A

REPORT
ON
VOCATIONAL TRAINING
AT

INDIAN OIL CORPORATION LTD. (IOCL)

SUBMITTED BY: SUBMITTED TO:

Mukesh Kumar Mr. Vishal Lal Goswami

(ROLL. NO. 1606531023) (HOD, ECE)

BSA COLLEGE OF ENGINEERING AND TECHNOLOGY

MATHURA,UTTAR PRADESH.
 ACKNOWLEDGEMENTS

I would like to thank Mr. B U RAJU-DGM (INST) Mathura Refinery, IOCL, for giving
me the opportunity to interact with experts of industry at Mathura refinery. I sincerely
express my gratitude to Miss Parul and Mr. Akaash gupta guiding me in my study of the
subject and for her/his valuable suggestions. I would also like to thank Mr. MADAN
SINGH, Mr. RAKESH KUMAR, Mr. ALOK RASTOGI for instructing me towards this
project. I would also like to thank the other staff members at the company for creating an
environment conducive for undertaking this kind of study. Finally I would like to express my
sincere gratitude to my parents, for helping me to undertake this training and constantly
encouraging me to interact with the experts and make the best use of the immense
opportunities available at the refinery.

1|P ag e
 CONTEXT
CONTENT PAGE NO.

Certificate

Acknowledgements

1.Introduction…………………………………………………………………… 3

2.Basic Overview of Mathura Refinary.………………………………………. 6

 Products of Mathura refinery……………………………………………………………. 7
 Old unit………………………………………………………………………………….. 8
 New unit………………………………………………………………………………… 8
 SRU(sulpher recovery unit)…………………………………………………………….. 8
 TPS(therml power station)……………………………………………………………... 9

3.Process Control Loop And Main Parameters Of Measurement…….......... 10

3.1 DCS………………………………………………………………………………………… 11

3.1.1 Field transmitters…………………………………………………………….......................................... 12

A. Pressure transmitter……………………………………………………………………………….... .12

B. Differential pressure transmitter…………………………………...................................................... 12
C. Temperature transmitter……………………………………………………………………………... 12
D. Flow transmitter…………………………………………………...................................................... .13
 Orifice meter……………………………………………………………………………………………………. .13
 Mass flow meter ………………………………………………............................................................................. .13
 Electromagnetic flow meter……………………………………………………………………………………... .14
E. Level transmitter…………………………………………………………………………………….. .14

3.1.2 Process flow diagram of dcs and its elements………………………………………………………........ .15

A. Junction box…………………………………………………………………………………………... .15

B. Zener barrier…………………………………………………………………………………………... .15
C. PID controller…………………………………………………………………………………………. .16
D. Human machine interface……………………………………………………………………………... .17

3.1.3 Final control valve………………………………………………………………………………………… .18

 Positioner……………………………………………………………………………………………..... .18

3.2 PLC(programmable logic control)……………………………………………………………. .20

2|P ag e
 1.INTRODUCTION
Indian Oil Corporation Ltd. is India's largest company by sales with a turnover of Rs.5,00,000(appr) crore
and profit of Rs. 20,221(appr.) crore for the year 2017-18.Indian Oil is the highest ranked Indian company in
the latest Fortune ‘Global 500’ listings, ranked at the 98th position (2011). Indian Oil's vision is driven by a
group of dynamic leaders who have made it a name to reckon with Indian Oil Company Limited, a wholly
owned Government company was incorporated on 30 June, 1959 to undertake marketing functions of
petroleum products. Later, Indian Oil Corporation Limited (IOC) was set up on 1st September, 1964 by
amalgamating the Indian Refineries Limited (started in August, 1958) with the Indian Oil Company Ltd., for
better coordination between refineries and marketing. Indian Oil Corporation Limited or IOCL is India’s
largest commercial enterprise and the only Indian company to be among the world’s top 200 corporations
according to Fortune magazine. It is also among the 20 largest petroleum companies in the world. The
Indian Oil Group of companies owns and operates 10 of India's 20 refineries with a combined refining
capacity of 65.7 million metric tons per annum (MMTPA, .i.e. 1.30 million barrels per day approx.). Indian
Oil's cross-country network of crude oil and product pipelines spans 10,899 km with a capacity of 75.26
MMTPA of crude oil and petroleum products and 10 MMSCMD of gas. This network is the largest in the
country and meets the vital energy needs of the consumers in an efficient, economical and environment-
friendly manner

Fig. 1

Main Divisions of IOCL

 Refineries
 Pipelines
 Research & Development
 Oil division
 Marketing

Fig. 2 Departments in IOCL

3|P ag e
 REFINERIES:
INDIAN OIL controls 11 of India’s 23 refineries. The group refining capacity is 80.7 million metric tons per
annum (MMTPA) - the largest share among refining companies in India. It accounts for 35% share of
national refining capacity. The strength of Indian Oil springs from its experience of operating the largest
number of refineries in India and adapting to a variety of refining processes along the way. The basket of
technologies, which are in operation in Indian Oil refineries include: Atmospheric/Vacuum Distillation;
Distillate FCC/Residue FCC; Hydrocracking; Catalytic Reforming, Hydrogen Generation; Delayed Coking;
Lube Processing Units; Visbreaking; Meroux Treatment; Hydro-Desulphurization of Kerosene & Gasoil
streams; Sulphur recovery; Dewaxing, Wax Hydro finishing; Coke Calcining, etc.

On the environment front, all INDIAN Oil refineries fully comply with the statutory requirements. Several
Clean Development Mechanism projects have also been initiated.
To address concerns on safety at the work place, a number of steps were taken during the year, resulting in
reduction of the frequency of accident

SR.NO. REFINARIES MMTPA

1. Digboi 0.65

2. Guwahati 1.00
3. Koyali 13.70
4. Barauni 6.00
5. Halida 7.50
6. Mathura 8.00
7. Panipat 15.00
8. Bongaigaon 2.35
9. Paradip 15.00

Table 1

PIPELINES:
Indian Oil Corporation Ltd. operates a network of about 12,848 km long crude oil, petroleum product and
gas pipelines with a throughput capacity of 93.7 million metric tons per annum of oil and 9.5 million metric

standard cubic meter per day of gas. Cross-country pipelines are globally recognized as the safest, cost-
effective, energy-efficient and environment-friendly mode for transportation of crude oil and petroleum
products. As a pioneer in oil pipelines in the country, managing one of the world's largest oil pipeline
networks, Indian Oil achieved the highest-ever throughput of 79.8 million tons during the year 2015-16,
which was about 5.5% more than that of the previous year. About 525 km of additional pipeline length was
added during the year, as part of Indian Oil’s plans to continuously expand its network in line with growth in
4|P ag e
business. Projects currently under implementation would further increase the length of the pipelines network
from 11,746 km currently to about 17,000 km, and throughput capacity from 85.5 to 102 MMTPA .With
due emphasis being given to scaling up of natural gas pipelines, the corporation is planning to lay a 1,167
km pipeline to reach LNG imported at Encore to Nagapattinam, Tuticorin, Madurai and Bengaluru. This
pipeline, along with three other upcoming gas pipelines - Mallavaram-Vijaipur, Mehsana-Bhatinda and
Bhatinda-Srinagar pipelines would ensure a significant presence of Indian Oil in gas transmission business.

Fig. 3 Pipe lines

MARKETING:
Indian Oil has one of the largest petroleum marketing and distribution networks in Asia, with over 43,000
marketing touch points. Its ubiquitous fuel stations are located across different terrains and regions of the
Indian sub-continent. From the icy heights of the Himalayas to the sun-soaked shores of Kerala, from Kutch
on India's western tip to Kohima in the verdant North East, IndianOil is truly 'in every heart, in every part'.

Indian Oil’s vast marketing infrastructure of petrol/diesel stations, Indane (LPG)

distributorships, SERVO lubricants & greases outlets and large volume consumer pumps are backed by bulk
storage terminals and installations, inland depots, aviation fuel stations, LPG bottling plants and lube
blending plants amongst others. The countrywide marketing operations are coordinated by 16 State Offices
and over 100 decentralized administrative offices

5|P ag e
 2.BASIC OVERVIEW OF MATHURA REFINARY:
The Mathura Refinery, owned by I.O.C.L is situated in Mathura, Uttar Pradesh. It is the sixth refinery of
Indian Oil was commissioned in 1982 with a capacity of 8.0 MMTPA to meet the demand of petroleum
products in north western region of the country, which includes National Capital Region. Refinery is located
along the Delhi-Agra National Highway about 154 KM away from Delhi. The refinery processes low sulfur
crude from Bombay High, imported low sulfur crude from Nigeria, and high sulfur crude from the Middle
East.

The refinery, which cost Rs.253.92 crores to build, was commissioned in January; 1982.Construction began
on the refinery in October 1972. The foundation stone was laid by Indira Gandhi, the former prime minister
of India. The FCCU and Sulfur Recovery Units were commissioned in January, 1983. The refining capacity
of this refinery was expanded to 7.5 MMTPA in 1989 by debottlenecking and revamping. The present
refining capacity of this refinery is 8.00 MMTPA.

Fig. 4 Top View IOCL

6|P ag e
 BI
T
U
M
E
N

C
D H SKO
U

Mainly Mathura refinery consists four units which as described below:

1. Old Unit

2. New Unit.

3. TPS (Thermal Power station).

4. SRU (Sulphur recovery unit).

Products of Mathura refinery:

1. Liquid Petroleum Gas (LPG)

2. Fuel Oil Products:
 Motor Spirit (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)
 Naphtha
 Gasoline

7|P ag e
 3. Tube Oil Products:
 Inter Neutral, Heavy Neutral & Bright Neutral HVI

4. Other Products:

 Slack Wax
 Carbon Black Feed Stock
 Bitumen
 Sulpher

Old Unit: The old unit consists of many sub units which are:

 CRU(Catalytic reforming unit)

 FCCU(fluid cracker catalyst unit)
 VBU(Viscous breaking unit)
 ADU(atmospheric distillation unit)
 VDU(vacuum distillation unit)

New Unit : the NEW UNIT consists of various sub units which performs various functions which are :

 HGU 1(Hydrogen generation unit)

 HGU 2(Hydrogen generation unit)
 OHCU (Once through hydrogen cracking unit)
 DHDS(diesel hydrogen desulphurization)
 DHDT(Diesel hydrogen treatment)

SRU (SULPUR RECOVERY UNIT):

IN SRU , the reduction in the Sulphur content is done and octane number of the fuel is increasing .The fuel
generated in SRU is of good quality which is blending with the fuel generated by other units .SRU consists
of various units which are :

 MSQU(MOTOR SPIRIT QUALITY UPGRADATION)

 PRIME-G
 OCTAMAX

OCTAMAX is designed by IOCL. As we know that after blending with the fuels coming from other
units, the octane number of the fuel decreases, so to increase it octamax is used.

8|P ag e
TPS (thermal power station):

TPS stands for thermal power station. It is the main part of refinery which supply power supply to other
plants. Its products are:

 Power generation
 Steam generation
 DM water plant

It consists of:

 3 Gas turbine( Capacity 3*22.5 MW)

 3 steam turbine (capacity 3*12.25 MW)
 3 boilers(capacity 3*150 tons/hr)
 3 HRSG( Heat Recovery steam generation)

Power demand in Mathura refinery is 60 to 70 MW so, to meet our requirement we use only 3 gas turbine
and 2 steam turbine.

For DM water plant, the capacity is 300 meter cubic per hour but requirement of plant is 200 meter cubic per
hour. Steam generated from TPS is used for power generation and for other plants and DM water is supplied
to boiler and co- boilers in other plants.

9|P ag e
3.PROCESS CONTROL LOOP AND MAIN PARAMETERS OF MEASUREMENTS:

A control system manages, commands, directs, or regulates the behavior of other devices or systems
using control loops. There are mainly two types of control systems which are:

 Open loop control system

 Close loop control system
Open loop control system:
In an open-loop control system, the control action from the controller is independent of the process
variable. An example of this is a central heating boiler controlled only by a timer. The control action is the
switching on or off of the boiler. The process variable is the building temperature .This controller applies
heat for a constant time regardless of the temperature of the building. other example of the open loop
control system is within the industry when we have to simply indicate the level ,pressure, temperature of
the vessel by using various gauges.

Fig. 5 Open Loop CS

Close loop control system:

A Closed-loop Control System, also known as a feedback control system is a control system which uses the
concept of an open loop system as its forward path but has one or more feedback loops (hence its name) or
paths between its output and its input. The reference to “feedback”, simply means that some portion of the
output is returned “back” to the input to form part of the systems excitation.

Closed-loop systems are designed to automatically achieve and maintain the desired output condition by
comparing it with the actual condition. It does this by generating an error signal which is the difference
between the output and the reference input. In other words, a “closed-loop system” is a fully automatic
control system in which its control action being dependent on the output in some way.

10 | P a g e
 Fig. 6 Close Loo[p CS

Controlling is performed by two ways:

 DCS(distributed control system)

 PLC( programmable logic controller)

3.1 DISTRIBUTED CONTROL SYSTEM:

A distributed control system (DCS) is a computerized control system for a process or plant usually with a
large number of control loops , in which autonomous controllers are distributed throughout the system, but
there is central operator supervisory control. This is in contrast to non-distributed control systems that use
centralized controllers; either discrete controllers located at a central control room or within a central
computer. The DCS concept increases reliability and reduces installation costs by localizing control
functions near the process plant, with remote monitoring and supervision.

Fig. 7 Components of DCS

The processors receive information from input modules, process the information and decide control actions
to be signaled by the output modules. The field inputs and outputs can be analog signals e.g. 4–20 mA DC
current loop or 2 state signals that switch either "on" or "off", such as relay contacts or a semiconductor
switch.

11 | P a g e
DCSs are connected to sensors and actuators and use set point control to control the flow of material through
the plant. A typical application is a PID controller fed by a flow meter and using a control valve as the final

control element. The DCS sends the set point required by the process to the controller which instructs a
valve to operate so that the process reaches and stays at the desired set point. (see 4–20 mA schematic ).

Although 4–20 mA has been the main field signaling standard, modern DCS systems can also
support fieldbus digital protocols, such as Foundation Fieldbus, profit bus, HART, Modbus, PC Link etc.,
and other digital communication protocols such as Modbus.

3.1.1 Field transmitter:(pt,dpt,tt,ftt,lt)

Mainly we have to measure four parameters in the field which are pressure, temperature, flow, level. So
various parameters sensors and transmitters are used which measure and convert the parameter in to
appropriate 4- 20 mA signal and send to the controller.

A. Pressure transmitter: Pressure transmitters are used to measure the pressure or level of industrial
liquids and gases. The output is transmitted to a control system. Accurate and stable process measurements
ensure the safe, reliable, and profitable operation of your plant.

B. Differential pressure transmitter:

Differential Pressure (DP) transmitters measure the difference between two pressures. They use a reference
point called the low-side pressure and compare it to the high-side pressure. Ports in the instrument are
marked high-side and low-side. The DP reading can be either negative or positive depending on whether the
low-side or high-side is the larger value. A DP transmitter can be used as a gauge pressure transmitter if the
low-side is left open to the atmosphere.

Fig. 8 (Differential Pressure Transmitter)

C. Temperature transmitter:

Temperature transmitter is used to measure the temperature of various vessals and reactors . so that it can be
maintain within a limited range done by thermocouple.

12 | P a g e
D. FLOW TRANSMITTERS : A flow meter (or flowmeter) is an instrument used to measure linear,
nonlinear, volumetric or mass flow rate of a liquid or a gas. When choosing flow meters, one should
consider such intangible factors as familiarity of plant personnel, their experience with calibration and
maintenance, spare parts availability, and mean time between failure history, etc., at the particular plant site

The following types of flow transmitters are:

 Orifice meter

 Mass flow meter

 Electromagnetic flow meter

ORIFICE METER:

With an orifice plate, the fluid flow is measured through the difference in pressure from the upstream side to
the downstream side of a partially obstructed pipe. The plate obstructing the flow offers a precisely
measured obstruction that narrows the pipe and forces the flowing fluid to constrict .

Fig. 9

The orifice plates are simple, cheap and can be delivered for almost any application and in any material.

The Turn Down Ratio for orifice plates are less than 5:1. Their accuracy are poor at low flow rates. A high
accuracy depend on an orifice plate in good shape, with a sharp edge to the upstream side. Wear will reduce
the accuracy.

MASS FLOW METER:

Mass measurement is not sensitive to changes in pressure, temperature, viscosity and density. With the
ability to measure liquids, slurries and gases, Coriolis flowmeters are universal meters .

13 | P a g e
 Fig. 10

Coriolis Mass Flowmeter uses the Coriolis Effect to measure the amount of mass moving through the
element. The fluid to be measured runs through a U-shaped tube that is caused to vibrate in an angular
harmonic oscillation. Due to the Coriolis forces, the tubes will deform and an additional vibration
component will be added to the oscillation. This additional component causes a phase shift on some places
of the tubes which can be measured with sensors.

ELECTROMAGNETIC FLOW METER:

Electromagnetic flowmeter is different from all other flowmeters due to its uniqueness on several accounts.
The basic principle of operation can be understood from that electromagnetic induction that is when a
conductor moves in a magnetic field, the induced e.m.f. produced perpendicular to the direction of flow

Fig. 11

D. LEVEL TRANSMITTERS: Level Transmitters are sensors with an electrical transmission output
for remote indication of liquid, powder or bulk level. Capacitive, float, mechanical, submersible, and
ultrasonic models are the different types available of level transmitters.

14 | P a g e
These are the various types of transmitters which is used to transmits the parameters from the field to the
control room .

3.1.2 PROCESS FLOW DIAGRAM OF DCS :

Fig. 12

An example of process control is represent below :

Fig. 13 Example

A. JUNCTION BOX:

Junction boxes form an integral part of a circuit protection system where circuit integrity has to be provided,
as for emergency lighting or emergency power lines, or the wiring between a nuclear reactor and a control
room. In such an installation, the fireproofing around the incoming or outgoing cables must also be extended
to cover the junction box to prevent short circuits inside the box during an accidental fire. Many branch
cables connections from various transmitters coming to junction box and metallic core is the output of the
junction box. To detect the problem in any wire addressing is done on each connection from junction box to
analog input module.

Fig. 14
15 | P a g e
 B. ZENER BARRIER:

For an explosion, all three of gas/dust, oxygen and source of ignition (spark or heat) need to be present.
Intrinsic Safety works on the principle of removing the source of ignition. This can be achieved by using a
Zener Barrier or Galvanic Isolator.

Fig. 15

A Zener barrier is a simple device where the voltage & current (Power, Energy) is limited into the hazardous
area. The voltage is limited/clamped by a Zener diode and the current limited by an output resistor. The fuse
is there to protect the Zener diode. The key to safety is the intrinsically safe earth. Without it, there is no
protection. These components are all ‘Safety Components’ meaning components upon which safety
depends.

C. PIDCONTROLLER :

A proportional–integral–derivative controller (PID controller or three term controller) is a control

loop mechanism widely used in industrial control systems and a variety of other applications requiring
continuously modulated control. A PID controller continuously calculates an error

value as the difference between a desired set point(SP) and a measured process variable (PV) and
applies a correction based on proportional, integral, and derivative terms (denoted P, I, and D respectively)
which give the controller its name.

16 | P a g e
 Fig. 16 AID Operation

In practical terms it automatically applies accurate and responsive correction to a control function. An
everyday example is the cruise control on a road vehicle; where external influences such as gradients would
cause speed changes, and the driver has the ability to alter the desired set speed. The PID algorithm restores
the actual speed to the desired speed in the optimum way, without delay or overshoot, by controlling the
power output of the vehicle’s engine. The first theoretical analysis and practical application was in the field
of automatic steering

Systems for ships, developed from the early 1920s onwards. It was then used for automatic process control
in manufacturing industry, where it was widely implemented in pneumatic, and then electronic, controllers.
Today there is universal use of the PID concept in applications requiring accurate and optimized automatic
control.

D. HMI(HUMAN MACHINE INTERFACE):

The Human Machine Interface (HMI) is the interface between the process and the operators – in essence an
operator’s dashboard. This is the primary tool by which operators and line supervisors coordinate and
control the industrial and manufacturing processes in the plant. HMIs serve to translate complex process
variables into usable and actionable information. Displaying near real-time operational information is the
domain of the HMI. Visual process graphics give meaning and context to motor and valve status, tank levels
and other process parameters. HMIs give operational insight into the process and enable control and
optimization by regulating production and process targets.

Mainly it works in two modes:

 Auto mode

 Manual mode

17 | P a g e
 Fig. 17 DCS Screen

3.1.3 Final control element (control valve):

A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed by a
signal from a controller.[1] This enables the direct control of flow rate and the consequential control of
process quantities such as pressure, temperature, and liquid level.

In automatic control terminology a control valve is termed a “final control element”.

Control action

Taking the example of an air-operated valve, there are two control actions possible:

 “Air or current to open” – The flow restriction decreases with increased control signal value.
 “Air or current to close” – The flow restriction increases with increased control signal value.

There can also be failure to safety modes:

 Air or control signal failure to close” – On failure of compressed air to the actuator, the valve closes
under spring pressure or by backup power.
 Air or control signal failure to open” – On failure of compressed air to actuator, the valve opens under
spring pressure or by backup power.

The modes of failure operation are requirements of the failure to safety process control specification of the
plant. In the case of cooling water it may be to fail open, and the case of delivering a chemical it may be to
fail closed.

The modes of failure operation are requirements of the failure to safety process control specification of the
plant. In the case of cooling water it may be to fail open, and the case of delivering a chemical it may be to
fail closed.

18 | P a g e
 Fig. 18 Control valve

Types of Valves:

Ball Valve. Ball valve is a quarter turn operated valve.

Fig. 19

Gate Valve. Gate valve is a sliding type of valve

Fig. 20

Plug Valve. Similar to ball valves, plug valves are also quarter turn type of valves.

Fig. 21

Butterfly Valve. Butterfly valves are most simple yet versatile valves.
19 | P a g e
 Fig. 22
Positioner
The part of a control valve used to control the opening or closing of the actuator based on electric, or
pneumatic signals

3.2 Programmable logic controller:

A programmable logic controller (PLC), or programmable controller is an industrial digital

computer which has been ruggedized and adapted for the control of manufacturing processes, such
as assembly lines, or robotic devices, or any activity that requires high

reliability control and ease of programming and process fault diagnosis.

They were first developed in the automobile industry to provide flexible, ruggedised and easily
programmable controllers to replace hard-wired relays, timers and sequencers. Since then they have been
widely adopted as high-reliability automation controllers suitable for harsh environments. A PLC is an
example of a "hard" real-time system since output results must be produced in response to input conditions
within a limited time, otherwise unintended operation will result.

Fig. 23

In mathura refinary PLC is basically used forshutdown handling purpose . in case any controlling is not
performed by DCS ,it is tripped out or shutdown by plc

PLC can be programmed by mainly two languages :

Ladder Logic

FBD(Function Block Diagram)

20 | P a g e
 Fig. 24

In case of plc final control element is solenoid valve and field input are switches. As in any vessal pressure
is crosses its maximum limit and unable to control by DCS so plc is shutdown the system by trip the input or
close the solenoid valve

21 | P a g e