Air Compressor Analysis of LPG

Indane Bottling
Plant, Budge Budge (IOCL)
A PROJECT REPORT IS SUBMITTED IN PARTIAL
FULFILLMENT OF THE REQUIREMENTS FOR THE
DEGREE OF BACHELOR OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING,
BATNAGAR INSTITUTE OF ENGINEERING,
MANAGEMENT
AND SCIENCE (A GROUP OF TECHNO INDIA)

Institutional guide:
Mr. J. Haider Submitted by:
Head of Department
Batanagar Institute of Engg. Rahul Kumar
Management & Science (BIEMS) B.Tech 4th Year

Organizational guide:
Mr. J. Panda
Plant Safety Officer
LPG Indane Bottling Plant
Indian Oil Corporation Limited
 DECLARATION
I hereby declare that the project report
titled “AIR COMPRESSOR ANALYSIS OF
LPG INDANE BOTTLING PLANT, BUDGE
BUDGE (IOCL)” for internship dated
15.06.2015-15.07.2015 is submitted in
partial fulfillment of the requirement for
the award of the degree of BACHELOR OF
TECHNOLOGY at Department of
Mechanical Engineering, under West Bengal
University Of Technology (WBUT) is an
original piece of work and not submitted
for award of any other degree, diploma,
fellowship or any other similar title Prizes.
As per my knowledge and belief, the
substance in the report does not form the
part of any other business or research work.
Also this report has never been submitted
earlier or used for any academic purpose.
Rahul Kumar
Date:16.06.2015 (Regd no.-
Place: Kolkata 123320110073 of
( 2012 – 2013 )
7th Semester,
Mech. Engg.(B. Tech)
West Bengal University
of Technology(WBUT)

2
 ACKNOWLEDGEMENT

This project, wouldn’t have been possible without the

constant help and guidance of a few individuals whose
support have been vital to the completion of the project.

At the outset, we would like to thank Mr. Jaidev Bose

(Chief Plant Manager) and Mr. J. Panda (Plant Safety
Officer) for providing me the opportunity to do a project at
LPG INDANE BOTTLING PLANT, BUDGE BUDGE
(IOCL) & Mrs. Maria Bhattacharya (CH. T&D Manager.
ER).
The research project would not have been possible without
the support of many people. I wish to express my gratitude
to our supervisor, Mr. Anubhav Soni (Plants Operations
Officer) at LPG INDANE BOTTLING PLANT, BUDGE
BUDGE (IOCL), who was abundantly and offered invaluable
assistance, support and guidance.
I would also like to convey thanks to my college faculty,
Prof. J. Haider (Prof. & Head Of Mechanical Engg.
Deptt.), Batanagar Institute Of Engineering,
Management & Science, Kolkata.

And finally I wish to express my love and gratitude to

my beloved family, for their understanding and endless
love through the duration of this internship.

Rahul Kumar
Place: Kolkata
4th Year, B. Tech
West Bengal University Of Technology

3
 Indian Oil Corporation
A Maharatna Company

Indian Oil Corporation (IndianOil) is India's

largest commercial enterprise, with a
sales turnover of Rs. 4,50,756 crore (US$
73.7 billion) 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.

4
 History
Indian Oil began operations in 1958 as Indian Oil
Company Ltd. The Indian Oil Corporation was
formed in 1964, with the merger of Indian
Refineries Ltd.
Recently Indian Oil Corp (IOC) has raised $500
million by selling 10-year dollar-denominated
bonds, its fourth such issue overseas in the last
three and a half years.
• In 2003, its Gujarat Refinery was awarded the
"Best of all" Rajiv Gandhi National Quality
Award.

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.
5
Indian Oil operates the largest and the widest
network of fuel stations in the country,
numbering about 20,575 (16,350 regular ROs
& 4,225 Kisan Seva Kendra). It has also started
Auto LPG Dispensing Stations (ALDS). It
supplies Indane cooking gas to over 66.8
million households through a network of
5,934 Indane distributors.

Brands

• Indane Gas - Domestic and Industrial Gas

• AutoGas - Automotive Natural Gas
• Xtra Premium - Automotive Premium Petrol
• Xtra Mile - Automotive Premium Diesel
• Servo - Lubricants and Greases
• Propel - Petrochemicals
• IndianOil Aviation - Aviation fuel
• LNG at Doorstep - LNG by cryogenic
transportation
6
Refineries

IOCL has various

Refinerirs in India:-
In assam:
Digboi Refinery is India's oldest refinery and
was commissioned in 1901. Capacity 0.5
MMTPA later in 1996 modernisation project
of this refinery was complete and now has an
enhanced capacity of 0.65 MMTPA.
Guwahati Refinery, the first public sector
refinery of the country, was built with
Romanian collaboration and was inaugurated
on 1 January 1962. Its capacity is 1 MMTPA.
Bongaigaon Refinery became the eighth
refinery of Indian Oil in 25 March 2009. It is
located at Dhaligaon in Chirang district of
Assam, 200 km west of Guwahati.
In Bihar: Barauni Refinery, in Bihar, was built
in collaboration with Russia and Romania. It
was commissioned in 1964 with a capacity of
1 MMTPA. Its current capacity is 6 MMTPA.

7
In Gujarat: Gujarat Refinery, at Koyali (near Vadodara) in
Gujarat, is Indian Oil’s second largest refinery. The refinery was
commissioned in 1965.Its present capacity is 13.70 MMTPA.
In West Bengal: Haldia Refinery is the only coastal refinery of
the Corporation, situated 136 km downstream of Kolkata in the
East Medinipur district. It was commissioned in 1975 with a
capacity of 2.5 MMTPA, which has since been increased to 7.5
MMTPA.
In Uttar Pradesh: Mathura Refinery was commissioned in 1982
as the sixth refinery in the fold of Indian Oil and with an original
capacity of 6.0 MMTPA. Located strategically between Delhi and
Agra, the capacity of Mathura refinery has been increased to 8.8
MMTPA.
In Haryana: Panipat Refinery is the seventh and largest refinery
of Indian Oil. The original refinery with 6 MMTPA capacity was
built and commissioned in 1998. Panipat Refinery has since
expanded its refining capacity to 12 MMTPA. There are plans to
further expand the capacity to 21 MMTPA.
In Odisha (Orissa): Paradip Refinery - The commissioning of 15
million tonnes per annum refinery in November 2012 has been
delayed and is now expected to be operational only in June
2015.

8
Listing and Shareholding

0.13%
0.42%

1.50% 0.83% 0.07%

Govt.of India

30.13% Private single body

Insurance Companies

Individual shareholders

Trusts

Foreign Institutional
Investors (FII)
68.92% Others

9
 LPG Bottling Plant,
Budge Budge
About Plant: It
is located in Budge Budge
Municipality, Kolkata, West Bengal 15 mins
from Budge Budge Railway station.
LPG bottling plant is a plant where LPG is filled in-
to bottles (cylinders) for storage and distribution
among various LPG distributors. Specifications of
Storage or capacity is explained below:
Storage:
LPG In
Container Number Capacity
Horton sphere 1 (One) 1400 MT

Bullets 3 (Three) 150 X 3 = 450

MT
Tankers Various Types 12 MT, 17 MT,
In a day
In an hour 18 MT, Etc.
30,000
Production Per day 1200
Cylinders are
Bottles
:
4
(two shifts) (Four) Types
cylinders are5 KG, 14.2 KG,
filled and
filled
(Cylinders) 19 KG, delivered.
47.5 KG
10
Cylinder details:-

Top
Ring
O Ring
Vertical
Stay

LPG

Horizontal oval shape to detect

the cyl. brand

11
Loading/Unloading

12
Procedure followed during
loading / unloading
• Switch off everything like battery
cutoff etc.,
• Hand-brake
• Wheel Chokes (Wooden blocks)
• Two Fire extinguishers
• Earth

(cont.,)

13
• Connect Vapour loading arm
• Connect LPG loading arm
• Check the level of LPG using ROTOGAUGE
• Check the vapour line (Leakage)
• Check leakage of LPG loading line by small
opening
• If OK, Start decanting and regular check of
level done using Rotogauge
• After compeleting decantation, Close the flow
line of LPG and remove out the air and vapour
from tanker through vent

14
 Pump House:
Pump house consists of the following components:
 Three reciprocating compressors.
 Two Centrifugal pump.
 Assisting pipe structure.
 Tripping circuits
 It is used in LPG/Auto LPG decantation as well as in
filling.
 It provides LPG at high pressure for cylinder filling.
 It provides auto LPG at high pressure to fill it in tank.
Operations:
 Decantation of LPG from tanks into storage reservoirs through
pressure difference.
 Loading of auto LPG from storage reservoir to tank lorry.
 Pumping of LPG from storage tank to carousal.

15
 Decantation operation:
Vapours are send from storage tank to
tank lorry through compressor.
Pressure difference created.
LPG moves from higher pressure to
lower pressure.
Loading of auto LPG:
Vapours are send from storage tank and
send to tank lorry.
Pressure difference created.
LPG moves from higher pressure to
lower pressure.
Pumping of LPG:
Centrifugal pump is used.
Suction from storage tanks and delivery
to carousal .
Pop action valves in delivery line to take
into account for expansion of LPG.
16
Compressor operation for
cylinder evacuation:

17
Flow process of LPG and
Vapour:

Tanker
Storage
Vessel
Vapour Vapour

LPG LPG

Compres
sor

18
 For safe loading/unloading,
Equipment’s required are:
• High Level alarm
• Safety release valve
• Excess flow check valve
• NRV (Non-Return Valve)
• ROV (Remote operated valve)
• Proper bonding within loading arm
• Proper earthing
• Rochester Gauge ( Bullet )

ROV NRV SAFETY

RELEASE VALVE
19
 SAFETY FOR TANK
TRUNK
• 2 DCP fire extinguishers
• Pressure gauge
• Excess flow check valve
• Safety relief valve
• Hand break
• Master Switch
• Double pole wiring
• Spark arrestor
• ABS (Anti-Lock Braking System)

20
 Flow chart for cylinder
unloading and loading:

Check for safety

Truck entry in
fittings and
premises
documentation

Counting of
Returning of ERV
cylinders by
at S & D
security personnel

Parking at
unloading bay

21
 Contd...

Recounting by tally
Unloading through
operator at
boom
unloading bay

Allotment of filled
cylinders for Filling Shed
loading according Operations
to indent by S & D

The allotted truck

goes to the loading
bay

22
 Contd...

Loading takes Loaded truck halts

place before Gate No. 3

Recounting of Challan AC4 is

cylinders by issued to driver at
security as per AC4 S & D.

Truck leaves for

destination.

23
Filling Shed:

24
Flowchart of Filling Shed:
Unload Unload cappin cappin Co
Co
ing1 ing2 g1 g2 nt
nt
… …

Washin Washin
g g
& & Valv
Drying Drying e
1 2 AVTS1 leak O AVTS2
Rin
g

Decapp Decapp O
ing1 ing2 Ring

Electro Electro
nic nic
check check
O O scale1 scale2
Ring1 Ring2

Carous Carous
Tare Tare
el with el with
Wt. Wt.
24 24
Entry1 Entry2
guns1 guns2

25
 Con Con
td… td…

AVTS- AUTOMATIC VALVE

TESTING SYSTEM

Hamme Hamme
ring1 ring2

Water Water
bath1 bath2

PVC & PVC &

Hot Air Hot Air Loading
Sealing Sealing Loading 2
1 2 1

Manua
l
sealing
2
Manua
l
sealing
1
26
 Safety fittings in a storage
vessel

 Liquid &
Vapour Lines

 Man hole

 Safety Relief
Valve

 Fixed Tube
Gauge

 Magnetic
Level Gauge

 Rochester
Gauge

 High Level
Alarm

27
 Safety fittings
outside of storage
vessel

• (Bullets) Inclined at 1:100 for easy draining.

• Vapour Trap
• Water Tanks(sufficient water should be
present in case if fire happens)
• Concrete flooring
• Water monitor
• Cortzet bulb(fuses or blast at 79 deg.)
• Water sprinkler

28
 Safety
FIRE FIGHTING SYSTEM
Active fire fighting
• Hydrant System
• Fire Extinguisher
• Sprinklers
• Monitors
Passive fire fighting
• Detectors for Hazardous Atmosphere
• Bonding
• Earthing
• Anti-static Mastic flooring
• Flame proof Electrical Equipments
• Open Filling Station
• MCP(Manual Call Point)
• Cortzet bulb(79°c blast)

29
 HYDRANT SYSTEM:

COMPONENTS:-
• Water Tanks
• Fire Pump Engines
• Safety Air System
• QB (79 degree cels.)
• Delurge Valve
• Water Sprinkler
• Water Monitor
• Double Hydrant
• Hose pipe (15m length, 63mm dia.)

30
EARTHING & LIGHTNING
PROTECTION
:
Earthing at LPG Bottling plant done as per IS-
3043.
The size of the
earth conductor shall be corelated with the size
of the current carrying
conductor and size of earth conductor shall not
be less than 1/2 of the
largest current carrying conductor, provided the
minimum size of earth
conductor is not less than 1.5 Sq.mm for copper
& 2.5 Sq.mm for
aluminium and need not be greater than 70
Sq.mm for copper and 120
Sq.mm for Aluminium.
In LPG Plant, earth electrodes are
interconnected in grid to reduce the
overall resistance of the Earthing system. It is
desirable that overall
earth resistance should be one ohm. Generally
14 earth electrodes
connected in parallel give a resistance of one
ohm or less.

31
Fire Extinguisher:
• DCP
• Carbon Dioxide FE

32
 Fire Water Pump House

Security air to DV at
Lake 3Kg/cm^2
Fire Water tanks
3 X 3754 kl Compres
(20m dia.) sor1

Compres Filling
sed air Shed
vessel (Carouse
Compres ls)
sor2

Joc Joc
Fire Fire Fire key key
Fire Fire
Engi Engi Engi pu pu
Engi Engi
ne ne 4 ne 2 mp mp
ne 3 ne 1 7-
5,6,7 stand
8kg/s
by
qcm

Hydrant water at
33 7kg/cm^2
 Fire Sirens
• Small fire: No siren
• Major fire: A wailing siren for two minutes. Sirens
will be sounded three times for thirty seconds
with an interval of fifteen seconds in between.
• Disaster: Same type of siren as in the case of
major fire but the same will be sounded for three
times at an interval of two minutes.
• All clear (for fire): Straight run siren for two
minutes.
• Test: Straight run siren for two minutes.

34
 PPEs (personal protective
equipment’s):
• Helmet
• Safety Shoes
• Body Harness And Safety Belt
• Ear Plugs
• Goggles
• SCABA (Self-Contained Breathing
Apparatus)
• Fire Proximity Suit
• Water Gel Blanket

35
Evacuation and cold repair

Evacuation unit
Depressurizing unit
 Cold repair
 Valve replacement
 Bung thread
 VP ring and foot ring
alignment
Degassing unit

36
 PROJECT TITLE:

AIR COMPRESSOR
ANALYSIS OF LPG INDANE
BOTTLING PLANT,BUDGE
BUDGE (IOCL).

CALCULATION OF DISCHARGE,
VELOCITY, MINOR LOSSES, MAJOR
LOSSES, FRICTION OF FACTOR AND
TYPE OF FLOW.

37
LPG Indane Bottling Plant
layout, Budge Budge:

38
 Case 1: Present Condition
of Bottling Plant:
Length of the cylinder (L) = 8 inches
= (8 x 2.54) cm = 20.32 cm
Diameter of bore cylinder (D) = 7
inches = (7 x 2.54) cm = 17.78 cm
Diameter of pipe (d) = 1.43 inch =
(1.43 x 2.54) = 3.63cm
Now, Volume of Cylinder (V1) = ∏/4
D²L cu. Unit = ∏/4 x 17.78² x 20.32
=5045.18cm³
Now, We know that,
P1(V1)^ȣ = P2(V2)^ȣ
Where,
P1 = atmospheric pressure =
1.01325 kg/cm²
V1 = Volume of cylinder
P2 = Cylinder pressure =
8kg/cm²
(V2) = Discharge
ȣ(Gamma)=1.4

39
1.01325 x (5045.18)^1.4 = 8 x
(V2)^1.4
(V2)^1.4 = 19348.7965
V2 = 1153.17 cm³/sec.
(Theoretical value of
discharge)
For actual discharge value,
Volumetric efficiency = 0.9
Q = V2 x η
Q = 1153.17x 0.9
Q = 1037.8586cm³/sec.
Again, We know that,
A1v1 = Q
∏/4 D²v1 = Q
∏/4 x 17.78² x v1 = 1037.8586
248.29 v1 = 7611.24
v1 = 1037.8586/248.29
v1 = 4.18 cm/sec.
40
 Minor loss:
hь = K v1² x N/2g
Where,
N = number of bends
=24
hь = minor loss due to
bending of a pipe
K = coefficient of bend =
0.5
v1 = velocity of
flow=4.18 cm/sec
g = 9.81 m/sec.²
=981cm/sec.²
So,
hь = 0.5 x (4.18)^2 x 24 /
2 x 981
hь = .1068 cm Present condition
where size is quite
large and bend is
bigger in number.

41
 Major loss:
hғ = 4 f L v1² / 2 g d
Where,
hғ = head loss due to friction
f = friction of factor
L = length of pipe = 280 m =
28000 cm
v1 = velocity of flow
d = diameter of pipe = 3.63
cm
Now,
hғ = {P1(initial)-P2(final)}Kg/cm^2
hғ = (7.5 -7.0) kg/cm²
hғ = 0.5 kg/cm²
So,
hғ = 4 f L v1² / 2 g d
0.5 x 981 = 4 x f x 28000 x
4.18² / 2 x 981 x 3.63
f = 2 x 0.5 x 981² x 3.63 / 4 x
28000 x 4.18²
f = 1.785
42
Now,
Re = v1 x d / v
Where,
Re = Reynold’s number
v1 = velocity of flow=30.65cm/sec
v = kinematic viscosity of air at 200
farh=2.4*10^-4
d = diameter of pipe
So,
Re = 4.18 x 3.63 / 2.4*10^-4
Re = 63222.5
Hence Re>4000,therefore flow is
turbulent.
We know,f for laminar flow,
f = 16 / Re
f = 16 / 63222.5
f = 2.5307*10^-4
43
We also know , f for turbulent flow,
f = 0.079 /(Re)^1/4
f = 4.9*10^-3

Hence, the value of f for turbulent

flow is closer to the value of friction
of factor. Therefore, the flow is
turbulent .

44
 Case 2: When length of the
pipe is decreased:
Minor loss:

hь = Kv1² x N/2g
Where,
N = number of bends = 8
hь = minor loss due to bending of a pipe
K = coefficient of bend = 0.5
v1 = velocity of flow=4.18cm/sec
g = 9.81 m/sec.² = 981 cm/sec.²
So,
hь = 0.5 x (4.18)^2 x 8 / 2 x 981
hь = 0.0356 cm

Straight pipe
lenth is
decreased and
bend is
minimized.

45
Major loss:

hғ = 4 f L v1² / 2 g d
Where,
hғ = head loss due to friction =
0.5
f = friction of factor
L = length of pipe = 150 m =
15000 cm
v1 = velocity of flow=4.18 cm/sec
d = diameter of pipe = 3.63 cm
So,
hғ = 4 f L V1² / 2 g d
0.5 x 981 = 4 x f x 15000 x 4.18² / 2 x
981 x 3.63
f = 2 x 0.5 x 981² x 3.63 / 4 x 15000 x
4.18²
f = 3.33
46
We know, for laminar flow
f = 16 /Re
Where,
Re = Reynold’s number = 63222.5
So,
f = 16 / 63222.5
f = 2.5307*10^-4
We also know, for turbulent flow
f = 0.079 /(Re)^1/4
f = 0.079 / (63222.5)^1/4
f = 4.9*10^-3
Hence, the value of turbulent flow is
closer to the value of friction of factor.
Therefore, the flow is turbulent flow.

47
Case 3: When the diameter
of the pipe is increased:

Minor loss:
hь = Kv1² x N/2g
Where,
N = number of bends = 24
hь = minor loss due to
bending of a pipe
K = coefficient of bend = 0.5
v1 = velocity of flow=4.18
cm/sec
g = 9.81 m/sec.² = 981
cm/sec.²
So,
hь = 0.5 x (4.18)^2 x 24 / (2 x
981)
hь = 0.107 cm

48
Major loss:

hғ = 4 f L v1² / 2 g d
Where,
hғ = head loss due to friction
f = friction of factor
L = length of pipe = 280 m =
28000 cm
v1 = velocity of flow=4.18 cm/se
d = diameter of pipe = 2 inch = (2
x 2.54) cm = 5.08 cm
So,
hғ = 4 f L v1² / 2 g d
0.5 x 981 = 4 x f x 28000 x 4.18² /( 2 x
981 x 5.08)
f = 2 x 0.5 x 981² x 5.08 / (4 x
28000 x 4.18²)
f = 2.4985 49
Now,
R = v1 x d / v
Where,
Re = Reynold’s number
v1 = velocity of flow=4.18 cm/sec
v = kinematic viscosity of air at 200 farh=2.4*10^-4
d = diameter of pipe = 5.08 cm

So,
Re = 4.18 x 5.08 / 2.4*10^-4
Re = 88476.66
Since Re >4000, therefore flow is turbulent.
We know,
f = 16 / Re
f = 16 / 88476.66
f = 1.8 * 10^-4
We also know,
f = 0.079 /(Re)^1/4
f = 0.079 /(88476.66)^1/4
f = 4.5 * 10^-3
Hence, the value of turbulent flow is closer to the
value of friction of factor. Therefore, the flow is
turbulent flow.

50
 Comparing different cases
490.5

490
Pressure drop(Kg\cm^2)

489.5

489

488.5

488
Case Case 2(length Case 3(dia of
1(present of pipe pipe
condition) decrease) increases)

51
 CONCLUSION

My hypothesis for this project was

to give the information about the
work done in the company and the
knowledge gained by me through
this training. My results do support
my hypothesis. I think the training
I did went smoothly and I had no
problems. I also got a chance to
perform a job of an Air Compressor
Analysis. And I think that this
training will be very much helpful in
my future.

52
 BIBLIOGRAPHY
This project is completed by Rahul Kumar
a student of Batanagar Institute of
Engineering, Management and Science (A
Group Of Techno India), under West
Bengal University Of Technology, for the
training held at LPG INDANE BOTTLING
PLANT,BUDGE BUDGE (IOCL), which
was not possible without the help and
contribution of many members. For
making this project Mr. Anubhav Soni
(Plants Operations Officer) LPG INDANE
BOTTLING PLANT,BUDGE BUDGE
(IOCL), who guide us in his tough
schedule.

The references for making this project

are:
 INTERNET
 BOOKS REFERRED:
 Fluid Mechanics and Hydraulic Machines By Dr.
R.K. Bansal
53
Thank you