INTODUCTION:

• Petroleum is a naturally occurring liquid found in rock formations. It consists

of a complex mixture of hydrocarbons of various molecular weights, plus
other organic compounds. It is generally accepted that oil, like other fossil
fuels, formed from the fossilized remains of dead plants and animals by
exposure to heat and pressure in the Earth's crust over hundreds of millions
of years. Over time, the decayed residue was covered by layers of mud and
silt, sinking further down into the Earth’s crust and preserved there between
hot and pressured layers,gradually transforming into oil reservoirs.
• The most prolific and dynamic industries of this century are petroleum and
petrochemical. In recent decades, the energy industry has experienced
significant changes in oil market dynamics, resource availability and
technological advancement. However our dependence on fossil fuels as our
primary energy source has remained unchanged. It has been estimated that
global energy consumption will grow about 50% by the end of the first
quarter of the 21s century and about 90% of the energy is projected to be
supplied by fossil fuels such as oil, natural gas and coal. This significantly
reveals the magnitude, economic edifice and necessity of this industry. In
this supply and demand scenario, the need is for the development of
upgrading processes in order to fulfill market demand as well as to satisfy
environmental regulations. From the most primitive methods of extraction
and refining of petroleum, great transformation has occurred throughout
these years to materialize the modern refinery.
INDIAN OIL CORPORATION LTD. (IOCL) has been the pioneer of petroleum
refining in India over the last few decades.

IOCL:-An overview
Indian Oil Corporation Ltd.(IOCL)is a major diversified, transnational,
integrated energy company, with national leadership and a strong
environment conscience, playing a national role in oil security & public
distribution. Indian Oil Corporation Ltd. (IndianOil) is India's largest
commercial enterprise. Beginning in 1959 as Indian Oil Company Ltd., Indian
Oil Corporation Ltd. was formed in 1964 with the merger of Indian Refineries
Ltd. (established 1958). IndianOil and its subsidiaries account for 49%
petroleum products market share, 40.4% refining capacity and 69%
downstream sector pipelines capacity in India.

There are ten refineries under Indian Oil Corporation Limited (IOCL) located
at
Guwahati (Assam)
Barauni (Bihar)
Baroda (Gujarat)
Haldia (W.B.)
Mathura (U.P)
Panipat (Haryana)
Paradweep (Orissa)
Bongaigaon (Assam)
Digboi (Assam)
Koyali
The combined rate capacity of these ten refineries is 49.30MMPTA.IOC
accounts for 42% of India’s total refining capacity.

HALDIA REFINERY (IOCL)

Haldia Refinery, one of the seven operating refineries of Indian Oil, was
commissioned in January 1975. It is situated 136 km downstream of Kolkata
in the district of Purba Medinipur, West Bengal, near the confluence of river
Hooghly and Haldia. From an original crude oil processing capacity of 2.5
MMTPA, the refinery is operating at a capacity of 5.8 MMTPA at present.
Capacity of the refinery was increased to 2.75 MMTPA through de-
bottlenecking in 1989-90. Refining capacity was further increased to 3.75
MMTPA in 1997 with the installation/commissioning of second Crude
Distillation Unit of 1.0 MMTPA capacity. Petroleum products from this
 refinery are supplied mainly to eastern India through two product pipelines
as well as through barges, tank wagons and tank trucks. Products like MS,
HSD and Bitumen are exported from this refinery. Haldia Refinery is the only
coastal refinery of the corporation and the lone lube flagship, apart from
being the sole producer of Jute Batching Oil. Diesel HydroDesulphurization
(DHDS) Unit was commissioned in 1999, for production of low Sulphur
content (0.25% wt) High Speed Diesel (HSD). With augmentation of this unit,
refinery is producing BS-II and Euro-III equivalent HSD (part quantity) at
present. Resid Fluidized Catalytic Cracking Unit (RFCCU) was commissioned
in 2001 in order to increase the distillate yield of the refinery as well as to
meet the growing demand of LPG, MS and HSD. Refinery also produces eco
friendly Bitumen emulsion and Microcrystalline Wax. A Catalytic Dewaxing
Unit (CIDWU) was installed and commissioned in the year 2003 for
production of high quality Lube Oil Base Stocks (LOBS), meeting the API Gr-II
standard of LOBS.

Desulphurization (DHDS) Unit was commissioned in 1999, for production of low

Sulphur content (0.25% wt) High Speed Diesel (HSD). With augmentation of this
unit, refinery is producing BS-II and Euro-III equivalent HSD (part quantity) at
present. Resid Fluidized Catalytic Cracking Unit (RFCCU) was commissioned in 2001
in order to increase the distillate yield of the refinery as well as to meet the growing
demand of LPG, MS and HSD. Refinery also produces eco friendly Bitumen emulsion
and Microcrystalline Wax. A Catalytic Dewaxing Unit (CIDWU) was installed and
commissioned in the year 2003 for production of high quality Lube Oil Base Stocks
(LOBS), meeting the API Gr-II standard of LOBS.
Finished products from this refinery cover both fuel oil products as well as lube oil
products.
Fuel oil products include:-
• LPG
• Naphtha
• Motor sprit(MS)
 • Mineral Turpentine Oil ( MTO )
• Superior Kerosene ( SK )
• Aviation Turbine Fuel ( ATF )
• Russian Turbine Fuel ( RTF )
• High Speed Diesel ( HSD )
• Jute Batching Oil ( JBO )
• Furnace oil(FO)
Lube oil base stocks are:
• Inter Neutral HVI grades
• Heavy Neutral HVI grades
• Bright Neutral HVI grades.
Beside the above, Slack Wax, Carbon Black Feed Stock (CBFS), Bitumen and
Sulphur are the other products of this refinery.
There are four main units in this refinery.
1. FUEL OIL BLOCK (FOB)
2. LUBE OIL BLOCK (LOB)
3. DIESEL HYDRO-DE SULPHURISATION BLOCK (DHDS)
4. OIL MOVEMENT AND STORAGE (OM&S) BLOCK
Two new units namely Sulphur Recovery Unit(SRU) and ResidFludised Catalytic
Cracking Unit (RFCCU) have been installed and are operating under DHDS
BLOCK.Haldia Refinery also possesses a captiveThermal Power Station (TPS),
also a Quality Control (QC) and Technical Services department.
FIRE SAFETY
FIRE: -
Fire is a rapid ,self sustained oxidation process accompanying by the release of
energy in the form of heat and light of varying intensity. Fire results from the
combustion of fuel, heat & oxygen.

Fire triangle:-
Three elements are necessary for initiation of fire: -
1. Fuel in the form of vapor, liquid or solid.
2. A source of ignition is sufficient to initiate and propagate the fire.
3. Oxygen is sufficient proportion to form a combustible mixture.

Combustion process is observed in two modes:-

1.flaming combustion:- to occur, solid or liquid fuel must be converted
into vapor which then mixes with air and reacts with oxygen.
2.Smoldering combustion:- on the other hand , involves a reaction
between oxygen and the surface of the fuel: this a complex process and in general occurs with
solid fuels.

SAFETY:
The main & utmost thing , which is to be known to all is the safety during working
in an industry. A person in an industry should well aware about the safety rules to
keep him safe & others from any unwanted mishap.

The main principle points which one should keep in mind are:-

1. One should ware safety helmet to avoid injury.

2. The second important thing is the safety shoes.

3. The third important thing is that one should use Safety jackets.

4. When a person is poling heavy material he should wear PVC gloves.

These are the major things which one should maintain during work. But there are
many small things which should be maintained properly.

a.A person should wear safety goggles during welding.

b. When a person is working at a high construction He should wear safety belts.

c.A person should use a ladder having rubber covered legs, neither can he slip.

d.When a person is working in a chemically hazard place he should use gas mask.

e.One should keep safe distance from furnace & should operate it very carefully.

f.Workers should keep in mind that not to work near inflammable gases.
g.The cylinder should store in proper manner &in proper places.

h.One should always keep safe distance from pit.

i.The fire extinguisher should keep in proper places & after work workers
should keep it back in the proper place.

If any problem occur regarding safety workers should immediately inform his
higher officers.

These are some safety associated rule which one should keep in mind. But these
rule do not work until a person has a sense of safety.

Another main important thing is workers should know how to fight with fire. To
know this we have to know first what fire is. In industrial language fire is nothing
but a combination of heat, inflammable material, oxygen, free radicals.

This is called fire tetrahedron. If on of the side is removed then it can be

controlled.
[Note: During fight with fire with CO2 one should always about the direction of air
flow, because one may feint if he is in wrong direction.]

FUEL OIL BLOCK (FOB):-

It was commissioned in August 1974, originally designed for processing Light

Iranian Aghajari crude but presently crudes like Arab Mix (lube bearing) and
Dubai crude (non-lube bearing)( 60:40 wt ratio) are processed. The capacity has
been increased from 2.5 MMPTA to 6.0 MMPTA.
Fuel oil block produces fuel oil from crude and this block consist of eight subunits
as given below:
CRUDE DISTILLATION UNIT (Unit 11 & 16)
1.Prefractionator section
2. Topping Section: Atmospheric distillation unit (ADU)
3. Naphtha stabilization unit
4. Naphtha re distillation unit

GAS PLANT (Unit 12)

1. De-ethaniser
2.Amine-washing of LPG
3. De-propaniser

MEROX UNIT (Unit 13)

1. LPG extractive merox
2. ATF/ Gasoline sweetening merox

NAPTHA HYDRO DESULPHURIZATION UNIT-(NHDT) (Unit 21)

CATALYTIC REFORMING UNIT (Unit 22)

KHDS UNIT (Kero Hydro Desulphurization Unit)( Unit23)

CRUDE DISTILLATION UNIT (Unit 11 & 16):

Flow sheet (CDU):-