OIL & NATURAL GAS CORPORATION

LTD. KDMIPE, ONGC ACADEMY

DEHRADUN

BY.
SKAND KUMAR
B.TECH. (MECHANICAL ENGINEERING)
HERITAGE INSTITUTE OF TECHNOLOGY
KOLKATA

MENTORED BY: THANKS TO:

Mr. AKSHAY CHAUHAN Mr. VIVEK MALVIYA
The training opportunity I had with ONGC ACADEMY, DEHRADUN was a great
chance for learning and professional development. Therefore, I consider myself as a 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 training period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to my Mentor Mr. Akshay Chauhan sir 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 my project at their esteemed organization and
extending during the training.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to

Mr. Jagtar Singh sir for his careful and precious guidance which were extremely
valuable for my study both theoretically and practically. Thanks a lot sir once again for
the important learning you gave me.

I express my deepest thanks to Mr.Vivek Malviya Sir, [Chief Engineer] for giving
necessary advice and guidance and arranged all facilities to make life easier. I choose this
moment to acknowledge his contribution gratefully.

I perceive as this opportunity as a big milestone in my career development. I 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 !!

The Industrial Training is an important part of Engineering Course and
Curriculum. This not only provides students the oppurtunity to interact
with the professionals but also helps in acquiring sufficient working
knowledge in the respective fields. It gives a long lasting experience.It is
an oppurtunity to engage with the profession to which we aspire in a
realistic work environment; appreciate and understand the practical
application of the academic program; work with professional mentors
and begin to build networks within their profession !!!
In 1955, Government of India decided to develop the oil and natural gas resources in the
various regions of the country as part of Public Sector development. With this objective,
an Oil and Natural Gas Directorate was set up in 1955 under the then Ministry of Natural
Resources and Scientific Research. The department was constituted with a nucleus of
geoscientists from the Geological survey of India.

A delegation under the leadership of Mr. K D Malviya , the then Minister of Natural
Resources, visited several countries to study the oil industry and to facilitate the training
of Indian professionals for exploring potential oil and gas reserves. Foreign experts from
USA, West Germany, Romania and erstwhile USSR visited India and helped the
government with their expertise. Finally, the visiting Soviet experts drew up a detailed
plan for geological and geophysical surveys and drilling operations to be carried out in
the 2ndFive Year Plan (1956-57 to 1960-61).

In April 1956, the Government of India adopted the Industrial Policy Resolution, which
placed mineral oil industry amongst the Schedule 'A' industries, 20the future development
of which was to be the sole and exclusive responsibility of the state.

Soon, after the formation of the Oil and Natural Gas Directorate, it became apparent that
it would not be possible for the Directorate with limited financial and administrative
powers to function efficiently. So in August, 1956, the Directorate was raised to the status
of a commission with enhanced powers, although it continued to be under the government.
In October 1959, the Commission was converted into a statutory body by an act of
Parliament, which enhanced powers of the commission further. The main functions of the
Oil and Natural Gas Commission subject to the provisions of the Act, were "to plan,
promote, organize and implement programmes for development of Petroleum Resources
and the production and sale of petroleum and petroleum products produced by it, and to
perform such other functions as the Central Government may, from time to time, assign to
it. The act further outlined the activities and steps to be taken by ONGC in fulfilling its
mandate.

ONGC - The Largest Energy Company in India

This Public Enterprise Represents India's Energy Security Through its Pioneering Efforts.
Maharatna ONGC is the largest crude oil and natural gas Company in India, contributing
around 70 per cent to Indian domestic production. Crude oil is the raw material used by
downstream companies like IOCL, BPCL, and HPCL to produce petroleum products like
Petrol, Diesel, Kerosene, Naphtha, and Cooking Gas-LPG.
This largest natural gas company ranks 11th among global energy majors (Platts). It is the
only public sector Indian company to feature in Fortune’s ‘Most Admired Energy
Companies’ list. ONGC ranks 18th in ‘Oil and Gas operations’ and 183rd overall in
Forbes Global 2000.
Acclaimed for its Corporate Governance practices, Transparency International has ranked
ONGC 26th among the biggest publicly traded global giants. It is most valued and largest
E&P Company in the world, and one of the highest profit-making and dividend-paying
enterprise.
A central heating ventilation and air conditioning system has been installed at KDMIPE
complex , Kaulagarh Road, Dehradun, to cater to the year round environmental control
need for human comfort and equipment requirements at new computer centre Building,
Lab Blocks and Mini Auditorium.

The above system is further divided into two parts. The first
consisting of one No. 575 TR Centrifugal chilling machine cater exclusively to the New
Centre Building, whereas the second 575 TR Centrifugal chilling machine is meant for
various selected areas of Lab Blocks and Mini-Auditorium.Both theses systems can be
operated independent of each other and are complete in themselves.

The System meant for New Computer Building has centrifugal

chilling unit for full load operation during day time and reciprocating machines are meant
for emergency operation and should be used for only computer hall on first floor of
N.C.C. building. These reciprocating machines can also be used for overnight operation
or emergency operation through generator when power supply goes out. In total there are
twenty five Air Handling units serving different areas of New Computer Centre Building.
Out of these four Air Handling Units meant for Computer Hall are equipped with
pre-heaters and pan humidifiers for humidity control and fine for clean supply air. These
accessories render the system more suited to special requirements of Computer Hall.

Besides in computer hall temperature and relative humidity sensors

have also been provided as a extra warning systems.

As load in computer hall may sometimes require cooling even in

winters,we have abstained from utilizing reverse cycle operation . Instead , strip heaters
have been provided in every Air Handling Unit for winter heating. In short the full system
is quite versatile and is desired to look after all possible fluctuations and safety
requirements.
 Similarly the second system for lab blocks and Mini auditorium ,
consists of a single 575 TR nominal capacity centrifugal water chilling machine wit
provision for a standby unit which can be installed in future.

It feeds chilled water into twenty four Air Handling Units installed in lab
blocks and Mini Auditorium. The chilled water pipeline for both the plant has been
designed on reverse return system for auto balancing in various Air Handling Unit of any
riser. To cater to special equipment requirements on A.H.U. installed on Lab 4 first floor
is equipped with fine filters installed in supply air duct. Unlike previous system it is
achieved winter heating for this system by reverse cycle operation.

For both the above systems a centralized control-cum-indicating panel has been installed
in service block. This enables the operator to :

(a) Switch on-off any air handling unit from service block itself.

(b) Switch on-off heaters in AHU of Computer Centre Building.

(c) Monitor Computer Hall temperature and relative humidity.

(d) Note fault indication of all chilling machines.

COMPONENTS IN AIR CONDITIONING PLANT :
As the name suggests the basic function of this centrifugal water chilling machine is to
cool water being circulated in chilling water lines, while employing a centrifugal
compressor.
The centrifugal compressor being utilized for our system is an open type
single stage compressor with capacity control through inlet folding vanes. It is employed
to compress the refrigerant sucked from evaporator of the chilling unit .

Below the compressor is located a huge Shell Housing the condensor in

upper portion and evaporator in lower half. The compressed refrigerant being fed in the
condensor is water cooled there and is brought in liquid form. In our condensor the
refrigerant flows in the shell and whereas water circulates through tubes of this shell and
tube heat exchanges ( condensor effectively is a form of heat exchanger). However to
prevent hot gas to come in direct contact with water cooled tubes a baffle plate has been
installed at gas inlet.

The unit cooler (Evaporator) is of the horizontal shell and tube type. It
is divided into two sections by the partition plate of the unit cooler. From condensor,
liquid refrigerant flows to evaporator through a float valve . This float valve maintains
liquid level in the evaporator.

To maintain safety operation our machine has been provided with

following safety devices :
(a) Low chilled water cut out and indication.
(b) Low oil pressure cut out and indication.
(c) Low evaporator pressure cut out and indication.
 (d) High condensor pressure cut out and indication.
(e) Oil heater temperature control.

These are similar in function to centrifugal water chilling machines described above
except for some constructional deviations. Here we are employing reciprocating
compressor instead of centrifugal decribed before.

Each chilling unit consists of :

i. One No. AC-1670 Compressor :

It is a direct driven open type open type reciprocating compressor employing

sixteen cylinders to continously compress R-22 refrigerant . It employs forced lubrication
system and has a separate oil pump to achieve this objective.

ii. One no. 150 H.P. Motor :

The above motor is operated through a KILBURN AT-15 auto-transformer starter

and is directly coupled to the compressor.

iii. One No. DXC-2410 Shell and tube , direct expansion type chiller :

The compressed gas is first cooled and liquified in condensor before being sent in
chiller through expansion valve.The above refrigerant gas thus vaporises in chiller and
draws away heat from water being circulated in the shell thus cooling the same.

iv. One No. CDS-1610 Shell And Tube Condensor :

As expained earlier compressed gas is liquified (thus rejecting heat) in condensor. It

employs water cooled in cooling tower to transfer this heat to atmosphere. In reverse
cycle operation in winter , this outing water is being used to heat up air being
supplied to conditioned areas.

For circulating chilled water between chiller to cooling coils and back in
summer for both system and condensor water between condensor to cooling coils and
back during winter five no chilled water pumps have been provided. Chilled water pump
number, 1 to 3 are 6 UP4M Model Kirloskar make directly coupled to 100 H.P. EFC
SIEMEN induction motor. Whereas pump No. 4 &5 are 4UP3 Model Kirloskar make
directly coupled to 50 H.P. TEFC SIEMEN induction motor.

Chilled water pump number one is meant for Lab centrifugal water chilling
machine. Similarly chilled water pump number thre is meant for N.C.C. centrifugal water
chilling machine. Pump No. Two acts as standby and can be used in anyone of these
circuits after shuting off gate valves for isolating it from other chilled water circuit.

As for New computer centre the centrifugal water chilling machine and
reciprocating water chilling machines are installed paralled to each other with common
heador. It is necessary that the chilling machine which is not working should be isolated
from circuit immediately on switching off of the connected pump.Otherwise it may result
in pump motor overloading for other pumps besides reduced efficiency of water chilling
machine.

For circulating condensor water between condensor to cooling tower and back in
summer and chilled water between chiller and cooling tower in water during reverse cycle
operation (possible for Lab Water Chilling machine only), five Nos. Condensor water
pumps have been installed .
Condensor water pump No. 1 to 3 are 8UP2M Model Kirloskar make directly
coupled to 120 H.P. TEFC SIEMEN induction motor. Whereas pump No. 4 &5 are 4UP3
model Kirloskar make directly coupled to 50 H.P. TEFC SIEMEN induction motor.
 Condensor water pump No. One is meant for Lab centrifugal water
machine. Similarly condensor water pump no three is meant for N.C.C.
centrifugal water chilling machine. Pump No. two acts as a standby and can be used in
any one of these condensor water circuits after isolating it from other circuit. Condensor
pump No. 4 & 5 are meant for two reciprocating water chilling machines (one pump
serves one 120 TR chilling machine) .

For effective heat transfer to atmosphere from chilling unit , five Nos. Induced
Draft 300 TR capacity FRP , `PAHARPUR` make cooling Towers have been installed. In
summer season these cooling tower cool down condensor water by evaporation and heat
incharge , whereas , in winter , they heat up chilled water coming from chillar(only in
case of reverse cycle system).

Each cooling tower employes a No. Of fins spraying nozzles for

water spraying and one no. fan for including air circulation. For better contact between
water and air , water flowing down is slowed by no. of filter PVC eliminator housed in
the FRP box.

In Our system cooling tower no1 serves both the reciprocating

units,cooling tower no. 2 & 3 serves N.C.C. , centrifugal water chilling machine and
cooling tower no. 4 and 5.serves S and T centrifugal water chilling machines.

For effective chilled water and condensor water circulation from chiller to
cooling coil and back and from condensor to cooling tower and back , M.S. “C Class
piping has been installed. All these pipe has been properly sized to have a smooth and
noiseless water flow. Besides , to prevent any heat loss from water flowing in these pipes
to atmosphere, thermocole insulation as per specification has been wrapped on them.
 To ensure that water going in vital equipment e.g. condensor , chiller ,cooling coil and
pump is free of pebbles and big dust particles , Y-Strainers and pot strainers have bee
installed in our water piping , before condensor and chiller pump in and cooling coils .

Each air -handling unit consists of three basic parts:

i. Fan Section : Housing the forward curved centrifugal blowers ensures required flow
of air through the cooling coil to various conditioned space and back.
Coil Section : Houses the cooing coil through which cold/hot water is circulating. This
in turn is utilized to pre - condition mixture of fresh air and return air before sending
the same to individual rooms.
Filter Section : As the name suggests filters off air before circulation .

In total 47 A.H.U`s . 23 serving N.C.C. , 22 serving Lab blocks and 2 serving Mini
Auditorium has been installed .

(I)

G.I. sheet metal ducting has been installed to effectively distribute conditioned air to
various areas being served by any AHU as per their load rquirement. All ducting has been
properly sized to achieve the optimum conditions. Besides Duct dampers/splitter dampers
and Diffuser dampers have also been installed to very air-flow in any specific area as per
requirement.

Thermostat is one of the basic control device used in any air-conditioning

application. It senses Temperature of fluid and accordingly gives on/off signals to various
auxilliary equipment .
 For capacity control of reciprocating compressor , thermostat senses chiller
out temperature and actuates solenoid valve which in turn offloads/onloads compressor .

Similarly in AHU `s another thermostat senses return air temperature coming

back from conditioned space and actuates modulating motor which in turn diverts water
cooling coil of that AHU.

Similarly safety thermostats and anti-freeze thermostats are utilized to cut off
power supply to equipment when a particular preset temperature is reached in any
particular area.

Humistat is used to sense humidity in any system/area and accordingly give

control signal to Humdification/ dehumidification equipment .

In our plant there are 2 humidistats in four AHU `s serving computer hall (Two
in each AHU). A the humidity decreases below a preset value one humidistat switches on
the Pan Humidifier thus adding steam in return air to increase relative humidity (R.H.).
Similarly when humidity increases above a preset value other humidistat switches on
preheaters in supply air which in turn indirectly decreases R.H. in conditioned space.

(L) :

Designed for maximum heat transfer efficiency , cooling coil made of copper
tubes are housed in an angle frame and have 12-14 aluminium fins per inch. These
effectively precondition fresh air and return air mixture before the same is circulated in
any conditioned space.
 (M)

There is also a provision of fire safety system to prevent damage in case of

fire. This is achieved by shutter type fire - dampers , which in case of fire shall
completely isolate our AHU Rooms from other areas . Each fire damper has been fitted
with a fusible plug which melts thus shutting the damper and one no. Micro-switch to cut
off power supply to blower as soon as the damper shuts off.

(N)

In climate like Dehradun where winter temperature is around 7-8 degree

Celsius , winter heating can be achieved by Reverse Cycle Operation of chilled water
system . In this system during water season , we divert hot condensor water to cooling
coils for heating air being set in conditioned space.
Similarly chilled water from chiller is diverted to cooling tower for gaining heat from
atmosphere . But as per law of thermodynamics .

 ( coeffiecient of performance ) Heat Engine = 1+ Co-effiecient of performance

Refrigeration

The heating capacity of these units is always more than the cooling capacity . We suggest
run two or more no. of cooling towers for each chilling unit during winter. As pointed out
earlier this system has been provided for lab block and Mini Auditorium only.
 SERVICE BLOCK LAY OUT
VOLTAS UNIT NO.3 150 H.P. 188 Amps
CHILLED WATER PUMP NO.3 120 H.P. 155 Amps
CONDENSOR WATER PUMP NO.2 100 H.P. 135Amps
CONDENSOR WATER PUMP NO.3 100 H.P. 135Amps
COOLING TOWER FAN MOTOR NO.1 10 H.P. 14.5Amps
COOLING TOWER FAN MOTOR NO.2 15 H.P. 14.5Amps
VENTILATION FAN MOTOR 25 H.P. 37 Amps
VOLTAS UNIT NO.4,5,6,9&10 750 H.P. 940 Amps
(150 H.P.EACH)

TOTAL 1619 Amps

 Actual load not more than 1055 Amps.

1. CENTRIFUGAL WATER CHILLING UNIT :

i. Clean unit of all dirt and oil.

ii. Check for any unusual noise or vibration.
iii. Check various log book parameter are within recommended range.
iv. Check bearings.
v. Check operation of float valve.

2. RECIPROCATING WATER CHILLING MACHINE

i. Clean unit of all oil and dirt.

ii. Check manufacturing due to lubrication.
iii. Check for unusual noise and vibration.
iv. Observe compressor and motor bearing temperature.

3. PUMPS

i. Check for any unusual noise and vibrations

ii. Check mechanical seal leakage.
iii. Check/lubricate bearings.

4. AIR HANDLING UNITS

i. Check belt tension , damper opening and shaft rotation.

ii. Check temperature in various user`s areas and record the same.
5. PIPING AND OTHER CONNECTED EQUIPMENT

i. Check water level in expansion tanks, cooling tower etc. and fill them.
ii. Check position of various valves.
iii. Purge entrapped air , if any.
iv. Check operation of cooling tower fan motor including current drawn.
v. Check valve gland for leakage.

1. CENTRIFUGAL WATER CHILLING MACHINE

i. Lubricate all motor bearings and compressor coupling.

ii. Check operations of various controls and interlocking of various equipment.
iii. Clean oil strainers.
iv. Send condensor ,chilled and liquid resistance starter wwater samples for chemical
analysis.
v. Check oil heater continuity.

2. RECIPROCATING WATER CHILLING MACHINE

i. Check condition and alignment of compressor coupling and leakage through shaft
seal.
ii. Lubricate all bearings.
iii. Clean oil and liquid line strainer and expansion valve,if needed.
iv. Send condensor and chiller water for chemical analysis.
v. Tighten various foundation bolts.

3. PUMPS

i. Check alignment and condition of drive to prevent damage to shaft.

ii. Lubricate all bearings and check for any possible damage.
iii. Tighten various nut-bolts.
4. AIR HANDLING UNITS

i. Lubricate motor and AHU bearings.

ii. Clean all filters.
iii. Check pulley alignment.
iv. Check all fusible plugs and operation of dampers.
v. Tighten blowers on shaft and check for shaft slippage in bearings.

5. PIPINGS AND OTHER CONNECTED EQUIPMENTS

i. Check flow switch operation.

ii. Clean all pot strainers and flush pipe lines.
iii. Clean cooling towers basins.
iv. Check valves for gland leakage.
v. Tighten all flanges and supports.
 BRIEF ON BUILDING GEOPIC

Geodata Processing and Interpretation Centre ( Geopic ) (Computer Processing

Centre Of ONGC ) is a new Computer building where Processing and
Interpretation of Geophysical Data For Oil Exploration Activities of ONGC
occurs.
This a 8 storey Building with number of computers in each hall.
There were so many restricted area in the building where only authorised
persons have access to go.

The main auditorium (Conference Room) having a seating capacity of more than
300 persons , its dimension should be of 90’x52’x28’ and is to be
air-conditioned including winter heating for comfort requirements.

There were some problems of excessive cooling like at 1st Floor and Ventilation
problem was also find out. At 4th Floor , Officers were complaining that
ventilations are not contolled properly . At places this is more cooling while at
others there is moderate so making the room uncomfortable.
In the conference hall it was good and Comfort Condition properly maintained
there !
Different Issues Faced By Maintenance Team at Refrigeration Plant And their
possible Solutions :

While giving comfort conditions to different halls 24*7 it has a great possibility that there
can be some Problems which can be faced by Maintenance department . so while
discussing with team we get to know some possibilities and their solutions :

1. Compressor Starts But Stops immediately :

 Low pressure cut out gets activated

Ensure that all the suction line valves are in open condition, the refrigeration is
properly charged and the low pressure cut out is not defective

 Defrosting timer is getting activated frequently

If the defrost timer is getting activated frequently, leading to cutout of compressor,

check and repair defrost timer.

2. Compressor is Running Continuously :

The function of compressor in a refrigeration system is to act as a pump to circulate the

refrigerant in the cooling circuit. It can happen that to maintain the cooling temperature in
the rooms, the compressor is running continuously. If this happens following can be the
causes for the same:

 Refrigerant not sufficient for cooling evaporator

Ensure thermostatic expansion valve is working properly and clean the filters
inside TEV.

 Refrigerant charge is low in the circuit

Check for leakage of refrigerant and charge with required refrigerant

3. Unusual Sound from Compressor :

One of the most common problems in any machinery is abnormal sound coming from
some of its parts. This may be due to trouble with mechanical components inside the
compressor or due to the reasons stated below:

 The oil pressure is low

Ensure that the oil level is maintained and no foaming of oil is developed.
Replenish or refill the lube oil if required

 Incorrect alignment of compressor and motor

Check the alignment and set motor and compressor in one line.
 Loose foundation

Ensure that the compressor foundation is secured and all foundation bolts
are checked for tightness.

 Loosening of driving belt

Ensure to check the elasticity of the belt and renew if the belt is slack.

4. High Compressor Discharge Temperature

It may happen that all the rooms are maintained at correct temperature, but in doing so the
discharge temperature of the compressor is going above the limit. This problem may arise
due to following reasons:

 Excessive suction temperature due to less refrigerant in the circuit

 Recharge the circuit to maintain refrigerant quantity in the circuit. Ensure
TEV is set properly and supplying enough to the evaporator, else degree of superheat will
result in increase of suction and discharge temperatures of the compressor.

 Leak in the discharge valve leads to generation of heat

Renew the leaky valve

5. Reduced Cooling Capacity

If the cooling capacity of the plant has reduced and it is not being able to maintain the
room temperature, following may be the causes:

 Inadequate refrigeration

Charge refrigerant in the circuit

 Poor thermostat location that senses cold temperatures

Place the sensor of the TEV in proper location i.e discharge of the evaporator

 Room door is kept open

Ensure to close the door while exiting the provision room

 CONCLUSION

For the proper maintenance of plant of plant ,there must be proper checking of all
ducts ,TEVs , Pipings , Insulation and all.
It must be noted that while refrigeration unit is on , a user must stand at some distance
because things can misbehave anytime. So care should be taken.
There should be a separate team who will visit all the rooms and check the ventilation
system and note down all the readings whether it is working good or not .
According to me there are some standards which are set by the Engineers of The
American Society of Heating, Refrigeration And Air Conditioning and it should be
followed by the maintenance team .
For example as per conferance room size which is main Auditorium ,Ventilation
requirements can be as per ASHRAE 62. which is as follows:

Room Temperature - 22 ± 2 degree Celsius.

Relative Humidity - not exceeding 65% even in monsoons.
Air filters - washable synthetic woven filters.

Also the users of GEOPIC should also report on time if they are facing any problem
regarding air conditioning otherwise if there is any fault in duct supply or else ; it can turn
out to be bigger one .
Taking at last consideration on plant noise level it should be noted that the design,
construction and workmanship should be such so as to achieve vibration level at the
minimum and the noise level should not be more than 35 to 40 Decibels when the plant is
operating at maximum capacity.

THANKING YOU !!