Summer Training Report

Undertaken at
INDIAN OIL CORPORATION LIMITED
Barauni, Bihar

Submitted in Partial Fulfillment of the Requirements for the Degree

of
Bachelor of Technology
in Department of Mechanical Engineering
By

RUMAN AHMAD (MEB14037)

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING
TEZPUR UNIVERSITY
August, 2017

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 Table of Contents

S. No. Topics Page No.

1 IOCL OVERVIEW 1
1.1 Introduction 1
1.2 2

2 FIRE & SAFETY 5

2.1 Introduction 5
2.2 6

3 THERMAL POWER STATION 7

3.1 Introduction 6
3.2 6

4 VALVES 7
4.1 Introduction 7
4.2 8
4.3 9
4.4 9

5 HEAT EXCHANGERS 10
5.1 Introduction 10
5.2 10
5.3 11

6 PUMPS 13

7 14
7.1 Introduction 14
7.2 14

8 15
8.1 Introduction 15

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 Chapter 1

INTRODUCTION

1.1 Indian Oil Corporation Limited

Petroleum is derived from two words petro means rock and oleum means oil.
Thus the word petroleum means rock oil. This is a mixture of hydrocarbons; hence it
cannot be used directly and has got to be refined. Petroleum is refined in petroleum
refinery.
The Indian Oil Corporation Ltd. operates as the largest company in India in terms of
turnover and is the only Indian company to rank in the Fortune Global 500" listing.
The oil concern is administratively controlled by Indias Ministry of Petroleum and
Natural Gas, a government entity that owns just over 90 percent of the firm. Since 1959,
this refining, marketing, and international trading company served the Indian state with
the important task of reducing India's dependence on foreign oil and thus conserving
valuable foreign exchange. That changed in April 2002, however, when the Indian
government deregulated its petroleum industry and ended Indian Oils monopoly on
crude oil imports. The firm owns and operates seven of the17 refineries in India,
controlling nearly 40 percent of the countrys refining capacity.
It is also the 17th largest petroleum company in the world. Indian Oil has a sales turnover of
Rs. 4, 73,210 crore and profits of Rs. 7,019 crore. Indian Oil has been adjudged second in
petroleum trading among the 15 national oil companies in the Asia-Pacific region.
As the premier National Oil Company, Indian Oils endeavor is to serve the national
economy and the people of India and fulfill its vision of becoming An Integrated,
Diversified and Transnational Energy Major.
Beginning in 1959 as Indian Oil Company Ltd, Indian Oil Corporation Ltd. was formed in
1964 with the merger of Indian Refineries Ltd. (Est. 1958).As India's flagship national oil
company, Indian Oil accounts for 56% petroleum products market share,42% national
refining capacity and 67% downstream pipeline throughput capacity.
IOCL touches every Indians heart by keeping the vital oil supply line operating relentlessly
in every nook and corner of India.
It has the backing of over 33% of the countrys refining capacity as on 1St April 2002 and
6523 km of crude/product pipelines across the length and breadth of the country.
IOCLs vast distribution network of over 20000 sales points ensures that essential
petroleum products reach the customer at the right place and at the right Time.
Indian Oil controls 10 of India's 18 refineries - at Digboi, Guwahati, Barauni, Koyali,
Haldia, Mathura, Panipat, Chennai, Narimanam and Bongaigaon

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 1958 Indian Refineries Ltd. formed in August with Mr. Feroze Gandhi as the
Chairman.
1959 Indian Oil Company Ltd. established on 30th June 1959 with Mr. S.Nijalingappa
as the Chairman.
1960 MV Uzhgorod carrying the first parcel of 11,390 tonnes of DieselFforIndianOil
docked at Pir Pau Jetty in Mumbai on 17th
.Agreement for supply of Kerosene and Diesel signed with the thenUSSR1962

Construction of Barauni Refinery commenced

1964
Barauni Refinery commissioned
Indian Refineries Ltd. merged with Indian Oil Company with effect from 1st September,
1964, and Indian Oil Company renamed as Indian Oil Corporation
Ltd.1967 Haldia Barauni product pipeline commissioned.1965 Barauni-Kanpur product
pipeline and Koyali- Ahmedabad product pipeline commissioned1998 Haldia-
Barauni crude oil pipeline completed

1.2 Barauni Refinery

Barauni Refinery was built in collaboration with Russia and Romania. Situated 125
kilometers from Patna, it was built with an initial cost of Rs 49.40 crore. Barauni Refinery
was commissioned in 1964 with a refining capacity of 1 Million Metric Tones per Annum
(MMTPA) and it was dedicated to the Nation by the then Union Minister for Petroleum,
Prof. Humayun Kabir in January 1965. After de-bottlenecking, revamping and expansion
project, it's capacity today is 6 MMTPA. Matching secondary processing facilities such
Reside Fluidised Catalytic Cracker (RFCC), Diesel Hydro treating (DHDT), Sulphur
Recovery Unit (SRU) have been added. Theses state of the art eco-friendly technologies
have enabled the refinery to produce environment- friendly green fuels complying with
international standards.

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of
Assam. After establishment of other refineries in the Northeast, Assam crude is unavailable
for Barauni. Hence, sweet crude is being sourced from African, South East Asian and
Middle East countries like Nigeria, Iraq & Malaysia. The refinery receives crude oil by

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pipeline from Paradip on the east coast via Haldia. With various revamps and expansion
projects at Barauni Refinery,
Capability for processing high-sulphur crude has been added high-Sulphur crude oil
(sour crude) is cheaper than low-Sulphur crudes thereby increasing not only the capacity
but also the profitability of the refinery.

1.3 Awards/Accolades
Barauni Refinery achieved safety award in gold category of Green Tech
Foundation Safety Award on 04.05.09.
BR bagged 2nd prize in Golden Jubilee Indian Oil Album in Aug 09.
Barauni Refinery accredited in Oct 09 with prestigious Jawaharlal Nehru
Centenary
Awards (3rd prize) for Energy Performance in Refinery for the year2008-09 by Mo
PNG.
Barauni Refinery has been accredited first prize in the refinery sector for National
Energy
Conservation Awards-2009 by Ministry of Power. Award received by ED,BR on
14.12.09.

Barauni Refinery was initially designed to process low sulphur crude oil(sweet crude) of
Assam. After establishment of other refineries in the Northeast, Assam crude is unavailable
for Barauni. Hence, sweet crude is being sourced from African, South East Asian
and Middle East countries like Nigeria, Iraq & Malaysia. The refinery receives crude oil by
pipeline from Paradip on the east coast via Haldia. With various revamps and expansion
projects at Barauni Refinery, capability for processing high-sulphur crude

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 Chapter 2

Fire & Safety

2.1 Introduction

Fire and safety refer to the precautions that are taken to prevent or reduce the likelihood of
a fire that may result in death, injury or property damage, alert those in a structure to the
presence of fire in the event one occurs, better enable those threatened by afire to survive,
or to reduce the damage caused by a fire. Fire safety measures include those that are
planned during the construction of a building or implemented in structures that are already
standing. Threats to fire safety are referred to as fire hazard. A fire hazard may include a
situation that increases the likelihood a fire may start or may impede escape in the event a
fire occurs.

Basics of Fire:
Fires start when a flammable or a comfortable material, in combustion with a sufficient
amount of an oxidizer such as oxygen or another oxygen-rich compound, is exposed to a
source of heat or ambient temperature above the flash point for the fuel /oxidizer mix,
and is able to sustain a rate of rapid oxidation that produces a chain of reactions. This is
commonly called fire tetrahedron. Fire cant exist without all these elements in a place
and in right proportions.

Fire Triangles: The fire triangles or combustion triangles are simple models for
understanding the necessary ingredients for most fires. The triangle illustrates the three
elements a fire needs to ignite: heat, fuel, and an oxidizing agent (usually oxygen).

If we cut any of these fires can be avoided.

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Safety PPE (Personal protective equipment) is compulsory.

There are three mandatory PPE: shoes, helmet, and goggles.

Use of PPE such as safety belts, hearing aids, hand glove, aprons, gas mask etc. also
there.

Fire & Safety Regulations:

No smoking except at the prescribed smoking booths.

Mobile phones, litter, torch etc. are prohibited in battery area.
Self controlled Breathing apparatus (SCBA) must be used in case of any toxic gas
emission.
Do not sit/eat/rest in inside unit. Particularly near running equipment.
In case of any fire, one should use emergency phone to dial 333/7777 for IOCL fire
control Department and 301 for first aid.
Fire call can be given through fire alarm also, which are provided along the road.
Know emergency siren code.
During emergency move to the closest assembly point, total 13 assembly point is are
there in Barauni refinery.
Without having proper Knowledge, nothing should be touched.
No photography/videography allowed inside refinery.
Work permit

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 Chapter 3

TPS
3.1 Introduction

This is one of the most important units of any Refinery. Here electric power is generated from
steam and this power is utilized for running the various machineries of the refinery as well as
provides power for the homes in the refinery colony. The demineralised water required to
generate steam is provided by the DM plant. Demineralised water is required as presence of
minerals may lead to a phenomenon known as Scaling and may also cause corrosion. Scaling
is the process where layer of mineral is deposited on the inner metal surface of the boiler pipes
and boiler drum and reduce the efficiency of the boiler. Corrosion will lead to formation of
cracks and holes in the pipes and drum.

3.2 Working / Flow Process of TPS

The TPS of Barauni Refinery consist of four boilers and three turbine generators sets.
The water is heated and converted to steam in the boiler pipes and sent to boiler drum. The
heat required is generated by burning fuel oil or fuel gas in burner. The fuel oil and fuel gas is
generated internally in the refinery and nothing is bought from outside. The fuel oil is
subjected to atomizing steam before firing and then mixed with combustion air sucked in with
the help of FD (forced draft) fan and exhaust is led out into the atmosphere through stacks by
passing it through economizers along the path. The steam generated is collected in the steam
drum which is 50% steam and 50% water. The steam is then sent to the super heaters where
any remaining water is removed from the steam and then sent to the turbine. The control
systems used in the boiler system are 3 element control and combustion control, which deals

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with the function of maintaining level and managing the combustion in the burner
respectively. The three elements of 3 element control are steam level in boiler drum, steam
flow & feed water flow.
The pressure of steam is maintained at 37kg/cm2 which is the high pressure steam. Medium
and low pressures of respective pressures of 12-13 and 3-4 kg/cm2 are also generated. The
turbine is a steam turbine which converts the pressure of steam into rotational motion and this
rotational motion is converted into electrical energy by generators. There are 3 steam turbine
generators with generator 3 & 4 having capacity of 8MW each and generator 5 having a
capacity of 12MW.

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 Chapter 4

PUMPS

4.1 Introduction
A pump is a device that moves fluids or sometimes slurries by mechanical action. Pumps can
be classified into three major groups according to the method they use to move the fluid: direct
lift, displacement, and gravity pumps.

Pumps operate via many energy sources and by some mechanism (typically reciprocating or
rotary), and consume energy to perform mechanical work by moving the fluid by manual
operation, electricity, engine or wind power.

Fig-2.1 General Components of Centrifugal Pump

4.2 Common Pumps Used In IOCL

4.2.1 Centrifugal Pumps

A centrifugal pump is a pump that consists of a fixed impeller on a rotating shaft that is
enclosed in a casing, with an inlet and a discharge connection. As the rotating impeller swirls

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the liquid around, centrifugal force builds up enough pressure to force the water through the
discharge outlet. This type of pump operates on the basis of an energy transfer, and has certain
definite characteristics which make it unique. The amount of energy which can be transferred
to the liquid is limited by the type and type and size of the impeller, the type of material being
pumped, and the total head of the system through which the liquid is moving.
Centrifugal pumps are designed to be used as a portable pump, and are often referred to as a
trash pump. It is named so because the water that is being pumped is not clean water. It is most
often water containing soap or detergents, grease and oil, and also solids of various sizes that
are suspended in the water.

4.2.2 The major types of centrifugal pumps used in the refinery are:
1. Vertical Cantilever Pump

It is a specialized type of vertical sump pump designed to be installed in a tank or sump but
with no bearing located in the lower part of the pump. Thus, the impeller is cantilevered
from the motor, rather than supported by the lower bearings.
A cantilever pump is considered a centrifugal pump configured with the impeller
submerged in the fluid to be pumped. But unlike a traditional vertical column sump pump,
there are no bearings below the motor supporting the impeller and shaft.
The cantilever pump has a much larger diameter shaft, since it has no lower sleeve bearings
that act to support the impeller and shaft.
In general, cantilever pumps are best for relatively shallow sumps, usually around 8 to 10
feet maximum. This is because the deeper the sump, the larger the shaft diameter that is
required to cantilever the impeller

2. Split Case Pumps

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 . This type of pump has a split casing at the suction side. It prevents the turbulence and
formation of eddies at inlet.

Split Case pumps are designed to pump clean water or low viscosity clean liquids at
moderate heads more economically, which is widely used for liquid transfer and circulation
of clean or slightly polluted water. And the typical applications are Municipal water supply,
Power plants, Industrial plants, Boiler feed and condensate systems, Irrigation and
dewatering and marine service.

Advantages:

Less noise and vibration, suitable to a lifting speed working condition.

Inverted running is available for the same rotor; the risk of water hammer is lower.

Unique design for high temperature application up to 200 , intermediate support, thicker
pumps casing, cooling seals oil lubrication bearings.

Vertical or horizontal with packing seal or mechanical seal can be designed according to the
different working condition.

Beautiful outline design.

Specifications of a Centrifugal Pump in Refinery

Offered Capacity: 317 LPM

RPM: 1450

Efficiency: 93%

Mounting: Horizontal

Sealing: Mechanical Seal

Power Rated: 7 KW

Applications of Centrifugal Pump in Barauni Refinery

For circulation of cooling water.

For pump the fluid (crude oil, VGO, diesel etc.) in reactors, coulombs etc. with high
pressure.

In liquid storage tanks

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4.3 Net Positive Suction Head (NPSH)

Net Positive Suction Head (NPSH) NPSH Available is a function of the system in which the
pump operates. It is the excess pressure of the liquid in feet absolute over its vapor pressure as
it arrives at the pump suction. In an existing system, the NPSH Available can be determined
by a gauge on the pump suction.

The Hydraulic Institute defines NPSH as the total suction head in feet absolute, determined
at the suction nozzle and corrected to datum, less the vapor pressure of the liquid in feet
absolute. Simply stated, it is an analysis of energy conditions on the suction side of a pump
to determine if the liquid will vaporize at the lowest pressure point in the pump.

The pressure which a liquid exerts on its surroundings is dependent upon its temperature. This
pressure, called vapor pressure, is a unique characteristic of every fluid and increased with
increasing temperature. When the vapor pressure within the fluid reaches the pressure of the
surrounding medium, the fluid begins to vaporize or boil. The temperature at which this
vaporization occurs will decrease as the pressure of the surrounding medium decreases.
A liquid increases greatly in volume when it vaporizes. One cubic foot of water at room
temperature becomes 1700 cu. ft. of vapor at the same temperature.

It is obvious from the above that if we are to pump a fluid effectively, we must keep it in
liquid form. NPSH is simply a measure of the amount of suction head present to prevent this
vaporization at the lowest pressure point in the pump.

4.3.1 NPSH can be defined as two parts:

1. NPSH Available (NPSHA): The absolute pressure at the suction port of the
pump.

2. NPSH Required (NPSHR): The minimum pressure required at the suction port of the
pump to keep the pump from cavitating.

NPSHA is a function of your system and must be calculated, whereas NPSHR is a

function of the pump and must be provided by the pump manufacturer. NPSHA must be
greater than NPSHR for the pump system to operate without cavitation. Thus, we must
have more suction side pressure available than the pump requires.

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 4.4 Cavitation

Cavitation is a term used to describe the phenomenon, which occurs in a pump when there
is insufficient NPSH Available. When the pressure of the liquid is reduced to a value equal
to or below its vapor pressure the liquid begins to boil and small vapor bubbles or pockets
begin to form. As these vapor bubbles move along the impeller vanes to a higher pressure
area above the vapor pressure, they rapidly collapse.

The collapse or "implosion" is so rapid that it may be heard as a rumbling noise, as if you
were pumping gravel. In high suction energy pumps, the collapses are generally high
enough to cause minute pockets of fatigue failure on the impeller vane surfaces. This
action may be progressive, and under severe (very high suction energy) conditions can
cause serious pitting damage to the impeller.

4.4.1 Cavitation is often characterized by:

Loud noise often described as a grinding or marbles in the pump.

Loss of capacity (bubbles are now taking up space where liquid should be Pitting damage to
parts as material is removed by the collapsing bubbles

Vibration and mechanical damage such as bearing failure

Erratic power consumption

The way to prevent the undesirable effects of cavitation in standard low suction energy
pumps is to insure that the NPSH Available in the system is greater than the NPSH required
by the pump.

4.5 Common Problems encountered in Pumps

The types of pumps that are most commonly used in a Refinery plant are centrifugal
pumps. These pumps use centrifugal action to convert mechanical energy into
pressure in a flowing liquid. The main components of the pump that are usually prone
to problems are impellers, shafts, seals and bearings.

An important aspect of the impeller is the wear rings. If the impeller is too close to
the stationary element, the impeller or the casing will be worn out. The other part is
the shaft. It runs through the center of the pump and is connected to the impeller at
the left end.

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 Seal is a very important part in the pump. Seals are required in the casing area where
the liquid under pressure enters the casing.

The last main part of the pump is the bearing. The pump housing contains two sets of
bearings that support the weight of the shaft. The failures causing the stoppage of the
pumps are primarily experienced by these parts and will be termed as failure modes.

4.6 There are 12 major failure modes (bad actors) for the most pumps. The following is
the definition adopted to characterize the various modes of failure:

Shaft: The pump failed to operate because of shaft problem, such as misalignment,
vibration, etc.

Suction Valve: A failure due to something wrong with the pump suction, such a
problems in valve, corroded pipes or slug accumulated in the suction.

Casing: A failure due to defective casing, such as misalignment or corrosion.

Operation Upset: Failure of a pump due to operational mistakes, such as closing

a valve which should not be closed.

Coupling: A failure due to coupling distortion or misalignment.

Gaskets: A failure due to a gasket rupture or damage caused by leaks.

Control Valve: A failure due to malfunction of the control valve due to pressure or
flow in the line of service.

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 Chapter 5

VALVES

5.1 INTRODUCTION

A valve is a mechanical device which regulates either the flow or the pressure of the fluid.
Its function can be stopping or starting the flow, controlling flow rate, diverting flow,
preventing back flow, controlling pressure, or relieving pressure.
Basically, the valve is an assembly of a body with connection to the pipe and some
elements with a sealing functionality that are operated by an actuator. The valve can be
also complemented whit several devices such as position testers, transducers, pressure
regulators, etc.

Common Valves Used In Barauni Refinery

1. Gate valves

Application In Refinery

Gate valves have an extended use in the petrochemical industry due to the fact that
they can work with metal-metal sealing.

They are used in clean flows

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When the valve is fully opened, the free valve area coincides with area of the pipe,
therefore the head lose of the valve is small.

Limitations

This valve is not recommended to regulate or throttling service since the closure
member could be eroded. Partially opened the valve can vibrate.

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 Opening and closing operations are slow. Due to the high friction wear their use is
not recommend their use in often required openings. This valve requires big actuators
which have difficult automation. They are not easy to repair on site.

2. Ball Valves

The ball valve has a spherical plug as a closure member. Seal on ball valves is
excellent, the ball contact circumferentially uniform the seat, which is usually made
of soft materials

Depending on the type of body the ball valve can be more or less easily maintained.
Drop pressure relative its hole size is low.

Application in Refinery

They are used in steam, water, oil, gas, air, corrosive fluids, and can also handle slurries and
dusty dry fluids. Abrasive and fibrous materials can damage the seats and the ball surface.

Limitations
The seat material resistance of the ball valve limits the working temperature and
pressure of the valve. The seat is plastic or metal made.

Ball valves are mostly used in shutoff applications. They are not recommended to be
used in a partially open position for a long time under conditions of a high pressure drop
across the valve, thus the soft seat could tend to flow through the orifice and block the
valve movement.

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