PROJECT REPORT

FOR

FOUR MONTHS INDUSTRIAL TRAINING AT

GURU GOBIND SINGH REFINERY, BATHINDA

HPCL-MITTAL ENERGY LIMITED

Submitted for Partial Fulfillment of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by :-

Sahil (1413808)

GIANI ZAIL SINGH CAMPUS COLLEGE OF ENGINEERING AND

TECHNOLOGY,

BATHINDA-151001

1
 CANDIDATE’S DECLARATION

I hereby declare that the work, which is being presented in the project report in
partial fulfillment for the award of Degree of “Bachelor of Technology” in
department of Mechanical Engineering at GZSCCET, Bathinda, Punjab is a
record of my own investigation carried under the guidance of Er. Gurwinder
Singh (KARTAR CONSTRUCTION &CO.) in GURU GOBIND SINGH
REFINERY, HPCL-MITTAL ENERGY LIMITED,BATHINDA.

Signature:
Sahil

2
3
 ACKNOWLEDGMENT

I have taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organizations. I
would like to extend my sincere thanks to all of them.
I am highly indebted to Er. Gurwinder Singh for their guidance and constant
supervision as well as for providing necessary information regarding the whole
process in refinery
I would like to express my gratitude towards my parents & member of
GZSCCET, BATHINDA for their kind co-operation and encouragement
which help me in completion of this training
I would like to express my special gratitude and thanks to industry persons for
giving me such attention and time
I would also like to offer my sincere thanks to all those staff, officials
for their untiring support and help at various levels.

Name of student:
Sahil (1413808)

4
 CONTENTS

1. INTRODUCTION AND KEY ASSETS OF REFINERY 6

2. HOW REFININERY WORKS 8

3. CRUDE OIL COMPONENTS 10

4. FRACTIONAL DISTILLATION 12

5. CHEMICAL PROCESSING 14

6. ROLE OF MECHANICAL ENGINEERING IN REFINERY 17

7. PIPELINES 23

8. PROBLEMS RELATED TO PIPELINES 24

9. APPLICATION OF COMPRESSOR OIL & GAS REFINING 26

10.TROUBLESHOOTING COMPRESSORS SYMPTOMS 27

11.PRODUCTS 29

12.SOLID PRODUCTS 29

13.LIQUID PRODUCTS 32

14.SAFETY MEASURES 34

5
 INTRODUCTION AND KEY ASSETS OF REFINERY
HPCL-Mittal Energy Limited (HMEL) is a joint venture between Hindustan
Petroleum Corporation Limited (HPCL) and Mittal Energy Investment Pvt. Ltd,
Singapore. Both the JV partners hold a stake of 49% each in the company and the
remaining 2% is held by financial institutions. It is located in village Phulokhari,
Bhatinda, Punjab, India. Fifth biggest refinery in India.

The work for refinery started in 2008 and the refinery became operational in March
2012.[1] Its annual capacity is nine million tons (180,000 barrels per day).[2] It
was built at a cost of $4 billion.[3] The refinery will get its crude oil supply from
Mundra a coastal town in Gujarat through a 1,017 km pipeline, where the oil is
imported from abroad.[1]

Engineers India Limited (EIL) as the Project Management Consultancy (PMC) has
done Engineering (design), Procurement and Construction Management for the
entire job.[4]

HPCL-Mittal Energy Ltd (HMEL) owns and operates the Guru Gobind Singh
Refinery (GGSR) of 11.3 MMTPA capacity at Bathinda, Punjab. HMEL’s wholly
owned subsidiary, HPCL-Mittal Pipelines Limited (HMPL), owns and operates a
Single Point Mooring (SPM) for receipt of Crude Oil, Crude Oil Terminal (COT)

6
for storage of Crude Oil and 1017km cross country pipeline for transportation of
the crude from Mundra, Gujarat to the refinery at Bathinda.

The enormity of the Guru Gobind Singh Refinery project makes it the single
largest investment in the state of Punjab. It is the first oil and gas project to be set
up in the state. The refinery produces eight liquid product and three solid products
of EURO-IV specifications using world-class environment-friendly technologies.
The refinery is a zero-bottom plant, with a very high Nelson Complexity Index.

HMEL’s guiding beacon are its six core values which have helped build an
environment of trust, transparency and teamwork; growing from 25 employees in
2008 to present number of over 1200 committed employees with diverse
experience from over 150 leading organizations from India and abroad working
relentlessly towards our vision of being the best refining company in the world.

KEY ASSETS

Single Point Mooring (SPM): For handling VLCCs 7 km in the sea.

Crude Oil Terminal: 14 crude tanks of 60,000KL each & 4 blending headers.

Crude Pipeline: 1017 km underground pipeline sized to carry 18 MMT of crude.

Complex Refinery: Best in class refinery recently expanded to 11.3 MMTPA.

Captive Power Plant: Power plant with gross capacity of 165 MW.

Petchem. Complex: PP unit with design capacity of 440 KTPA (multiple

grades).

Township: Housing facility at Bathinda equipped with recreational facilities.

7
 HOW REFININERY WORKS

Crude Oil

Crude oil is the term for "unprocessed" oil, the stuff that comes out of the ground.
It is also known as petroleum. Crude oil is a fossil fuel, meaning that it was made
natural-ly from decaying plants and animals living in ancient seas millions of years
ago -- most places you can find crude oil were once sea beds. Crude oils vary in
color, from clear to tar-black, and in viscosity, from water to almost solid. Crude
oils are such a useful starting point for so many different substances because they
contain hydrocarbons. Hydrocarbons are molecules that contain hydrogen and
carbon and come in various lengths and structures, from straight chains to
branching chains to rings.\There are two things that make hydrocarbons exciting to
chemists: Hydrocarbons contain a lot of energy. Many of the things derived from
crude oil like gasoline, diesel fuel, paraffin wax and so on take advantage of this
energy. Hydrocarbons can take on many different forms. The smallest hydrocarbon
is methane (CH4), which is a gas that is a lighter than air. Longer chains with 5 or
more carbons are liquids. Very long chains are solids 5 like wax or tar. By
chemically cross-linking hydrocarbon chains you can get everything from synthetic
rubber to nylon to the plastic in Tupperware.

The major classes of hydrocarbons in crude oils include: Paraffins general formula:
CnH2n+2 (n is a whole number, usually from 1 to 20) straight- or branched-chain
molecules can be gasses or liquids at room temperature depending upon the
molecule examples: methane, ethane, propane, butane, isobutane, pentane, hexane.

Napthenes or Cycloalkanes general formula: CnH2n (n is a whole number usually

from 1 to 20) ringed structures with one or more rings rings contain only single

8
bonds between the carbon atoms typically liquids at room temperature examples:
cyclohexane, methyl cyclopentane.

Other hydrocarbons Alkenes general formula: CnH2n (n is a whole number,

usually from 1 to 20) linear or branched chain molecules containing one carbon-
carbon double-bond can be liquid or gas examples: ethylene, butene, isobutene
Dienes and Alkynes general formula: CnH2n-2 (n is a whole number, usually from
1 to 20) linear or branched chain molecules containing two carbon-carbon double-
bonds can be liquid or gas examples: acetylene, butadienesTo see examples of the
structures of these types of hydrocarbons, see the OSHA Technical Manual and
this page on the Refining of Petroleum.Now that we know what's in crude oil, let's
see what we can make from it.

9
CRUDE OIL COMPONENTS

On average, crude oils are made of the following elements or compounds:

Carbon - 84%

Hydrogen - 14%

Sulfur - 1 to 3% (hydrogen sulfide, sulfides, disulfides, elemental sulfur)

Nitrogen - less than 1% (basic compounds with amine groups)

Oxygen - less than 1% (found in organic compounds such as carbon dioxide,

phenols, ketones, carboxylic acids

)Metals - less than 1% (nickel, iron, vanadium, copper, arsenic)

Salts - less than 1% (sodium chloride, magnesium chloride, calcium chloride

From Crude Oil

The oil refining process starts with a fractional distillation column. The problem
with crude oil is that it contains hundreds of different types of hydrocarbons all
mixed together. You have to separate the different types of hydrocarbons to have
anything useful. Fortunately there is an easy way to separate things, and this is
what oil refining is all about.

Different hydrocarbon chain lengths all have progressively higher boiling points,
so they can all be separated by distillation. This is what happens in an oil refinery -
in one part of the process, crude oil is heated and the different chains are pulled out
by their vaporization temperatures. Each different chain length has a different
property that makes it useful in a different way.To understand the diversity

10
contained in crude oil, and to understand why refining crude oil is so important in
our society, look through the following list of products that come from crude oil:

Petroleum gas - used for heating, cooking, making plastics small alkanes (1 to 4
carbon atoms) commonly known by the names methane, ethane, propane, butane

Kerosene - fuel for jet engines and tractors; starting material for making other
products

Gas oil or Diesel distillate - used for diesel fuel and heating oil; starting material
for making other products

Lubricating oil - used for motor oil, grease, other lubricants

Heavy gas or Fuel oil - used for industrial fuel; starting material for making other
products

Residuals - coke, asphalt, tar, waxes; starting material for making other products

You may have noticed that all of these products have different sizes and boiling
ranges. Chemists take advantage of these properties when refining oil.

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 Fractional Distillation

The various components of crude oil have different sizes, weights and boiling
temperatures; so, the first step is to separate these components. Because they have
different boiling temperatures, they can be separated easily by a process called
fractional distillation.

The steps of fractional distillation are as follows:

1.You heat the mixture of two or more substances (liquids) with different boiling
points to a high temperature. Heating is usually done with high pressure steam to
temperatures of about 1112 degrees Fahrenheit / 600 degrees Celsius.

2.The mixture boils, forming vapor (gases); most substances go into the vapor
phase.

3.The vapor enters the bottom of a long column (fractional distillation column) that
is filled with trays or plates. The trays have many holes or bubble caps (like a
loosened cap on a soda bottle) in them to allow the vapor to pass through. They
increase the contact time between the vapor and the liquids in the column and help
to collect liquids that form at various heights in the column. There is a temperature
difference across the column (hot at the bottom, cool at the top).

4.The vapor rises in the column.

5.As the vapor rises through the trays in the column, it cools.

6.When a substance in the vapor reaches a height where the temperature of the
column is equal to that substance's boiling point, it will condense to form a liquid.
(The substance with the lowest boiling point will condense at the highest point in

12
the column; substances with higher boiling points will condense lower in the
column.).

7.The trays collect the various liquid fractions.

8.The collected liquid fractions may pass to condensers, which cool them further,
and then go to storage tanks, or they may go to other areas for further chemical
processing

9.Fractional distillation is useful for separating a mixture of * substances with

narrow differences in boiling points, and is the most important step in the refining
process.

Process of Fractional Distillation

13
 Chemical Processing

You can change one fraction into another by one of three methods:

1 breaking large hydrocarbons into smaller pieces (cracking)

2 combining smaller pieces to make larger ones (unification)

3 rearranging various pieces to make desired hydrocarbons (alteration)

Cracking

Cracking takes large hydrocarbons and breaks them into smaller ones.

Unification
Sometimes, you need to combine smaller hydrocarbons to make larger ones -- this
process is called unification. The major unification process is called catalytic
reforming and uses a catalyst (platinum, platinum-rhenium mix) to combine low

14
weight naphtha into aromatics, which are used in making chemicals and in
blending gasoline. A significant by-product of this reaction is hydrogen gas, which
is then either used for hydrocracking or sold.

Unification Process diagram

Alteration

Sometimes, the structures of molecules in one fraction are rearranged to produce

another. Commonly, this is done using a process called alkylation. In alkylation,
low molecular weight compounds, such as propylene and butylene, are mixed in
the presence of a catalyst such as hydrofluoric acid or sulfuric acid (a by-product
from removing impurities from many oil products). The products of alkylation are
high octane hydrocarbons, which are used in gasoline blends to reduce knocking.

Rearranging Chains

15
Treating and Blending the Fractions

Distillated and chemically processed fractions are treated to remove impurities,

such as organic compounds containing sulfur, nitrogen, oxygen, water, dissolved
metals and inorganic salts. Treating is usually done by passing the fractions
through the following:

a column of sulfuric acid - removes unsaturated hydrocarbons (those with carbon-

carbon double-bonds), nitrogen compounds, oxygen compounds and residual
solids (tars, asphalt) an absorption column filled with drying agents to remove
watersulfur treatment and hydrogen-sulfide scrubbers to remove sulfur and sulfur
compounds

After the fractions have been treated, they are cooled and then blended together to
make various products, such as:gasoline of various grades, with or without
additiveslubricating oils of various weights and grades (e.g. 10W-40, 5W-30.

Kerosene of various various grades:

1. Jet fuel
2. diesel fuel
3. heating oil
4. chemicals of various grades for making plastics and other polymers

Mechanical components used

1 COMPRESSORS
2 HEAT EXCHANGERS
3 TURBINES
4 PIPELINES

16
 ROLE OF A MECHANICAL ENGINEER IN AN REFINERY

During the construction of the plant, mechanical engineers are responsible for the
mechanical equipment and components within the plant. This includes vessels
(tanks, reactors, pressure vessels, boilers), machinery (pumps, compressors, fans,
blowers, packaged equipment), and piping.

The responsibilities typically include:to ensure the equipment is erected, pre-

commissioned, tested (if required) and commissioned in accordance with agreed
contracts. Coordination with equipment suppliers is important task during
construction.Resolve with the suppliers, clients if there are any non-confirmities
noticed while discharging the above duty.

TURBINE ROTOR PROBLEMS AND SOLUTION

Steam turbine rotors bend during operation, but the bearing and supports are
designed to keep the static and dynamic forces under control. However, bending
can cause impact between stationary and rotating parts—often cascading impacts.
An operator of many utility-scale steam turbines shares its extensive field
experience identifying the root cause of failures as well as successful solutions.

Rotor bending that results in premature failure of steam turbine blades and other
internal components is one of the most serious problems experienced in power
plant operations. The problems often reduce plant availability by limiting
generation and increase plant operation and maintenance cost. Extreme rotor
bending problems often involve interaction between the turbine’s rotor and
stationary parts. Rotor bending may be caused by a variety of static and dynamic
factors, many of which will be explored in this article.

17
We begin with mechanical factors related to the rotor, the largest rotating assembly
in the turbine. Working from the inside out, we next look at rotor balance issues,
followed by rotor and casing misalignment problems, and problems caused by the
casing.

Avoid Rotor Rubs

It almost goes without saying that rubbing in the labyrinths or diaphragms, caused
by insufficient clearances, disrupts the end sealing of the rotor. This situation
commonly occurs when the high-mass rotor at operating speed comes in contact
with a stationary surface, typically caused by a too-small clearance between the
labyrinth or diaphragm gland seals and the rotor. Secondarily, there may be a
localized temperature increase at the point of contact, causing increased metal
temperatures at the point of contact due to friction.

The forces produced by the impact of the large rotating rotor mass with the poorly
functioning stationary seals often impress a layer of metal on the surface of the
rotor. The rub can cause elastic deformation of the rotor at the point of impact and
temporary rotor shaft bending. The shaft bending will usually cause increased
vibration levels (Figure 1).

1. Blade rubs cause bending. Rubbing in the sealing of a high-pressure rotor of a

300-MW unit caused bending of this rotor and blade tip rubs. Courtesy: Ahwaz
Power Generation Management Co.

Uneven cooling of the rotor, particularly after shutdown, also causes the rotor to
contact stationary parts. After a unit shuts down, the relatively high-temperature

18
rotor may bend solely due to the mass of the rotor and the distance between
bearing supports, if left in a stationary position to cool.

The effect of a permanent shaft bend caused by uneven cooling will immediately
appear as high rotor vibration at the next startup. The vibration is caused by
insufficient clearance between stationary and rotating parts, as well as a shaft
located off-center in its bearing. Even if the clearance change is small, there may
be significant rubbing along the rotor to cause damage. Again, the rubbing causes
friction between stationary and rotating parts, localized heating of the rotor metal
at the contact point, and shaft bending.

Furthermore, uneven shaft warming caused by rubbing between rotating and

stationary parts can cause further bending of the shaft in the same direction of the
existing bow and cause additional contact with stationary parts, increasing
temperatures and therefore causing more bending. The effect cascades if allowed
to continue. If the bending is allowed to continue, it is possible that the yield
strength of the metal could be exceeded, causing a permanent deformation of the
shaft. The allowed bending in 3,000-rpm turbines is up to 0.02–0.03 mm in each
section. When on turning gearing, the limit is 0.05 mm.

To avoid rotor bending during cooling, turbine vendors provide very specific
instructions on the allowable rate of cooling. For example, the turbine should
remain on turning gear until the high-pressure (HP) cylinder temperature is below
150C and the oil temperature is below 75C. The turbine vendor also defines the
rotational speed of the turning gear.

Misalignment of the coupling between two shafts or between a shaft and bearing
may cause bending in the system. Misalignment between two shafts of an

19
integrated rotor can cause an eccentricity of the mass center of the rotor, and this
eccentricity at high rotational speed will produce a centrifugal force in the radial
direction, causing bending of the rotor. Misalignment between the axis of rotation
and the axis of the shaft can also cause bending in the rotor. There are six primary
factors that can cause misalignment.

A poor connection between the turbine casing and the bearing pads on the
foundation frame is one cause. If a pad experiences increased friction or stops
sliding during thermal expansion (usually during startup) in the axial direction, the
result is a tipping torque on the casing. This torque can cause a misalignment
between the casing and bearing surface, causing vibration in the forward end of the
turbine, foundation frame surface support deformation, and bearing pad stall.

Also pay close attention to the foundation frame—including bolts, keys, and
pads—so that free movement of the bearing surfaces is possible, particularly while
undergoing startup and load changes. The extent of the longitudinal and lateral
thermal expansion bore centers of the cylinders and pad travel should be recorded
for future comparisons. This process should be part of routine maintenance
equipment inspections.

Another factor concerns the difficulty in assembling the HP turbine front bearing.
While the shaft is rotating in its journal bearing, the shaft pushes oil from the
bottom of the bearing, causing the oil film thickness to change. When this happens,
the centerline of the shaft moves up and to one side. To account for this shaft
movement, the segmented bearing should automatically adjust and the contact
surface of the journal bearing will remain in a good position. If there is too much
contact surface, friction will increase on the bearing surface, causing increased

20
rubbing and corrosion of the bearing surface and increasing vibration and rotor
eccentricity. The result will be bearing oil leakage and rubbing in the sealing
glands. On the other hand, if the bearing contact area decreases, the oil film will
cause uneven movement of the rotor within the segmented bearing, and the oil film
will not form, also resulting in increased vibration (Figure 2).

Steam turbine rotor vibration

2. Shaft must stay centered. Relocation of shaft center in a segmented bearing

while rotating can cause vibration. Courtesy: Ahwaz Power Generation
Management Co.

Don’t overlook the concentricity of the rotor with the bores and couplings. Correct
rotor alignment is lost when the axis of one rotor is not continuous with the rotor in
the following casing, in multi-casing steam turbines. The individually connected
drivelines must operate as one long continuous, yet flexible driveline. After major

21
steam turbine maintenance, it is important to confirm the alignment of the rotor to
the couplings as well as any other factors that may cause change to the primary
positions of individual casings, bearing, and rotors. During maintenance, if rubbing
is observed at the end or intermediate sealing of the rotor or eccentricity of
couplings, it is necessary to realign the driveline to avoid high turbine vibration,
contact and rubbing of glands or labyrinth seals, and so on (Figure 3).

Steam turbine rotor vibration

15.Properly align the diaphragms. The diaphragms must be carefully aligned to

the shaft centerline within the casing of this 315-MW turbine to avoidcontact
with the rotor blades. Courtesy: Ahwaz Power Generation Management Co.

22
 16.Remember that the axis from the center of the gland’s bore should coincide
with the axis of the turbine rotor during normal temperatures experienced
during turbine operation. Furthermore, it is essential to quickly identify any
loss in sealing clearances during steam turbine warm-up. Changes in
clearance may occur during warming that could cause bending of the
cylinders due to differential temperatures between the upper and lower
sections of the cylinder.

PIPELINES
Pipe is a pressure tight cylinder used to convey a fluid or to transmit a fluid
pressure, ordinarily designated pipe in applicable material specifications.Materials
designated tube or tubing in the specifications are treated as pipe whenintended for
pressure service.

Piping is an assembly of piping components used to convey, distribute,

mix,separate, discharge, meter, control or snub fluid flows.Piping also includes
pipe- supporting elements but does not include support structures, such as
buildingframes, bents, foundations, or any equipment excluded from Code
definitions.

Piping components are mechanical elements suitable for joining or assembly into
pressure-tight fluid-containing piping systems.Components include pipe, tubing,
fittings, flanges, gaskets, bolting, valves and devices such as expansion joints,
flexible joints, pressure hoses, traps, strainers, in-line portions of instruments and
separators.

23
PROBLEMS RELATED TO PIPELINES

- Corrosion
- Dents and gouges
- Buckling
- Stress corrosion cracking
- Slugging
- Plug formation
- Unpiggable pipelines
- Leaks
- Remaining strength of corroded pipe / maximum operating pressure
- Oil theft & hot tapping
- Pollution & oil spills
- Pipeline repairs/ live welding
- Utility pigging\
- Pipeline reduced flow due to deposit of wax from waxy crude
oil
-
THE MAIN REASONS OF THE PROBLEMS ARE

1 Water content in the flow with respect to temp and pressure.

2 The type of the metals used in pipeline with respect to the flow.

3 Pressure and temperature must be optimized to avoid many problems.

24
4 Area (diameter) it’s concerned in the design but it must recalculated if a plugging
or normal life time corosion is happend.

5 Momentum transfer calculation must be so accurate because mistake could

destroy all the pipeline.

6 Start and shutdown , it’s so important becease it could resulte an entire damge to
the pipeline by plugging or other problem specialy when the pipeline is started to
work.

25
 Application of Compressor Equipment in Oil & Gas Refining

Compressors constitute an important part of the mechanical equipment in oil and

gas refineries and petrochemical plants. Compressors are used for different
applications in the main and auxiliary process cycles:

Recycling compressors designed to provide a steady flow of process gas through a

closed circuit in order to maintain the required process parameters in the plant units
(for example, hydrogen-rich gas recycling in a hydrotreater)

Feed compressors supplying process gas to reactor

Booster compressors

Sales gas compressors (for example, methane).

Electrically-driven reciprocating and centrifugal compressors are most commonly

used in oil and gas refining facilities.

26
 Troubleshooting Compressors Symptoms And Possible Cause(s)

1.Failure to deliver output

-Excessive clearance between vanes,

- lobes or screws (rotary compressors).

-Worn or broken valves and/or defective unloader(s) (reciprocating compressors).

2 .Insufficient output or low pressure –

Restricted or dirty inlet filter.

-Excessive leakage (air system).

-Inadequate speed. –

Worn or damaged piston rings (vanes, lobes or screws on rotary systems).

-System demand exceeds capacity. -Worn valves or defective unloader(s).

3.Compressor overheats

-Carbon deposits on discharge valves.

-Excessive discharge pressure.

-Worn or broken valves.

-Excessive speed.

-Inadequate cooling.

-Dirty cylinder water jackets.

27
-Inadequate cylinder lubrication.

-Defective unloader(s)

4.Compressor running gear overheats

-Inadequate lubrication.

-Excessive drive belt tension (where used).

-Excessive speed.

-Excessive discharge pressure.

-Worn or damaged rotating components (rotary compressors) . -Excessive

discharge pressure.

5.Compressor knocks

-Inadequate lubrication.

-Insufficient head clearance

. -Excessive crosshead clearance.

-Loose piston rod(s).

-Excessive bearing clearance.

-Loose or damaged piston(s)

28
 Products

 Solid Products

1.Polypropylene (PP)

As part of the Refinery project, HMEL has setup a Polypropylene Unit (PPU),
utilising Novolen® Gas-phase polypropylene process, with a production capacity
of 4,40,000 MT/annum of Homo-Polymer Polypropylene. HMEL is producing
entire range of PP Homo-Polymers, to service the demand of customers from all
application segments.

HMEL’s PP Unit is integrated with its world class Refinery, ensuring feedstock
security at all times.

In addition to the World class technology, HMEL is implementing Best industry

practices, in all aspects of our businesses. We are setting up a state of the art R&D
and Testing facility, to ensure continuous improvement in our product and to
support application development initiatives for customers.

Polypropylene is one of the fastest growing polymers, with worldwide growth

forecast at 5-6% annually in the near foreseeable future. It is expected to grow at
twice the rate of growth of the GDP.

29
 Higher growth of PP can be attributed to the ability of Polypropylene to replace
the conventional materials (such as paper, wood, glass, metal etc.) and some other
polymers, by demonstrating equal or better properties and at a lower cost. It is the
lightest of the widely used thermoplastics with specific gravity of less than one. It
has no taste or odour and is non toxic. Polypropylene is the most versatile of all
thermoplastic polymers, with following characteristics:

 Lowest density of all major thermoplastic polymers, which makes it a preferred

material on overall economics, and being light weight
 Excellent chemical resistance for packaging applications such as cosmetics,
medical use, caps and closures
 Good stiffness suitable for applications like furniture, containers and thin-wall
packaging
 High transparency, for film applications
 Good impact strength suitable for technical applications, such as in automotive
and appliances applications
 Good heat resistance suitable for hot & cold water piping applications
 Low water absorption suitable for hygiene and geo-textile applications
 Good moisture barrier suitable for packaging of hygroscopic & food products
 Good Stretchability for high tenacity fibres, nonwoven fabric and tape yarns, and
biaxally oriented film for flexible packaging, adhesive tape and lamination.

30
2. Petcoke

Our refinery’s state of the art Delayed Coker Unit (DCU) produces high sulphur
Petroleum Coke (Pet Coke) which is the carbonaceous solid residue remaining
after the distillation of petroleum materials. Pet coke has more than twice the
calorific value of coal and is widely used as an alternative to coal in power plants,
cement kilns and blast furnaces.

3. Sulphur

Our Sulphur Recovery Unit (SRU) produces Sulphur in powder and lump form.
Maximum usage of Sulphur is for production of Sulphuric Acid which is widely
used as a raw material for producing phosphatic and nitrogenous fertilizers. In raw
form Sulphur is also used in explosives, sugar industry, match sticks etc.

31
  Liquid Products

1. LPG

Our Bathinda refinery is designed to deliver a high yield of the environment

friendly fuel Liquid Petroleum Gas (LPG) to cater to both the domestic and
commercial demand in the northern region of the country.

2. Specialty Grades

Our special products portfolio includes Premium Grade Mineral

Turpentine Oil (MTO) that meets the stringent norms set by major paint
manufacturers and Food Grade Hexane that meet the requirements of
sensitive industries like Pharmaceuticals.

32
3.Aviation Fuel

Our Refinery is capable of producing Aviation Turbine Fuel for use by

the Indian Aviation Industry. Aviation fuel will be marketed with the
help of HPCL to aerodromes and airfields in the northern region.

33
 SAFETY MEASURES
GENERAL SAFETY REGULATIONS:
Because of hazardous nature of operation in the refinery, which handles large
volume of hydrocarbons of extreme inflammable nature a comprehensive safety
system has been put together to take care of in emergency. Some of the salient
features of the safety system is as follows:
1. SIREN SYSTEM:
In case of any emergency the same is communicated through sirens of three
different types.
2. Major fire: a wailing type siren, shall be blown for two minutes at a stretch.
3. Disaster: three times wailing type siren with a gap of one minute in between.
4. All clear: two minute straight siren.
2. 15
Some items, which have been identified to have potential risk for
battery area operations have been banned in the operational area. These
are:
5. Matchbox
6. Lighter
7. Mobile phones
8. Laptop
9. Pen drives
Apart from the above, all people working inside the operational area are
compulsorily required to wear helmets and safety shoes.

PREVENTIVE ACTION AGAINST DAMAGE BY CHEMICALS:

10.Inside the battery area of individual units visual boards have been erected
with MSDS(material safety datasheet) of relevant chemicals written on
them.

34
11.Operators handling corrosive chemicals are provided with PVC jackets and
gum boots.

12.Safety showers have been provided near all major chemical handling areas.

FIRE WATER NETWORK:

13.The total fire water network is designed as per OISD(oil industry safety
directorate) 117 norms.

14.Maintenance of 7 kg/sqcm gauge pressure is ensured in the fire water

network for which pressure gauges have been provided at different locations.

15.To take care of power failure emergency, apart from electrical motors two
diesel operated jockey pumps have been provided in the fire water network.

16.Fire water sprinklers have been provided in identified areas like hot pumps,
hydrogen bullets, and LPG Horton spheres. These are automatic water spray
systems actuated by heat detection.

FIRE FIGHTING MEASURES:

Panipat refinery’s fire fighting system is designed to handle two simultaneous

major fires and for these following arrangements have been made:

17.Mobile equipments: foam tenders (7 numbers), foam nurser (4 numbers),

DCP tender (2 numbers), emergency rescue tender(1 number), hydraulic
platform(1 number), rim seal protection in all floating group tanks.

18.Automatic hydrocarbon detectors near identified equipments handling very

volatile hydrocarbons.

19.Hydrant risers at all technological platforms.

20.HVLR (high volume long range monitors) in units of various capacities

(750/1000/2000/4000 GPM).

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 SAFETY PREPAREDNESS:

21.Toxic gas detectors in units as per OISD and licensor guidelines.

22.Low temperature gas tight suits for handling cryogenic substances.

23.Regular mock drills, both onsite and offsite.

24.Compulsory fire fighting training for all employees, both at induction level
as well as at mid job level.

25.Regular touch with mutual aid partners i.e. other industries in the vicinity
and fire brigade of local administration.

26.Emergency exits at different locations as per guidelines of external safety

audit committee.

27.Assembly points at different locations for gathering of employees under

emergency situations.

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28.Imparting safety training- both operational and shutdown safety-to all
contractor personnel and truck drivers.

MOTIVATION FOR ADHERING TO SAFETY NORMS:

29.Monthly awards to maximum near-miss incident reporters.

30.Regular hosting of safety quizzes.

31.Hosting of Safety slogans and safety poster making competitions.

Make safety a habit

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