March 2013, the company had 34,084 employees, out of
which 2643 were women (7.8%). Its workforce includes 14,981
officers. The attrition rate in Indian Oil is around 1.5%.The
company incurred INR 78 billion on employee benefits during the
FY 2012-13.

Competitors
Indian Oil Corporation has two major domestic competitors,Bharat
Petroleum and Hindustan Petroleum. Both are state-controlled, like

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Indian Oil Corporation.There are two private competitors: Reliance

Industries and Essar Oil.

Profile Of Gujarat Refinery

IndianOil Gujarat Refinery was dedicated to the Nation in 1966
changing the landscape of a town, a state and the country. Today,
Gujarat Refinery is the Flagship Refinery of IndianOil.
The expansion in Gujarat Refinery has taken place in phases over
the years from 2 Million Metric Tonnes (MMT) per year to the
present capacity of 13.7 MMT per year and is gearing up for
further expansion. Gujarat Refinery and the city of Vadodara have
been witness to each others phenomenal growth.
Today, Gujarat Refinery is the Mother Industry of Vadodara and is
catering to the increasing energy demand due to the fast-paced
development and economic prosperity of the vibrant state of
Gujarat. The Refinery has been playing a catalytic role in
encouraging over 200 small and big industries over the course of
five decades.
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One of the most complex refineries in India, Gujarat Refinery has

about 40 operating units. Over the course of five decades, the
Refinery has kept up with the latest technological advancements
and boasts of every modern unit and technology that is available in
the IndianOil Oil & Gas industry today.

Electrical System Engineering

INTRODUCTION :Gujarat refinery is equipped with two power plants CoGeneration Power Plant (CGP) and Thermal Power station
(TPS). Complexity of power system is due to different
Generation voltage levels, Grounding and Protection system
employed. Even a small lapse while designing for
the expansion / modification of generation / distribution system
may lead to catastrophic consequence in the stability of power
system.Various equipment specification standa rds for se
lection of equipment are available in the refinery.
Expertize for engineering and selection
of equipment are also available. Need has been felt to
consolidate all good design practices gained through experience,
equipment selection specification etc. to serve as a guideline to the
electrical design engineers of the refinery to achieve consistency
in design on regular basis.

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Power Generation
The total installed Power Generation capacity of Gujarat Refinery
is 216.5 MW.
TPS (Thermal Power Station) = 12+12+12.5 = 36.5 MW.
CGP-1(Co-Generation Plant) = 30+30+30 = 90 MW.
CGP-2 (Co-Generation Plant) = 30+30+30 = 90 MW.
Total = 216.5 MW

CGP-2 (Co-Generation Plant)

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Gas Turbine Operating Principle

When the turbine starting system is actuated and the clutch is engaged,
ambient air is drawn through the air inlet plenum assembly, filtered
compressed in the 17 stage axial flow compressor. For pulsation protection
during startup, the 11th stage extraction valves are kept open and the variable
inlet guide vanes are in the closed potion. When the turbine reaches 95%
speed, the variable inlet guide vanes are opened to the normal turbine
operation position. Compressed air from the compressor flows into the
annular space surrounding the ten combustion chamber, from which it floe

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into the space between the outer combustion casing and the combustion
liners and enters the combustion zone through metering holes in each of the
combustion liners.
Fuel from an off-base source is provide to ten equal flow lines, each
terminating at fuel nozzle located at the individual combustion chamber.
Prior to being distributed to the nozzle, the fuel is accurately controlled to
provide an equal flow into the ten nozzle feed line at a rate consistent with
the speed and load requirement of the gas turbine. The nozzles introduce the
fuel into the combustion chambers where it mixes with the combustion air
and is ignited by one or both of the spark plugs. When fuel is ignited in one
combustion chamber flame is propagated, through connection crossfire
tubes, to all other combustion chambers. After the turbine reaches operating
speed combustion chamber pressure causes the spark plugs to retract to
remove their electrode from the hot flame zone.
The hot gases from the combustion chamber expand into the ten separate
transition pieces attached to the aft end of the combustion chamber liners
and flow from there to the three-stage turbine section of the machine. Each
stage consists of a row of fixed nozzles followed by a row of rotatable
buckets. In each following row of moving buckets, a portion of the kinetic
energy of the jet is absorbed as useful work on the turbine rotor.
After passing through the third-stage buckets, the gases are directed into the
exhaust hood and diffuser, which contain a series of turning vanes to turn the
gases from an axial direction to a radial direction, thereby minimizing hood
losses. The gases then pass into the exhaust and are introduced to
atmosphere

Discharge pressure

: 219.7 PSI (15.0Kg/cm2)

Rated speed

: 45561 RPM

Total weight

: 1070 lbs

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Starting Means
Gas turbine is fully independent machine on loaded condition, but to start-up
a standstill gas turbine some external means are needed. This may be done
by a motor or diesel engine. In this gas turbine diesel engine is used. Diesel
engine alone is not sufficient to break away such huge mass. So torque
converts and ratchet assemblies are used to achieve this. During the starting
sequence, the gas turbine is driven through the accessory gear by the diesel
engine, torque converter output gear and the starting clutch. The starting
clutch assembly and the engagement cylinders are mounted on the accessory
gear assembly. The accessory gear is permanently coupled to the turbine
compressor shaft by a flexible coupling. The starting system provides power
for both cranking and turning during gas turbine startup and shutdown
cycles. In the starting cycle there are three primary functions provide by the
starting system:
I.
ii.
iii.

Start the gas turbine rolling (breakaway from standstill);

Accelerate the gas turbine to a speed where it can be fired
After the turbine has fired, further-accelerate it to a self sustaining
speed (a speed at which gas turbine develops net positive power
output).

Stages of operation of Gas turbine

I.
II.
III.

Stage 1
Continuously drawing fresh air through inlet air filters
Between Stage 1 and Stage 2
Compressing this air to high pressure
Between Stage 2 and 3
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Adding and burning fuel in the compressed air to increase its

energy level.
IV.

Stage 3
Directing this high pressure, high temperature air to an
expansion turbine that converts the gas energy to the
mechanical energy of rotating shaft

V.

Stage 4
The resulting Low pressure, low temperature gases are
discharged to atmosphere/heat recovery steam
generator(HRSG)

Support System of Gas turbine

1. The lube oil system for furnishing normal lubrication and
absorbing the heat rejection of the gas turbine.
2.

The hydraulic supply system which provides the necessary

hydraulic flows and pressures for control devices on the
turbine

3.

The trip oil system which operates devices for the control,
hydraulic trip sub-system
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4.

The cooling water system which cools the lube oil.

5.

The starting system including the starting device and the

required logic sequence for starting the gas turbine and
bringing it up to operating speed.

6.

The cooling and sealing air system which provides the

necessary airflow from the turbine compressor to the other
parts of the turbine rotor and stators to prevent excessive
temperature build up and prevent bearing oil leakage.

7.

The fuel system which supplies, controls the flow and directs
the fuel to the fuel nozzles in the gas turbine combustors. The
fuel system includes gas, liquid and dual fuel systems.

8.

The atomizing air system provides sufficient pressure in the

air atomizing chamber of the fuel nozzle to break the fuel jet
up to a fine mist permitting ignition and combustion with
increased efficiency.

9.

The ventilating and heating system provides the ventilation

of hot air from compartments so that various devices in these
compartments work in the allowable compartment
temperatures.

10. The fire protection system is provided to extinguish fires in

the compartments, in case any fire takes place.
11. The inlet and exhaust system provides atmosphere air to be
brought into the compressors through inlet ducting and let

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exhaust gases to atmosphere or to heat recovery steam

generators.

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Equipment Specifications

Gas Turbine
Frame

: 6

Make

: BHEL / GE

Type

: MS 6000, Single shaft Design.

Base load capacity

: 30 MW

Fuel

: Dual (Gas & Distillate)

Compressor type & size

: Axial flow type 17 state

Compressor with air handling
capacity 400 T/H and
Compression ratio 11:1

Rated Speed

: 5100 RPM

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Generator
Make

: BHEL

Type

: TARI 800-26P

Rating

: 30MW, 37.5 MVA

Stator Current

: 1968 A

Voltage

: 11KV + 10%

Frequency

: 50 Hz

Power Factor

: 0.8 Lag

1st Critical Speed

: 27.77 Hz

2nd Critical Speed

: >83.3 Hz

Moment of Inertia of rotor shaft : 1330 Kgm2

Weight of Stator

: 50000 Kg

Weight of Rotor

: 14500 Kg

Cooling

: Forced Air Cooling

Cooling Air Flow

: 18 M3/ Sec.

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Turbine
Number of stages

: 3

Type

: Impulse

Casing

: Horizontal split

Max. Blade tip speed

: 450 M/Sec.

Minimum continuous speed

: 5089 RPM

Ignition speed

: 940 RPM

Self sustaining speed

: 2640 RPM

Critical speed (GT only)

: 1658 1877 RPM

3256 3908 RPM
7049 7360 RPM

Mechanical trip speed

: 5737 + 50 RPM

Rotor construction

: Disc & Through Bolts

1st , 2nd & 3rd Stage bucket material

: Ni based super Alloy

1st & 2nd Stage nozzle material

: Co based super Alloy

Material of Turbine wheel

: Cr-MO-V steel forging

Material of Turbine shell

: Ductile Iron

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No. of Turbine nozzle 1st stage

: 2 x 18 = 36

2nd stage

: 3 x 16 = 48

3rd stage

: 4 x 16 = 64

No. of Turbine buckets 1st stage

: 92

2nd stage

: 92 (Tip shrouded)

3rd stage

: 92 (Tip shrouded)

Compressor
No. of stages
Type

: 17
: Axial flow

Direction of rotation

: CCW as seen from Inlet end.

Casing

: Horizontal split

Compressor ratio

: 1: 11

Rated speed

: 5100 RPM

Blade tip speed

: 340 M/Sec.

Rotor construction

: Discs and through Bolts

Blade attachment

: Dove tail

Extraction

: From 5th , 11th and 17th Stages

Blade material

: 12% Cr Steel, Ni-Cd coated

Inlet, forward &

: Grey cast Iron

After casing material

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Discharge casing

: Ductile Cast Iron

Combustors
Type

: Reverse flow type

No. of combustion

: 10

No. of fuel nozzle

combustor)

No. of Ignition

: 2 (Located in 1st & 10th

10

(one

in

each

Combustor) Automatic
retractable
No. of flame detector

: 2( In 3,4,7&8 Combustor)
Ultra violet type

Firing temperature
of

: 1104 0C at trailing edge

1st stage nozzle

Auxilliary oil pump (AOP)

Type

: Centrifugal, vertical mounted.

Driver

: 50HP, 2900 RPM IND Motor.

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Capacity

: 1741 LPM

Discharge pressure

: 4.57 kg/cm2

Minimum suction pressure

: 0.0278 kg/cm2 .

Generator Transformer(GTR)
Capacity

: 40/45 MVA

Voltage(H.V)

: 34.5 KV

Voltage(L.V)

: 11 KV

Current(H.V)

: 753.7/669.39 Amperes

Current(L.V)

: 2361.89/2099.46 Amperes

%Impedence

: 12.5%

Vector Group

:Ynd11

Aux. ProtectionOil Temp

Winding Temp

Bucholz

Alarm

850C

900C

YES

Trip

950C

1000C

YES

The CGP has at present 3 nos. BHEL make, Gas turbine

Generators (GTG) with individual Heat Recover Steam Generator
(HRSG). The GTGs are rated 30 MW each. The generation voltage
is at 11 kv.

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Then it is stepped up to 33Kv by GTR and transmitted to various

substations where it is steeped down to 6.6kv or 415v by
distribution transformers

Thermal Power Station (TPS)

In Thermal Power Station there are three Generators. Two
Generators are manufactured by Russia and other is manufactured
by BHEL (Bharat Heavy Electrical Limited).
Generator manufactured by Russia is of 12 MW and 3000
RPM while the one manufactured by the BHEL is of 12.5 MW and
5000 RPM.
The Generation at TPS is done at 6.9 kV which using reactors is
brought down to 6.6Kv. These reactors are used for the protection
purpose also. It reduces the fault current. There are also Reserve
Reactor for stand by purpose. In TPS the Bus couplers are also
used at 6.6 kV and supply system.
There are 3 Russian Boiler steam capacity of 75 tonnes/hour and
one Indian Boiler (BHEL) having capacity of 130 tonnes/hour.

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SPECIFICATION OF RUSSIAN BOILER

DESIGN DATA :

Generation Capacity = 75 T/hr.

Steam pressure in drum = 44 kg/cm2.
Steam Pressure after main steam gate = 39 kg/cm2.
Super Steam temp. = 4400C.
Safety Valve drum Pressure = 44 kg/cm2.
OPERATING PERAMETERS :

Steam Drum Pressure = 40 atm 1 kg/cm2.

Superheated Steam Pressure = 36 atm 1 kg/cm2.
Fuel oil line Pressure = 20 atm 1 kg/cm2.
Superheated Steam Temp. = 435 5 0 C.
Feed Water without h.p heater = 100 50 C.
Safety Valve Super heater = 39 kg/cm2 .

SPECIFICATION OF BHEL MADE BOILER

Type = Front wall fired pressurized furnace.
Natural circulation.
Radiant closed bottom with oil and gas fire.

Boiler
Location
Generation Cap.
Furnace

: F 16/22 vv 60.66/25.36 .
: Outdoor.
: 125 T/hr .
: Type vv 60.
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 Superheater
Drum

: Stage spaced 225 m2.

: Twin Drum.

PROCESS IN TPS :
The TPS consist of four boilers and three turbine generators sets.
The boiler generate superheated steam by burning the fuel obtained
from other plants of the refinery itself. This superheated steam can
be utilized to supply steam to other plants and can also be used for
generating power using steam turbines. This steam rotates the
blades which in turn produces the induced voltage. This voltage is
then transferred to reactor.
The Steam produced is through fuel OIL or REFINERY
GASSES (RCO).
The feed water to the boiler comes from a CM plant that demineralize the feed water to prevent the corrosion of boilers
vessels. All Russian Boilers are water tube boiler while the Indian
boiler operates on forced draft.

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SRU(Sulphur Recovery unit)

H2S removed in the AGR process is sent to the sulfur recovery unit
(SRU) as acid gas. SRU recovers H2S as elemental sulfur through
the Claus reaction (see the attached figure). Reactions occur in two
stages: the flame reaction stage and the catalytic reaction stage.
The former consists of a high-performance burner, mixing
chamber, and heat removing boiler, while the latter has two to three
reactor stages. The sulfur recovery rate of the Claus process is
about 95 to 97%. The tail gas that contains unrecovered sulfur is
fed to the tail gas treating unit (TGT). The recovered sulfur is
stored in the sulfur pit and shipped as product after undergoing a
degassing process to remove H2S. The Claus process is an
equilibrium process, and a modified version of it with direct
oxidation catalysts stored in the final stage is called
SUPERCLAUS. Since this improved process does not depend on
Claus equilibrium, it can attain a 99% recovery ratio without TGT

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Electrical maintenance at SRU

The electrical equipment at SRU consist of only motors
These motors are used for pumping operations in the plant.
PCC(Power Control Centre)
The power first comes to the power control centre from which it is
send to the MCC(motor control center)
MCC(Motor Control Centre)
The motor control center consists of various breakers and SFUs
(Switch Fuse units) for controlling the operation of the motor.
For motors above 55kw rating, Breakers are used Whereas for
smaller rating motors SFUs are used.

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Time to time maintainance of these motors is carried out in the

plant.

SRU Incomming Transformer Specification

Make

: Voltamp

Capacity

: 2500 kVA

Traformation Ratio

: 11kv/415v

Current Ratio

: 131.22/3333.43A

%Impedence

: 8.57%

Vector Group

:Dyn11

LAB/MSQ Plant Electrical

Maintenance
LAB stands for linear alkaline benzene and MSQ stands for
motor spirit control plant
These 2 plants also consists of motors in the electrical section
for the pumping function.

Maintainence of Motors
The maintenance of the motors is carried out by 2 methods
1. Preventive Maintenance
2. C Schedule

Preventive Maintenance
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 Carried out Every 6 Months

The connections in the junction box of the motors are
checked for tightness
Sealant is applied to the junction box for preventing
the entry of moisture
Bearing Lubrication is done
Outer body is checked for any abnormality
Cleaning of cooling fan is done
Eathing of the motor is checked
Meggar test is performed on the motor(b/w 2 windings
and b/w winding and earth)

C- Schedule Maintenance

Carried out every 5 years.

Entire Rotor is taken out from the motor for maintenance.
Rotor is Dried in the Oven
Rotor is Cleaned using kerosene
Resistance and inductance of windings is checked
Bearing is replaced

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Results/Findings
Hence during my training at IOCL , I learned about the power
generation in CGP-2 and TPS power plants and about Electrical
maintenance in SRU and LAB/MSQ plants.

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