The document provides an overview of the BPCL Kochi Refinery located in Kochi, India. Some key points: - The refinery has a capacity of 9.5 MMTPA and refines 30,000 tonnes of crude oil per day. - It produces various petroleum products and has implemented several quality and safety management systems. - Over the years it has expanded its capacity and operations through various projects and now exports products internationally. - The document discusses the refinery's organizational structure, departments, operations, and competitors.

1. Presented by
Jeevan P George
Vibration Analysis of Motor Cp1b

2. Overview
 Kochi Refinery, a unit of Bharat Petroleum Corporation Limited,
embarked its journey in 1966.Formerly known as Cochin Refineries
Limited originally established in collaboration with Phillips Petroleum
Corporation, USA and Duncan Brothers of Calcutta.
 The capacity –
2.5MMTPA(1966)<3.3MMTPA(1973)<4.5MMTPA(1984)<7.5MM
TPA(1994)<9.5MMTPA(2010).
 Refining capacity- 30000 tonnes of crude oil per day

3.  It is an ISO 14001 Environmental management system (EMS) and
ISO 9001:2000 quality management system (QMS) and also ISO
17025(Testing method in quality control) certification from NABL.
 The refinery has successfully implemented the Occupational Health
and Safety Management System(OHSAS) 18001:2007
 Products-
Liquefied Petroleum Gas(LPG),naphtha,gasoline,kerosene,
AviationTurbine Fuel(ATF),Gas Oil ,Furnace Oil andAsphalt.
Specialty products for domestic market include
benzene,toluene,white spirit,poly Iso-butane and sulphur.

4.  The BPCL installation at Irumpanam, to which the refinery is
connected by pipelines, is the major product distribution Centre of the
refinery.
 Petro net CCK is looking after this pipeline.
 The refinery’s foray into direct marketing began since 1993 as with
aromatic products such as benzene and toluene.
 The entry into the international petroleum business stream began with
its first parcel of Fuel Oil exported in January 2001.

5. MILESTONES AND GROWTH Year
Developments
 1966 Unit commissioned with crude oil refining capacity of 2.5
MMTPA.
 1973 Capacity expanded from 2.5 to 3.3 MMTPA.
 1984 Capacity expanded from 3.3 to 4.5 MMPTA. Secondary
processing facilities (1MMPTA FCCU) were added.
 1989 Aromatic production commenced (87,200TPA benzene and
12,000TPA toluene).
 1991 Captive power plant (26.3mw) commissioned.
 1994 Capacity expanded to 7.5 MMTPA.FCCU revamped to 1.4
MMTPA.
 1998 Steam turbine generator (17.8 mw) commissioned

6.  2000 DHDS unit commissioned.
 2000 Company renamed as Kochi Refineries Ltd.
 2000 The 2 MMTPA Diesel Hydro-Desulphurisation (DHDS)
Unit was commissioned.
 2001 Tank FarmAutomation Facilities installed.
 2001 Exporting products.
 2003 Kochi Refinery goes live in SAP, the enterprise resource
planning initiative.
 2003 LPG bottling plant was commissioned.
 2003 Started Hydrogen sale to HOCL through pipeline.

7.  2003 Commenced operation of 2nd RO under BPCL banner near
Trissur.
 2004 Kochi Refinery certified ISO 9001 compliant.
 2005 Completion of Bitumen Emulsion Plant.
 2006 KRL becomes BPCL Kochi Refinery.
 2007 Completion of Single Point Mooring (SPM) and ShoreTank
Farm (STF).
 2008 Started capacity expansion cum modernization project.
 2009 The company is to gear the “Auto Fuel Policy” to upgrade the
quality of Fuels to meet Euro III.
 2012 IREP (Integrated Refinery Expansion Project)The Company is
looking forward to increase its capacity by 15.5MMTPA by the year
2015.

8. CORPORATE MISSION ANDVISION
CorporateVision
 We are a leading energy company with global presence through
sustained aggressive growth and high profitability.
 We are the first choice of customers, always.
 We exploit profitability growth opportunity outside energy.
 We are the most environment friendly company.
 We are a great organisation to work for.
 We are a learning organisation.
 We are a model corporate entity with social responsibility.

9. Corporate Mission
 Participate prominently in Nation building by meeting its energy
needs by efficiently deploying all available resources and aiming
towards global competitiveness in the energy sector.
 Strengthen & expand areas of core competencies.
 Create awareness among people on imperatives of energy
conservation & efficient consumption of petroleum resources.
 Availing opportunities for expansion and diversification
 Promote ecology, environment up gradation and national
heritage.

10. COMPETITORS OF BPCL KR
HPCL
IOCL
RELIANCE
MRPL

11. ORGANISATIONAL STRUCTURE
ORGANOGRAM - BPCL KOCHI REFINERY

12. The BPCL-KR constitutes various departments they
are:
 Operations Management Department
 Technical Department
 Finance Department
 Project Department
 Human Resource Department
 Vigilance Department
 Research & Development Department
 Information System Department.
 Marketing Department.

13. OPERATIONS MANAGEMENT
DIRECTOR
( REFINERY)
GM
(Operation)
DGM
(Manufacturing)
DGM
(Maintenance)
DGM
(OM&S)
DGM
(P&U)
DGM
(Fire & Safety)

14. FIRE & SAFETY DEPARTMENT
DGM
(F&S)
CM(F) SM(S)
Shift Engineers
Shift
engineers
88 fire work
men(3 shift)

15.  Assist in administrating safety in the refinery fire prevention &
control.
 Co-ordination with advisory boards
 Accident/incident enquiry and analysis
 Safety audit and conduct every year
 Organizes accident prevention programmes for creating safety
awareness
 Set up safety committee.

16. (P&CS)
DGM
CM(contract
service) CM( inventory)
M M
CM(material
procurement)
M

17. Procurement process is done in the following manner,
 Purchase request(PR)
 Request for quotation(RFQ)
 Bid tabulation
 Proposal to tender evaluation committee(TEC)
 Purchase orders to vendors
 Goods receipt(GR)
 Logistic invoice verification(LIV)
 Suppliers enlistment
 Suppliers evaluation
 Warehousing
 Analysis of inventory

18. MAINTENACE DEPARTMENT
DGM
CM(INSTUMENTATION
)
CM(ELECTRICAL)
CM(RELIABILIT
Y CENTRE)
Engineers Engineers Engineers

19. TYPES OF MAINTENANCE
The main four types of maintenance done in BPCL-Kochi Refineries are:
 Preventive maintenance
 Predictive maintenance
 Corrective (breakdown) maintenance
 Turn around maintenance

20. Functions
 Matching the available resources to the total maintenance job.
 Planning the job as per the right information based on the
notification of operators.
 Monitoring the job to ensure the competition within the
scheduling time.

21. POWER & UTILITIES (P&U) DEPARTMENT
DGM
CM CM
M M
Engineer Engineer

22. Functions
 Generation and distribution of power
 Production and distribution of steam
 Plant air distribution
 Control and supply of raw materials and cooling department
 Demineralization of water in the required areas

23. FINANCE DEPARTMENT
DGM
FM
DY.M(taxation DY.M(pay roll)
DY.M(project
finance)
DY.M(financial
account)

24. FUNCTIONS OF FINANCE DEPARTMENT:-
 Managing financial resources of the company.
 Examination of reports and detailed project reports.
 Establishing and maintaining proper systems for budgetary
control and management information.

25. Human Resource Department
GM(HR)
DGM(HR
)
Personnel
HRD
IR
ESI/PF
BEN.ADMIN
DGM(L&D)
TRAINING
LIBRARY
CSO(SECURITY) CM(ESTATE)
SPORTS
ADMINISTRATION
OFFICIAL
ESTATE-ADMN.

26. Activities
 Human resource development
 Recruitment and promotion of the eligible candidate
 Benefits
 Welfare
 Safety and health
 Industrial relation

27. Problem definition
 The CP1B motor has generated severe noise.
 There are various reasons which cause of decline of its
performance.
 This study is focus on how to reduce the severe noise that affects
the performance of the motor.

28. Data Collection
The data which given below are the notifications provided to operators
to do the maintenance.

29. Detection
 The motor vibration reading are taken at 4 different locations
namely,
a) Motor non drive end
b) Motor drive end
c) Pump drive end
d) Pump non drive end

31. Vibration spectrum(before)

34. Vibration spectrum(after)

38. Vibration Spectrum Analysis
The increase in vibration could be due to variety of problems like
unbalance, misalignment, bearing damage flow problem, electrical
fault etc.
And some analysis carried out is shown follows;
 There were no peaks corresponding to 1X vibrations.This rule out
unbalance as the cause of vibration.
 No peaks were present at the 2X position. Hence we could
ascertain the reason was not mechanical looseness.

39.  Peaks were not observed in random turning speed like 3x, hence
misalignment was not the cause for the excessive vibrations.
 While observing the vibration spectrum we found out harmonics
of non-synchronous peaks and sideband peaks appearing around
the rotating face frequency.
 By analysis the progressive side band peaks on either side of high
amplitude peak we can say that this may be due to any damage of
bearing.

40. Corrective Action
 Unwanted vibration caused due to defect in the bearings.
 This was the reason for erratic vibration peak values which
was observed.
 This problem was rectified by replacing the faulty carbon
alloy steel ball bearing with stainless steel ball bearing which
has high corrosive resistant strength

41. Conclusion
 The work carried out enabled us to have a detailed study of condition
monitoring of rotary equipment through vibration analysis.
 The unwanted noise generated due to the aberration of the bearing
caused due to corrosion.
 Eliminate the noise of the motor and hence prevent failure of the motor.
 The machine life was extended.Thus with the condition monitoring the
condition of the machinery is known beforehand and its chances of
failure can be eliminated.

42. References
1. International standard ISO 10816 second edition 2009-
2010