MRPL Vocational Training Report

[MANGALORE REFINERY AND PETROCHEMICALS LIMITED] January 13, 2016
Vocational Training Report 1 January 2016 to 14 January 2016
0
Vocational Training Report
1 January 2016 to 14 January 2016
By
Mr SATYAJEET MALLA
4VP13ME088
VIVEKANANDA COLLEGE OF ENGINEERING & TECHNOLOGY,
PUTTUR
For
Mangalore Refinery and Petrochemicals Limited
(A subsidiary of Oil and Natural Gas Corporation Limited)
मंगलूर ररफाइनरी एं ड पेट्र ोके ममकल्स मलममट्ेड
(ऑयल एण्ड नेचुरल गैस कॉर्पोरेशन लललिटेड की सहायक कं र्पनी)
Kuthethoor P.O., Via Katipalla, MANGALORE, INDIA – 575 030

1
ABSTRACT
MRPL, a subsidiary of ONGC, currently processes over 15 Million Metric Tonnes of crude
per Annum, and is the only refinery in India to have two hydrocrackers producing premium
diesel, and two CCRs producing high octane unleaded petrol and a versatile design with high
flexibility to process crudes of various API gravity and with high degree of automation,
which requires establishment of safe minimum levels of maintenance, changes to operating
procedures and strategies and the establishment of capital maintenance regimes and plans.
The actions include the combination of technical and corresponding administrative,
managerial and supervision actions.

2
ACKNOWLEDGEMENT
The internship opportunity I had with Mangalore Refinery and Petrochemicals Limited was a
great chance for learning and professional development. Therefore, I consider myself as very
lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for
having a chance to meet so many wonderful people and professionals who led me though this
internship period.
Bearing in mind previous I use this opportunity to express my deepest gratitude and special
thanks to the DGM of Mangalore Refinery and Petrochemicals Limited who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct
path and allowing me to carry out training at their esteemed organization.
We express our deepest thanks to Harish Baliga, DGM (Admn & Training) for taking part in
useful decision & giving necessary advices and guidance and arranged all facilities to make
life easier. We choose this moment to acknowledge his contribution gratefully.
It is our radiant sentiment to place on record our best regards, deepest sense of gratitude to
Mr Hariprasad, Mechanical Maintenance In charge CDU Block, Mr Suresh Kumar J,
Mechanical Maintenance In charge HCU Block, Mr Adarsh G.A, Mechanical Maintenance In
charge CREG/CM, Mr Lakshmiah, Mechanical Maintenance In charge Workshop, Mr.
Shrikanth Bhat, Mechanical Maintenance In charge CCR Block and Mr Umesh Udupa,
Mechanical Maintenance In charge CPP for their careful and precious guidance which were
extremely valuable for our study both theoretically and practically.
MRPL perceive as this opportunity as a big milestone in our career development. We will
strive to use gained skills and knowledge in the best possible way, and I will continue to work
on their improvement, in order to attain desired career objectives. Hope to continue
cooperation with all of you in the future,
Sincerely,
Satyajeet Malla
Date: - 13 January 2016 Place:- Mangalore, India

1
CONTENTS
INTRODUCTION........................................................................................................................ 2
THE TRAININGORGANISATION............................................................................................. 3
STAGED DEVELOPMENT..................................................................................................3
DIVISION OF LABOUR ...................................................................................................... 4
ADDING VALUE................................................................................................................. 4
FLEXIBILITY...................................................................................................................... 5
CHECKS AND BALANCES.................................................................................................6
A CREDIT-WORTHY COMPANY....................................................................................... 6
FORMAL TRAINING PROVIDED.............................................................................................. 7
Safety Facilities ........................................................................................................................ 7
Fire Alarm System ................................................................................................................ 7
INDUSTRIAL TRAINING........................................................................................................... 9
TYPICAL LAYOUT FOR OIL REFINERY AND BASIC OPERATION.................................. 10
CRUDE OIL DISTILATION UNIT......................................................................................... 11
CDU/VDU Unit and Facilities.............................................................................................. 11
Process............................................................................................................................... 12
HYDRO CRACKING UNIT................................................................................................... 15
CRITICAL ROTATING EQUIPMENT GROUP/ CONDITION MONITORING....................... 18
Critical ............................................................................................................................... 18
Semi-Critical....................................................................................................................... 18
Non-Critical........................................................................................................................ 18
Maintenance ....................................................................................................................... 18
Mechanical Equipment’s...................................................................................................... 19
WORK SHOP ........................................................................................................................ 26
Machines:........................................................................................................................... 26
CONTINUOUS CATALYTIC REGENERATION................................................................... 34
CAPTIVE POWER PLANT.................................................................................................... 37
Boiler section:..................................................................................................................... 37
Steam Turbine Section:........................................................................................................ 37
Raw Water Plant: ................................................................................................................ 38
Demineralization:................................................................................................................ 38
Cooling Towers:.................................................................................................................. 41
CONCLUSIONS................................................................................................................. 42

2
INTRODUCTION
Industrial Training program provides pre-professional work experience with specific
assignments and responsibilities. An Industrial Training should be relevant to a student’s
personal career interests and academic courses of study, serving as a bridge between
university and the world of work. Productive Industrial Trainings help students make
informed decisions and improve their marketability after graduation. Encourage students to
apply the skills and knowledge gained at the university to benefit the organizations. Nurture
quality graduates well verse with informative, versatile, competitive, innovative and
resourceful. Trains and prepare students with knowledge and skills requirements of current
and future industry environments.

3
THE TRAINING ORGANISATION
Mangalore Refinery and Petrochemicals Ltd (MRPL), located in southern India, is a leading
processor of various grades of crude oil, and generator of upstream value-added petroleum
products.
MRPL, a subsidiary of ONGC (Oil & Natural Gas Corporation), currently processes over 15
Million Metric Tonnes of crude per Annum, and is the only refinery in India to have two
hydrocrackers producing premium diesel, and two CCRs producing high octane unleaded
petrol.
MRPL produces LPG, naphtha, gasoline, jet fuel (kerosene) oils of various qualities, bitumen
and sulphur. Company, for the past five years, has been in joint venture with Shell Aviation
Ltd for supplying Aviation Turbine Fuel (ATF). MRPL’s Refinery is located in south India,
strategically positioned bet MRPL en markets in the Gulf region and Singapore, and only 10
kilometres from the nearest port.
STAGED DEVELOPMENT
MRPL was incorporated in 1988 as a joint venture between MRPL M/s Hindustan Petroleum
Corporation Limited (HPCL), a government-owned state enterprise, and M/s IRIL &
Associates (AV Birla Group).
MRPL grew in phases. Phase I was commissioned in 1996 with an initial processing capacity
of three million tonnes per annum. In 1995, Phase II of the refinery’s expansion was initiated
and it was commissioned in September 1999. This has been expanded to 15 million tonnes
per annum in March 2012.
The refinery is designed to maximise middle distillates, keeping in view of the domestic
consumption, with a capability to process light to heavy and sour to sweet crudes with 24 to
46 API (American Petroleum Institute) gravity.
Due to market situation, the financing pattern of the expanded capacity under Phase II, and
the withdrawal of APM for refineries effective 1-4-1998, the viability of the refinery project
during the initial years came under duress resulting in the underutilisation of available
capacity, triggering a vicious circle of low utilisation, strained cash flow, and increased
operating costs. This resulted in a tailspin with continuous loss and erosion of equity base.
The government scouted for a partner to revive the ailing company. On 28th March 2003,
ONGC – India’s premier E&P company – acquired a 51 per cent stake, and by June 2003, the
total shareholding of A.V. Birla Group. This takeover scripted an extraordinary revival and,
in less than six months, the fortunes of MRPL changed from ‘terminal sicknesses to a
position among the 30 most valuable companies in India. In less than two years, MRPL was
able to earn the highest A1+ credit rating.
MRPL have never looked back since MRPL started operating at full capacity, having more
than doubled the refining capacity, and having continued to outperform, notching

4
benchmarks across all performance parameters. MRPL gross turnover for 2012 was US$11.5
billion.
DIVISION OF LABOUR
MRPL is run by a Board of Directors with its own non-executive Chairman. The other Board
members are the Managing Director (MD), Director of Finance, the Director of Refinery, and
other representative directors from the Government of India and HPCL. MRPL also have
independent directors on our Board, as well as government nominee directors. The day-to-
day running and performance of the refinery is the responsibility of the functional directors
and the MD.
The Director of Refinery oversees operations; technical services; maintenance; safety, health
& environment practices; materials management; corporate planning; and projects & business
development activities. The Director of Finance regulates the finance-related activities,
besides guiding the Integrated Crude Oil Trading Desk that ensures uninterrupted crude
supplies, fund management, investor relations.
ADDING VALUE
MRPL’s infrastructure facilities include primary units – namely, Crude and Vacuum
Distillation Units, Naphtha Splitting Units; secondary units, via Hydrocracker Units to
produce high quality sulphur-free diesel and ATF (aviation turbine fuel) – both domestic
grade ATF and export grade ATF meeting Defence Standard 91-91; Shell Soaker Visbreaker
technology to upgrade heavy vacuum residue to gas, naphtha and gas oil – a first in India; and
a Continuous Catalytic Regeneration (CCR) platforming unit, producing lead-free, high
octane petrol. Hydrogen generated as a by-product of this is used in the hydrocracker unit,
while the other by-product is LPG. In addition, MRPL has one LPG Merox Unit to reduce
sulphur in LPG; and a bitumen unit employing the Biturox process to produce various grades
of asphalt.
The above processes add value to the products from the refinery, thereby increasing
profitability. Also, Treating Units play an important role in removing impurities like sulphur,
nitrogen and metals from the products, thereby meeting the stipulated product specifications.
MRPL has planned to produce some more value-added products such as petcoke and
polypropylene – this initiative is scheduled to start in few months. MRPL has recently made
an investment to the tune of US$2.2 billion in its Phase III development. These units produce
value-added derivatives, and upgraded petroleum products like diesel and petrol. MRPL has
built a Single Point Mooring facility 16 kilometres away from the seashore, to bring in Very
Large Crude Carriers (VLCCs) for sourcing opportunity crudes from Latin American and
African countries. Petcoke production is expected to rollout in few months. Also on the cards
is another US$360 million plant for polypropylene production scheduled to go on-stream
early next year.
MRPL’s own research & development unit conducts process-related research and catalyst
evaluation, as well as developing new processing methods. A Memorandum of

5
Understanding (MoU) has been signed with the National Institute of Technology in
Surathkal, Karnataka, for carrying out collaborative research in the area of hydrocarbons.
Ideas for new products, like polypropylene, are first deliberated, analysed, and then detailed
feasibility reports are drawn up by Corporate Planning before the blueprint is finalised.
MRPL also has a range of support facilities, including an oil jetty to receive crude oil and
dispatch petroleum products through ocean tankers, 104 storage tanks, including six
Mounded Bullets, and six pipelines running from the refinery to the coastal terminal. There is
also a Captive Power Plant (CPP) with 118.5 MW capacities for Phase I and II units and
another 118 MW CPP for Phase III.
The refinery is currently operating at a capacity of 15 million tonnes per annum – producing
300,000 tonnes of LPG; 1.3 million tonnes of gasoline; 1.7 million tonnes of naphtha; 1.8
million tonnes of Jet Fuel; 6.8 million tonnes of Diesel; and 2.1 million tonnes of bunker Fuel
Oil, although the latter figure will come down considerably once MRPL start making more
upstream products.
FLEXIBILITY
MRPL’s ability to make more value-added products, and its flexibility to produce a wide
range of different products from oil, are key strengths of the company. MRPL can produce
different grades of each product category according to customer requirements and to meet
various legislative and regulatory requirements, particularly those of the API. “For example,
MRPL offer a wide range of gas oil products varying in the ppm (parts per million) levels of
by-product and additives.” In addition, MRPL’s return to full production capacity has enabled
it to attain its current high levels of profitability.
Another of our strengths is the fact that about 50 per cent of our output is exported. MRPL
started exporting 10 years ago, and today most of the exports go to the Singapore markets,
with the rest going to Europe and the west. MRPL are fortunate in not being dependent on the
domestic market – MRPL sell whatever MRPL can domestically, although products that do
not sell well here always do better in international markets. A significant market for us is
Mauritius, which has been purchasing about 1.1 million tonnes of the entire product range
annually for the last seven years.”
MRPL employs about 1,350 staff working in the first two phases of the refinery. MRPL is
recruiting manpower for Phase III, which will eventually increase the total head-count to
1,700, although, once Phase III has been completed, it might be necessary to raise this
number to 1,800. In addition, several very experienced staffs are retiring and will need
replacing. This will lower the average age of the workforce to about 36 years, although it will
also place an additional burden on our annual intensive staff training programme.
MRPL’s Training Centre provides in-house training in induction and orientation, fire
fighting, first-aid, and skills development. In addition, staffs are sent on external courses
where they learn about quality management systems, amongst other topics.

6
CHECKS AND BALANCES
A separate Quality Control Department and Laboratory are responsible for analysing crude
oil that is to be processed in the refinery, and also for analysing and monitoring all products,
to check that they conform to required standards and specifications, and to enable MRPL to
have its products certified. The laboratory also checks the purity of raw materials. Additional
activities of the laboratory include analysis of a range of cooling water samples and plant and
instrument air samples; as well as ambient air quality and weather monitoring and
investigation and failure analysis. It uses standard test methods of recognised international
bodies, including the American Society for Testing & Materials (ASTM), the Institute of
Petroleum (IP), ISO, the Bureau of Indian Standards (BIS), Universal Oil Products (UOP)
USA, and Shell International BV (SMS).
The Laboratory is certified to ISO 9001: 2004 for quality management and also to ISO/IEC
17025-2005 (NABL) – a quality system for the competence of testing and calibration
laboratories. It is also approved by numerous Indian Government bodies, such as the
Directorate General of Civil Aviation (DGCA), the Aviation Ministry, Centre for Military
Airworthiness & Certification (CEMILAC) and the Directorate General Aeronautical Quality
Assurance (DGAQA), as well as the Ministry of Defence for Aviation Turbine Fuel Testing
& Certification.
MRPL also takes its responsibilities with regards to environmental protection seriously, as
attested to by its ISO14001 certification. It has installed a state-of-the-art wastewater
treatment plant to treat refinery wastewater containing sulphide, phenol, oil and grease and
numerous other contaminants. An advance Reverse Osmosis plant is built in as part of Phase
III Effluent Treatment Plant, in order to maximise the volume of the treated effluent. There is
also a biogas plant designed for anaerobic organic food waste treatment arising from the
refinery and the office complex. In addition, 120 acres of land is being developed as a green
belt and the entire company site has been landscaped to provide lawns, hedges, different
flowering and non-flowering shrubs, perennial trees and water features.
A CREDIT-WORTHYCOMPANY
MRPL has won many plaudits, the most recent being two official awards by international
credit rating agencies for the highest credit quality rating and the lowest credit risk. In
addition, the company has been recognised for excelling in energy performance,
environmental management, safety performance, export performance, accounting standards,
industrial relations, information technology, investor relations and community development,
for which MRPL was presented the ‘Refinery of the Year’ award as part of the ‘PETROFED
Oil & Gas Industry Awards 2010’.
As for the future, MRPL intend on boosting our capacity to 18 million tonnes – and then to
21 million tonnes within six years. MRPL also wish to make more upstream products,
particularly linear alkylbenzenes, for which MRPL are constructing a US$461 million
facility.

7
FORMAL TRAINING PROVIDED
Safety Facilities
Fire Alarm System
Fire alarm Detectors and Manual Call Points:
Automatic detectors have been installed in various unmanned and other critical areas of the
Refinery designed to convey alarm upon detection to the Fire Control room panel. In addition
Break Glass type Manual call points are located around Process Plants for quick
communication of outbreak of fire by manual operation. Actuation of the alarm conveys
audio-visual indication on the Control and Repeater panel.
Hydrocarbon detectors:
Critical areas of the Refinery have been installed with toxic and hydrocarbon Gas detectors
with local alarms with added facility to simultaneously notify Control rooms through the
DCS system for early detection of hydrocarbon leaks. In addition to this we have portable
intrinsically safe gas detectors carried by personnel during rounds in Units to detect gas leaks.
Fire Protection
MRPL's fire protection measures conform to Bureau of Indian Standards and Oil Industry
Safety Directorate standards. Fire Protection measures have been devised to cater to the
various hazards associated with different Units and its related processes. The fire protection
system has been divided into fixed installations, Mobile appliances and Portable first aid fire
fighting equipment.
Portable First Aid Fire Fighting equipment:
Fire extinguishers of dry chemical powder type and carbon di-oxide type of various
capacities have been installed at various locations for fighting fires at its incipient stage.
Dedicated maintenance crews keep the fire extinguishers in good working order.
Fixed Installations:
Critical Process Units have been provided with medium velocity water spray systems and
deluge systems for Horton spheres and hot pumps. These systems are augmented by Fire
water monitors and hydrants all around the Refinery. Floating and fixed roof hydrocarbon
storage tanks have been provided with cooling system in addition to fixed foam system.
Central hose stations, hose boxes and hose reels have been located as support systems. The
firewater network has dedicated water storage of 40,0000𝑚3
with additional provision of 1x
1,50,000𝑚3
and 2 x 55,000 0𝑚3
from the Raw water reservoirs. The entire fire water
network of 40.05 kilometers is energized by firewater pumps which sustain a pressure of 10
𝑘𝑔𝑠 𝑐𝑚2⁄ by auto start facility during emergencies.
Mobile Appliances:
Foam Tenders with one Foam Nurser as back-up and Dry Chemical Powder Tenders make up
the mobile appliances. The foam tenders have rear mounted pumps driven via the Power
Take-off in addition to foam tank and water tank. Each DCP Tender carries 2000 kgs of

8
powder with Nitrogen batteries for expelling the powder. Foam Nurser has 7500 litres foam
tank and can replenish foam tenders at location with its own gear pump. Jeep and Tata mobile
vehicles are used to carry out inspections. Trailor pumps to fight fires from open water source
is an additional equipment available.
Communication Systems:
The modern communication system includes telephones, Nuemann paging systems,
intrinsically safe Wireless radio, pagers and public address system. Long range siren has been
installed to alert all concerned during declaration of any emergency.
MRPL is dedicated to the cause of Safety and endeavour to adhere to the highest standards in
our Health Safety and Environment management system to prevent and minimize loss due to
fires and other accidents and for the protection of the environment.
The following systems for Fire & Emergency handling procedures are in place:
 Fire Orders: Duties and responsibilities during emergencies of the various
Departments / Sections have been established in detail and brought out in the Fire
Order'.
 Fire Call Rota: Designated Groups consisting of members of various disciplines are
detailed on rotation to facilitate the mobilization of additional manpower during
emergencies.
 Mutual Aid Scheme: Mutual Aid schemes have been established with nearby large
Industries with the specific objective of sharing resources and manpower during the
occurrence of large-scale emergencies. Periodic interaction by way of Onsite / Offsite
Mock exercises between the Mutual aid members enable them to acclimatize with the
potential hazards and the various fire protection measures adopted in either facility.
 Disaster Management Plan: MRPL has well-developed Onsite Disaster Management
Plan which has the approval of the Director of Factories. Mock exercises are
conducted to test the response and efficacy of the emergency and allied services
including mutual aid members. Observers are appointed and observations and
suggestions are implemented to further improve the system. In addition District
Authorities in close association with MRPL developed Off-Site Disaster Management
Plans. Mock Off-site emergency exercises are also conducted.

9
INDUSTRIAL TRAINING
The training includes visiting following units and accessing the data and to provide report.
 CRUDE OIL DISTILATION UNIT
 HYDRO CRACKING UNIT
 CRITICAL ROTATING ELEMENT GROUP/ CONTROL
MONITORING
 WORK SHOP
 CONTINUOUS CATALYTIC REGENERATION
 CAPTIVE POWER PLANT

10
TYPICAL LAYOUT FOR OIL REFINERY AND BASIC OPERATION
Seven Basic Operations in Petroleum Processing
Separation
 Distillation
 Solvent Refining
Combination
 Catalytic Polymerization
 Alkylation
Conversion
 Carbon Removal
 Hydrogen Addition
Treating, Finishing, Blending
 Motor Spirit, Kerosene and Diesel
 Lubes and Waxes
 Asphalt
Reforming
 Isomerization
Protecting the Environment
 Waste water treatment
 Disposal of solids
 Sulphur Recovery

11
CRUDE OIL DISTILATION UNIT
The crude oil distillation unit (CDU) is
the first processing unit.
The CDU distils the incoming crude oil
into various fractions of different boiling
ranges, each of which are then processed
further in the other refinery processing
units.
The CDU is often referred to as the
atmospheric distillation unit because it
operates at slightly above atmospheric
pressure.
The Atmospheric, Vacuum Distillation Units and Naphtha Splitter Unit designed by M/s
Engineers India Ltd., are heat integrated, using Pinch Technology to achieve high-energy
efficiency, thereby reducing Fuel Oil consumption and in turn reducing air emissions.
CDU/VDU Unit and Facilities
The unit broadly consists of crude pre-heating section, two stage desalting, post heating
section for heat recovery, crude heater, crude distillation column, crude column overhead
system, crude column product withdrawal, and cooling system, vacuum distillation column,
vacuum column overhead system, ejector system, vacuum column product withdrawal, and
cooling system, Naphtha stabiliser column to recover fuel gas and LPG, Naphtha splitter

12
column, product caustic wash, and water wash system wherever required, LPG Amine
treating unit, LPG Mercaptan removal unit, and Kerosene treating unit.
The following products meeting various specifications leave the unit battery limit Fuel gas,
LPG, Light Naphtha, Middle range Naphtha, Heavy Naphtha, Kerosene, Diesel, Heavy
Diesel, Vacuum Gas Oil and Short Residue. The unit consists of the following main
processing facilities sections:
1) Feed Treatment Facilities
• Electric Desalter: 3.0 MMTPA. Distilation Facilities
• Atmospheric Distillation Unit - to match 3.0 MMTPA crude distillation
capacity.
i. Pre-flash Drum: 3.0 MMTPA.
ii. Crude Column/Stabiliser/Naphtha Splitter.
• Vacuum Distillation Unit: To match 3.0 MMTPA crude distillation capacities.
2) Product Treatment Facilities
• LPG Amine Section: To match 3.0 MMTPA crude distillation capacities.
• Light Naphtha Caustic wash: To match 3.0 MMTPA crude distillation
capacities.
• Medium Naphtha Caustic wash: To match 3.0 MMTPA crude distillation
capacities.
• Heavy Naphtha Caustic wash: To match 3.0 MMTPA crude distillation
capacities.
Process
Distillation is the first step in the processing of crude oil and it takes place in a tall steel tower
called a fractionation column. The inside of the column is divided at intervals by horizontal
trays. The column is kept very hot at the bottom (the column is insulated) but as different
hydrocarbons
boil at
different
temperatures,
the
temperature
gradually
reduces
towards the
top, so that
each tray is a
little cooler
than the one
below. The
crude needs to
be heated up

13
before entering the fractionation column and this is done at first in a series of heat exchangers
where heat is taken from other process streams which require cooling before being sent to
rundown. Heat is also exchanged against condensing streams from the main column.
Typically, the crude will be heated up in this way up to a temperature of 200 - 280 ºC, before
entering a furnace.
As the raw crude oil arriving contains quite a bit of water and salt, it is normally sent for salt
removing first, in a piece of equipment called a desalter. Upstream the desalter, the crude is
mixed with a water stream, typically about 4 - 6% on feed. Intense mixing takes place over a
mixing valve and (optionally) as static mixer. The desalter, a large liquid full vessel, uses an
electric field to separate the crude from the water droplets. It operates best at 120 - 150 ºC,
hence it is conveniently placed somewhere in the middle of the preheat train. Part of the salts
contained in the crude oil, particularly magnesium chloride, are hydrolysable at temperatures
above 120 ºC. Upon hydrolysis, the chlorides get converted into hydrochloric acid, which
will find its way to the distillation column's overhead where it will corrode the overhead
condensers. A good performing desalter can remove about 90% of the salt in raw crude.
Downstream the desalter, crude is further heated up with heat exchangers, and starts
vaporising, which will increase the system pressure drop. At about 170 -200 ºC, the crude
will enter a 'pre-flash vessel', operating at about 2 - 5 Bar, where the vapours are separated
from the remaining liquid. Vapours are directly sent to the fractionation column, and by
doing so, the hydraulic load on the remainder of the crude preheat train and furnace is
reduced (smaller piping and pumps). Just upstream the preflash vessel, a small caustic stream
is mixed with the crude, in order to neutralise any hydrochloric acid formed by hydrolysis.
The sodium chloride formed will leave the fractionation column via the bottom residue
stream. The dosing rate of caustic is adjusted based on chloride measurements in the
overhead vessel (typically 10 - 20 ppm). At about 200 - 280 ºC the crude enters the furnace
where it is heated up further too about 330 -370 ºC. The furnace outlet stream is sent directly
to the fractionation column. Here, it is separated into a number of fractions, each having a
particular boiling range. At 350 ºC, and about 1 bar, most of the fractions in the crude oil
vaporise and rise up the column through perforations in the trays, losing heat as they rise.
When each fraction reaches the tray where the temperature is just below its own boiling
point, it condenses and changes back into liquid phase. A continuous liquid phase is flowing
by gravity through 'downcomers' from tray to tray downwards. In this way, the different
fractions are gradually separated from each other on the trays of the fractionation column.
The heaviest fractions condense on the lower trays and the lighter fractions condense on the
trays higher up in the column. At different elevations in the column, with special trays called
draw-off trays, fractions can be drawn out on gravity through pipes, for further processing in
the refinery. At top of the column, vapours leave through a pipe and are routed to an
overhead condenser, typically cooled by air fin-fans. At the outlet of the overhead
condensers, at temperature about 40 ºC, a mixture of gas, and liquid naphtha exists, which is
falling into an overhead accumulator. Gases are routed to a compressor for further recovery
of LPG (C3/C4), while the liquids (gasoline) are pumped to a hydrotreater unit for sulphur
removal. A fractionation column needs a flow of condensing liquid downwards in order to

14
provide a driving force for
separation between light and heavy
fractions. At the top of the column
this liquid flow is provided by
pumping a stream back from the
overhead accumulator into the
column. Unfortunately, a lot of the
heat provided by the furnace to
vaporise hydrocarbons is lost
against ambient air in the overhead
fin-fan coolers. A clever way of
preventing this heat loss of
condensing hydrocarbons is done via the circulating refluxes of the column. In a circulating
reflux, a hot side draw-off from the column is pumped through a series of heat exchangers
(against crude for instance), where the stream is cooled down. The cool stream is sent back
into the column at a higher elevation, where it is been brought in contact with hotter rising
vapours. This provides an internal condensing mechanism inside the column, in a similar way
as the top reflux does which is sent back from the overhead accumulator. The main objective
of a circulating reflux therefore is to recover heat from condensing vapours. A fractionating
column will have several (typically three) of such refluxes, each providing sufficient liquid
flow down the corresponding section of the column. An additional advantage of having
circulating refluxes is that it will reduce the vapour load when going upwards in the column.
This provided the opportunity to have a smaller column diameter for top sections of the
tower. Such a reduction in diameter is called a 'swage'. The lightest side draw-off from the
fractionating column is a fraction called kerosene, boiling in the range 160 - 280 ºC, which
falls down through a pipe into a smaller column called 'side-stripper'. The purpose of the side
stripper is to remove very light hydrocarbons by using steam injection or an external heater
called 'reboiler'. The stripping steam rate, or reboiled duty is controlled such as to meet the
flashpoint specification of the product. Similarly to the atmospheric column, the side stripper
has fractionating trays for providing contact between vapour and liquid. The vapours
produced from the top of the side stripper are routed back via pipe into the fractionating
column. The second and third (optional) side draw-offs from the main fractionating column
are gasoil fractions, boiling in the range 200 - 400 ºC, which are ultimately used for blending
the final diesel product. Similar as with the kerosene product, the gasoil fractions (light and
heavy gasoil) are first sent to a side stripper before being routed to further treating units. At
the bottom of the fractionation column a heavy, brown/black coloured fraction called residue
is drawn off. In order to strip all light hydrocarbons from this fraction properly, the bottom
section of the column is equipped with a set of stripping trays, which are operated by
injecting some stripping steam (1 - 3% on bottom product) into the bottom of the column.

15
HYDRO CRACKING UNIT
The process of converting higher molecular weight hydrocarbons into more valuable lower
molecular weight hydrocarbons is called hydrocracking.
The high-boiling, high molecular weight hydrocarbons used as feed stocks for catalytic
hydrocrackers include what are commonly referred to as atmospheric gas oil from
atmospheric crude oil distillation units, vacuum gas oil from vacuum distillation units,
delayed coking gas oil from delayed coking units and cycle oil from fluid catalytic cracking
units. For describing the hydrocracking process depicted in the typical flow diagram below,
the feedstock will be referred to as simply gas oil.
The gas oil from the feedstock pump is mixed with a stream of high-pressure hydrogen and
then flows through a heat exchanger where it is heated by the hot effluent reaction products
from the hydrocracker's first stage reactor. The feedstock is then heated further in a fuel-fired
heater before it enters the top of first stage reactor and flows downward through three beds of
catalyst. The temperature and pressure conditions in the first stage reactor depend upon the
specific licensed hydrocracker design, the feedstock properties, the desired products, the
catalyst being used and other variables. As a broad generality, the pressure in the first stage
reactor may range from 35 to 200 Bar and the temperature may range from 260 to 480 °C.
After the effluent reaction product stream from the reactor bottom is cooled by the incoming
gas oil feedstock, it is injected with wash water, partially condensed in a water-cooled
condenser and routed into a high-pressure vapour-liquid separator for separation into three
phases: hydrogen-rich gas, hydrocarbon liquid and water. Sulphur and nitrogen compounds in
the gas oil feedstock are converted into gaseous hydrogen sulphide and ammonia by the
hydrogenation that takes place in the first stage reactor. The purpose of the wash water is to
dissolve some of the hydrogen sulphide and ammonia gases present in the first stage reaction
product stream. The resulting aqueous solution of ammonium hydrosulphide (NH4HS) is
referred to as sour water and is typically routed to a sour water stripper elsewhere in the

16
petroleum refinery. The sour water stripper removes hydrogen sulphide from the sour water
and that hydrogen sulphide is subsequently converted to end product elemental sulphur in a
Claus process unit.
The hydrogen-rich gas from the high-pressure separator is routed through an amine scrubber
where it is contacted with an aqueous amine solution to absorb and remove residual hydrogen
sulphide in the gas. The rich amine solution (containing the absorbed hydrogen sulphide) is
typically routed to a central amine gas treating unit elsewhere in the refinery.
The hydrocarbon liquid phase from the high-pressure separator flows through a pressure let-
down (i.e., pressure reduction) valve and into a low-pressure separator. The reduction in
pressure partially vaporizes (see flash evaporation) the liquid. The resulting vapour (referred
to as off gas) is routed to a central amine gas treating unit elsewhere in the refinery. The
hydrocracked the end products of hydrocarbon liquid phase from the low-pressure separator
is heated in a fuel-fired heater and fed into the fractionator.
The fractionator is a continuous distillation tower that separates the hydrocracked
hydrocarbon stream into naphtha, jet fuel (or kerosene) and diesel oil. The off gas from the
tower's associated reflux drum joins the off gas from the low-pressure separator.
Not all of the feedstock hydrocarbons to the first stage reactor are hydrocracked (i.e.,
converted) into lower-boiling, lower molecular weight hydrocarbons. The bottom stream

17
from the fractionator consists of the unconverted hydrocarbons from the first stage reactor
and that stream is mixed with high pressure hydrogen and recycled as feed to the second
stage reactor. It is first heated by the hot effluent reaction products from the second stage
reactor. The recycled feed is then heated further in a fuel-fired heater before it enters the top
of second stage reactor and flows downward through three beds of catalyst. The temperature
and pressure conditions in the second stage reactor depend upon the same variables as
determine the conditions in the first stage reactor. As a broad generality, the pressure in the
second stage reactor may range from 80 to 200 bar and the temperature may range from 345
to 425 °C.
After the effluent reaction product stream from the second stage reactor bottom is cooled by
the incoming recycle feed, it is partially condensed in a water-cooled condenser and routed
into second high-pressure vapour-liquid separator for separation into two phases: hydrogen-
rich gas and hydrocarbon. No water washing of the second stage reactor effluent is needed
because the second stage reactor effluent is essentially free of hydrogen sulphide and
ammonia gases. For the same reason, the gas from the second high-pressure separator does
not require amine scrubbing to remove hydrogen sulphide.
The two hydrogen-rich gas streams (the amine-scrubbed
gas from the first high-pressure separator and the gas
from second high-pressure separator) are joined and then
compressed and recycled for use in both the first and
second stage reactor systems.
The hydrogenation of sulphur and nitrogen compounds in
the first stage reactor requires the consumption of
hydrogen. Likewise, the saturation of olefins and
aromatics, in both the first stage and second stage reactors, to form paraffinic hydrocracked
products consumes hydrogen. To a large extent, the amount of hydrogen consumption
depends on the feedstock content of sulphur, nitrogen, olefins and aromatics. As a broad
generality, the consumption of hydrogen in a hydrocracker may range from 1,000 to 3,000
standard cubic feet per barrel of feedstock (195 to 585 normal cubic metres per metric ton of
feedstock).

18
CRITICAL ROTATING EQUIPMENT GROUP/ CONDITION MONITORING
CREG is a group which looks after the maintenance of critical equipment’s in each plant.
Equipment in each plant is distinguished based on their importance, as
 Critical  Semi-critical  Non-critical
Critical
These equipment’s are the sole performer of a particular task in the plant, hence
these machines or equipment are under constant inspection in a interval of a week.
Such as the Make-up Gas Compressor in HCU, Power generators in CPP, etc.
Failure of this equipment can lead to shutdown of the entire plant.
Semi-Critical
These equipment or machines are inspected with an interval of 15 days .The plant can
run without these machines, but not for long time.
Non-Critical
These machines are classified as non-critical machines as the plant can be run without
them or they don’t play important role in production .These are tested once in a
month.
Maintenance
 The machines are inspected and well maintained by preventive maintenance and
condition maintenance.
 In preventive maintenance the machines are checked for oil replacement and Pressure
Monitoring. Here a maintenance engineer personally checks the equipment.
 In conditional maintenance equipment’s are inspected while its working/functioning
and Non Destructive test such as temperature ,vibration will be studied and monitored
.Overall Classification
The equipment’s in the company are classified overall as:-
 Stationary  Rotary
Stationary Equipment’s Are:-
 Heat Exchangers
 Vessels
 Columns
 Storage tanks
 Valves
Rotary Equipment’s Are:-
 Pumps
 Fans
 Compressor
 Turbine

19
MechanicalEquipment’s
The equipment’s widely used in the company are:-
 Pumps
 Compressors
 Heat exchangers
 Steam Turbines
 Boilers
 Valves.
Pumps
A pump is a device that moves fluids or sometimes slurries by mechanical action. Pumps can
be classified into three major groups according to the method they use to move the fluid:
Direct lift, Displacement and Gravity pumps.
The mechanical power of rotation to the pump is supplied by motor, through shafts. Shaft is
supported by bearings. Bearings also enable easy rotation. There will be casing to the pump.
The lubrication oil is supplied to bearings if required. There might be gear box between
motor and the pump, which outputs requires speed to shaft of pump.
Parts of Pump
 Impeller
 Casing
 Bearing housing and bearing
 Coupling
 Mechanical seal.
At MRPL mainly centrifugal pumps and reciprocating pumps are used.
Centrifugal Pumps
These are a sub-class of dynamic axis
symmetric work absorbing turbo
machinery. Centrifugal pumps are
used to transport fluids by the
conversion of rotational kinetic
energy to the hydro dynamic energy
of the fluid flow. The rotational
energy typically comes from an
engine or electric motor. The fluid
enters the pump impeller along or
near to the rotating axis and is
accelerated by the impeller, flowing
radically outward into a diffuser,
from where it exits. Centrifugal pump
is used to pump lower heights with
high flow rates.
These are negative displacement pumps i.e. there is back flow. Centrifugal pump has impeller
at the centre which rotates with its blades. The fluid input is energized to high kinetic energy
and thrown out through the outlet. The outlet is larger than the suction end of pump casing.
Based on the position of impeller relative to bearings centrifugal pumps are classified as
overhang impeller and between bearing impellers. In Over hang impeller, impeller is placed
like a cantilever beam i.e. impeller is not placed between the bearings. In between bearing
arrangement, impeller is simply supported between the bearings.

20
Reciprocating Pump
This is a positive plunger pump. It is often used where relatively small quantity of liquid is to
be handled and where delivery
pressure is quite large. Reciprocating
pump is used to pump fluid to high
heights at low flow rate.
Such pumps are positive
displacement i.e. is no back flow of
fluid. The inflow and out flow of
liquid inside cylinder is controlled by
valves. This pump has reciprocating
piston which compresses the fluid
from large suction to small outlet.
Small outlet increases pressure but small constant cross section of liquid is flown out. The
piston is reciprocated directly by combustion of diesel or indirectly by motor through
connecting rods.
Reciprocating pumps can be classified based on
 Sides in contact with water
a) Single acting Reciprocating pump
b) Double Reciprocating pump
 Number of cylinder used
a) single cylinder pump
b) Two cylinder pumps
c) Multi -cylinder pumps
In HCU Power recovery turbines (PRT) are seen next to some of motors. Here turbine utilizes
high pressure hydrogen from HPS (high pressure separator) to run and produce extra power
to start the motor. Thus PRT is clutched to motor. Lots of energy is saved due to PRT.
COMPRESSORS
Compressors work similar to pumps, but here gases are used.
Compressors are devices which compress gasses up to very high pressure and transported to
various points. Gases are compressible fluids, thus the volume can be reduced during
compression.
Reciprocating compressors and centrifugal compressors are operated in MRPL.
Reciprocating compressors
This has reciprocating piston. Piston is reciprocated by connecting rods connected to crank.
Crank is rotated by motor. Suction and exhaust to the cylinder is regulated by valves. The gas
enters cylinder gets compressed and sent out at high pressure. Double acting compressors are
also seen. In such compressors gas is compressed on either sides of piston. This saves energy
and faster larger production compressed gas takes place. In order to achieve very high
pressure gases are taken to multiple stages.

21
Screw Compressors
A rotary screw compressor is a type of gas compressor which uses a rotary type positive
displacement mechanism. The gas compression process of a rotary screw is a continuous
sweeping motion, so there is very little pulsation or surging of flow, as occurs with piston
compressors.
Rotary screw compressors use two meshing helical screws, known as rotors, to compress the
gas. Gas enters at the suction side and moves through the threads as the screws rotate. The
meshing rotors force the gas through
the compressor, and the gas exits at
the end of the screws.
The effectiveness of this mechanism
is dependent on precisely fitting
clearances between the helical
rotors, and between the rotors and
the chamber for sealing of the
compression cavities.
Centrifugal compressors
These have impellers which increase intake gas kinetic energy and discharge to the outlet.
Outlet is placed such that it is tangential to the direction of rotation. These compressors are
seen at places in MRPL where continuous supply of air is required.

22
Heat Exchangers:
Heat exchanger is a device which exchange heat between two fluids. Heat exchanger helps in
re-using the heat, it preheats a fluid and it can post cool the fluid or any other heat exchanges
required.
Types of heat exchangers:
1. Parallel flow type
2. Counter flow type
Classification of heat exchangers:
1. Shell and tube heat exchanger
2. Plate heat exchanger
3. Plate and shell heat exchanger
Heat is exchanged between a solid medium or by direct contact between fluids. Only the first
types of heat exchangers are seen in MRPL. Shell and tube heat exchangers and plate
exchangers are used in MRPL.
Shell and tube heat exchanger is prominent in MRPL. These types of exchanger have shell
side and tube side.
Tube side has set of small tubes called tube bundle which are joined by welding at their tips.
One of the heat exchanging fluid is passed through tubes. Shell side has other heat
exchanging fluid which passes by the tube bundle in wavy fashion. The wavy movement is
guided by placing number of alternate blocks in upper and lower section of tube bundle. Such

23
motion ensures majority of portion from shell side exposed to tube bundle. Shell and tube
exchangers have U-tube and straight heat exchangers. In straight tube exchanger inlet and
outlet are at two extreme ends of exchanger.
Where as in U-tube type, the tubes form a U-tube at one end. The exit and inlet of tube side
lie opposite to u-tubes. This end is divided into upper compartment and lower compartment
for inlet and outlet.
A typical section view of u-tube heat exchanger
Fin Fan
Fin fans are cooling fans used to cool fluid passing through coils. Fin fans are used in many
units of MRPL.
Fluid is passed above the fan through coils and fan is rotated. Fluid cools by blowing
atmosphere air continuously on them.
Fin fan looks like fan which runs nearly at 1475 rpm. It has three to four blades. The blades
are made up of FRP (fiber re-enforced plastic). FRP makes the blade light and helps for easy
rotation. The blade angle is about 20o. Blade angle is adjusted either manually or by control
adjusters.
The blade holder is used to connect blades to center of the fan. Impeller is placed coaxially
with top of the fan. This helps in more cooling.
Forced Draft Fan: (FD)
FD fan is used to supply air from atmosphere to required processes in MRPL. Combustion air
is continuously provided by FD fan to furnace resulting in continuous burning of fuel gases.
Induced Draft Fan: (ID)
ID FAN is used to evacuate exhaust gasses out of a process. The flue gasses from combustion
chamber are expelled using ID fan. This is done by creating negative pressure in a system.
BEARINGS:
Bearing is device used to hold the shaft and permit free rotation. Bearing is designed as per
the load carrying capacities. Thus a bearing takes certain limited load.

24
Ball Bearing:
Ball bearings have
spherical smooth balls
placed between the
races. The spheres
have point contact and
when there is relative
motion between races
due to rotation of
shaft, friction offered
is very low. It
supports radial and
axial loads.
Roller Bearing:
Roller bearings have smooth cylinders (rollers) in
between bearing rings. The roller has a line contact on
races which reduces friction thus by making providing
free rotation of shaft. The roller bearing takes axial and
radial loadings. It has higher capacity then ball bearing.
Journal Bearing:
Journal bearing consists only bearing surface with hydrodynamic oil. This oil reduces friction
between bearing surface and the shaft. The shaft is rotated on hydrodynamic oil freely. The
oil thickness varies throughout bearing and thickness is low at highest load acting point. This
bearing only takes radial loads but not axial loads.
Pump Seals
Cartridge pump seals:
Are the easiest seal for a mechanic to
install. Only being required to slide
onto the pump shaft and bolt to the
pump gland, the cartridge seal
cannot be missing
installed. Cartridge seals must fit the
stuffing box.

25
Mechanical seals:
Mechanical seals are engineered for most pumps, mixer and agitator applications in
maintenance. In many cases the designs have been proven to be workhorses over years of
use. In others seals must be designed for evolving industrial demands.
Mechanical seals deliver a full range or rotary configurations and component materials - to
handle virtually and fluid moved by any equipment. When you specify engineered pump
seals you have the advantage of the most advanced pump seal technology, the latest in field
proven design and when working with an outside sales force there is hands on technical
support.
Rotating face units are the dependable pump seal answer for worn equipment when your shaft
seals must be replaced. They are ideal for new equipment designs or to improve the
usefulness of existing equipment by converting from pump packing to mechanical seals.
Mechanical seals feature:
 Invisible leakage
 Less friction/power loss
 No to little wear on the shafts or sleeves
 Flexibility - to accommodate shaft deflections and "End Play"
 No period maintenance
 Long Life
Types of Mechanical Seals
Unbalanced
Balanced
Single Spring
Multiple Spring
Pusher Type
Non Pusher Type
Bellows Seals
Metal
Elastomer
TFE
O-Ring
V-Ring
Wedge Ring

26
WORK SHOP
The workshop here is for maintenance and emergency purposes.
The machines used here are:
 Slotting machine
 Central Lathe
 Shaping machine
 Grinding machine
 Milling machine
 Column drill
 Radial drill
 Industrial presses
 Power hack saw
 Hot tapping machine
Welding processes adopted here are:
 Arc welding
 TIG welding
 Oxy acetylene gas cutter is also used
Types of valves used:
 Gate valve
 Ball valve
 Needle valve
 Safety valve
 Globe valve
 Non return valve
Electrical workshop is used for electrical works.
Machines:
Slotting Machine:
The slotting machine is a reciprocating machine tool in which, the ram holding the tool
reciprocates in a vertical axis and the cutting action of the tool is only during the downward
stroke. The slotter can be considered as a vertical shaper and its main parts are:
 Base, column and table
 Ram and tool head assembly
 Saddle and cross slide
 Ram drive mechanism and feed
mechanism.
Lathe:
The lathe is a machine tool which holds the work piece between two rigid and strong supports
called centres or in a chuck or face plate which revolves. The cutting tool is rigidly held and
supported in a tool post which is fed against the revolving work. The normal cutting
operations are performed with the cutting tool fed either parallel or at right angles to the axis
of the work.
The cutting tool may also be fed at an angle relative to the axis of work for machining tapers
and angles.

27
Milling machine:
Milling is the cutting operation that removes metal by feeding the work against a rotating,
cutter having single or multiple cutting edges. Flat or curved surfaces of many shapes can be
machined by milling with good finish and accuracy. A milling machine may also be used for
drilling, slotting, making a circular profile and
gear cutting by having suitable attachments
The work piece is holding on the worktable of
the machine. The table movement controls the
feed of work piece against the rotating cutter.
The cutter is mounted on a spindle or arbor and
revolves at high speed. Except for rotation the
cutter has no other motion. As the work piece
advances, the cutter teeth remove the metal from
the surface of work piece and the desired shape
is produced.
Drilling Machine:
The drilling machine or drill press is one of the most common and useful machine employed
in industry for producing forming and finishing holes in a work piece. The unit essentially
consists of:
1. A spindle which turns the tool (called drill)
which can be advanced in the work piece either
automatically or by hand.
2. A work table which holds the work piece
rigidly in position.
Working principle: The rotating edge of the drill
exerts a large force on the work piece and the hole
is generated. The removal of metal in a drilling
operation is by shearing and extrusion.
The above figure shows the vertical column drilling machine. The head has got only vertical
motion. This is radial drilling machine. This has the provision to move along three directions-
vertical, horizontal and radial.

28
Shaper machine:
A shaper is a type of machine tool that uses linear relative motion between the work piece
and a single-point cutting tool to machine a linear tool path. Its cut is analogous to that of a
lathe, except that it is linear instead of helical. (Adding axes of motion can yield helical tool
paths, as also done in helical planning). A shaper is analogous to a planer, but smaller, and
with the cutter riding a ram that moves above a stationary work piece, rather than the entire
work piece moving beneath the cutter. The ram is moved back and forth typically by
a crank inside the column.
Grinding machine:
It is used for surface finishing. The machine contains magnetic bed.

29
Hot tapping:
Hot tapping, or pressure tapping, is the method of making a
connection to existing piping or pressure vessels without the
interruption of emptying that section of pipe or vessel. This
means that a pipe or tank can continue to be in operation
whilst maintenance or modifications are being done to it. The
process is also used to drain off pressurized casing fluids.
Hot tapping is also the first procedure in line stopping, where
a hole saw is used to make an opening in the pipe, so a line
plugging head can be inserted.
Power hacksaw:
A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its
own electric motor or connected to a stationary engine.
Valves:
A valve is a device that regulates, directs or controls the flow of a fluid by opening, closing,
or partially obstructing various passageways. Valves are technically valves fittings, but are
usually discussed as a separate category. In an open valve, the fluid flows in a direction from
higher pressure to lower pressure.
Types of valves used in MRPL are:
Gate valve:
The gate valve, also known as
a sluice valve, is a valve that opens
by lifting a round or rectangular
gate/wedge out of the path of
the fluid. The distinct feature of a
gate valve is the sealing surfaces
between the gate and seats are
planar, so gate valves are often
used when a straight-line flow of
fluid and minimum restriction is
desired

30
Globe valve:
A globe valve, different from ball
valve, is a type of valve used for
regulating flow in a pipeline,
consisting of a movable disk-type
element and a stationary ring seat in
a generally spherical body.
Ball valve:
A ball valve is a valve with
a spherical disc, the part of the valve
which controls the flow through it. The
sphere has a hole, or port, through the
middle so that when the port is in line
with both ends of the valve, flow will
occur. When the valve is closed, the hole
is perpendicular to the ends of the valve,
and flow is blocked
Needle valve:
A needle valve is a type of valve having a small port and
a threaded, needle-shaped plunger. It
allows precise regulation of flow, although it is generally
only capable of relatively low flow rates.
Non return valve:
A check valve, clack valve, non-return valve or one-way valve is a valve that normally
allows fluid (liquid or gas) to flow through it in only one direction.
Check valves are two-port valves, meaning they have two openings in the body, one for fluid
to enter and the other for fluid to leave.
1. Safety valve:

31
A safety valve is a valve mechanism which automatically releases the substance from a boiler
or other system, when the pressure or temperature exceeds present limits.
2. Plug valve:
3. Check valve
4. Relief valve

32
Welding:
TIG
TIG has non consumable tungsten electrode which with stands high temperature. The tip of
TIG chord consists of collet, TIG torch and a ceramic cup (withstands high temperature). An
arc is created between electrode and the workpiece which melts the junction along with filler.
The arc is created with help of external power supply. Inert atmosphere is created by supply
of inert gases. This provides shield to weld pool, electrode and solidified weld. Argon is used
as inert gas
SMAW
This is most prominent welding process. The electrode here is consumable electrode which
acts as filler too. The tip of electrode is made to touch the work piece creating spark and
pulled out quickly to a certain distance from work piece thus creating arc. External power
supply is used create polarity between work piece and electrode. Heat produced melts
electrode and portion of work piece thus welding is done. Electrode is coated with de
oxidizing agents which when melted during welding provides shield from oxygen. Positive
and reverse polarities are used.
SMAW is used for most of the welding purposes.
For TIG filler wires of diameter 2.5mm, 3mm, 4mm are used.
Carbon steel 7018 electrode
7052 filler wire
SS 304 electrode/filler wire
Alloy material P5 8018B239
P9 8018B6
P11 8018B8
P22 9018B2
Inconel metal 2424 or 2427
Welding checks
 Developer and penetration
 Radiography
 UT
Heavy Equipment’s:
Heavy weight equipment like cranes, bull dozers, fork lifts, drum lifts and hydras comes
under heavy equipment section. Cranes with capacities of 250, 150, 55, 45 and 20 ton, hydras
of 3, 5, 8,12ton capacities, forklift of 9ton capacity, bulldozer of 3ton and drum lifts are
available in MRPL.
Cranes are used to operate at tall heights like flares, etc. the maximum capacity of crane is the
maximum weight can be lifted by it. The lifting arm of crane is called telescope or boom.

33
Gibb is an extra supplementary arm given to the boom. The loading capacity decreases as
boom stretches out. Therefore maximum lifting weight will be at minimum length.
The load carrying application of crane is carried out by hydraulics. Whereas the control
system is electro-pneumatically controlled. Counter weights are added to balance the crane
during lifting. Deric cylinders are used as Counter weights. Overriding raises the crane from
ground level. This prevents wheels carrying any load. The tyres contain water along with
pressurized air. This also acts as counter weights. The thickness of slings increases with load
lifting capacity. Belts are also used instead of slings for some applications.
TOOLS ROOM:
Tools room contains lot of tools of various sizes. It has all the tools required for mechanical
operations in MRPL.
Tools room has spanners of various types: Non sparking slugging ring, Non sparking
slugging open end, Non sparking slugging double end ring and Non sparking slugging double
end open types.
Pipe threading die sets, tap wrench, c-clamp, bearing puller, pipe wrench, torque wrench,
drilling machines, drill bit, emery paper, hallen key, calipers, divider, scribers, adhesives, ear
plugs, asbestos gloves, hand grinding machines (disk type), square sockets, universal joint,
screw drivers, files, chisels, hammers, axe-saws, lapping compounds are tools present in tools
room. Tools room for heavy equipment section have stocks of belts, wires, pins, all of various
sizes and types used for heavy equipment are seen here.

34
CONTINUOUS CATALYTIC REGENERATION
The objective of the hydro treating processes is to remove sulphur as well as other unwanted
compounds e.g. unsaturated hydrocarbons, nitrogen from refinery process streams.
For hydro treating, two basic processes are applied; the liquid phase process for kerosene and
heavier straight run and cracked distillates up to vacuum gas oil and the vapour phase process
for light straight run and cracked fractions. Both processes use the same basic configuration:
the feedstock is mixed with hydrogen - rich make up gas and recycle gas. The mixture is
heated by heat exchanger with reactor effluent and by a furnace and enters a reactor loaded
with catalyst. In the reactor the sulphur and the nitrogen compounds present in the feedstock
are converted into hydrogen sulphide and ammonia respectively. The olefins present are
saturated with hydrogen to become di-olefins and part of the aromatics will be hydrogenated,
a higher pressure is needed in the reactor compared to the conventional operating mode.
The reactor operates at temperatures in the range of 300-380 degree Celsius and at a pressure
of 10-20 bar for naphtha and kero , as compared with 30-50 bar for gas-oil , with excess
hydrogen supplied. The temperature should not exceed 380 degree Celsius, as above this
temperature cracking reactions can occur, which deteriorates the colour of the final product.
The reaction products leave the reactor and after having been cooled to a low temperature,
typically 40-50 degree Celsius, enter a liquid/gas separation stage. The hydrogen – rich gas
from the high pressure separation is recycled to combine with the feedstock, and the low
pressure off- gas steam rich in hydrogen sulphide is removed. The clean gas is then used as
fuel for the refinery furnaces. The liquid steam is the product from hydro treating. It is
normally sent to the stripping column where H2S and other undesirable components are
removed. In cases where the steam is used for stripping, the product is sent to a vacuum drier
for removal of water. Some refiners use a salt dryer instead of a vacuum drier to remove the
water. The catalyst used is normally cobalt, molybdenum and nickel finely distributed on

35
alumina extradites. Motor gasoline production starts with the distillation of crude oil. One of
the products out of that process is a fraction of low octane gasoline, normally referred to as
naphtha, typically boiling in the range of 100- 160 degree Celsius. Other gasoline products
are produced as a result of secondary processes like catalytic cracking, isomerisation,
alkylation and platforming. Petrol is then produced by blending a variety of these gasoline
components of different qualities to meet a series of product specifications.
The role of the plat former is to pave the way for this by a process which reforms the
molecules in low octane naphtha to produce high octane gasoline component. This is
achieved by employing a catalyst with platinum as its active compound; hence the name
platformer.
The main reactions of platforming process are as follows:
 Dehydrogenation of naphthenes, yielding aromatics and hydrogen
 Dehydro- isomerisation of alkyl cyclopentanes to aromatics and hydrogen
 Isomerisation of paraffins and aromatics
 Dehydrocyclisation of paraffins to aromatics and hydrogen
 Hydrocracking of paraffins and naphthenes to lighter, saturated paraffins at
the expense of hydrogen
The above reactions take place concurrently and to a large extent also sequentially. The
majorities of these reactions involve the conversion of paraffins and naphthenes and result in
an increase in octane number and a net production of hydrogen. The main characteristic of
these reactions is their high endothermicity, which requires the continuous supply of process
heat to maintain reaction temperature in the catalyst beds. That is why the reactions are
mainly done in series with furnaces in between, in order to remain sufficiently high reactor
temperatures.
The reactions take place at the surface of the catalyst and are very much dependent on other
factors, on the right combination of interactions between platinum, its modifiers or activators,
the halogen and the catalyst carrier. During operating life of the catalyst, the absolute and
relative reaction rates are influenced negatively by distributing factors like gradual coak
formation, poisons and deterioration of physical characteristic of the catalyst.
In the CCR unit, the reactors are suitably stacked so that the catalyst can flow under gravity.
From the bottom of the reactor stack, the spent catalyst is lifted by nitrogen to the top of the
regenerator stack. In the regenerator the different steps, coke burning, oxychlorination, and
drying are done in different sections segregated via a complex system of valves, purge flows
and screens. From the bottom of the regenerator stack, catalyst is lifted by hydrogen to the
top of the reactor stack in a special area called the reduction zone. In the reduction zone, the
catalyst passes through a heat exchanger in which it is heated up against hot feed. Under hot
conditions it is brought in contact with hydrogen which performs a reduction of the catalyst
surface thereby restoring its activity. In such a continuous regeneration process, a constant
catalyst activity can be maintained without unit shut down for a typical run length of 3- 6
years. After 300-400 cycles of reaction regeneration, the surface area of the catalyst will drop
to such a level that it becomes more difficult to maintain a catalyst activity and at such a time,
normally the catalyst will be replaced by a fresh batch. The batch of the spent catalyst is then
sent for platinum reclaim to recover the valuable precious metal.

36
For economic reasons, the design capacities of the platformer units vary from 1000-4500t/d;
operating pressures can vary over a wide range, units ranging from 3.5 bars up to 30 bars can
be found. A lower pressure enhances the endothermic reactions, which gives less cracking
reactions and thereby a higher liquid yield. However, at a lower reactor operating pressure,
the hydrogen partial pressure will be lower as well, which favours coke formation. The
reason why semi regen platformers will not operate at too low pressure. Otherwise the cycle
length between regeneration becomes too short. A second disadvantage of operating at a
lower pressure is that a larger compressor will be required to boost the pressure of the
hydrogen up to the normal pressure of the hydrogen system. Typical design reformate octane
numbers are in 05-104 range. The reactor temperature is in the region of 450-530 degree
Celsius.
At the outlet of the last reactor the product is still well above a00 degree Celsius. It is cooled
down against cold feed in massive heat exchanger, called Packinox plate pack heat
exchanger. The special design of those heat exchangers ensures that minimum heat loss
occurs in order to minimize the fuel consumption of the furnaces. After passing the effluent
heat exchanger, the reaction products are cooled in water coolers and routed to a product
separator, where hydrogen is the main product. Part of the hydrogen produced is recycled
back to the feed, in order to maintain a high enough hydrogen partial pressure in the reactors.
The remainder of the gases are compressed and brought in contact again with the liquid from
the product separator. This step is called “recontacting” and is done to recover as much as
possible hydrocarbons from the hydrocarbons produced. The reactor product, now in liquid
form, goes to the platform stabilizer which removes Liquid Petroleum Gas (LPG) and other
gases to leave a liquid high octane gasoline component called platformate, ready for blending
into the refinery mogas pool. Summarizing, the platformer unit produces about 85% liquid
condensate, 10% hydrogen and 5% LPG.

37
CAPTIVE POWER PLANT
Unreliable nature of power supply in and around
Mangalore makes mega Industries like MRPL which
works round the clock to depend on some other means
for electricity. For huge industries like MRPL it is not
economical to buy electricity as well. So power
generation facilities have been setup within the MRPL
campus to power all plants and utility section of MRPL.
Since the power is being generated in MRPL the power
generation facility is called Captive Power Plant.
There are two phases, phase 1 and phase 2, for refining 3MMPTA crude oil, phase 1 plant
takes nearly 30MVA power. While for refining 6MMPTA crude oil, phase 2 plant takes place
nearly 42MVA power from the Captive Power Plant.
M/s Larson & Turbo Ltd. has setup power plant for phase 1 and phase 2. Phase 1 has two
22.5MW power generation capacities. It has three boilers of 100 ton capacity each and two
turbines. Phase 2 has 26.5MW power generation capacity with four boilers and three turbines.
Power plant can be divided into two sections:
1. Boiler section 2. Turbo generator
Boilersection:
It supplies the high power superheated steam turbine. In the boiler, high pressure steam
104kg/sq.cm at a temperature of 510 degree Celsius is produced. The furnace of the boiler
has four burners. Fuel oil is burnt in the furnace. Air for combustion is sucked in from the
atmosphere by the FD fans. The fuel gas heat up the fresh gas getting in to the furnace in
primary. Air preheater(PAPH) and secondary air preheator(SAPH). The fuel gas are made to
pass through the stalk by ID fan. Water from de mineralization plant comes to deaerator
where oxygen present in the water is removed. Water in the Economizer gets converted to
wet steam and it goes to the tube in the furnace during which it gets more heat. The steam is
collected in the steam drum. This superheated steam is then passed over the turbine blades.
SteamTurbine Section:
The turbine generator consists of a series of steam turbines interconnected to each other and a
generator on a common shaft. There is a high pressure turbine at one end, followed by an
intermediate pressure turbine, two low pressure turbines, and the generator. As steam moves
through the system and loses pressure and thermal energy it expands in volume, requiring
increasing diameter and longer blades at each succeeding stage to extract the remaining
energy. The entire rotating mass may be over 200 metric tons and 100 feet (30 m) long. It is
so heavy that it must be kept turning slowly even when shut down (at 3 rpm) so that the shaft
will not bow even slightly and become unbalanced. This is so important that it is one of only
five functions of blackout emergency power batteries on site. Other functions are emergency
lighting, communication, station alarms and turbo generator lube oil.

38
Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm) diameter
piping to the high pressure turbine where it falls in pressure to 600 psi (4.1 MPa) and to
600 °F (320 °C) in temperature through the stage. It exits via 24–26-inch (610–660 mm)
diameter cold reheat lines and passes back into the boiler where the steam is reheated in
special reheat pendant tubes back to 1,000 °F (540 °C). The hot reheat steam is conducted to
the intermediate pressure turbine where it falls in both temperature and pressure and exits
directly to the long-bladed low pressure turbines and finally exits to the condenser.
The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a stationary
stator and a spinning rotor, each containing miles of heavy copper conductor—no permanent
magnets here. In operation it generates up to 21,000 amperes at 24,000 volts AC as it spins at
either 3,000 or 3,600rpm, synchronized to the power grid. The rotor spins in a sealed
chamber cooled with hydrogen gas, selected because it has the highest known heat transfer
coefficient of any gas and for its low viscosity which reduces windage losses. This system
requires special handling during start up, with air in the chamber first displaced by carbon
dioxide before filling with hydrogen. This ensures that the highly explosive hydrogen–
oxygen environment is not created.
CPP facility also includes:
1. Raw water plant 2. Demineralization plant 3. Cooling tower
Raw WaterPlant:
The raw water to MRPL is got from river Netravati
from a place called Sarapdi at distance 41 kms
from MRPL through underground pipeline. This
water is stored and treated raw water site at south
of MRPL site. The treated water is stored in RCC
reservoir. This water is provided for the following
requirements in the refinery.
1. Make up to cooling water system
2. Feed to DM water system
3. As service water to upper and
lower plateau
4. As drinking water system
5. Make up to five system
Demineralization:
It is the process of removing mineral salts from water by using the ion exchange process.
Demineralised water is water completely free (or almost) of dissolved minerals as a result of
one of the following processes:
 Distillation
 Deionization
 Membrane filtration (reverse osmosis
or nanofiltration)

39
 Electrodyalisis  Or other technologies
Demineralized water also known as Deionized water, water that has had its mineral ions
removed. Mineral ions such as cations of sodium, calcium, iron, copper, etc and anions such
as chloride, sulphate, nitrate, etc are common ions present in water. Deionization is a physical
process which uses specially-manufactured ion exchange resins which provides ion exchange
site for the replacement of the mineral salts in water with water forming H+ and OH- ions.
Because the majority of water impurities are dissolved salts, deionization produces a high
purity water that is generally similar to distilled water, and this process is quick and without
scale buildup.
De-mineralization technology is the proven process for treatment of water. A DM Water
System produces mineral free water by operating on the principles of ion exchange,
Degasification, and polishing. Demineralized Water System finds wide application in
the field of steam, power, process, and cooling.
Principle:
Raw water is passed via two small polystyrene bead
filled (ion exchange resins) beds. While the cations
get exchanged with hydrogen ions in first bed, the
anions are exchanged with hydroxyl ions, in the
second one.
Process:
In the context of water purification, ion-exchange is a rapid and reversible process in which
impurity ions present in the water are replaced by ions released by an ion-exchange resin. The
impurity ions are taken up by the resin, which must be periodically regenerated to restore it to
the original ionic form. (An ion is an atom or group of atoms with an electric charge.
Positively-charged ions are called cations and are usually metals; negatively-charged ions are
called anions and are usually non-metals).
The following ions are widely found in raw waters:
Cations Anions
Calcium (Ca2+) Chloride ( Cl-)
Magnesium (Mg2+) Bicarbonate (HCO3-)
Sodium (Na+) Nitrate (NO3-)
Potassium (K+) Carbonate (CO32-)
Ion Exchange Resins:
There are two basic types of resin - cation-exchange and anion-exchange resins. Cation
exchange resins will release Hydrogen (H+) ions or other positively charged ions in exchange
for impurity cations present in the water. Anion exchange resins will release hydroxyl (OH-)
ions or other negatively charged ions in exchange for impurity anions present in the water.

40
The application of ion-exchange to water treatment and purification. There are three ways in
which ion-exchange technology can be used in water treatment and purification: first, cation-
exchange resins alone can be employed to soften water by base exchange; secondly, anion-
exchange resins alone can be used for organic scavenging or nitrate removal; and thirdly,
combinations of cation-exchange and anion-exchange resins can be used to remove virtually
all the ionic impurities present in the feedwater, a process known as deionization. Water
deionizers purification process results in water of exceptionally high quality
Deionization:
For many laboratory and industrial applications, high-purity water which is essentially free
from ionic contaminants is required. Water of this quality can be produced by deionization.
The two most common types of deionization are:
• Two-bed deionization • Mixed-bed deionization
Two-bed deionization:
The two-bed deionizer consists of two vessels - one containing a cation-exchange resin in the
hydrogen (H+) form and the other containing an anion resin in the hydroxyl (OH-) form.
Water flows through the cation column, whereupon all the cations are exchanged for
hydrogen ions. To keep the water electrically balanced, for every monovalent cation, e.g.
Na+, one hydrogen ion is exchanged and for every divalent cation, e.g. Ca2+, or Mg2+, two
hydrogen ions are exchanged. The same principle applies when considering anion-exchange.
The decationised water then flows through the anion column. This time, all the negatively
charged ions are exchanged for hydroxide ions which then combine with the hydrogen ions to
form water (H2O).
Mixed-bed deionization:
In mixed-bed deionizers the cation-exchange and anion-exchange resins are intimately mixed
and contained in a single pressure vessel. The thorough mixture of cation-exchangers and
anion-exchangers in a single column makes a mixed-bed deionizer equivalent to a lengthy
series of two-bed plants. As a result, the water quality obtained from a mixed-bed deionizer is
appreciably higher than that produced by a two-bed plant.
Although more efficient in purifying the incoming feed water, mixed-bed plants are more
sensitive to impurities in the water supply and involve a more complicated regeneration
process. Mixed-bed deionizers are normally used to ‘polish' the water to higher levels of
purity after it has been initially treated by either a two-bed deionizer or a reverse osmosis
unit.
Electrodeionization EDI :
Electrodeionization Systems remove ions from aqueous streams, typically in conjunction
with reverse osmosis (RO) and other purification devices. Our high-quality deionization
modules continually produce ultrapure water up to 18.2MW/cm. EDI may be run
continuously or intermittently

41
Advantages :
 Variety of cost effective standard
models.
 Improved aesthetics and rugged
design.
 User friendly, low maintenance and
easy to install.
 Simpler distribution and collection
systems.
 Quick availability.
 Pre dispatch assembly check.
 The multiport valves are top
mounted as well as side mounted
with the necessary high pressure
rating PVC piping.
 Economical
 Single valve operation as compared
to the six valves in conventional
filters.
 Each operating step is clearly
marked on the valve, thereby
eliminating chances of error in the
operating sequence.
 Single valve assembly, with its
simplified frontal Piping, simpler
distribution collecting systems is
Very easy to install.
 Rust free
 Less power consumption
 Durable
 High shelf life
Major Applications:
 Boilers feed waters, Textiles, Pharmaceuticals, Chemicals, Breweries, Swimming
pools, Potable Water, Hospitals, Automobile, and Battery, Fertilizers.
 Ion Exchange Plants
 Softener
 Industrial DM Plant
 Two Stage & Multi Stage DM Plants
 Mix Bed Demineraliser
 De-Gasifiers
 Cation Polisher
 Manual/Automatic Plants
 Pharmaceutical Industry
 Power Plant
 Oil & Gas sector
 Chemical Industries
 Textile Industries
Cooling Towers:

42
CONCLUSIONS
Mangalore Refinery And Petrochemicals Limited was a challenging place for students to do
their internship program. By this internship program, we have gained a wide knowledge of
technical works from our superiors, secretaries and colleagues from other department.
The company provided me with the real working environment. Not only learning the general
work scope here but the practical students also have got the opportunities to implement the
work scope with their own strength and abilities during the internship. It was an advantage
for me to be in the Mechanical Maintenance Division where I have boosted up my skills and
abilities. The conclusion that I can make is that Mangalore Refinery And Petrochemicals
Limited is the right place for students to do their industrial training.

MRPL Vocational Training Report

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to MRPL Vocational Training Report

Similar to MRPL Vocational Training Report (20)

More from Home

More from Home (20)

Recently uploaded

Recently uploaded (20)

MRPL Vocational Training Report