VocationalTraining Presentation

WRPL-CHAKSU, JAIPUR

Presented By:Sarthak Sharma

11EJCEE057EE, 7th Sem

JECRC

Brief Coverage:1. Introduction to WRPL and SMPL

2. Mainline Components and Engine auxiliaries

3. Electrical Department and Electrical Assets

4. Pipeline Corrosion and Cathode Protection

5. Observations during Training Period

Western Region Pipelines (WRPL)

1. Crude Oil Pipelines:• SMPL (Salaya-Mathura Pipeline)• MPPL (Mundra Panipat Pipeline)

2. Product Oil Pipelines:• KSPL (Koyali-Sanganer)• KRPL (Koyali-Ratlam)• KAPL (Koyali-Ahmedabad)• KDPL (Koyali-Dahej)

Headquarters: Rajkot (Gujarat)

Salaya-Mathura Pipeline (SMPL)• Construction Progressively Commissioned by IOCL during 1978-1981.

Section Outer Diameter x LengthSalaya-Viramgam 28’’ x 275 km. mainline.

28’’ x 159.7 km. loop line (in sections)Viramgam-Koyali 28’’ x 148.3 kmViramgam-Chaksu 24’’ x 606 km mainline

24’’ x 110 km loop line (in sections)Chaksu-Mathura 24’’ x 197 kmChaksu-Panipat 24’’ x 349 km

Chaksu Base Pump Station• T point

• Two Sections: Chaksu-Mathura and Chaksu Panipat

• Capacity1. CM Section- 7.5 MMTPA2. CP Section- 7.0 MMTPA

• 6 Storage tanks with 60,000 KL capacity

Mainline Components and Engine Auxiliaries

1. Mainline Engines• 1787 BHP (CM section) & 1592 BHP (CP section), 600 RPM, WH-Allen UK make, total (3+3)

2. Mainline Pumps• Diff. head 314 m (CM) & 208 m (CP), capacity-1462 Kl/hr, BPCL make, total (3+3)

3. ITCL Pump Motors• 1.1 KW, 2.4 A, 415 V, 2890 RPM, Brook Crompton make, total (3+3)

4. Crude and Diesel Pump Motors• 0.75 HP (~ 560 W), 415 V, 1.4 A, 1440 RPM, total (6+6)

5. Air, Water and Oil Radiator Motor• 10.5 Kw, 19 A, 415 V, 1440 RPM, total (6+6)

6. Booster Pumps• 160 KW, 260 A, 415 V, 1480 RPM, make CG, total 3

7. Firefighting Motors• 160 KW, 276 A, 415 V, 1480 RPM , make Kirloskar, total 1

8. Jockey Pump Motors• 18.5 Kw & 30 Kw, 31 & 53 A resp. , 415 V, make CG, total 2

9. Sump Pump Motors• 45 Kw & 5.5 Kw, 80 & 11 A resp. , 415 V, make CG, total 2

10. Other Motors:• Centrifuge Motors• Stirrer Motors• O/W Motors• Foam motors

Electrical Department and Electrical Assets

1. Diesel Generator Set / Emergency Generator 1 • 750 KVA, 433 V, 1043 A, make Kirloskar, total 2 (1 spare)

2. Diesel Generator Set / Emergency Generator 2 • 500 KVA, 433 V, 667 A , make KEL, total 1

3. Transformer• 1250 KVA, HT side 11 KV, LT side 433 V

4. Minimum Oil Circuit Breaker (MOCB)• 630 Fault MVA, 12 KV, 800 A, make Jyothi Elec.

5. Compressor Motors• make Kirloskar Electric (1,2) and Bharat Bijli Ltd (3,4) 11kw & 15 kw resp, 20.5 & 28.3 A resp

Pipeline Corrosion1. What is Corrosion?• Degradation of a material through environmental interaction.• Thermodynamically Instability.• A redox reaction (metal or anode oxidizes, moist water etc. are reduced as cathode)

2. Corrosion in pipelines?• Exposure to differential Oxygen Concentration• Also, Moist soil act as a conductive electrolyte.

3. How we detect Corrosion?• By means of Potential measurements.• Copper Sulphate Electrode (CSE) is a common reference electrode for soil potential measurements.• More positive the potential is, more the substance resistant towards the corrosion.

4. How do we mitigate corrosion?a) Pipeline Coatings

Isolation of metal surface from the surrounding electrolyte. Coatings are self subjected to the corrosion. Regardless overall quality, coatings have holes, voids called Holidays. A corrosion at a Holiday, can lead to rupturing of pipeline.

b) Cathode Protection

Cathode Protection• Basic Idea: Corrosion occurs at Anode(metal surfaces)? Make it cathode!

• At the anodic areas, current flows from the pipeline steel into the surrounding electrolyte (soil or water) and the pipeline corrodes.

• If every bit of exposed metal on the surface of a pipeline could be made to collect current, rate of corrosion could be drastically reduced. This is what a CP unit does.

•Current is forced to flow onto the pipe at areas that were previously discharging current, the driving voltage of the CP system must be greater than the driving voltage of the corrosion cells that are being overcome.

•For the CP system to work, current must be discharged from an earth connection (ground bed)

There are generally two methods for Cathode Protection

1. Cathode Protection with Sacrificial Anode (Galvanic Anode)• Purposely establish dissimilar metal cell strong enough to counteract corrosion cells.• This is accomplished by connecting a very “active” metal to the pipeline.• By this method Corrosion is not eliminated, It is just bypassed.• Limited driving voltage, non controllable.• Sacrificial anodes are used in low resistivity soils.

2. Cathode Protection with Impressed Currents• No limiting voltage as in sacrificial anode.• Current from some outside power source is impressed on the pipeline by using a ground bed and a

power source.• A TRU (Transformer Rectifying Unit) is heart of CP Unit.• Operation range: 10-50 V

Observations1. Monthly maintenance of Transformer• General Cleaning• Position of valves, leakage check, silica gel in breather check.• Oil in conservator tank and thermometer pockets were checked.• Winding temperature and Oil temperature readings are noted.

2. Defective Capacitor from Capacitor bank• Bank of 6 cylindrical capacitors, rating 58.4 mf, 440 VAC

3. Maintenance of CT-06 (Crude Storage Tank)• 60,000 KL storage capacity, stores BH and MI type of crude in it.• 60 yard diameter, floating roof tank with MS floor at 5.5-6 feet minimum height.• Total height 15 meters• Steam Abrasive Blasting

4. Levelling of Junction Boxes (JB) at CT-06 field• Raise the height of JBs to minimum height of periphery boundary wall.• Reduces the risk of any mishappening.• 1 out of 3 JBs could not be raised, because of the absence of the wire loop.

5. Heat shrink Cable joint at CT-06 site• Kit includes shrink tubes for conductors, lugs, copper wire mesh, cage installation tube, outer jacket

tube, XLPE insulation layer.

6. Auto Power Factor Control Panels (APFC)• A transducer in APFC continuously checks the phase angle between Voltage and Current.• Depending on the phase angle, the APFC controller Automatically switches capacitors from Capacitor

banks, the desired equivalent capacitor from series parallel connection of Capacitor banks provides equivalent Reactive power balance thereby improving p.f almost to unity.

• APFC now consists of Thyristor Switching Modules.• At IOCL chaksu, net saving of Rs 11 Lacs per annum has been done.

7. Contactors• Electrical controlling switch in Power circuits, with very high current ratings.

8. Visit to the New Pump Shed• Under construction.• Will replace Mainline Engines with Electrical Motors for Pumping.• The new HT motors has ratings (1550 KW CM Section x3, 1255 KW CP Section x3, 11 KV)• Will have higher efficiency, • Overall electricity would cost much less than crude/diesel consumption.• Noise level (120-150 dB) would reduce to significant level with operating on HT motors.• New 33 kV HT line has been given by RSEB already and establishment of Transformer (33 kV : 11 kV) and cabling

is being done. • The new pump shed will be in working state within 5-6 following months.

9. Emergency Mock Drill• Conducted Every month.• 2 persons has to remain inside the Control Room for Operational Purpose.• Rescue Response time was 7 minutes.• Overall response time was around 12 minutes including fire fighting operation, foam producing etc.• Each department representative had a walkie-talkie having 2 private radio frequency channels.• There was a slight disturbance and the siren could not be heard around the mainline engine area due to the

working of mainline engines.• Overall Response was satisfactory.

Thank You References:

• IOCL Apex manual

• IOCL Cathode Protection manual

• IOCL Operations manual

• Peabody’s Control of Pipeline Corrosion by A.W Peabody.