Report on Vocational Training

July 31

2014

Submitted By:

Name: Rishabh Rajan

Semester: VIIth Sem.Roll: 11EMTEC093

Electronic & Communication Engineering

M.A.I.E.T. Jaipur / R.T.U. Kota (Raj.)

Vocational Training at IOCL (June 16, 2013 to July 31, 2014 )

Indian Oil Corporation Limited

Barauni Refinery, Bihar

Acknowledgement

I would like to thank Mr. A.B. Minz, Chief Manager(Training & Development) for giving me anopportunity to explore my ideas and interact withexperts of the industry at Barauni (Bihar) Refinery. Iextend my heartiest thanks to Mr. Abhijeet Sir, Dy.Manager (Inst.) and Mr. Nishant, Sr. Inst. Engineer(BXP Unit) for their inspiration and kind support. Thistraining would have not been so fruitful without theirguidance.

I would also like to thank all officers and staff of thecompany for their support and cooperation. Finally Iwould like to express my sincere gratitude to myparents, for helping me to undertake this training andconstantly encouraging me to interact with the expertsand make the best use of the immense opportunitiesavailable at the refinery.

CONTENTS

1. OVERVIEW

Indian Oil Corporation Ltd

Indian Oil, is an Indian state-owned oil and gas

corporation with its headquarters in New Delhi,

India.

Indian Oil and its subsidiaries account for a 49%

share in the petroleum products market, 31%

share in refining capacity and 67% downstream

sector pipelines capacity in India.

Indian Oil operates the largest and the widest

network of fuel stations in the country, numbering

about 20,575 (16,350 regular ROs & 4,225 Kisan

Seva Kendra).

It supplies Indane cooking gas to over 66.8

million households through a network of 5,934

Indane distributors.

REFINERIES

Barauni Refinery, in Bihar. It was commissioned

in 1964 with a capacity of 1 MMTPA. Its capacity

today is 6 MMTPA.

Gujarat Refinery, at Koyali (near Vadodara) in

Gujarat in Western India, is Indian Oil’s 2nd largest

refinery.

Panipat Refinery is the 7th and largest refinery of

Indian Oil. The original refinery with 6 MMTPA

capacity was built and commissioned in 1998.

Haldia Refinery is the only coastal refinery of the

Corporation. It was commissioned in 1975 with a

capacity of 2.5 MMTPA, which has since been

increased to 7.5 MMTPA.

Barauni Refinery

Barauni Refinery, in Bihar. It was commissioned

in 1964 with a capacity of 1 MMTPA. Its capacity

today is 6 MMTPA.

Barauni Refinery in the Bihar state of India was

built in collaboration with the Soviet Union at a

cost of Rs.49.4 crores and went on stream in July,

1964.

Barauni Refinery was built in collaboration with

Russia and Romania. It is situated 125 kilometres

from Patna.

Barauni Refinery receives crude oil by pipeline

from Paradip on the east coast via Haldia.

Highlights of Barauni Refinery:

The establishment of a totally electronic-based

communication system within the refinery.

The presence of four ambient air monitoring

stations that were in place well before the refinery

was in use.

It is an eco-friendly refinery, as indicated by a

green belt outside it.

Zero discharge of effluent gases.

It has the lowest manpower of all refineries in the

region with similar capacities.

2. Field Instruments

> Pressure Measurement :

Instruments used to measure pressure are called

pressure gauges or vacuum gauges.

Pressure gauge performs the mathematical

operation of subtraction through mechanical

means, obviating the need for an operator or

control system to watch two separate gauges and

determine the difference in readings.

.

1. Bourdan pressure gauges

2. Diaphragm

pressure gauges

Types of Pressure Gauge

Barometer Pressure gauge : It has a glass tube

closed at one end, with an open mercury-filled

reservoir at the base.

Monometer Pressure gauge : This is the most

simple and precise device used for the measurement

of pressure.

Capacitive: This is applied measurement of low

pressure.

Electromagnetic: It measures the displacement of a

changes in inductance, Hall Effect, or eddy current

principle.

Piezoelectric: It uses the piezoelectric effect in

certain materials such as quartz to measure the strain

upon the sensing mechanism due to pressure. This

technology is commonly employed for the

> Temperature Measurement :

Thermocouples: It consists of two dissimilar

conductors in contact, which will produce a

voltage when heated. Conductor will experience

the temperature gradient, and develop a voltage

of its own.

Thermistors: It is a resistor whose resistance

varies significantly with temperature. These are

used as in rush current limiters & temperature

sensors.

Fig:

Thermistors

Pyrometer: A pyrometer has an optical system

and a detector.

> Magnetic Flow Meter :

The magnetic flow meter A mass flow meter is a

device that measures mass flow rate of a fluid

traveling through a tube. It requires a conducting

fluid and a non-conducting pipe liner. The

electrodes must not corrode in contact with the

process fluid.

> Level Measurement :

Radar : Radar is an object detection system which

uses radio waves to determine the range, altitude,

direction, or speed of objects. It is mounted on the

top of the vessel.

Ultrasonic : In this method ultrasonic sound

waves are used in place of radio waves. It also

works on the basis of Doppler Effect for level

measurement.

Capacitive : In this method, the property of a

capacitor is used that the capacitance of the

capacitor changes when a dielectric material

(medium) is introduced between its two plates. The

capacitance of the capacitor is directly proportional

to the level in the vessel.

> Control 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

various passageways.

Valves are found in every industrial process,

including water & sewage processing, mining,

power generation, processing of oil, gas &

petroleum, food manufacturing, chemical &

plastic manufacturing and many other fields.

Components of Control Valves:

Air Filter Regulator (AFR): It filters the air &

removes the small unwanted dust particles. The

filtered air can also be regulated with the help of

AFR.

Positioner: This is used for position control. It

receives air from AFR & it also receives a signal

from control room. Positioner supplies that amount

of air to the valve which fulfills the control room

demand.

3. Process Control & Monitoring:

> Distributed Control System (DCS):

DCS (Distributed Control System) is a

computerized control system used to control the

production line in the industry. The entire system of

controllers is connected by networks for

communication and monitoring.

A DCS typically uses custom designed processors

as controllers and uses both proprietary

interconnections and communications protocol for

communication.

DCSs are connected to sensors and actuators and

use set point control to control the flow of material

through the plant.

DCSs may employ one or more workstations

(FCS or HIS) and can be configured at the

workstation or by an off-line personal computer.

>Programmable Logic Controller

(PLC):

A Programmable Logic Controller, PLC is a digitalcomputer used for automation ofelectromechanical processes.PLC is designed formultiple inputs and output arrangements.

It is also called Programmable Controller.

It performs sequential relay control, motioncontrol, process control, distributed controlsystems and networking.

Allen Bradley PLC :

> Vibration Analysis :

Vibration Analysis is monitoring instrumentation

company, providing services for sensors, systems,

and monitoring machinery vibration.

Vibration Analysis

>Plant Resource Manager (PRM):

Plant Resource Manager (PRM) is a plant assetmanagement (PAM)software tool that works withproduction control systems CENTUM.

PRM can monitor the condition of plant assetsremotely.

Typical applications:

1. Impulse line blocking diagnostics for differentialpressure

transmitters.

2. Heat trace diagnostics for a group of pressure transmitters.

3. Diagnostics for magnetic flow meters.

4. For control valves

5. Valve health monitoring

Alarm & Shutdown System

All the important equipment are provided with alarm and shutdown devices for critical operating parameters.

All the storage devices are provided with high level alarms.

Emergency shutdown switch is provided in control room to shutdown the plant in any case of emergency.

Remote shutdown switches are provided in the local panels of two most important equipment-inlet gas compressor and expander compressor.

Status monitoring is done round the clock through DCS work stations. Operation tested during running condition, planned and non-planned shutdown of the plant.

Conclusion

The vocational training enhanced our practical

knowledge . Most importantly , we were oriented

to the industrial scenario and its many challenges

and subtleties . The smooth functioning of an

industry depends to a large extent on the mutual

co-operation among its different wings.

Nevertheless , we did enjoy the training to the

fullest and are very sure that this training will help

us in our future endeavors.

T H A N K I N G __ Y O

U