IOCL BOKARO

8/12/2019 IOCL BOKARO

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EXCURSION REPORT

ON

LPG BOTTLING PLANT

IOCL, BALIDIH,

BOKARO

JHARKHAND

Submitted byASHISH PANDEY

2010JE0868PETROLEUM ENGG

SERIAL NO 71


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ACKNOWLEDGEMENT

I would especially like to thank Mr. B.P Yadav (Chief Engineer, IOCL

bottling Plant, Bokaro) for helping us understand the complete procedure of the

LPG filling process. The various information provided by him helped in making

this short report. The report quality has also been enhanced because of sharing

of his practical experience.

I also take this opportunity to express a deep sense of gratitude to the

Petroleum Engineering Department, Indian School Mines for arranging this

excursion.

I am also obliged to Prof. V P Sharma (Head of the Department,

Petroleum Engineering Dept, Indian School Of Mines) for the valuableinformation provided by him in the respective fields. I am also grateful to the

enthusiasm and encouragement provided by him through the course that helped

me reach the heights for preparation.

Lastly, I thank the Almighty, my parents and all my friends for theirconstant encouragement without which this assignment would not be possible.

ASHISH PANDEY

2010JE0868Petroleum Engg


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INTRODUCTION

Indian Oil Corporation Limited, or Indian Oil, is an Indian state-

ownedoil andgas corporation with its headquarters in New Delhi India. It is theworld's 88th largest corporation, according to the fortune global 500 list, and the

largest public corporation in India when ranked by revenue Indian Oil and its

subsidiaries account for a 49% share in the petroleum products market, 31% share in

refining capacity and 67% downstream sector pipelines capacity in India. The Indian

Oil Group of companies owns and operates 10 of India's 22 refineries with a

combined refining capacity of 65.7 million metric tonnes per year. Company entered

into LPG business in year 1997 in joint venture with Petronet LNG. In FY 2012 IOCL

sold 75.66 million tonnes of petroleum products and reported a PBT of 37.54 billion,

and the Govt. of India earned an excise duty of 232.53 billion and tax of 10.68

billion.

WHAT IS LPGLPG is a mixture of commercial butane and commercial propane having

saturated and unsaturated hydrocarbons. LPG is gaseous at normal atmospheric

pressure, but may be condensed to the liquid state at normal temperature, by the

application of moderate pressures. Although they are normally used as gases, they

are stored and transported as Liquids under pressure for convenience and ease of

handling. Liquid LPG evaporates to produce about 250 times volume of gas. Thus, a

large quantity of energy can be packed, stored, transported and used in small

containers.

Most commonly, LPG cylinders are available in compact 5 kg cylinders for rural, hilly

and inaccessible areas and 12 kg as well 14.2 kg cylinders for domestic use. For

commercial and industrial use, 19 kg and 47.5 kgs cylinders areavailable.

INDIAN LPG SCENARIO

Fourth largest consumer of LPG in the world after USA, China & Japan Thirdlargest consumer In domestic sector in the world after China & USA Major market of

LPG is Domestic Sector Home Delivery of 3 Million LP Gas cylinders per day(i.e900

Million/ year) Steady Growth @ 8% p.a.in LPG Consumption in India LPG According to

the latest scenario of the Natural Gas Analysis, the Natural Gas market in India is

expected to be the one of the fastest growing in the world during the next two

decades. Among its segments LPG has made a substantial progress to become the

most convenient, cost effective and pollution free means of fuel, especially in the

middle class segment. LPG market in India is not at all versatile and competitive.
http://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Petroleum


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INDANE GAS

Indane is today one of the largest packed-LPG brands in the world and has

been conferred the coveted Consumer Superbrand status by the Superbrands

Council of India.

Having launched LPG marketing in the mid-60s, IndianOil has been credited

with bringing about a kitchen revolution, spreading warmth and cheer in millions of

households with the introduction of the clean and efficient cooking fuel. It has led to

a substantial improvement in the health of women, especially in rural areas by

replacing smoky and unhealthy chulha. Indane is today an ideal fuel for modern

kitchens, synonymous with safety, reliability and convenience.

With the status of an exclusive business vertical within the Corporation, the

Indane network delivers 1.2 million cylinders a day to the doorsteps of over 53 million

households, making IndianOil the second largest marketer of LPG globally, after SHV

Gas of The Netherlands. Indane is available in compact 5 kg cylinders for rural, hilly

and inaccessible areas, 14.2 kg cylinders for domestic use, and 19 kg and 47.5 kg for

commercial and industrial use.

LPG is a blend of Butane and Propane readily liquefied under moderatepressure. LPG vapour is heavier than air; thus it normally settles down in low-lying

places. Since LPG has only a faint scent, a mercaptan odorant is added to help in its

detection. In the event of an LPG leak, the vapourisation of liquid cools the

atmosphere and condenses the water vapour contained in it to form a whitish fog,

which is easy to observe. LPG in fairly large concentrations displaces oxygen leading

to a nauseous or suffocating feeling.


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OVERVIEW OF PLANT OPERATIONS IN LPG (LIQUIFIED PETROLEUM

GAS) BOTTLING PLANT

LPG bottling plant is a plant where LPG is filled into bottles (cylinders) forstorage and distribution among various LPG distributors. The plant has the facility to

receive bulk LPG by Tank trucks (of various capacities e.g. 12MT, 17MT etc) or

pipeline from a reliable source e.g. Refinery or any other LPG Bottling Plant. After

receipt of Bulk LPG, filling of LPG into cylinders is done. Here we shall discuss the

filling operations in LPG Bottling Plant.

OVERVIEW OF PRIMARY OPERATIONS:

Primary Operations in a Bottling plant are main line activities, directly

associated with filling of LPG cylinders. Any obstruction in these activities will hamper

Plant production. Some activities are Cylinder receipt, filling, Check scale weighing,

Tightness testing etc. These are described below:

STAGE - I: RECEIPT OF CYLINDERS

Explanation:

(a) Incoming cylinders fall into following categories:

(info) New cylinders from manufactures

Cylinders in circulation from distributors (empty, under-filled, defective).

Cylinders received from Statutory Testing Plants, duly tested.

Repaired cylinders received from the approved repairers.(b) All cylinders received should be against valid documents and the actual receipt

should be tallied with the details on the relevant document and shortages or any

other shortcomings should be endorsed on the body of the document.

(c) All new cylinders received should be supported by Test Certificate for ISI (Indian

Standards Institute) inspection and approval from CCE (Chief Controller of

Explosives) before they are put to use.

STAGE -II: VISUAL INSPECTION/SEGREGATION - I

Explanation:(a) Based on visual inspection, cylinders should be segregated as under:

(i.) Cylinders for Statutory Testing (to be sent to testing Plant).

(ii.) Under-filled cylinders received from distributors, duly tagged (for further

processing).

(iii.) Leaky/defective cylinders received from the distributors, duly tagged (for

further processing)

(iv.) Spurious cylinders (for investigation/scrap).

(v.) Cylinders found unfit for filling (beyond repairs) on visual inspection (e.g.

heavily rusted or heavily dented).

(vi.) Cylinders found defective, but repairable such as:


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a. Cylinders having twisted valve spindle (to be segregated for valve

replacement)

b. Cylinders having broken/bent foot ring/valve protection ring (to be

segregated for cold/hot repairs depending upon the condition).(To be rejected as

scrap after closer re-examination).

(vii.) Cylinders owned by other marketing companies, wrongly mixed with own

cylinders. (to be segregated for handing over to OMC).(viii.) (a) Empty cylinders fit for filling. (to be sent for filling).

(b) Visual inspection of the cylinders should be done.

(c) Under-filled cylinders received from the distributors should be weighed

to verify the extent of under-filling.

(d) Reasons for leaky/defective cylinders received from distributors should

be verified as marked on the tag attached to the cylinder.

(e) Extra care should be exercised to check for spurious cylinders and

efforts made to identify the source of receipt. Spurious cylinders must be segregated

for scraping.

(f) New cylinders or cylinders received from Statutory Testing Plant or any

cylinder which has undergone pneumatic test must be purged before they are taken

up for filling.

(g) Cylinders due for Statutory Testing must not be taken up for filling but

sent to testing Plant.

(h) Cylinders without proper markings or without serial number should not

be taken up for filling.

(info) Cylinders of other marketing companies, unless specifically sent for filling,

should not be taken up for filling but segregated for exchange with concerned

marketing company.(j) Wherever on-line facilities on the conveyor for cleaning and re-painting of

cylinders are provided within the filling Plant, segregation for these operations also

would be necessary.

(k) At the time of visual inspection during unloading, check should be made

for shortage of removable items such as valve protection caps, security nuts, safety

caps, etc., and appropriate remarks put on the relevant transfer documents.

STAGE - III: CYLINDER FOR FILLING.

Explanation:(a) Remove valve protection cap wherever provided on the cylinder.

(b) Remove safety cap in case of 'SC' type valve (Self Closing Valve).

(c) Blow the cavity of 'SC' type valve with air to remove any dust particles or water

and also check for the presence of 'O'-ring fixed on the valve outlet.

STAGE - IV: TARE WEIGHT MARKING

Explanation:

(a) Wherever tare weight stenciling is not legible on the cylinder shoulder, mark

tare weight on the cylinder shoulder after checking punched tare weight marking on

the cylinder.


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(b) For accuracy of filling, especially in case of filling through overall-weight-system,

the correct and legible marking of tare weight on the cylinder body is essential. To

ascertain the accuracy of tare marking on the incoming LPG cylinders, few cylinders

should be weighed at random. This exercise should invariably be carried out on the

new cylinders. In case any major discrepancies are observed in a particular lot the

matter should be taken up with the manufacturer.

(c) Tare weight, in case of cap type cylinders, is exclusive of the weight of the cap.In case of cylinders with shroud or ring as valve protection means, the tare weight

includes the weight of the shroud or the ring as they form integral part of the

cylinder.

STAGE - V: FILLING OPERATION

Explanation:

(a) Cylinder with 'SC' type valve.

i. Fix appropriate filling head on to the valve.

ii. Start filling.

iii. Make tare-weight adjustment.

iv. Remove filling head on automatic shut-off the filling operation.

(b) Each filling machine should be checked against standard weight at least once

during a shift.

(c) The above sequence of operations of operations has been described for filling

machines having adjustment for 'tare weight' as well as 'specific weight" for the

product (i.e. LPG)

(d) In case the filling machines operate on 'gross weight' principle, the adjustment

required on the machine would be for gross weight only.

(e) In case the filling machines operate on 'tare-off' principle, no adjustment maybe required. However, in this case it must be ensured that the cylinders are

evacuated or safely drained before putting on to the filling machine.

STAGE - VI: CHECK WEIGHING

Explanation:

(a) Weigh all filled cylinders coming out of the carousel, (i.e. ensure 100% check

weighing)

(b) Check-weighing is performed to verify that the cylinder has been filled correctly

within the permissible limits. This check is very important from safety point of view.duct to

be filled in the cylinder. Accordingly, for the quantity of 15 kg of LPG, the cylinder

would be termed under-filled if the product weight is less than 14.7 kg and it would

be termed as over-filled if the product weight is more than 15.3 kg.

(d) All the cylinder coming out from the filling machines must be check-weighed to

ensure 100% checks.

(e) In case of change of composition of LPG to be filled in cylinder, the correct safe

weight of the product that can be filled will to be worked out.

(f) Over-filling, if not detected, subjects cylinders to very high pressure (due to

increase in ambient temperature, liquid in the cylinder would expand and hydrostatic

pressure developed may at times burst the cylinder): The danger point is reached


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when liquid expands to occupy fully the volumetric capacity of the cylinder, leaving

no space. Once this point is reached there would be pressure rise at the rate of 24

pressure for a LPG cylinder is 16.9 Kg/cm2 (1.66 Mega Pascal), Hydraulic Test

pressure is 25.35 Kg/cm2 (2.45MPa), normal working pressure is approx. 7Kg/cm2 &

burst pressure is approx 100 kg/cm2.

(g) Likewise, under-filling, if undetected, shakes consumer's confidence.(h) In case any cylinder is heavily covered with mud, the same may result in under-

filling when the method of overall filling is followed. It is, therefore, necessary that

such cylinders are washed before filling. Particular care should be exercised to inspect

the joint between foot ring and dished ends of the cylinder as there is greater

possibility of accumulation of mud there.

(info) Over-filled cylinder must be sent for immediate evacuation of excess

quantity.

(j) Each filling machine should be allotted serial no. at the Plant. Periodically, this

number should be marked on the cylinder under filling on respective machine. When

these cylinders are checked on the check-scales, record of actual observations should

be made. This process helps to identify a filling machine giving incorrect filling.

(k) Check-scales should be certified by the Weights and Measures Department, and

must be tested against standard weights at least once during the shift.

STAGE - VII: SEGREGATION - II

Explanation:

(a) Cylinders rejected at check-weighing are segregated as below:

i. Overfilled cylinders are segregated and sent to evacuation unit for removing excess

quantity.ii. Under-filled cylinders are segregated and sent for topping up on a separate

stationary weighing scale having a filling point.

(b) Cylinders having apparent leaks should also be segregated at this stage and

corrective action taken to stop the leak. If leak cannot be stopped, the cylinders

should be sent for evacuation.

STAGE - VIII: TIGHTNESS TEST - I

Explanation:

(a) 'SC' type valveIn case of 'SC' type valve the valve seat remains in closed position unless pressure is

applied against the spring. With the valve outlet open, any bubbles emerging out

through the valve outlet would indicate leak through the valve seat.

(b) General

i. At this stage, leakage through bung or cylinder body may also be noticed in the

form of bubbles emerging out from the leaky spot.

ii. In case of any leak of above nature the cylinder is marked for segregation with

appropriate marker to identify the type of leakage.

(c) The tightness tests are intended to check leak through the cylinders which could

be through:

i. Cylinder's parent metal or pin hole in weld joint.


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ii. Cylinder/valve joint commonly known as bung-joint.

iii. The valve seat (with valve closed).

iv. The valve spindle (with valve closed or open).

v. The valve body (very rare occurrence)

vi. The special adaptor/valve-outlet joint (in case of 'SC' type valve).

(d) The tightness test-I is basically intended to check leaks past the valve seat.

(e) Carousel type of tightness testing baths, which keep the cylinders in verticalposition, are ideally suited for checks at this stage.

(f) Painting of interior surface of the test bath with white paint, provision of

sufficient lighting arrangement and periodic changing of water for the test to ensure

that it is clean, help in easy detection of the leaks.

(g) Whenever leak is observed, attempts should be made to stop it, if possible

(e.g. by tight closure of 'F' type valve or fixing of security nut/cap etc.)

(h) If the leak cannot be stopped the cylinder should be sent for evacuation.

(info) Suitable markers should be used to identify type of leaks such as valve leak,

bung leak, etc.

(j) The leaky cylinder, before it could be evacuated, should be so placed that the

leakage is that of vapor and not liquid.

STAGE - IX: SEGREGATION - III

Explanation

(a)

Leaky cylinders from tightness test bath-I should be segregated and sent to

Evacuation Unit.

STAGE - X: PREPARING CYLINDER FOR TIGHTNESS TEST - II

Explanation:(a) Cylinder with 'SC' type valve

i. Water to be blown from the cavity of the valve, by air. (The cavity may be full of

water when the cylinder comes out from the test bath - I)

ii. Special type of adaptor (dummy pressure regulator) to be fixed, locked and

adjusted on the valve. After fixing the adaptor, the knob is to be turned in on position

to keep the valve seat open. The adaptor is basically a body of Pressure Regulator

with diaphragm and related parts removed and outlet blocked (i.e. dummy Pressure

Regulator). Alternatively the effectiveness of the 'O'-ring can also be checked

through portable leak-detector which could be mounted on the cylinder valve, andleak, if any, observed through the fluid in the detector.

STAGE - XI: TIGHTNESS TEST - II

Explanation:

(a) 'SC' type valve

i. With the valve seat in open position with the help of special adapter the

effectiveness of the 'O' ring (making a joint with the inlet of the pressure regulator)

is tested.

(b) General

i. Tightness test is carried out with the valve seat in open position and outlet closed,

with security nut in case of 'F' type valve and with adaptor in case of 'SC' type valve.


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ii. At this stage leakages through bung or cylinder body are also checked which may

be noticed in the form of bubbles emerging out from the leaky spot.

(c) Leakage past valve seat having checked at tightness test bath I (STAGE - VII),

other possible leaks are tested through tightness test bath II.

(d) Suitable markers should be used to identify types of leaks such as bung leak,

valve leak etc.

(e) Immediate action should be taken to stop the leak temporarily whereverpracticable. If the leak cannot be stopped, the cylinder should be sent for evacuation

and should receive priority over defective cylinders which are not leaking.

(f) The leaky cylinder, before it could be evacuated, should be so placed that the

leakage is that of vapor and not liquid.

STAGE - XII: SOAP SOLUTION TEST

Explanation:

(a) Soap solution test is applied to check bung leaks in case of both 'F' type and 'SC'

type cylinders. This is in addition to the two tightness tests carried out at stage VIII

and Stage XI. A suitable marker should be placed to identify bung leak.

(b) White applying soap solution to the bung/valve joint it must be ensured that

the solution is applied all around the valve/bung joint.

(c) Soap only should be used for making a soap solution and not a detergent.

(d) Soap solution test is done to detect minute leaks through the joint which

normally remain un-detected in water baths.

STAGE - XIII: SEGREGATION - IV

Explanation:

(a)

Leaky cylinders from tightness test-II should be segregated and sent toEvacuation Unit.

STAGE - XIV: FINISHING OPERATIONS

(b) Cylinders with 'Self-Closing' valve

i. Remove special adaptor (if fixed).

ii. Blow cavity of the valve outlet with air in case any water is observed.

iii. Fix the security cap on the valve outlet.

iv. Fix appropriate neck label.

v. Seal the valve outlet using sealing tape.

STAGE - XV: FINAL INSPECTION

Explanation:

(a) Check the cylinder visually for:-

i. Apparent sound condition.

ii. Presence of cap, and neck label in case of cylinders with 'cap' as valve protection.

(b)

Correct deficiency noticed, if any.

STAGE -XVI: DISPOSAL OF FILLED CYLINDERS IN SOUND CONDITION.

Explanation:

(a) At this stage the cylinders are ready for delivery:-


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i. If required the fit cylinders can be directly sent to the stake trucks for loading.

ii. If no stake-truck is available, the cylinders can be sent for stacking in the area

earmarked for the purpose

General overview about Bokaro bottling plant:

1.

TUP (Tanker unloading plant)

Plant consist of total 6 bay for unloading tankers, it means 6 tankers can be emptied

at a time.

Per tanker capacity : 10 metric tonne

Daily emptied tankers: 12


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2.

STORAGE FACILITIES:

(i). Horton sphere:

Numbers : 1

Capacity : 1400 metric tonne

Pressure in stored condition : 7 Kg (variable)

Pressure during unloading : 1012 Kg

(ii). Bullets:

Numbers: 3Capacity: 150 metric tonne per bullet

Total capacity: 1850 Metric tonne


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Safety measures while storage:

BLEED OFF VALVE: Main use of bleed off valve is in maintaining pressure inside the

storage facilities. If pressure inside the Bullets or Horton sphere increases above

certain limit, then valve is opened to bleed off extra pressure.

WATER SPRINKLER FIRE FIGHTING : A fire sprinkler system is anactive fire

protection measure, consisting of a water supply system, providing adequate pressure

and flow rate to a water distribution piping system, onto whichfire sprinklers are

connected.

FILLING SHED

WASHING UNIT

The Washing unit is on-line equipment used to wash the incoming cylinders

with multiple forced jet of water to Remove mud, dirt, stains, etc., from the outersurfaces
http://en.wikipedia.org/wiki/Active_fire_protectionhttp://en.wikipedia.org/wiki/Active_fire_protectionhttp://en.wikipedia.org/wiki/Fire_sprinklerhttp://en.wikipedia.org/wiki/Fire_sprinklerhttp://en.wikipedia.org/wiki/Active_fire_protectionhttp://en.wikipedia.org/wiki/Active_fire_protection


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DRYING UNIT

The Drying unit is an on - line equipment used to dry the cylinders, coming out

of washing unit by blowing the air on the sides and top surfaces of the cylinders asthey move.

KEROSEL UNIT

Kerosel Unit is an on-line equipment used to create vacuum in the first stage and filling LPG

vapor in the second stage in new / hot repaired empty cylinders.


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WEIGHT CHECK

The digital check weighing system with segregation unit is designed to check

the gross weight of a filled LPG cylinder and reject the cylinder from main stream on

to a loop conveyor if the gross weight is more or less than the stipulated value. The

electronic check scale is programmed in such a way to subtract 14.2 Kg or 19 Kg from

total weight of cylinder and the tare weight will be displayed. Operator has to

compare the displayed tare weight value with the tare weight value punched on the

cylinder and if the value is beyond the permissible limit, the cylinder will be rejected.

The unit is an on-line equipment used to ensure that correct weight of LPG fuel is

carried in the cylinders.

Under-filled cylinders are filled with additional quantity of LPG and the weight

is corrected. Overfilled cylinders are checked and the weight of LPG fuel is corrected

by evacuation process

LEAK CHECK AND O RING

Cylinder is checked for any leak at O-RING valve and if leak detected then it ischanged .Process can be accomplished manually or automatically. After placing O-

RING it is deflected for final sealing by means of placing seal cap on cylinder nozzle.

Again cylinder is checked for further leakage by passing through water bath .And, at

the end plastic cover is fixed on seal cap to ensure complete seal and cylinder is

ready for delivery.


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REFERENCES

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www.iocl.com

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