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No. Topic Page No.

1 Title Page 1

2 Figure: Thermal Power Station 6

3 Abstract 3

4 Detailed Report 4

5 Conclusion 12

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Summer Training Report

Name : Himanshu Mishra

Roll No. : 11010325

Phone : 8474859748 847

E-mail : h.mishra@iitg.ernet.in

Company Name : Indian Oil Corporation Limited

Refineries Division : Guwahati Refinery

Supervisor : Padmashri Sarma

Telephone Number : 0361-2597777

Internship Start Date : 18/5/2014

Internship End Date : 11/7/2014

Report Date : 10/7/2014

Department of Mechanical Engineering Indian Institute of Technology Guwahati

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Internship Report

1. Abstract:

We did our summer internship at Indian Oil corporation limited Guwahati

refinery. During the training, we witnessed how problems were diagnosed and

delivered. In the past two months we learnt how an industry runs and what the

work of an engineer is. It gave us a wide practical outlook of whatever we have

got to learn till now. The principle objective of the intern was to understand &

implement how Technology is the making, modification, usage, and knowledge of

tools, machines, techniques, crafts, systems, and methods of organization, in

order to solve a problem, improve a preexisting solution to a problem, achieve a

goal, handle an applied input/output relation or perform a specific function. Thus

for a science student, importance of industrial training is immense, without which

the principles learnt can’t be fully utilized.

The lessons which we got from internship are how to deal with different people

having diverse background, dealing with several mechanical equipment &

perceiving their practical applications. Came to know how a giant organization

works. Became aware of the fact that an engineering principle learnt in a

classroom is always borne out by practical experience; it creates a strange sense

of excitement running into an old friend amongst crowd of strangers. All the

pumps, compressors, turbines, valves, etc., pictures of whose pictures only have

we seen were right before us.

Learned about safety measures required in a plant to avoid casualties. Got

knowledge of company’s collaborations & its joint ventures. Things like different

working units, their joint operations & functioning are quite clear after sincere

inspection of the refinery for eight weeks. Interaction with corporate-personnel at

various departments gave proper understanding of life and challenges offered by

public sector organization. Also, exposing in an operating industry gave a lot of

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Visual experience to perceive and feel, whatever we have already learned in theory classes.

2. DETAILED INTERNSHIP REPORT

2.1 Introduction of the company:

Indian Oil Corporation (BSE: 530965) is an Indian State owned oil and gas

company. It is India’s largest commercial enterprise, ranking 105th on the fortune

global 500 list in 2009. Indian Oil Corporation (IOC) is the biggest company in

terms of revenue, followed by Reliance Industries, according to the Fortune 500

list of Indian companies for 2012.Indian Oil and its subsidiaries account for 47%

share in the petroleum products market, 40% share in refining capacities 67%

downstream sector pipe lines capacity in India. The Indian Oil groups of

companies owns and operate ten of India’s 19 refineries with a combined capacity

of 60.2 MMTPA. Indian oil’s product range covers petrol, diesel, LPG, Auto LPG,

ATF, Lubricants, Naptha, Bitumen, Paraffin, Kerosene etc. Xtra premium petrol,

Xtra Mile diesel, servo lubricants, INDANE LPG, auto gas LPG, Indian oil aviation

are some of its prominent brands.

Recently Indian Oil has also introduced a new business line of supplying LNG (Liquefied Natural Gas) by cryogenic transportation this called “LNG at doorstep”.

IOCL has its refineries at Digboi, Barauni, Gujarat, Haldiya, Mathura, Guwahati,

Panipat & few other subsidiaries. Our internship location was Guwahati refinery.

Guwahati Refinery (Assam), the first public sector refinery of the country, with a

capacity of 1 MMTPA, Guwahati Refinery processes crude oil received from the

Assam Oil Fields and cater to the requirements of the petroleum product of the

North Eastern Region. The Guwahati Refinery has the Following Units:-

Crude Distillation Unit (CDU) Delayed Coke Unit (DCU) Nitrogen Unit

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INDMAX Unit Sulphur Recovery Unit (SRU) Hydrogenation Unit (HGU) Hydrotreater Unit Oil Movement and Storage Effluent Treatment Unit

2.2 Leaning objectives and outcomes of the internship: Brief Description Of all units visited in the plant:

1. Mechanical Workshop

We started our vocational with 6 days of training in the mechanical workshop.

Being students of mechanical engineering, the workshop was the most

important place of learning since we got to know the internal working of a

variety of mechanical machines used in the refinery. The workshop here in IOCL,

Guwahati refinery was divided into various sections, such as:

Fabrication Pumps Valves Welding Mechanical seals

We saw and understand the principles of valve, both radial & roller (cylindrical &

non cylindrical) type bearings, pumps (centrifugal & reciprocating) and its

components like shaft, shaft sleeve, coupling & heat exchangers.

2. Thermal Power Station (TPS)

Here, the power is generated from steam turbines after generating steam from

the water taken from the river Brahmaputra. 3 impulse reactive turbines are used

here. One of them is kept stand-by. There are 5 boilers to produce the steam. The

water after being taken from the river Brahmaputra, is taken to the Water

Treatment Plant (WTP). After that it is demineralized in the DM plant. A part of

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the water after treatment is used for domestic consumption. The remaining part

is sent to the boiler to produce steam. The steam is then used to rotate the

turbines which produce the electricity for the plant. The process flow diagram

shows the entire process:

3. Cooling Tower

Cooling Towers are evaporative cooler used for cooling water or other working

medium to near ambient temperature. The given figure shows the basic working

of a cooling tower:

Components of a cooling tower:

Frame and casing: support exterior enclosures Fill: facilitate heat transfer by maximizing water / air contact

(1) Splash fill (2) Film fill

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Cold water basin: receives water at bottom of tower - Drift eliminators: capture droplets in air stream

Air inlet: entry point of air Louvers: equalize air flow into the fill and retain water within tower Nozzles: spray water to wet the fill Fans: deliver air flow in the tower

Types of cooling towers:

1. Natural draft cooling tower 2. Mechanical draft cooling tower 4. BOILERS

Boiler is an apparatus to produce steam. Thermal energy released by

combustion of fuel is used to make steam at the desired temperature and

pressure. The steam produced is used for:

(1) Producing mechanical work by expanding it in steam engine or steam turbine. (2) Heating the residential and industrial buildings. (3) Performing certain processes in the sugar mills, chemical and textile industries

They are divided in basically two types:

1. Fire tube 2. Water tube

Fire tubes boilers have a large volume of water, therefore more flexible and can meet the sudden demand of steam without much drop of pressure.

Fire tubes boiler is rigid and of simple mechanical construction, so greater reliability and low in first cost.

Fire tube boilers can be made in smallest sizes therefore simple to

fabricate and transport, occupies less floor space but more height.

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Due to mostly externally fired water tubes boiler so furnace can be altered considerably to meet the fuel requirements.

Water tubes boilers are more readily accessible for cleaning, inspection

and repairs, compared to the fire tube boilers.

Modern trend is in the favors of water tube boiler due to continuous increase in capacities and steam pressures.

5. DM PLANT

Demineralization is the process of removal of dissolved solids present in

water by using the ion exchange process. The process employs the use of

ion exchange resins capable of removing the cations and anions present in

water. Demineralizing (DM) water is used in Oil Refineries, Petrochemicals,

and Fertilizers, Power stations, Heavy chemical factories, Paper and

Semiconductors and in metallurgical and other industries for various uses

like production of steam to generate power and drive machinery and for

processes as such as distillation and reforming etc. Since cost of resins

constitutes a major part of the total cost of DM plants, due consideration to

be given to the proper design and selection of resins to obtain optimum

results and minimize operating costs.

Water in its natural form may contain various impurities in suspended and dissolved state.

The major impurities of natural water classified in three major groups.

(1) Ionic and dissolved impurities

(2) Non-ionic and undissolved impurities

(3) Gaseous impurities.

Ionic and dissolved impurities may be cations or anions. Normally cations

present in water are Calcium magnesium and sodium while anions are

mainly chlorides, sulphate, bicarbonate and silica with lower concentrations

of nitrate, phosphate etc. Dissolved impurities: 1. Cationinc impurities

(calcium, magnesium, sodium, potassium, ammonia, iron, manganese) 2.

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Anionic impurities (bicarbonates, carbonates, hydroxides, sulfates,

chlorides, nitrates, phosphate, silica, organic matter). Apart from all these

non-ionic, undissolved & gaseous impurities are also present there.

6. TURBINES

The motive power in a steam turbine is obtained by the rate of change in

momentum of a high velocity jet of steam impinging on a curved blade

which is free to rotate. The steam from the boiler is expanded in a nozzle,

resulting in the emission of a high velocity jet. This jet of steam impinges on

the moving vanes or blades, mounted on a shaft. Here it undergoes a

change of direction of motion which gives rise to a change in momentum

and therefore a force. Steam turbines are mostly 'axial flow' types; the

steam flows over the blades in a direction parallel to the axis of the wheel.

'Radial flow' types are rarely used.

On the basis of operation, steam turbines can be classified as:

(1) Impulse turbine: In impulse turbine, the drop in pressure of steam takes

place only in nozzles and not in moving blades. This is obtained by making

the blade passage of constant cross-sectional area. It primarily consists of: a

nozzle or a set of nozzles, a rotor mounted on a shaft, one set of moving

blades attached to the rotor and a casing.

(2) Impulse-reaction turbine: In this type, the drop in pressure takes place

in fixed nozzles as well as moving blades. The pressure drop suffered by

steam while passing through the moving blades causes a further generation

of kinetic energy within these blades, giving rise to reaction and adds to the

propelling force, which is applied through the rotor to the turbine shaft.

The blade passage cross-sectional area is varied (converging type).

7. CRUDE DISTILLATION UNIT (CDU)

The first step of refining crude oil is carried out in the crude distillation unit

often commonly called as the mother distillation unit. This unit comprises

of various units employed for crude oil pre-heating, desalting, fractionating,

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condensing hydro-carbon vapors, heating. The products obtained from this

unit may be termed as "straight run" products and needs treatment to

meet the product specification.

THE VARIOUS SECTIONS OF CDU SECTION ARE:

1. DESALTER, 2. PRETOPPING COLUMN (CL-1) 3. ATMOSPHERIC FURNACE (C-1A) 4. BURNERS

8. DELAYED COKER UNIT (DCU)

The Delayed Coking Unit has a primary objective of extracting some lighter

and valuable components from the Reduced Crude Oil (RCO) which comes

from the bottom of the crude distillation unit. The primary product

obtained from this unit is Reduced Petroleum coke; nevertheless some

lighter components of LPG, Gasoline and Kerosene fractions are extracted

from the feed i.e. RCO before coke formation occurs.

9. HYDROGEN GENERATION UNIT (HGU)

The Hydrogen unit consists of desulfurization, pre refilling and process gas

cooling and high now temperature shift conversion sections to increase the

hydrogen content of the process gas. Purification is done with a PSA unit.

The feedstock to the hydrogen unit is LRU off gas and naphtha feed.

Feed: Straight Run Naphtha (SRN), LRU off gas

Though LRU off gas is not used much because of its high diene content. Product: Hydrogen.

10. HYDRO TREATER UNIT (HDT)

The main function of this unit is to reduce the sulphur content of diesel and

to increase the efficiency of the fuel by increasing its cetane number.

Moreover, it also produces ATF from kerosene by increasing the smoke

point.

Cetane number or CN is a measurement of the combustion quality of diesel

fuel during compression ignition. It is a significant expression of diesel fuel

quality among a number of other measurements that determine overall

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diesel fuel quality. Cetane number or CN is actually a measure of a fuel's

ignition delay; the time period between the start of injection and the first

identifiable pressure increase during combustion of the fuel. In a particular

diesel engine, higher cetane fuels will have shorter ignition delay periods

than lower cetane fuels. Cetane numbers are only used for the relatively

light distillate diesel oils.

11. INDMAX

INDMAX is a high severity catalytic cracking process exclusively developed

by IOC, R&D center to produce very high yield of LPG from various

hydrocarbon fractions viz., Naphtha to Residues. The process employs

proprietary catalyst formulations having excellent metal tolerance with

coke and dry gas selectivity. The operating conditions of the unit are such

that the liquid hydrocarbon products are selectively over cracked to LPG

containing fractions of C3 and C4 olefins without proportionate increase in

dry gas and coke.

12. SULFUR RECOVERY UNIT (SRU)

Sulfur Recovery Unit has been designed to recover sulfur from the following acid gas streams:

Acid Gas from Amine Regeneration Unit(ARU) Sour Gas from Sour Water Stripper Unit(SWS)

13. Planning - Plan the Act. Act the Plan

Due to the record high and fluctuating crude prices, refineries are under

extreme pressure to cut down operating costs. This has led to a great focus

on the management processes and tools, which when effectively used,

result in significant benefits for the refinery. This section talks about the

practices that are followed while modeling the planning and scheduling

tools.

Data Consistency across Models

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The data that is present in the planning and scheduling models should be

accurate and tuned to represent the current conditions of the plant. There

should be a person/team of people who are given the responsibility of

having consistent data across all models used in planning and scheduling.

There should be a good business process for the model update.

3. CONCLUSION

Today, with competition in industry at an all-time high, Total Perfect

Maintenance (TPM) of the industry may be the only thing that stands

between success and a total failure for some companies. It has been proven

to be a program that works. It can be adapted to work not only in industrial

plants, but in construction, building maintenance, transportation, and in a

variety of other situations. Employees must be educated and convinced that

TPM is not just another “Program of the Month” and that management is

totally committed to the program and the extended time frame necessary

for full implementation. If everyone involved in a TPM program does his or

her part, an unusually high rate of return compared to resources invested

may be expected.

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