Indian Oil corporation Limited,

Barauni Refinery

Vocational Training Report

(4th Dec,2018 – 31st Dec,2018)

Under guidance of :
Sh. D.H. Rao Sh. Sunil Kumar
Dy. General Manager (Maint.) SMNM (Mech. Workshop)
Sh. N.D. Shah Sh. A.K. Thaker
CMNM (BXP & MSQ) SMNM (TPS)

Submitted to: Submitted by:

Sh. D.H. Rao Sachin Kumar Singh
Dy. General Manager (Maint.) (16ME10052)
Third-Year UG Student of
IIT Kharagpur
______________________
Signature
 ACKNOWLEDGEMENT

My indebtedness and gratitude to the many individuals who

have helped to shape this report in its present form cannot
be adequately conveyed in just a few sentences. Yet I must
record my immense gratitude to those who helped me
undergo this valuable learning experience at IOCL Barauni.

I am highly obliged to Mr D.H.Rao sir, Dy General Manager

(Maint) to give me the brief idea and providing me a proper
schedule to help improve my technical experience in Barauni
refinery. He is the one who motivates us to learn and grow
and also build an immense interest about taking industrial
interest at its best. I thank Sh. Sunil Kumar, SMNM
(Mechanical workshop) for sharing his deep knowledge about
various pumps and other equipment’s in workshop. I thank
Sh. N.D. Shah, CMNM (BXP) to appoint a technician named
Mr MD. Zafur who guide me to a visit to the inside of
industry.
I am very grateful to Mrs Krishna Kumari (Asst. Manager,
L&D) for providing me this opportunity to learn at IOCL
Barauni.
Last but not the least I am thankful to almighty god, my
parents and teammates for their immense support and
cooperation throughout the training period.
 Introduction
IndianOil is the largest commercial oil company in the country, with a net
profit of INR 19,106 crore for the financial year 2016–17. It is ranked 1st in
Fortune India 500 list for year 2016 and 168th in Fortune's ‘Global 500’ list
of world's largest companies in the year 2017. As of 31 March 2017.
IndianOil's employee strength is 33,135. It is India's largest downstream oil
company with a turnover of Rs. 506,428 crore and a net profit of Rs. 21,346
crore in 2017-18.
As on 31st March 2018, the Company owns 11 (including two of its
subsidiary) of India's 23 refineries with a combined refining capacity of
80.70 MMTPA, accounting for 33% of domestic refining capacity.
lndianOil operates a network of 13,400 km of cross-country pipelines for
transporting crude oil, refined petroleum products and natural gas, with a
cumulative throughput capacity of 94.79 MMTPA of oil and 9.5 MMSCMD of
gas. During the year, 543 km of new pipeline sections were commissioned.
During the year, lndianOil continued its dominance in the domestic market
with a market share of over 44%, covering the entire range of petroleum
products from LPG, petrol, diesel, CNG, aviation fuels, lubricants, naphtha,
furnace oil, speciality products , etc. The marketing and distribution
network was expanded to over 47,800 customer touch points during the
year.
lndianOil's R&D Centre, one of Asia's finest, currently has an inventory of
over 600 patents . The Centre is expanding its research prowess beyond
lubricants and refining technologies to new and emerging areas like bio-
fuels, nano-technology, battery storage and other horizon technologies.
Technologies developed in-house include the path-breaking INDMAX
technology for enhanced LPG yield, which bagged the Excellence Award for
Innovation at the World Petroleum Congress in Turkey this year
lndianOil is determinedly working on making its operations greener and
aims to reduce its specific carbon and water footprints by 18% and 20%
respectively by the year 2020, with 2012-13 as the base year.

Barauni Refinery
Barauni Refinery was commissioned in 1964 with a capacity of 1 MMTPA.
Now its capacity is 6 MMTPA and sooner will become 9 MMTPA with new
plant that will produce BS-VI grade fuel.
Built in collaboration with Russia and Romania, with an intial cost of Rs
49.40 cr, initially it was designed to process low sulphur Crude Oil (Sweet
Crude) of Assam. Now it handles both sweet and sour crude oil but due to
environmental factor sweet crude oil is more preferred. It receives crude oil
by pipeline from Paradip on the eastern cost via Haldia.
Petroleum products are transported through various modes like rail, road as
well as environment-friendly pipelines. The Refinery caters to the high-
consumption demand centres in North-Western India including the states of
Haryana, Punjab, J &K, Himachal, Chandigarh, Uttaranchal, as well as parts
of Rajasthan and Delhi.
 Main Products and their units
in Barauni Refinery
• LPG – from AVU
• Straight Run Naptha (SRN) – from AVU
• Superior Kerosene Oil (SKO) – from AVU
• High Speed Diesel (HSD) – from DHDT
• Motor Spirit – from MSQ
• Light Diesel (LDO) – from coker
• Sulphur – from SRU
• Carbon black Feedstock (CBFS)
• Furnace Oil (FO) – from coker
• Raw Petroleum Coke (RPC) – from coker
• Bitumen – from AVU

Abbreviation used:
AVU – Atmospheric & Vacuum Unit
MSQ – Motor Spirit Quality upgradation unit
DHDT – Diesel Hydrodesulphurisation Treatment Unit
SRU – Sulphur Recovery Unit
 Mechanical Workshop
• This department of refinery inspects and repairs the defective
mechanical equipment like pumps, compressor, heat
exchanger etc.
For these purpose mechanical workshop of BR has:
• 9 Lathe machine
• 1 Milling machine
• 1 Bend saw
• 1 cutter machine
• 1 Disc cutter
• 2 Balancing Machine and more

General problems arises in machines:

• Vibration in pump
• Mechanical seal
• Bearing failure
• Impeller damage etc.

Pump: A pump is a device that moves fluids (liquids or gases),

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 can be classified by their method of displacement into
two basic types of pumps: positive displacement and
centrifugal. Although axial-flow pumps are frequently classified
as a separate type, they have essentially the same operating
principles as centrifugal 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.
• When a casing contains only one revolving impeller, it is called a
single-stage pump. When a casing contains two or more revolving
impellers, it is called a double- or multi-stage pump.
Centrifugal pumps:
Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational
energy typically comes from an engine or electric motor. The fluid enters the
pump impeller along or near to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser or volute chamber (casing),
from where it exits.

Application of centrifugal pump

in BR:
• For circulation of cooling water.
• In liquid storage tanks.
• For pump the fluid (crude oil,
VGO, diesel etc.) in reactors,
coulombs etc with high pressure.

Positive displacement pumps:

• A positive displacement pump makes a fluid move by trapping a fixed
amount and forcing (displacing) that trapped volume into the
discharge pipe.
• Some positive displacement pumps use an expanding cavity on the
suction side and a decreasing cavity on the discharge side. Liquid flows
into the pump as the cavity on the suction side expands and the liquid
flows out of the discharge as the cavity collapses. The volume is
constant through each cycle of operation.
Positive displacement pump behaviour and safety:
Positive displacement pumps, unlike centrifugal or roto-dynamic
pumps, theoretically can produce the same flow at a given speed (RPM)
no matter what the discharge pressure. Thus, positive displacement
pumps are constant flow machines. Hence a positive displacement
pump must not operate against a closed valve on the discharge side of
the pump, because it has no shutoff head like centrifugal pumps. A
positive displacement pump operating against a closed discharge valve
continues to produce flow and the pressure in the discharge line
increases until the line bursts, the pump is severely damaged, or both.
A relief or safety valve on the discharge side of the positive
displacement pump is therefore necessary. The relief valve can be
internal or external.
Positive displacement types:
A positive displacement pump can be further classified according to the
mechanism used to move the fluid:
• Rotary-type: internal gear, screw pump, shuttle block, flexible vane or
sliding vane, circumferential piston, flexible impeller, helical twisted
roots or liquid-ring pumps
• Reciprocating-type: piston pumps, plunger pumps or diaphragm
pumps
• Linear-type: rope pumps and chain pumps

1. Rotary positive displacement pumps

These pumps move fluid using a rotating mechanism that creates a
vacuum that captures and draws in the liquid.
Advantages: Rotary pumps are very efficient because they can handle
highly viscous fluids with higher flow rates as viscosity increases.
Drawbacks: The nature of the pump requires very close clearances
between the rotating pump and the outer edge, making it rotate at a
slow, steady speed. If rotary pumps are operated at high speeds, the
fluids because erosion, which eventually causes enlarged clearances
that liquid can pass through, which reduces efficiency.
2. Reciprocating positive displacement pumps
Reciprocating pumps move the fluid using one or more oscillating
pistons, plungers, or membranes (diaphragms), while valves restrict
fluid motion to the desired direction.
This type of pump was used extensively in the 19th century—in the
early days of steam propulsion—as boiler feed water pumps. Now
reciprocating pumps typically pump highly viscous fluids like concrete
and heavy oils, and serve in special applications that demand low flow
rates against high resistance.
Typical reciprocating pumps are:
• Plunger pumps
• Diaphragm pumps
• Piston pumps
• Radial piston pumps

VALVES
A valve is a device that regulates, directs or controls the flow of a fluid
(gases, liquids, fluidized solids, or slurries) by opening, closing, or
partially obstructing various passageways.
The simplest valve is simply a freely hinged flap which drops to obstruct
fluid (gas or liquid) flow in one direction, but is pushed open by flow in
the opposite direction. This is called a check valve, as it prevents or
"checks" the flow in one direction. Modern control valves may
regulate pressure or flow downstream and operate on
sophisticated automation systems.
Different types of valve:
Gate valve Globe valve Check valve
Plug valve Ball valve Butterfly valve
Needle valve Pinch valve Pressure relief valve
 MECHANICAL SEAL

A mechanical seal is a device that helps join systems or mechanisms

together by preventing leakage (e.g. in a plumbing system),
containing pressure, or excluding contamination. The effectiveness of a
seal is dependent on adhesion in the case of sealants and compression
in the case of gaskets.

• Types of compressing unit used:

• Multiple spring
• Single spring
• Bellow type
• Since mechanical seal is the most expensive part of pumps. Hence it
is used In leak-proof pumps which are used for pumping oils to avoid
any loss and to prevent hazards.
While in pumps for pumping water, gland packing and pusher is used
(a type of rope) to prevent leakage. Since water is cheaper and
,generally, not hazardous. Such arrangement makes pump
economically more favourable.
• Bellow type mechanical seal is used in hot pumps.
Barauni Expansion Plant(BXP) consist of following unit:
• RFCCU (Residue catalytic cracking unit)
• SRU (Sulphur recovery unit)
• DHDT (Diesel Hydrotreatment Unit)
• Hydrogen unit
• Residue Fluid catalytic cracking (RFCC)
is one of the most important conversion processes used in
petroleum refineries. It is widely used to convert the high-
boiling, high-molecular weight hydrocarbon fractions of
petroleum crude oils into more valuable gasoline, olefinic
gases, and other products.

• Hydrogen unit:
provides H2 to other units wherever required to form bonds
with carbon and to make C-chain simpler as required and also
in order to remove sulphur from C-chain.
Motor Spirit Quality Upgradation Unit (MSQ):
This plant processes motor spirit obtained from other plant by
removing sulphur and rearranging its chain in order to obtain a better
quality of petrol which can match norms of BS-IV grade fuels.

In order to match norms of BS-IV grade:

Suphur(<50 ppm), Olefin (<21%), Aromatics (<42%)
RON(Research Octane Number) (>91%).

Role of mechanical technicians:

BXP and MSQ consists of many compressors, pumps, valves, heat
exchangers, pipes etc. On analysis of all pressure and temperature data
obtained from all units, production dept. assign jobs to other dept. like
instrumentation, electrical and mechanical dept. After getting a work
permit, they inspect and repair the defective device and locks it with
suitable colour to denote the completion of job by a particular dept. on
the basis of colour of lock.
Hence maintenance of all mechanical units are done through a mutual
collaboration of every dept.

Types of maintenance:
• Predictive maintenance – maintenance done after analysis of a
particular device in running condition.
• Preventive maintenance- maintenance done at a particular interval of
time, irrespective of condition of the machine.
• Breakdown maintenance- maintenance done after breakdown/
failure of the device.
 Fire and Safety
SEED- Safety in Each and Every Deed
• Any refinery is highly prone to fire and explosion hazards because of volatile and
inflammable products and its intermediates. Any human mistake or ignorance
can cause a accident or even loss human lives.
• In Barauni refinery, to avoid any such accident, Fire and safety training is given
to each and every employees. It also has a very effective Fire and safety dept. of
its own, which can reach any unit within 3 min of information.

Hazards in a refinery:
• Highly inflammable fluids
• Explosion due temperature & pressure in tanks and pipes
• Toxic gases (i.e. CO, NH3, H2S, CH4 etc. )
• Height, dust, electrical etc.

Classes of Fire:
• Class A – by ordinary comustible materials (wood, paper, cloth etc.)
• Class B – by flammable liquids (gasoline, oils, propane, butane etc.)
• Class C – by energized electrical equipment
- remove power source then becomes one of other types
• Class D – by combustible metals (Mg, Na, K, Zr etc.)
• Class K – by cooking oils and greese

Fire Extinguisher – works on the principle of removing one or more

elements of the Fire triangle (i.e. heat, fuel, oxygen and chemical rxn).
Types of Fire extinguisher:
• Water & Foam – for class A fire only
• CO2 – for class B & C only, ineffective on class A
• Dry chemical – for class A, B & C
• Wet Chemical – for class K
• Dry Powder – for class D only and ineffective on all other
• Water and Mist – for class A & C
PPE’s selection and its use:
Personal protection equipment protects from any minor hazard. Hence, one
should always wear his PPE’s before entering a hazardous zone. PPE’s may
include safety helmet, safety glasses, ear bud, safety shoes, mask, gloves etc.
and should be properly used.
5’S of safety: In case of any hazard, one should follow the following
keywords
• Sort out
• Set in order
• Shine
• Standardise
• sustain

Syren Codes: are used to alert other people at the time of emergency or to
convey any other message.
Assembly point: always remember any assembly point near your working
place. At the time of any hazards, people are immediately rescued from these
points.
Hazardous area classification: barricading tapes and symbols are used
to denote/classify any region as hazardous in different sense. Hence, its
important to know meaning of each symbol and follow them sincerely.
 Monthly safety theme
• Jan – off the job safety and Road safety
• Feb – chemical hazards and its prevention
• March- Behaviour based safety
• April – fire prevention and protection in refinery
• May – Project safety/ construction safety
• June – safety during hot job
• July – safety while working at height
• Aug – Electrical safety
• Sept – Toxic gas hazard and its prevention
• Oct – Work permit system
• Nov – safety in confined space
• Dec – Disaster Management