WORD DOCUMENT PROJECT REPORT ON VARIOUS MECHANICAL UNITS INVOLVED IN THE BOTTLING OF LPG CYLINDERS

1. ACKNOWLEDGEMENT
With due respect, I express my deep sense of gratitude to the respected and learned
guides of Indane Bottling Plant, Oil India Corporation Limited (marketing division) for
providing their painstaking and untiring supervision. I am thankful to the training
center for giving me the opportunity to learn deeper inside the basics of “study of
operation of various mechanical units involved in the bottling of LPG cylinders”.
I also express my sincere thanks to Mr. Hitesh Mehta, Assistant Manager
(Engineering), Indane Bottling Plant, OIL (Marketing Division) for providing me with a
conducive environment and necessary facilities, allowing me to reach the desired
accomplishment.
I am heartily thankful to all the Managers, Engineers and all Shift Operators
working under them to give me direction and valuable inputs on each and every
sections of study of operation of various mechanical units involved in the bottling of
LPG cylinders.
MOHIT DHULL
B.Tech 5th semester
Mechanical Engineering
Guru Jambheshwar University of
Science and Technology
(GJU S&T)

2. INTRODUCTION
Over 100 million LPG consumers in the domestic sector in India are serviced
Through a network of 9365 LPG distributors who are getting supply from 181 LPG
Bottling plants located across the country. In 2007-08, India consumed a total of
About 1170 TMT of LPG which is around 10% of the consumption of total
Petroleum products in the country. Out of the total LPG consumption during the
Year 2007-08, almost 75% was used for cooking, 17% as auto LPG and the
Remaining 8% for industrial use. Of the total supply of 11.7 Million Tonnes of LPG
During 2007-08, the indigenous production was 8868 TMT from crude oil and
Natural gas fractionation (3:1). Imports by PSUs and private entrepreneurs
Accounted for 2156 TMT and 673 TMT respectively.
LPG is transported from production installations i.e. Refineries, Fractionation
Plants and Import terminals to the bottling plants through pipelines, Bulk LPG
Wagons or Bulk LPG Tank Trucks. This LPG, subsequently, is bottled in 19 Kg,
14.2 Kg and 5 Kg cylinders and is then delivered to commercial consumers and
Individual households. Bottling operation of LPG is very critical, as LPG is a highly
Inflammable product and the systems are required to be intrinsically safe. The
Systems also require very comprehensive fire safety arrangements.
A typical LPG bottling plant has the following major energy consuming
Equipments:-
1. LPG pumps
2. LPG compressors
3. Conveyors
4. Blowers
5. Cold repair facilities including painting
6. Air compressors and air drying units.
7. Transformer, MCC & DG sets
8. Firefighting facilities
9. Loading and unloading facilities
Some of the LPG bottling plants use a comprehensive monitoring technique for
Keeping track of energy / fuel Consumption on per tonne basis. PCRA's energy
audit
Studies in various LPG plants have found 20-25% energy saving potential in the
LPG Plant operations. The following are major energy conservation opportunities
In a LPG Plan

3. INTRODUCTION (OIL)
Oil India Limited (OIL), an E & P company is a premier National Oil Company engaged in the
business of Exploration, Production and Transportation of crude oil and natural gas. A Navratna
Company under The Ministry of Petroleum and Natural Gas, Government of India, it is the
second largest national oil and gas company in India as measured by total proved plus probable
oil and natural gas reserves and production. Incorporated as a private company in 1959, OIL has
been present in the Indian oil and gas exploration and production industry for over five decades.
The company presently produces around 3.90MMTPA (Metric Million Ton Per Annum) of crude
oil, around 7.93MMSCUMD (Metric Million) of natural gas and more than 45,010 tons of LPG
annually.
Main Producing Areas:-
 Assam, Arunachal Pradesh and Rajasthan in India.
 Customers:
 Assam-AGCL, BVFCL, ASEB, NEEPCO, IOC and APL
 Rajasthan-RRVUNL
 The company operates a crude oil pipeline in the North-East for transportation of crude oil
produced for both OIL and ONGCL in the region to feed Numaligarh, Guwahati, Bongaigaon and
Barauni refineries and a branch line to feed Digboi refinery.
 Moreover it has also extended its blocks overseas in Iran, Libya, Gabon, Nigeria, Sudan, Yemen,
Egypt and Timor Leste.
 A reservoir of hydrocarbons from where natural gas and oil are collected through a drilling in the
earth is called a well.
 Types- Oil and gas well
 Oil well – crude oil + associated gas
 Gas well – natural gas(unassociated gas) + condensate
There are various departments in OIL a few are:-
 Production (Oil & Gas)
 Civil engineering
 Chemical engineering
 LPG
 Geological
 Electrical engineering
 Instrumentation
 IT
 Fire and Safety
 Transport
 Field communication
 Field engineering
 Drilling
 Well logging
 Geophysics
 Materials
 Medical
 Finance and maintenance
 Training and development

4. OIL’S LPG PLANT
The two major products of Oil India Limited are Crude Oil
and Natural Gas, LPG (Liquified Petroleum Gas) being an
important value addition to the natural gas produced. It
is the first diversification of OIL active since the last 29
years.
LPG department has two installations:-
(i) LPG Recovery Plant
(ii) LPG Filling Plant
The various sections at LPG department are:-
(a) Recovery Plant Operation
(b) Filling Plant Operation
(c) Mechanical and General Maintenance
(d) Electrical
(e) Instrumentation
(f) Quality control
(g) Safety
(h) Planning & Administration

5. LPG RECOVERY PLANT
This plant indulges in production of LPG and a by-product
i.e, Natural Gasoline (Condensate) from
natural gas.
Designed and commissioned in 1982 by The Randall
Corporation, USA, it is the second plant in India
where LPG is produced from natural gas.
Maintenance of high productivity, quality and
concern for safety, health and environment in a
professional manner has always been the main
motto of this department.
The plant was originally designed to handle 2.215
MMSCM/day of natural gas to produce 60,000 TPA
of 50:50 (w/w) C3H8:C4H10 LPG and 12,000 TPA of
condensate on 350 days working. But due to
changes in the feed gas composition the plant
design capacity has been re-rated as 55,000 TPA of
49:51 (w/w) C3H8:C4H10 LPG and 25,000 TPA of
condensate.

6. LPG is liquefied petroleum gas which is a mixture of
certain light hydrocarbons, derived from petroleum,
which are gaseous at ambient temperature and
atmospheric pressure but may be condensed to liquid
state at ambient temperature by the application of
moderate pressure. Liquefaction is accompanied by a
considerable decrease in the volume, thus the liquid
formed requires much less storage space stored in the
liquid phase in pressurized containers and systems,
finally allowed to revert to the vapour phase at or
near the point of eventual utilization.
The feed gas, i.e ,natural gas is first drilled from
oil well and gas well and then collected at the OCS
from where it is sent via pipelines to the main plant
area.
In the process of LPG production, the plant also
produces a high revenue-earning by-product, i.e,
Natural Gasoline, which contains pentane and hexane
and it is sold to solvent-manufacturing companies like
EPC International, Sikkim Organics, etc.

7. Important Properties of LPG
LPG is colourless, odourless, highly volatile and
hazardous liquid that mixes quickly with air. It is
heavier than air and one litre of LPG when expands
produces about 250 litres of vapour.
Max. Vapour pressure at 40 deg. C =1050 kPa, gauge
Volatility i.e. evaporation temp. In deg. C for 95 % by
volume at 760 mm of Hg pressure, Max = 2.0
Hydrogen sulphide ======= pass, i.e. Hydrogen
sulphide is not more than 5 ppm
Free water content======= none
Min. 20 ppm of ethyl mercaptan for odor.
Auto-ignition temperature==410 to 580 degree Celsius
Flash Point ============== -104.4 degree Celsius
In a closed liquid filled vessel or pipe, for 1 degree rise
in temperature, the pressure increases by 14 to 15
kg/cm^2
Explosive Limit =========== 1.85 to 9.5 % v/v in air

8. PROCESS
The process comprises of broadly the following:-
(a) Compression
(b) Dehydration
(c) Product extraction through:
(i) On stream cooling by heat exchanger
(ii) Turbo expansion
(iii) Removal of non-condensable and undesired lighter
fractions
(d) Product fractionation
 The different stages are as follows:-
• Compression:-
 1st stage -> Inlet Gas Compression Suction Scrubber
 The inlet gas enters at 14kg/cm^2, is compressed to
33.8kg/cm2 in a 4 stage centrifugal compressor driven by
York Manufacturer’s 4500HP electric motor operating on
11KV power supply.
 The heat of compression is partly used in re-boiling the
bottom liquid of de-ethanizer and then cooled to 37.8’c in
water cooled heat exchanger.

9. 2nd stage -> Booster Compression Suction Scrubber
 The gas is then compressed to 41.9 kg/cm2 driven by the turbo
expander and then cooled to 37.8’c.
 It is then sent through an inlet filter separator wherein any water
that may condense out is knocked out.
• Dehydration:-
 The gas is dried in one dehydrator while the other is being
regenerated.
 The pressure of compressed gas decreases to 39.6 kg/m2 as it
reaches dehydrator.
 Dehydrator consists of molecular sieve made of crystallized metal
Aluminum Silicate of 4A’ size of approx. 11650kg weight in which
water particles are retained.
 This process is required as the temperature of the gas can go
down up to minus 100’c where ice crystals form.
 The dehydrated gas passes through a dust filter to remove sieve
dust etc.
• Product extraction:-
 70% (by volume) of inlet gas is exchanged with cold residue from
de-ethanizer and expander separator overhead, 30% (by volume)
exchanges heat with the cold separator liquid in the gas-liquid
exchanger and also with the expander separator liquid.
 These two streams combine to enter the cold separator.
 Liquid condensed is separated by cold separator and then the
liquid is pressurised through the de-ethanizer reflux condenser.

10.  The inlet gas from the cold separator enters the expander where
the pressure is lowered, following Joule-Thompson Effect.
 The gas liquid mixture out of the expander of 1670 HP and 27000
rpm speed reducing temperature to -84’c, is separated in the
expander separator.
 Liquid thus collected flows to the de-ethanizer feed pre-heater
and then to the de-ethanizer.
• Product Fractionations:-
 A de-ethanizer column with three separate packed sections and
a reboiler.
 The liquid formed at the cold separator and the expander
separator enter it, by maintaining proper bottom temperature
with reboiler and reflux, the undesirable liquefied fraction
methane, ethane and excess of propane are knocked out from the
top.
 The temperature of LPG is increased by exchanging heat with
residue gas, whose refrigeration is in turn used in heat gas
exchangers.
 A de-butanizer column having 34 trays and reboiler provision
through closed circuit hot oil systems with direct fired heater.
 The bottom liquid flows on to de-butanizer tower where LPG and
condensate are separated out.
 LPG comes out at the top which is cooled to ambient temperature
and sent for storage in bullets and Horton spheres.
 The bottom condensate (Natural Gasoline) is similarly stored in
separate storage tanks.

11. Fire Protection & Safety
LPG is a colorless liquid which evaporates easily into a
gas, and the leakage of even a small volume can expand
into a large hazardous zone. Since it has no smell, a little
mercaptan is added to help detect leaks.
It can burn and explode when gets mixed with air and
meets a source of ignition and it can also cause cold
burns to skin.
Therefore, Fire Protection & safety is of utmost
importance in LPG plant.
Safety in LPG plant includes:-
 FIRE PROTECTION SYSTEM
 ALARM AND SHUT DOWN SYSTEM
 ESD DEVICE
 SAFETY RELIEF VALVES
 FIRE ALARM SYSTEM
 GAS DETECTION SYSTEM
 FIRE EXTINGUISHERS
 FIRE DRILL
 COMMUNICATION SYSTEM
 REGULAR INSPECTION OF PLANT

12. Fire Protection System
It comprises of:-
1) A continuously pressurized water network of approximately 2
km length, consisting of one 3000 kLs water reservoir, pumps,
hydrant points, monitors (water and foam), hose reels,
temperature sensing medium velocity water spray system.
2) Portable fire extinguishers and sand buckets.
3) Fire water pumps.
4) Manual fire call points at different locations.
One of the most important components of the safety system is the
Deluge Valve, which is the controlling valve of the pressurized
water network.
It can be operated either on auto mode or manually.
Auto Operation:-
1) Water pressure is maintained in the hydrant system through a
jockey pump.
2) DV is kept closed by maintaining air pressure in the network.
3) Due to rise in temperature, a heat detector bulb (Quartzoid bulb)
in the air network bursts releasing air pressure.
4) When air pressure drops, DV opens spraying water on the vessel.
Manual Operation:-
DV can be opened locally through a valve provided at the DV or by
operation of a switch provided in the control room.

13. EQUIPMENT QUANTITY
FIRE WATER PUMPS
JOCKEY PUMPS
HYDRANTS
MONITORS
FIRE ALARM POINTS
GAS DETECTION SYSTEM
Sr.No.
1
2
3
4
5
6
06 (04+02)
02
28 (21+7)
16 (9+7) +2
21 (12+9)
28 (20+8)

14. Pump Capacity Head Drive Auto start
pressure M3/ Hr meter WC (on discharge line)
Jockey 20 90 Electric Motor 4.6 kg/cm2
Pump [Auto stop pressure = 8.4 kg/cm2]
(02 Nos.)
Sprinkler 275 88 Electric Motor 4.0 kg/cm2
Pump
Spray 410 88 Electric Motor 1.0 kg/cm2
Pump
‘B’
Spray 410 88 Electric Motor 2.0 kg/cm2
Pump ‘A’
Hydrant 410 88 Electric Motor 3.0 kg/cm2
Pump
DEFP -1 410 88 Diesel Engine
DEFP -2 410 88 Diesel Engine 2.5 kg/cm2

15. Alarm and Shutdown System
The plant has got automatic in-built shutdown system to
protect the vital equipment and the plant as a whole from
any abnormal condition of operation. Audio-visual alarms
and shutdown indications are displayed in LPG control
room.
 All the important equipment are provided with alarm
and shutdown devices for critical operating
parameters.
 All the storage devices are provided with high level
alarms.
 Emergency shutdown switch is provided in control
room to shut down the plant in any case of emergency.
 Remote shutdown switches are provided in the local
panels of two most important equipment- inlet gas
compressor and expander compressor.
Status monitoring is done round the clock through DCS work
stations. Operation tested during running condition,
planned and non-planned shutdown of the plant.
Testing/calibration is done as and when required for smooth
running of the plant and also during the annual
maintenance of plant.

16. EMERGENCY SHUT-DOWN SYSTEM(ESD)
The plant is equipped with ESD switches which calls for shut down in emergency
situations. The plant has these emergency switches in three locations – (a) Top
Control Room (b) Bottom Control Room (c) Expander Compressor Panel
SAFETY RELIEVE VALVES
SRVs are required to release the excess pressure build-up in the system due to
process upset etc. so that they are protected from failure due to over- pressure.
These valves are provided in the scrubbers, inlet filter separators, dehydrators,
gas flow lines and in each of the process pressure vessels.
FIRE ALARM SYSTEM
The fire alarm system consists of alarm switch glass, which when broken will lead
to an audio –visual alarm at the bottom control room indicating the location of
emergency , and also hooting of sirens in LPG Recovery and Filling Plant areas.
GAS DETECTION SYSTEM
Gas Detectors, located at the vulnerable areas of the plant, detects the leakage of
any explosive gas displaying the amount of leakage in terms of %LEL, together with
hooting of an alarm in the DCS system of the control room.

17. FIRE EXTINGUISHERS
Fire Extinguishers are classified into the following categories, as per the
nature of associated fire-
 Type A: for general fire out of wood, paper and other such stationary sort
of stuffs.
 Type B: for fire from liquid as diesel, petrol, diesel etc. utilizing dry
chemical powder
 Type C: for gaseous fire, as LPG gas, Natural Gasoline etc. utilizing
carbon dioxide
 Type D: for electrical and metallic source fire
FIRE DRILL
Fire drill is carried out forth nightly in LPG Recovery and also in LPG Filling
Plant by the plant personnel from all sections along with personnel from
Fire Service Section ( General Engineering Department ) to test the
performance of the Fire Protection System of LPG Department and to take
corrective action as necessary.
COMMUNICATION SYSTEM
Both LPG Recovery and Filling Plant are provided with 2 fire sirens (1 km and 5
km region) incorporating the entire area. The smaller siren is operated in manual
mode in normal fire drill, else the bigger siren is operated. The bigger siren is
inter-locked with fire alarm switches which run in auto-operation mode.

18. Instrumentation
The role of this section is to quantify all physical parameters such as
pressure, temperature, flow rate and liquid level. It is an integral
part of LPG department of OIL.
 LPG implements PLC other than DCS dedicated to equipment
control only, sequential start and stop of all devices and tripping of
plants during emergency is done by PLC. Whereas DCS controls the
entire process temperature, flow and level.
=====Two types of control systems are=====
• Distributed Control System (DCS):- is a digital control system based
on distributed control philosophy. It means a control system which
works on the principle of power delegation, for which there should
be some connectivity to reach the data to all nodes i.e. Ethernet
dual ring network called distributed communication network.
• Programmable Logic Control (PLC):- is a digital computer used for
automation of electromechanical processes, designed for multiple
inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
• AC 460 is the heart of the system used to execute any function to
maintain it, acts as interface and reads and writes over the I/O
panel.
• Ethernet connection is used to communicate or integrate all the
nodes.
• Graphics package are used to build plant objects.
• Text package provides libraries through which the system is
configured and started.
• Database management might be there and uses oracle to send
report.
• Input devices- transmitter

19. The different devices used and maintained by this section are
as follows:
• Gas Chromatography: - used for analysing a mixture of
a sample, a fully electronically controlled device. It consists
of columns and detectors situated in the oven maintained
at 80’c.
• Moisture Analyzer: - If the temperature is less than -
80’C, the moisture in the gas will become saturated and
form ice crystals which blocks the pipelines and hence has
to be prevented. This is done by placing a device at
different locations for checking the amount of moisture
present and creates an electrical signals.
• TCD (Thermal conductivity detector):- uses the
property of thermal conductivity of gases and converts
into electrical signals unique for each and every gas
imitating the same property which are received by the
calibrated and programmed computers.
• Thermocouple is used for sensing temperature.
• Level transmitters work based on Archimedes Principle.
=======the different types are=======
 Magnetic level gauge
 Radar level gauge
 Servo level gauge
 Floatation method on the basis of buoyancy force

20. Flow rate indicator: -
• Mass flow meter: - senses both gravity and volume. It
carries out a lot of algorithms considering the resonant
frequency of the U wire which gives the inertia of the
liquid and temperature for gravity calculation.
• Orifice flow meter: - works on the Bernoulli’s principle and
specifies only volume.
Types of valves: -
• Shutdown valve
• Deluge valve
• Solenoid valve: - is a logical valve and operated by
solenoid coil which opens up at 110V of AC current or
240V DC.
• Safety relief valve: - are protection devices used in the
worst conditions and are always maintained.
• Remotely operated valve (ROV): - It is a logical valve
which either closes or opens and requires 60-70psi. The
feedback signal is received through PLC in control room
and is used only for shutdown, can’t be controlled.
• Control valves: - are the ultimate output devices.
• Audio, visual, olfactory and vibration are the four types of
alarms used.

21. Pressure gauges, based on the Hooke’s law relating stress
and strain, consists of the following components: -
• C-type tubes
• Spiral type
• Bello
• Diaphragm
• Dead weight tester
• Manometer
 DP (Differential Pressure) transmitter: - measures the
difference in pressure through micro-controller.
 LEL (Lower Explosive Limit): - calibrated optimum quantity
of a combustible substance which can support a self-propagating
flame when ignited. The device uses the
infrared radiation emitted by the gas which is dependent
on its concentration. The inner part is maintained at a
higher temperature causing convection i.e. the hot air rises
due to its lower density sucking in the air below which is at
a lower temperature.
• LELs of substances in terms of percentage present in the
atmosphere are-
• CH4- 5%
• LPG- 1.2%
• Condensate- 1.8%
• If LEL exceeds 10% sparking is prohibited.

22. Process water: -
• The pH must be maintained in the alkaline range i.e. more
than 7 as acidic process water may cause scaling in the
heat exchangers. This can be done by treating the water
with NaOH and KOH.
• The viscosity should not be very high.
• This water cannot be released into the environment
without being treated for its salinity, pH, minerals added
and oil accumulated.
The methods employed to dispose off this water without
causing any damage are: -
 Flocculent (gravity) and coagulant (sand) filters
 Aerobic and anaerobic treatment
 UV rays cleaning system
 Bleaching(chlorine)
 Demineralization: - is a series of anion and cation
exchanger to maintain the pH around 7.
 The minerals such as Ca, Mg, SO4-2, Cl-1 can be removed
completely but the water cannot be polished off silica if its
concentration is below 2ppm.
 The water is heated in a high pressure water boiler.
 If the toxic level of water is very high and cannot be
treated it is injected back into the well.

23. Quality Control Laboratory
It is a branch of the Chemical department of OIL, and being a service
section its main role is to evaluate the quality of products, LPG and
Residue Gas, along with the feed gas that is, Natural Gas.
It mainly performs two types of tests, viz., compositional and physical.
1. Physical Analysis: -
It includes Volatility and Vapor Pressure tests as per IS 4576: 1999
certification, depending on which one can decide whether the product
is good or bad.
a) Volatility: - It is measured by Weathering Test. In this test, the
sample is taken in a tube called weathering tube and a
thermometer is put in it. The temperature is noted at 25, 50, 90
and 95 percent (by volume) evaporation and the temperature
corresponding to 95% evaporation is called the Weathering
Temperature and it should be in the range of +2 degree C and -2
degree C.
b) Vapor Pressure: - For this we take the sample in a sampler and
put it in a temperature bath which is maintained at 40 degree C
and we check the pressure building up at this temperature
indicated by the pressure gauge.
Apart from these tests, some other tests are also performed to measure the
density of sample, moisture level and also the Ethyl Mercaptan (C2H5SH)
level in LPG. A hydrometer is used to measure density.
We use Doctor’s Test to check minimum value of Mercaptan added to LPG.
For this, Sodium Plumbate solution is taken in a cylinder and LPG sample is
added which mixes with it. A positive Doctor’s Test gives a yellow
precipitate/solution indicating presence of Mercaptan.

24. Dew Point Test: -
We have to check dew point at dehydrator inlet and outlet, gas
inlet and air inlet. As the feed gas, after compression, needs to
be dehydrated using dehydrator, hence we need to check
whether the molecular sieves (which are made of alumina
silicate) are working.
2. Compositional Analysis: -
It includes compositional analysis of the natural gas coming from
production department, LPG and Residue gas, done by Gas
Chromatography (GC), as explained below: -
GC, a common type of chromatography performed in a Gas
Chromatograph, is used in analytical chemistry for separating and
analyzing compounds that can be vaporized without decomposition. It
is based on different boiling points and retention time for different
components. It is used for testing the purity of a particular substance,
or separating the different components of a mixture.
GC consists of two phases: - mobile phase and a stationary phase.
Here the mobile phase is a carrier gas, usually an inert gas like Helium
or a non-reactive gas like Nitrogen.
The stationary phase is a microscopic layer of a liquid or a polymer on
an inert solid support, inside a piece of glass or metal tubing called a
column.
The molecules move to the wall of the column, coated with different
stationary phases, which causes each compound to elute at a different
time, known as the Retention Time of the compound.

25. GC Analysis:-
In a GC analysis, a known volume of gaseous or liquid analyte is
injected into the column using a micro-syringe. As the carrier
gas sweeps the analyte molecules through the column, this
motion is inhibited by the adsorption of the analyte molecules
either onto the column walls or onto packing materials in the
column. The rate at which molecules progress along the column
depends on the strength of adsorption, which in turn depends
on the type of molecules and on the stationary phase materials.
As each type of a molecule has a different rate of progression,
the various components of the analyte mixture are separated
as they progress along the column and reach the end of the
column at different times (retention time). A detector is used to
monitor the outlet stream from the column, hence the time at
which each component reaches the outlet and the amount of
that component can be determined.
Generally substances are identified by the order in which they
emerge from the column and by the retention time of the
analyte in the column. The chromatographic data is presented
as a chromatogram, which is a graph of detector response (y-axis)
against retention time (x-axis). This provides a spectrum of
peaks for a sample representing the analyte present in a
sample eluting from the column at different times. The area
under a peak is proportional to the amount of analyte present
in the chromatogram, and by calculating it, the concentration
of an analyte in the original sample can be determined.

26. Electrical maintenance
• The power house of OIL generates 14.45 MW with the help of two gas
turbines which are alternatively at running and standby modes.
• The power house supplies 11KV to the substation in the LPG plant through
two underground cables.
• This incoming power is sent into the feeder from two different power
houses, #1 and #2. These two sections are connected by a bus coupler
which is used only when the maintenance job needs to be done.
• From #1 the 11KV is supplied to the spare feeder, 4500HP motor starter
panel and to a transformer1 of 1000KVA capacity which steps 11000V down
to 415V.
• There are 8 vacuum circuit breakers. It is monitored by protective relays
such as VCB, ACB, SF6 of the circuits.
• UPS system gives an uninterrupted power supply normally of AC current
with a battery backup of 120KVA capacity. There are 2 types of UPS in
which input is 415V but outputs are 415V and 110V.
• A battery converts a voltage input of AC to DC. An 110V Ni-Cd battery set is
used.
• Another auto-transformer other than the two in the feeder circuits produce
450V line. It is a part of motor starter panel. During starting of motor the
load might reach seven times its full load and then drop back which can’t be
allowed. To reduce this we use this auto-transformer starter for 20 seconds
and then give back to the normal system.
• Motor control center (MCC) is provided by the 415V bus.
• Tripping is a condition when difference between the incoming and outgoing
currents of the isolator is more than a given value and the on-off switch of
the isolator turns off automatically.

27. AUTOTRANSFORMER: -
• Auto-transformer is used for applying reduced voltage to stator during
starting. Thereby the starting current is reduced. The auto-transformer is
provided with change-over switch. As the motor comes to full speed, the
change-over switch is thrown over to run position.
CIRCUIT BREAKER AND ITS TYPES: -
• Circuit Breaker is an automatic device capable of making and breaking an
electric circuit under normal and abnormal conditions such as short circuits.
The part of the circuit-breakers connected in one phase is called the pole. A
circuit-breaker suitable for three phase system is called a triple pole circuit-breaker.
• Each pole of the circuit-breaker comprises one or more interrupts or arc-extinguishing
chambers. The interrupters are mounted on support
insulators. The interrupter encloses a pair of fixed and moving contact. The
moving contacts can be drawn apart by means of the operating links or the
operating medium. The operating mechanism of the circuit-breaker gives
the necessary energy for opening and closing of contacts of the circuit-breakers.
• The arc produced by the separation of current carrying contacts is
interrupted by a suitable medium and by adopting suitable techniques for
extinction.
• Circuit Breaker is used for opening and closing circuits for normal switching
operations. During short circuits or abnormal conditions, relay operates and
gives opening command to circuit-breaker and circuit is opened
automatically.
TYPES OF CIRCUIT BREAKERs IN LPG PLANT: -
• Moulded Case Circuit Breaker (MCCB):
• Air Circuit Breaker (ACB): It utilizes air at atmospheric pressure for arc- extinction.
• Vacuum Circuit Breaker (VCB): The fixed and moving contacts are housed inside a
permanently sealed vacuum interrupter. The arc is quenched as the contacts are
separated in high vacuum.

28. POWER HOUSE
Power House generates power for the entire plant using the concept of
a Gas Turbine, which is based on the Bryton Cycle.
The following components comprise a Gas Turbine: –
(a) Axial Air Compressor
(b) Combustor
(c) Turbine
(d) Auxiliaries
Axial Air Compressor: -
Air after passing through the filter enters the axial compressor and
flows parallel to the axis .it consists of a stationary body called Casing
and a moving part called Rotor, and Blades , some of which are
attached to the casing and some to the rotor . A pair of stationary and
moving blades is called a Stage and the compressor has got 15 such
stages. Air gets compressed as it passes through the different stages.
Combustor: -
Air from the compressor enters the combustor which has 2 parts –a
transition piece and a combustor, the latter being divided into 3 zones,
viz, primary, secondary and tertiary, each consisting of a number of
holes.
Fuel is injected in the primary zone and ignited using spark from the
spark plug, thereby creating a cyclone.

29. In the secondary zone, complete burning of fuel is
ensured. As the temperature of air rises to a high value
of 1200 degree C, it needs to be cooled down to 899
degree C at least before entering the transition piece. For
this more air is to be supplied to the tertiary zone.
The transition piece has a nozzle which increases the
velocity of air.
Turbine: -
Air from combustor enters the turbine where it expands
and exits as exhaust gas. The rotating turbine then
generates power via a generator. The exhaust gas is at a
temperature of 370 degree C and this energy can be
utilized to produce more electricity using the steam
turbine. For this DM (De-Mineralized) plant is required
but this is a costly process. This produces about 7 M watt
power in addition to the actual power of 14.45 M watt.
As the Gas Turbine is not self-starting, a starter diesel
engine is required.
A total of 14.45Mwatt electricity is the output from the
generator. Out of this 10.4Mwatt is utilized to fulfill the
electricity requirement of the different units of the
industry.

30. Mechanical Maintenance
The Maintenance Section of the LPG department is
responsible for the following: -
1)Maintaining the plant availability to achieve MOU target.
2)Maintenance of all rotary and stationary equipment of the
LPG plant to keep them in proper working conditions.
3)Execution of various contract jobs under the department
related to maintenance of the plant.
4)Planning of maintenance activities for annual plant
maintenance.
5)Spare part management for maintenance of the plant.
This section aims to achieve the following targets: -
1)To reduce the cost of maintenance activities by 1 % of the
previous year.
2)To keep the minimum MTTR of critical equipment for
achieving the MOU target.
3)To keep good relations and understanding with the different
sections of the LPG department.
4)To keep good relations and understanding with the other
departments of the company.
5)To keep close watch on various activities so that there is no
misuse of approved funds and that these are properly
utilized.

31. The Mechanical Maintenance Section of the LPG department
is responsible to perform the following duties: -
1) Daily plant check up to ensure smooth operation of the plant and to
check lube oil level and vibration & sound and other parameters.
2) Monthly vibration measurement to ensure that vibration levels of
critical equipment are within limits and take necessary corrective
measurements.
3) Periodical lube oil testing to test lube oil of three major equipment of
LPG recovery section, namely, Inlet Gas Compressor, Gear Box and
Expander-Compressor.
4) Cleaning of cooling tower top chambers to ensure its proper
functioning.
5) Testing of SRV to ensure its correct functioning at its Set Pressure.
6) Sound level measurement to measure the intensity of sound at
specified locations and compare it with permissible limit.
7) Replacement of damaged or worn out Vee-Belt (Endless belts used
between driving pulleys to transfer power).
8) Replacement of empty Mercaptan drum of LPG storage area.
9) Top up lube oil into Expander Surge Tank to maintain a certain oil level
in it.
10) Air compressor lube oil top up to maintain the required level of oil.
11) Materials inspection and suitability report for the acceptability of
the materials received against direct charge Indents/purchase orders.
12) Engaging staff on overtime to complete the repairing job within the
day in view of urgent nature of work for operational as well as safety
requirements.

32. 13) Workshop job requisition to carry out emergency repair
and fabrication jobs at general workshop.
14) Breakdown maintenance of machines/ equipment.
15) Preparation of tentative maintenance schedule of air
compressor.
16) Ultrasonic thickness measurement to gauge metal
surfaces for the thickness.
13) Handling/cleaning services and day-to-day maintenance
in LPG recovery and filling plant.
14) Servicing, Inspection and Testing of LPG storage vessels.
15) To replace hot and cold insulation system of LPG
recovery plant with new insulation system at a specified time
interval.
16) Major overhauling of Inlet Gas Compressor and Expander
Compressor to ensure smooth and trouble free operation.
17) De-coupling of various motor devices to carry out
maintenance work on driver (motor) or driven side (pumps,
compressors, fans, etc.).
18) Hydro-testing of pressure vessels and storage vessels to
check the condition/health of vessel.
19) Periodical testing of lifting tools.
20) Storage, handling and disposal of lube oil and other
hazardous materials.

33. LPG Filling Plant
• In LPG Filling Plant –
(i) LPG is bottled into cylinders (packed form) in Carousel
machine containing 24 number of filling points or guns.
(ii) LPG is filled into road tankers (bulk form). These cylinders
and road tankers are handed over to IOCL for marketing.
• The LPG is pumped to LPG Filling Plant from LPG storage
vessels at LPG Recovery Plant.
• The incoming LPG pressure in the pipeline is about 14kg/cm2.
The cylinder consists of a head ring, 3 fins, valve, high
pressure seamed cylinder and a foot ring.
• The inside of the valve is installed with an O-ring and a valve
pin. The valve needs to be checked for any leak possible.
• The bottling capacity of the plant is about 6000-7000 cylinders
per day.
• The empty cylinders are first marked by TARE WEIGHT
MARKING and their marked weights are stored by a HMI
(Human Machine Interface) device called pre-check scale.
• The marked cylinders go to Carousel machine by chain
conveyor, run by 14 motor driven Gear boxes. In Carousel
machine the empty cylinders are first sensed by photo-electric
sensors.
• In each filling gun two sensors are linked which are placed at
the top and at the bottom side of the cylinder.

34. • The bottom side sensor is called wheel arm sensor. The bottom
photo-cell senses the position of the cylinder on the machine. The
top photocell senses the cylinder and gives instruction to the gun.
Then the respective gun shoots the respective cylinder.
• The cylinder is filled in the course of one rotation of the carousel,
the filling time is approximately 60 seconds.
• When the regulator’s pin when pressed together with the valve
pin, two holes are opened.
• The LPG filled in the cylinder should be of weight 14.2 kg. If the
gun is unable to fill the cylinder within one minute for delay error,
the cylinder will again revolve for one minute.
• In the outlet of the machine has a puller with sensor which
allows only those cylinders filled up to the standard weight to go
out of the machine, otherwise it will return back the cylinder to
the machine again.
• The cylinders are introduced through a check scale, which checks
the over weighted cylinders and bypass them to another section
called correction unit by pusher with photo-electric sensor.
• The over weighted cylinders are manipulated up to the standard
by manual filling. This over weighted range is considered as
+200gm.Now the corrected cylinders are lined up with the other
cylinders.
• Now the cylinders are fed to Gas detector and O-ring detector
unit to check the leakages and damages. In this unit the damaged
cylinders are rejected. The tested cylinders are then fed to
counting unit to count by a sensor and stored. In hot air sealing
unit the cylinders are sealed and fed to transportation section.

35. • The evacuation unit takes care of the rejected
cylinders which are found defective by applying
suction pressure on the LPG cylinder and the
valuable LPG is sent back in the form of vapor to the
storage tanks.
• In the sealing unit i.e. Hot air seal unit, a plastic cap
is placed over the cylinder along with a thin PVC seal
which then is exposed to 265’C of hot air.
• Compressed air of 7.5kg/cm2 is required for the
functioning of the plant, which is done by using V-type,
screw-type and vertical air compressor which
are manually checked after the working hours which
can be done.
• In bulk filling, LPG and condensate are filled into
tankers following the same procedure as that of
packed form.
• The tanker is checked for a hydraulic testing
certificate valid for a period of 5 years from the date
of issue.
• The tanker evacuation unit is utilized when excess is
sent into the tanker. The liquefied form of LPG filled
into the tank is 18% less than the total tanker
capacity.

36. •
CONCLUSION
The vocational training enhanced my practical
knowledge. Most importantly, I am oriented to the
industrial scenario and its many challenges and
subtleties. The smooth functioning of an industry
depends to a large extent on the mutual co-operation
among its different wings.
Nevertheless, I did enjoy the training to the fullest
and are very sure that this training will help me in
my future endeavors.
Thanking You

37. A REPORT ON INDUSTRIAL
TRAINING
AT
OIL INDIA LIMITED
BADSHAHPUR
INDANE BOTTLING PLANT
(MARKETING DIVISION)
Submitted by: -
MOHIT DHULL
Bachelor of Technology
5th Semester
Department of Mechanical Engineering
Guru Jambheshwar University of Science and Technology
Hisar

38. A
PRACTICAL TRAINING REPORT
AT
INDANE BOTTLING PLANT
BADSHAHPUR, GURGAON
INDIAN OIL CORPORATION LIMITED
(MARKETING DIVISION)
Submitted to: - Submitted by:-
Mr. Kaushal Mohit Dhull
Faculty of Mech. Deptt. 12162035
GJUS&T BTECH. 3rd Year

39. PLANT LAYOUT
SCOPE
The general layout principles of LPG
Storage, bottling and bulk handling facilities
Have been detailed in this chapter. The various
Facilities within LPG storage and bottling
Premises shall be located based on Table-I and
Table-II.
TABLE – I
INTERDISTANCES FOR LPG
FACILITIES
1 LPG STORAGE
VESSEL
2 T-11 T-11 15 T-11
2 BOUNDARY NOT
ASSOCIATED
WITH LPG
PLANTS
T-11 - 15 15 -
3 LPG SHED T-11 15 15 15 30
4 TANK TRUCK
GANTRY
15 15 15 NA 30
5 FIRE WATER
PUMP HOUSE
T-11 * 30 30 -

40. NOTES: - 1. ALL DIMENSIONS ARE IN MTS.
2. NOTATION
T-II: REFER TABLE II
*: ANY DISTANCE FOR OPERATIONAL CONVENIENCE
3. MAXIMUM PACKED STORAGE LIMITED TO 20000 KGS
TABLE – II
INTERDISTANCES BETWEEN LPG
STORAGE VESSELS, FILLING SHED,
STORAGE SHED
AND BOUNDARY/PROPERTY LINE/GROUP
OF BUILDINGS.
CAPACITY OF EACH
VESSEL
(CU. MTS. OF WATER)
DISTANCES
(MTS.)
10-20 15
20-40 20
41 – 235 Note 3
30

41. LOCATION & SAFETY DISTANCES
LOCATION
While assessing the suitability of any site
For location of LPG storage facilities, the
Following aspects shall be considered:
(a) In addition to the requirements for safety the
Plant should be located in such a manner so
As not to be contagious to any industry
Having open flame. Property line of the
Plant shall be away from the central line of
The road/railways as per statutory
Requirements and overhead high tension
Wire shall not traverse through the battery
Limit of the plant.
(b) Adequate availability of water from a nearby
Reliable source should be ensured.

42. (c) The topographical nature of the site wit
Special reference to its effect on the disposal
Of LPG, in the even of its escape, if any,
Shall be considered.
(d) The access for mobile fire fighting
Equipment to the storage vessels under all
Foreseen circumstances, preferably from two
Sides and upward prevailing wind direction
Is an important parameter.
(e) For any expansion beyond the specified
Limit, all provision under OISD-144 shall be
Applicable.
(f) Predominant direction of wind and velocity
Shall be considered.
(g) Longitudinal axis of horizontal vessels
(Bullets) shall not point towards other
Vessels, vital process equipment and other
Facilities.
(h) Storage vessels shall be located downward
Of processing units, important buildings.
(I) Storage vessels shall be laid out in single
Row within a group.
(j) Storage vessels shall not be located one
Above the other.

43. SAFETY DISTANCES
The safety distances as given in Table-I
and Table-II are the distances in plane between
the nearest point on a vessel other than the
filling/discharge line and a specified feature,
e.g.
adjacent vessel, site boundary etc.
TYPE OF STORAGE
VESSELS
HORIZONTAL CYLINDRICAL
VESSELS
Horizontal bullets with the total volumetric
capacity upto 235 Cu. M. Note 3 shall be used
for
storing LPG.

44. LAYOUT
The following aspects shall be considered while
Establishing layout of LPG storage vessels.
LPG STORAGE FACILITIES
GRADING
Area below the storage vessels
(Bullets) shall be free from vegetation, property
Graded with the slope of 1.100 (towards one
Side) away from the pipeline manifold.
PIPING
(i) Piping manifold shall be away from the
Shadow of the vessel.
(ii)Spring loaded quick closing valve with
fusible link or Rov to facilitate
immediate closure in the event of
emergency, if any, shall be provided in
the LPG liquid line of each vessel
between excess flow check valve
(EFCV) and pipeline manifold.

45. SURFACE DRAINAGE
In order to prevent the escape of spillage
into the main drainage system, surface water
from the storage area and from the manifold
area shall be directed to the main drainage
through a water seal designed to avoid the
spread of hydrocarbon.
GROUPING
Vessels shall be arranged in a group and
total volumetric capacity of the group shall
be ,limited to 235 Cu. M. Note 3. Interdistances
as specified in Table-I and Table-
II shall be maintained.
Top surfaces of all the vessels installed in a
group shall be on the same plane so that the
safety blowout from them do not affect each
Other.

46. LPG BULK HANDLING FACILITIES
1. LPG tank lorry loading/unloading gantry
shall be located in a separate block and
shall not be grouped with other petroleum
products.
2. Space for turning with a minimum radius
of 20 meters for tank lorries shall be
provided commensurate with the
capacities of the tank trucks.
3. LPG tank lorries upto the maximum of 2
Nos, at a time should only be taken for
unloading.
4. Adequate permanent protection for TLD
pipeline island shall be provided. The
minimum width of such pipeline island
shall be 1 metre.

47. LPG BOTTLIG FACILITIES
(1) LPG Bottling facilities should be located a
a safe distance from other facilities with
minimum ingress of trucking traffic and
downward wind direction with respect to
bulk storage.
There shall not be any deep ditches in the
surrounding area to avoid settling of LPG.
(2) Bottling section shedshall be of single story
having asbestos roofing and open from all
sides for adequate ventilation to ensure
quick dessipation of LPG Vapour in the
event of leakage, if any, RCC roofing
shall not be used. Anti-static mastic
flooring conforming to IS-8374 shall be
provided in the LPG filling shed/cylinder
storage shed to avoid frictional sparks.
Anti-static mastic coating up to 1.5 meters
Height from bottom of the supporting
Columns in the shed shall be provided.

48. (3) Stacking area for empty and filled
cylinders shall be marked specifically.
Cylinders shall always be stacked
vertically in two lines. For details of
cylinders stacking pattern refer Annexure
Plant should have one shed each for
filling and storing of filled./empty
cylinders.
(4) Valve changing operation should be
carried out in a demarcated place within
the filling shed itself.
(5) Cylinder storage shall be kept on or above
grade and never below grade in celler or
basement.
(6) Filled cylinders shall not be stored in the
vicinity of cylinders containing other
gasses or hazardous substances.
(7) Escape routes shall be specified in LPG
sheds for evacuation of employees in
emergency.

49. (8) There shall not be any trapping of
personnel in LPG sheds by conveyours,
cylinders and other facilities. If such
trapping cannot be eliminated, it should be
kept to the minimum. In such places
sufficient arrangements for escape routes
to be provided.
(9) Adequate lighting shall be provided in the
cylinder filling area.
(10)Water drains from cylinder filling areas to
out side drainage system shall be provided
with water seals (near the plant boundary)
PROTECTION OF FACILITIES
(1) There shall be road all around the various
facilities within the bottling plant areas for
accessibility of fire fighting operations.
(2) There shall be proper industry type
boundary wall all around the Bottling
Plant.

50. UTILITIES
Utilities consisting of Fire Water Pumps,
Admin. Building, Motor Control Center, DG
Room, Air Compressors, Dryers etc. shall be
separated from other LPG facilities and to
be located as per the area classification as
specified in Table-I.

51. CONTENTS

52. FACULTY CERTIFICATE
Forwarded here with a summer internship report on “STUDY OF VARIOS
MECHANICAL UNITS INVOLVED IN THE BOTTLING OF LPG CYLINDERS” of Indian
Oil Corporation Limited submitted by Mohit Dhull, Enrollment No- 12162035
student of Bachelor of Technology 5th Semester (2014-15).
This project work is partial fulfillment of the requirement for the degree of Bachelor
of Technology from Guru Jambheshwar University of Science and Technology
Hisar, Haryana.
--------------------------------
Mr. Kaushal
Deptt. Of Mechanical Engg.
Guru Jambheshwar University of Science and Technology