SUMMER INTERNSHIP REPORT

(01ST JUNE 2024 – 30TH JUNE 2024)

INDIAN OIL CORPORATION Ltd.

GUWAHATI REFINERY, ASSAM

SCHOLARS INSTITUTE OF TECHNOLOGY AND MANAGEMENT,

GUWAHATI, ASSAM
A Project on Mechanical Engineering Department
SUBMITTED BY : -
Ishmita Das
YEAR/SEM : - 3rd year/ 6th sem
BRANCH/DEPTT. : - [Link]./ M.E.
SUBMITTED TO : -
MR. ABHINAVA CHOWDHURY(Maintenance Manager, Mech., IOCL GR)
AND
MR. AMIT KUMAR(Mechanical Engineer, Mech., IOCL GR)

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 To Whom It May Concern
This is to certify that Ishmita Das(2021ME0002), a student of Final year in
[Link]. in Mechanical Engineering from Scholars Institute of Technology and
Management, Kamrup Metro, Assam has undertaken internship at Indian Oil
Corporation Limited, Guwahati Refinery from 01-06-2024 to 30-06-2024 and have
successfully completed it.

During the internship, She has been found to be punctual, diligent, eagerness to
learn, and demonstrated exceptional aptitude and dedication. We found her to be a
team player with great communication skills. Based on their performance she has a
bright future in the field of Mechanical Engineering and we would like to recommend
her for any positions that aligns with her career.

Internship Guide: MR. ABHINAVA CHOWDHURY (Maintenance Manager,

Mech., IOCL GR)
AND
MR. AMIT KUMAR(Mechanical Engineer, Mech., IOCL
GR)

We wish her all success in life.

Dated: 30-01-2024
Place: Guwahati Refinery

_____________________ ____________________ _____________________

Mr. Abhinava Mr. Saswat Rajowar Mr. Amit Kumar,
Chowdhury
Maintenance Manager, HOD, M.E., MLE,
Mech., SITM, Guwahati Mech.
IOCL GR IOCL GR

2
 ACKNOWLEDGEMENT

We would like to take this opportunity to express gratitude to the training

department of Indian Oil Corporation Limited, Guwahati Refinery for
granting us the opportunity to be a part of this esteemed organization as
a vocational trainee. We want to thank Mr. S. Prabhu, Senior
Manager(MS,L&D) for his constant assistance provided during the time
of this training, We would also like to thank the fire and safety
department, Guwahati refinery, Indian Oil Corporation Limited for making
us aware of the various risks and potential hazards present in the
refinery campus and the measures taken to mitigate them.

We are grateful to Mr. Abhinava Chowdhury, Maintenance

Manager(Mech.), IOCL GR and Mr. Amit Kumar, MLE(Mech.), IOCL
GR for his constant guidance during the course of this training.

We would like to thank Mrs. Jhumur Lodh, Director and Mr. Saswat
Rajowar, HOD, M.E. Deptt. of Scholars Institute of Technology and
Management for encouraging us to undergo this Summer Internship
training in IOCL, We will be doing injustice if we forget to thank all the
shift in-charges and engineering assistants who dedicatedly educated us
about the processes undergoing in the plant, Last but not least, we
would like to thank our parents for their constant help, support, and
guidance,

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 PREFACE

Any amount of theoretical knowledge is incomplete without exposure to

industrial practice. Industrial training plays an essential role in the
progress of future engineers. Not only does it provide insights about the
future concerned, but it also bridges the gap between theory and
practical knowledge. Hence, in-plant training is of great importance for
engineering students.
We got the opportunity to undergo our industrial training in Guwahati
Refinery of Indian Oil Corporation for 30 days. The experience gained
during this period was highly educative for us. As a trainee, we learned
about the different units incorporated in refining processes and
maintenance work being carried out in the refinery. We also got to learn
about different maintenance processes of machines.
During our training, we realized that to be a successful Mechanical
engineer one needs to put his/her skills and concepts into action. The
training serves as a stepping stone for us in becoming a sound engineer
and helps us carve a niche for ourselves in this field.

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 CONTENTS

Sl. No. Topics Page No.

1. Abstract 6
2. Introduction 7-8
3. Divisions Of the Refinery 9-10
3.1. Refining Division
3.2. Marketing Division
3.3. Pipeline Division

4. Guwahati Refinery Overview 11-12

5. Workshop 13-14
5.1. Vault
5.2. Rotary
5.3. Machine
5.4. Fabrication

6. Skill Development Centre 15-19

7. Units Of Refinery 20-33
7.1. Crude Distillation Unit
7.2. Delayed Coker Unit
7.3. Hydrogen Generation Unit
7.4. Hydrotreater Unit
7.5. INDMax
7.6. INDAdeptG
7.7. Sulphur Recovery Unit
7.8. Effluent Treatment Plant
7.9. Themal Power Station
7.10. DM Plant

8. Machineries and Equipments 34-42

8.1. Pumps
8.2. Compressors
8.3. Heat Exchangers
8.4. ID Fans and FD fans
8.5. Valves

9. Maintenance Processes 43
9.1. Breakdown Maintenance
9.2. Preventive Maintenance
9.3. Predictive Maintenance
9.4. Shutdown Maintenance
9.5. Proactive Maintenance

10. Conclusion 44
ABSTRACT
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This report is prepared at Indian Oil Corporation Ltd, Noonmati,
Guwahati by Ishmita Das as a part of Industrial Training of 30 (thirty)
days from 01-06-2024 to 30-06-2024 and contains a brief description of
the refining process employed in the refinery.
It mainly focuses on the process description of various Units and
respective diagrams of the process. The details of each unit are briefed
as a part of practical training along with the methodology and the
procedure adopted are also included in this report.

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 INTRODUCTION

The oil business is a complex global industry encompassing exploration, production,

transportation, refining, and marketing of petroleum products. It's structured around
supermajors, national oil companies, and independents operating across upstream
(exploration and production), midstream (transportation and storage), and
downstream (refining and distribution) sectors. Key products include gasoline, diesel,
jet fuel, and petrochemicals. The industry is characterized by price volatility
influenced by geopolitics and supply-demand dynamics, with OPEC playing a
significant role. Technological innovations like fracking and deepwater drilling have
reshaped production capabilities. However, the sector faces increasing
environmental scrutiny due to carbon emissions and oil spills, prompting a gradual
shift towards cleaner energy sources. Future trends include greater focus on natural
gas, investment in renewables, and development of carbon capture technologies, as
the industry adapts to changing global energy needs and environmental concerns.
The first refinery set up in india was the Digboi Refinery in 1901. To understand a
refinery we need to know about the oil business. In Oil business there are four
divisions : -

1. Exploration & Extraction

2. Refining
3. Marketing
4. Pipelines
These three divisions are controlled by three key sectors : -

1. Upstream : Exploration and extraction

2. Midstream : Transportation and storage
3. Downstream : Refining and marketing

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IOCL is a Downstream sector as it focuses on refining and marketing division. IOCL
was first established on 1962 as Guwahati refinery in Noonmati. It is the India’s
largest commercial enterprise and national oil company
IOCL mainly focuses on refining, marketing and setting up pipelines.
It operates total of 11 refineries out of 23 total refineries in India. The 11 refineries of
IOCL and their year of establishment are given below : -
1. Guwahati Refinery, Assam (1962)
2. Barauni Refinery, Bihar (1964)
3. Gujarat Refinery, Vadodara (1965)
4. Haldia Refinery, West Bengal (1975)
5. Mathura Refinery, Uttar Pradesh (1982)
6. Digboi Refinery, Assam (1901, acquired by IOCL in 1981)
7. Panipat Refinery, Haryana (1998)
8. Bongaigaon Refinery, Assam (1979, merged with IOCL in 2009)
9. Paradip Refinery, Odisha (2016)
10. Narimanam Refinery, Tamil Nadu (1993, CPCL subsidiary)
11. Manali Refinery, Tamil Nadu (1969, CPCL subsidiary)
It is also the largest fuel retailer of India as it has over 30,000 retail outlet.
The key aspects of IOCL includes that it has vertically integrated operations, plays a
major role in petrochemicals, expanding into natural gas and alternative energy
sources.

DIVISIONS OF THE IOCL REFINERY

3.1. Refining Division : -

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 Indian Oil Corporation Limited's (IOCL) Refining Division is a cornerstone of
India's energy sector, operating 11 of the country's 23 refineries. These
facilities account for about 32% of
India's refining capacity, processing
a variety of crude oils to produce a
wide range of petroleum products.
Strategically located across the
country, from Digboi in the
northeast to Narimanam in the
south, these refineries cater to
regional needs while contributing to
the national supply chain.
Over the years, IOCL has
continuously invested in upgrading and expanding its refining capabilities.
This includes implementing advanced technologies to improve efficiency,
enhance product quality, and meet stringent environmental norms. The
company's newer refineries, like Paradip and Panipat, feature state-of-the-art
technology to process heavier and sourer crude oils, demonstrating IOCL's
commitment to technological advancement.
The Refining Division plays a crucial role in IOCL's vertical integration
strategy, providing feedstock for petrochemical units and supplying products
to its vast marketing network. It's also a hub of innovation, with IOCL's R&D
center working closely with refineries to develop new products and explore
sustainable refining technologies. As India's energy landscape evolves,
IOCL's refining division is adapting to future challenges, investing in biofuels,
hydrogen production, and other clean energy technologies.

3.2. Marketing Division : -

IOCL's Marketing Division is the largest and most extensive fuel retail network
in India. With over 30,000 retail outlets spread across the country, it ensures
the availability of petroleum products to millions of consumers daily. This vast
network includes not only urban
centers but also remote and
rural areas, playing a crucial role
in India's energy distribution.
The division handles a wide
range of products including
petrol, diesel, LPG, lubricants,
and specialty products.
The division leverages cutting-
edge technology to enhance
customer experience and
operational efficiency. This
includes automated fuel stations, digital payment systems, and loyalty
programs like XTRAREWARDS. IOCL has also been at the forefront of
implementing government initiatives such as direct benefit transfer for LPG
subsidies and the transition to cleaner fuels like BS-VI compliant petrol and
diesel.
Beyond traditional fuel retailing, IOCL's Marketing Division has been
diversifying its offerings. It has ventured into alternative energy solutions,

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 setting up electric vehicle charging stations and CNG dispensing facilities at
many of its outlets. The division also focuses on non-fuel retail, offering
services like convenience stores, quick service restaurants, and banking
facilities at select outlets. This strategy aims to transform fuel stations into
comprehensive "energy stations" catering to various consumer needs.

3.3. Pipeline Division : -

IOCL's Pipeline Division operates one of the largest networks of crude oil and
petroleum product pipelines in the world. This extensive network spans over
14,000 kilometers across India, serving as a vital artery for transporting crude
oil to refineries and finished products to distribution centers. The division plays
a crucial role in ensuring energy security by providing a cost-effective, energy-
efficient, and environmentally friendly mode of transportation for petroleum
products.
The pipeline network is equipped with
advanced technology for monitoring and
control. It utilizes SCADA (Supervisory
Control and Data Acquisition) systems,
leak detection mechanisms, and intelligent
pigging for maintenance. These
technologies ensure safe, efficient, and
uninterrupted operations, minimizing the
risk of accidents and product losses. The
division also employs sophisticated
scheduling and optimization tools to
manage the complex logistics of multi-
product transportation through its
pipelines.
Looking towards the future, IOCL's
Pipeline Division is continuously
expanding and upgrading its network to
meet growing demand and enhance
operational efficiency. It is also exploring innovative solutions like reverse flow
operations and multi-product pipelines to maximize asset utilization.
Additionally, the division is investigating the potential for transporting
alternative fuels like ethanol blends and even considering the feasibility of
hydrogen transportation through its pipeline infrastructure, aligning with India's
evolving energy landscape.

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 GUWAHATI REFINERY OVERVIEW

Fig : - IOCL Guwahati Refinery

The Guwahati IOCL refinery, nestled in Noonmati, Assam, stands as a landmark in

India's oil industry. Commissioned in 1962, it holds the distinction of being India's
first public sector refinery and marked the inception of IOCL's refining operations.
From its initial capacity of 0.75 Million Metric Tonnes Per Annum (MMTPA), it has
grown to its current capacity of approximately 1 MMTPA, processing crude oil
primarily from Assam's oil fields.

Over the years, the refinery

has evolved significantly,
undergoing several
modernization and expansion
projects. It produces a range of
petroleum products including
LPG, petrol, diesel, and
kerosene, as well as specialty
products like food-grade
hexane and mineral turpentine
oil. The facility has also
implemented various
environmental and safety measures, focusing on improving energy efficiency and
reducing emissions.

The Guwahati refinery plays a crucial role in meeting the petroleum product demand
of Northeast India and contributes significantly to the region's industrial development.
Despite challenges such as aging infrastructure and environmental concerns due to

11
its proximity to populated areas, it continues to be a vital asset in IOCL's operations.
Recent efforts have been directed towards exploring possibilities for further capacity
expansion, underscoring its ongoing importance in India's oil refining sector.

The Guwahati refinery's strategic location has been instrumental in fostering

economic growth in the Northeast region. By providing a steady supply of petroleum
products, it has supported various industries, transportation, and everyday life in this
part of India. The refinery has also been a significant source of employment and skill
development in the area, training generations of oil and gas professionals who have
contributed to India's energy sector.

Moreover, the refinery has adapted

to changing times and environmental
concerns. It has implemented several
eco-friendly initiatives, including
effluent treatment plants and air
quality management systems. The
facility has also been exploring ways
to reduce its carbon footprint and
increase its energy efficiency. As
India moves towards cleaner energy
sources, the Guwahati refinery is
likely to play a role in this transition,
potentially incorporating more sustainable practices and exploring the production of
cleaner fuels. Despite the challenges of an evolving energy landscape, the Guwahati
refinery remains a testament to India's journey towards energy self-sufficiency and
continues to be an integral part of IOCL's operations.

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 WORKSHOP

A workshop is the place where the maintenance of the machineries takes place. The
workshop mainly has four sections mentioned below :-

5.1. Vaults : -
The vault section of a refinery workshop is a specialized area dedicated to the
storage and maintenance of critical equipment and components. Here's a brief
overview:
The vault section serves as a secure storage facility for high-value, sensitive,
or critical parts and equipment used in refinery operations. It ensures that
these items are protected, well-organized, and readily accessible when
needed for maintenance or emergency repairs.

5.2. Rotary : -
The rotary section of a refinery workshop is crucial because it ensures the
continuous and efficient processing of raw materials, maintains necessary
pressure and flow rates, and contributes to energy conversion essential for
refining operations. Proper functioning of rotary equipment, such as pumps,
compressors, and turbines, directly impacts the reliability, safety, and
production output of the refinery. Efficient rotary machinery reduces energy
consumption and operational costs while supporting various stages of the
refining process, making it indispensable for the refinery's overall performance
and cost efficiency.

13
5.3. Machine : -
In the machine section of a refinery workshop all the necessary machineries
for drilling, milling, cutting and turning are seen. Here all the minute repairing
and shaping takes place. The machine section is mainly operated by the
technicians.

5.4. Fabrication : -
In the fabrication section of the refinery workshop the welding works are
carried out. . In a refinery, the welding section must adhere to stringent safety
and quality standards to ensure the integrity of the welded joints under high-
pressure and high-temperature conditions typical in refinery operations.
There are two types of welding carried out in this refinery oxyacetylene
welding and argon welding
Oxyacetylene Welding: Oxyacetylene welding, also known as gas welding,
uses a flame produced by burning a mixture of oxygen and acetylene gas to
melt and join metal parts.
Argon Welding: Argon welding, commonly referred to as TIG (Tungsten Inert
Gas) welding, uses an inert argon gas shield to protect the weld area from
atmospheric contamination while a tungsten electrode produces the weld.

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 SKILL DEVELOPMENT CENTRE

1. DIAPHRAGM DOSING PUMP : -

Uses a flexible diaphragm moved by a solenoid or mechanical drive to

precisely draw and discharge fluid.

2. MECHANICAL SEAL

Prevents fluid leakage with two close-contact surfaces, one rotating with the
shaft and one stationary.

3. MULTISTAGE CENTRIFUGAL PUMP

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 Multiple impellers increase fluid pressure in stages, providing higher
discharge pressure.

4. DOUBLE SUCTION IMPELLER

Allows fluid to enter from both sides, balancing hydraulic forces and
increasing efficiency.

5. SINGLE STAGE CENTRIFUGAL PUMP

Uses a single impeller to accelerate fluid, converting kinetic energy into

pressure.

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6. GEAR BOX (Worm & Wheel type)

Transfers motion and torque between non-parallel shafts using a worm gear
and wheel, reducing speed and increasing torque.

7. GLOBE VALVE

Regulates flow by moving a disc against or away from a stationary seat within
a spherical body.

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8. PRESSURE SAFETY VALVE

Automatically releases excess pressure to prevent equipment damage,

resealing when normal conditions are restored.

9. PLUG VALVE

Controls flow by rotating a cylindrical or conically-tapered plug with a through-

hole, aligning or blocking the flow path.

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10. BALL VALVE

Uses a spherical ball with a hole through its center, rotated to open or close
fluid flow.

11. GATE VALVE

Controls flow by raising or lowering a flat or wedge-shaped gate into or out of

the fluid path.

19
 UNITS OF REFINERY
5.1. Crude Distillation Unit (CDU) : -
The Crude Distillation Unit (CDU) at IOCL's Guwahati refinery is the primary
processing unit and the heart of the refinery's operations. Commissioned in
1962, it has undergone several upgrades to maintain efficiency and meet
modern standards. The CDU at Guwahati is designed to process about 1
Million Metric Tonnes Per Annum (MMTPA) of crude oil, primarily sourced
from Assam's oil fields. In this unit, crude oil is heated and separated into
various fractions based on their boiling points. The unit's operations are
critical in determining the overall productivity and product slate of the
Guwahati refinery, playing a vital role in meeting the petroleum product
demand of Northeast India.
The output sourced from this
unit are : -
1. Refinery fuel gas
2. LPG
3. Gasoline
4. Solvents
5. Aviation fuels (ATF)
6. Diesels
7. Heating oils
8. Lube oils
9. Asphalts
10. Industrial fuels
11. Refinery fuel oil
The stored crude oil is first sent to the desalter to remove salt, water, and
other impurities from crude oil before it enters the main distillation process, to
prevent corrosion and fouling of downstream equipment. The working
principle of a desalter is that an electrostatic field is applied by electrodes in
the settling tank, inducing polarization of the water droplets floating in the
larger volume of oil which results in water droplets clumping together and
settling to the bottom. The desalted crude is preheated in a series of heat
exchangers using
heat from various
product streams.
The preheated
crude oil is then
moved to the
Fractional distillation
column where the
crude oil is heated
at around 350°C to
400°C. The heated

20
 crude enters the distillation column where it separates into various fractions
based on boiling points. As the vapours rise, they cool and condense at
different levels respective to their cooling points and are collected on trays
that contain gas valves, i.e. Bubble cap valves or Sieve valves (The choice
between these valve types depends on factors like operating conditions,
desired efficiency, and cost considerations. Some modern distillation columns
may use more advanced valve designs) which allows only the gas to pass
through it. The heaviest fraction exits from the bottom of the column. Products
are cooled and sent to storage tanks or to other units for further processing.
Heat from hot product streams is used to preheat incoming crude, improving
energy efficiency. This process forms the foundation of the refinery's
operations, producing various components that are either used as final
products or serve as feedstock for other refining processes.

5.2. Delayed Coker Unit (DCU) : -

The Delayed Coker Unit (DCU) is the secondary unit and a critical component
in modern oil refineries, designed to process heavy residual oil from the
bottom of the distillation column into more valuable lighter products by thermal
cracking. DCUs are valuable for maximizing the yield of lighter, more valuable
products from heavy crude oils,
thereby improving refinery
economics and reducing the
production of less desirable heavy
fuel oils. In this process, the heavy
residual oil is heated to high
temperatures (around 480-510°C)
and then fed into large coke
drums where it undergoes thermal
cracking. As the oil decomposes, it
forms lighter hydrocarbons that
are recovered as valuable
products like naphtha, diesel, and
gas oil, while the heaviest components form petroleum coke.
The process starts when the reduced crude oil received from the CDU is
pumped by steam driven reciprocating pump 1(P1A/B) to the saturation
column . there are 4 passes through which the RCO is feed to the saturation
column. The column contains two main zones radiation zone and convection
zone .In the Radiation zone 10 burners and 5 blowers to radiate the heat
throughout the whole column which converts the fuel into gas. This fuel gas
then enters the convection zone which contains 1 induced draft fan(ID fan)
and 1 forced draft fan(FD fan) . the ID fan to maintain the draft pressure
suctions the air in the furnace which passes through the air pre-heater fed by
FD fan and the air is forced back to the furnace. This process is done to
maintain the draft pressure. It also contains a damper which helps in
maintaining the optimum pressure.

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 Then the crude oil is
heated to a very high
temperature of
around 480-510°C, in
a coke drum of
capacity 0.44
MMTPA, which is
then delayed for 24
hrs to obtain the
required products.
The process is
"delayed" because
the final coke
formation occurs in
the drums, not in the heating furnace. Then after extracting the products are
hard residue or the coke is cut by drilling and radial cutting with the help of a
high speed water jet of length 21m, this coke is transferred to other industries
that use coke as their feedstock.

5.3. Hydrogen Generation Unit : -

The Hydrogen Generation Unit (HGU) is a crucial component in modern oil
refineries, including those operated by IOCL. Its primary purpose is to produce
high-purity hydrogen, which is essential for various refining processes,
particularly hydrotreatment and hydrocracking. These processes remove
impurities like sulphur, nitrogen, and metals from petroleum products, improving
their quality and meeting stringent environmental regulations. The HGU also
supports the
production of cleaner
fuels and plays a role
in maximizing the
yield of valuable light
products from heavier
crude oil fractions.
The catalytic cracking
method of hydrogen
generation in refinery
is steam methane
reforming (SMR). In
this process, natural
gas (primarily
methane) or other
light hydrocarbons react with steam at high temperatures (800-900°C) in the
presence of a catalyst, typically nickel-based. This reaction produces a mixture
of hydrogen and carbon monoxide, known as syngas. The syngas then
undergoes a water-gas shift reaction, where the carbon monoxide reacts with
more steam to produce additional hydrogen and carbon dioxide.

22
 After the reforming and shift reactions, the gas mixture passes through a
purification system. This typically involves pressure swing adsorption (PSA)
units, which remove impurities and separate the high-purity hydrogen (99.9%+)
from other gases. The purified hydrogen is then compressed and distributed to
various units within the refinery where it's needed. The off-gas from the PSA
unit, containing unreacted methane and other components, is usually recycled
back to the reformer as fuel, enhancing the overall efficiency of the process.

5.4. Hydrotreater Unit (HDT) : -

The Hydrotreater Unit is an essential component in modern oil refineries,
designed to remove impurities from petroleum fractions. Its primary function is to
reduce sulphur, nitrogen, oxygen, and metal content in various hydrocarbon
streams, improving product quality and meeting environmental regulations.
Hydrotreaters play a crucial role in producing cleaner fuels with lower emissions
and in preparing feedstocks for other refinery processes that require low-impurity
inputs.

The hydrotreating process begins with the preheating of the hydrocarbon

feedstock, which is then mixed with hydrogen-rich gas. This mixture is further
heated in a fired heater before entering the heart of the unit - the hydrotreating
reactor. Inside the reactor, the feedstock and hydrogen flow over a fixed bed of
catalyst, typically containing metals like cobalt, nickel, or molybdenum on an
alumina support. The high temperature (300-400°C) and pressure (30-130 bar)
conditions, combined with the catalyst, facilitate reactions that remove impurities.

In the reactor, sulphur compounds are converted to hydrogen sulphide, nitrogen

compounds to ammonia, oxygen compounds to water, and metals are deposited
on the catalyst surface. After leaving the reactor, the treated product is cooled
and separated from the excess hydrogen and gaseous impurities in a series of
separators. The hydrogen-rich gas is recycled back to the process, while the
liquid product undergoes further separation to remove any remaining light gases

23
 and sour water. The final treated product, now with significantly reduced impurity
levels, is then sent for further processing or blending into final products. The
removed impurities, particularly hydrogen sulphide, are typically sent to a sulphur
recovery unit for conversion into elemental sulphur.

5.5. INDAdeptG : -

The INDAdept unit at the IOCL Guwahati Refinery is a state-of-the-art

processing unit designed to enhance the refinery's capacity for producing
high-quality fuels and petrochemicals. INDAdept, which stands for Indian
Advanced Energy-efficient and Environment-friendly Processing Technology,
focuses on upgrading and refining crude oil into valuable end products using
advanced techniques. The process involves several stages, starting with
crude distillation where the crude oil is separated into different fractions based
on boiling points. These fractions undergo further treatment in hydrocracking
and catalytic reforming units to improve their quality and remove impurities.
The hydrocracking process
breaks down heavier
hydrocarbons into lighter,
more valuable products such
as gasoline and diesel, while
catalytic reforming enhances
the octane rating of gasoline.
Throughout these processes,
the INDAdept unit employs
energy-efficient technologies
and stringent environmental
controls to minimize
emissions and reduce the refinery's carbon footprint. This advanced unit plays
a crucial role in meeting the increasing demand for cleaner fuels and adhering
to environmental regulations.

24
5.6. INDMax : -

The INDMax unit is an innovative, proprietary technology developed by Indian

Oil Corporation Limited (IOCL) for maximizing propylene and light olefins
production from heavy petroleum fractions. This technology is designed to
convert low-value heavy feedstocks into high-value petrochemical products,
particularly propylene, which is in high demand for the plastics and chemicals
industries. The INDMax unit represents a significant advancement in refinery-
petrochemical integration, allowing refineries to diversify their product slate and
improve overall profitability.
The working principle of the INDMax unit is based on a modified fluid catalytic
cracking (FCC) process. The feedstock, typically vacuum gas oil or other heavy
refinery streams, is preheated and then injected into the reactor along with a
specialized catalyst. The reactor operates at high temperatures, causing the long
hydrocarbon chains to break down (crack) into smaller molecules. The unique
aspect of INDMax is its catalyst formulation and reactor design, which selectively
favours the production of propylene and other light olefins.
After the cracking reaction, the product stream enters a separation section where
various components are isolated. The main products – propylene, other light
olefins, and gasoline – are recovered and sent for further processing or storage.
The spent catalyst, which becomes coated with coke during the reaction, is
continuously regenerated in a separate vessel by burning off the coke, and then
recirculated back to the reactor. This continuous catalyst regeneration allows for
stable, long-term operation. The INDMax technology also incorporates advanced
control systems and optimization techniques to maximize propylene yield while
maintaining flexibility to adjust to market demands for various products.

25
5.7. Sulphur Recovery Unit : -
The Sulphur Recovery
Unit (SRU) is a critical
component in modern
refineries, designed to
convert toxic hydrogen
sulphide (H2S) gas into
elemental sulphur. This
process is essential for
environmental protection
and regulatory
compliance, as it
prevents the release of
harmful sulphur
compounds into the
atmosphere. The SRU
also allows refineries to recover sulphur as a valuable by-product, which can be
sold for use in various industries, including agriculture and chemical
manufacturing.
The SRU typically employs the Claus process, which operates in two main
stages. In the first stage, about one-third of the H2S is burned with air in a
reaction furnace, producing sulphur dioxide (SO2). This SO2 then reacts with the
remaining H2S in the furnace to form elemental sulphur and water vapor. The
reaction is represented by the equation: 2H2S + SO2 → 3S + 2H2O. This initial
stage typically converts about 60-70% of the H2S into sulphur.

The second stage involves a series of catalytic converters. The gas from the
reaction furnace is cooled, and liquid sulphur is separated out. The remaining
gas, still containing H2S and SO2, passes through multiple catalytic beds
(typically two to three) where additional H2S and SO2 react to form more
sulphur. Between each catalytic stage, the gas is reheated and sulphur is
condensed and removed. This multi-stage process can increase the overall
sulphur recovery to 98-99%. The final tail gas, containing traces of sulphur
compounds, is either treated further in a tail gas treatment unit or incinerated
before being released to the atmosphere. The liquid sulphur produced is
collected, stored, and often solidified for easier handling and transportation.

26
5.8. Effluent Treatment Plant : -

The Effluent Treatment Plant (ETP) is a crucial facility in refineries, designed to

treat wastewater generated from various refining processes before it's
discharged into the environment. This unit ensures that the released water
meets stringent environmental regulations and minimizes the refinery's impact
on local ecosystems. The ETP handles a complex mixture of contaminants
including oil, grease, dissolved and suspended solids, organic compounds, and
various chemicals used in refining processes.
The ETP typically employs a multi-stage treatment process. The first stage is
primary treatment, which involves physical separation methods. Wastewater
enters an API (American Petroleum Institute) separator or a similar oil-water
separation system, where oil and grease are skimmed off the surface, and heavy
solids settle at the bottom. This is often followed by dissolved air flotation (DAF)
units to remove finer oil droplets and suspended solids.
Secondary treatment follows, which primarily involves biological processes. The
wastewater is fed into aeration tanks where microorganisms break down organic
contaminants. This can be done through processes like activated sludge
treatment or moving bed biofilm reactors (MBBR). After biological treatment, the
water passes through clarifiers where treated water is separated from biological
sludge. In many modern ETPs, a tertiary treatment stage is also included. This
might involve advanced filtration systems, such as membrane filtration or
activated carbon filters, to remove residual contaminants. Final polishing steps
like chlorination or UV disinfection ensure that the water is safe for discharge.
Throughout the process, the ETP is monitored and controlled to maintain optimal
conditions for treatment, with regular testing to ensure compliance with
environmental standards.

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5.9. Thermal Power Plant (TPS) : -

Thermal Power Station is a power plant in which the input is heat energy
and the output is electrical energy with water (demineralized) as the
working fluid. The output electricity from TPS is supplied to the production
units and it is also supplying required steam to the production units. The
whole TPS works on a Rankine cycle (i.e., as shown in the figure below) , in
this Rankine cycle there are four processes namely:

 Process 1-2: The working fluid is pumped from low to high pressure. As
the fluid is a liquid at this stage, the pump requires little input
energy. Process 1-2 is isentropic compression.

 Process 2-3: The high-pressure liquid enters a boiler, where it is

heated at constant pressure by an external heat source to
become a dry saturated vapour. Process 2-3 is constant
pressure heat addition in the boiler.

 Process 3-4: The dry saturated vapour expands through a

steam turbine, generating power. This decreases the
temperature and pressure of the vapour, and some
condensation may occur. The output in this process can be
easily calculated using the chart or tables noted above.
Process 3-4 is isentropic expansion.

 Process 4-1: The wet vapour then enters the condenser,

where it is condensed at a constant pressure to become
a saturated liquid. Process 4-1 is constant pressure heat
rejection in the condenser.

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In the TPS, at first the raw water from Brahmaputra is fed into the
water treatment pump which is then pumped into Demineralising
plant (a.k.a DM plant) for removing the cations and anions as well
as the minerals present in the raw water; from the DM plant the
demineralised water is sent to the deaerator to remove the
dissolved oxygen; the output water from the deaerator is fed into
the boiler to be converted in to steam required to generate the
electricity from the Turbine, the High pressure steam from the boiler
is also used for different applications in different production units;
after the turbine the high pressure steam is converted into low
pressure and medium pressure steam which is inturned stored in
the condenser to be condensed into liquid with the help of cold
water from the TPS cooling tower for reusing in the cycle.

Turbine:- A turbine is a rotary mechanical device that extracts energy from

a fluid flow and converts it into useful work or energy. The work produced
by a turbine is used in generating electrical power when the shaft of the
turbine is coupled with a generator. A turbine is a turbomachine.

The following observations were made upon study, such as:

Condensate Extraction Pump is used to pump the condensate

(conversion of steam into water in condenser) from the condenser.
CEP pump then circulates the condensate again into the deaerator
tank which prevents plant from huge loss of water.

Ejector is used for accelerating high pressure steam and converting the
pressure energy into velocity.

Auxiliary Oil Pump (AOP) supplies oil to bearings of turbine. Generally,

operated during startup and shut-down when the turbine shaft is not rotating
fast enough for the main pump to deliver the required pressure and flow.

Factors affecting the exhaust vacuum in the condensing type turbines:

 Vacuum Ejector System - Vacuum ejector system

creates and maintains the vacuum in the surface
condenser by removing the air/inerts ingress.
Removal of air/inert ingress is important, as
accumulation of this hampers the performance of the
surface condenser, which reduces the surface
condenser vacuum.
Motive steam condition shall be maintained as
specified. Inter-after condenser shall be cleaned in the
available opportunity, as they get choked due to
foreign material coming with cooling water. Flange
joints shall be tightened properly to avoid any ingress
of air. Exhaust side of the turbine shall be properly
steam sealed to avoid any ingress of air.

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  Higher size of exhaust pipe - In many condensing turbines it
is observed that the exhaust vacuum of these turbines is
much less than the vacuum at the condenser.
Mainly, it is due to;
 Higher pressure drop in the
exhaust pipeline from turbine
exhaust to the condenser.
 In order to improve the vacuum at
turbine exhaust so as to reduce steam
consumption in the turbine, exhaust
pipeline of these turbines can be
replaced with higher size.

5.10. Demineralization Plant (DM Plant) : -

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De-mineralization is the process of removing mineral salts from water by using
the ion exchange process. The ion exchange process is a reversible process.
The process of this plant is used for generating power and to drive machinery
and it is also used in other units for distillation and reforming. The river water
from the Brahmaputra River enters the intake plant from where the water is
pumped to the Water treatment plant in which filtration is done. The river water
contains impurities in suspended and colloidal states, it can contain muds,
sand, loose insoluble particles along with minerals.
The raw water is stored in a storage tank. There are 3 raw water pumps.
The DM plant has 3 chains (namely A, B and C).
Note: Capacity of Chain A and B =612 m3/50m3 per hour between
regenerators Capacity of Mixed Bed A and B=4200 m3

PRESSURE SAND FILTER(SPF) OR PRESSURE FILTER

For chain A and B, water is firstly pumped to Pressure Filters vessels. The pressure
filters vessels are named PF-A and PF-B. The pressure filter vessels are similar in
bed construction to rapid sand gravity filters. The pressure vessel is packed with
layers of under bed materials like pebbles of different sizes and layers of sand. The
pressure filters contain a porous medium to remove matter (suspended slit, clay,
colloidal, micro-organism etc).The pressure filter safeguard the packing media of
downstream equipment from getting fouled and contaminated. The cation and the
anion present at the outlet water of the pressure filter are then sent to the ion
exchange vessel. The ion exchange vessel consists of two types, the first being the
Strong Acid Cation and the Strong Base Anion.

STRONG ACID CATION (SAC-A AND SAC-B)

This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion. The strong base anion exchange unit removes weakly dissociated
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
pH: 7.5 to 9.5
Conductivity: less than
10µS/cm
Silica, SiO2: less than

31
0.15 ppm
DEGASSER

The Degasser is made of acid proof material (usually wood or rubber line steel) as it
must handle acidic water of the cation exchange unit. In the degasser tower, the
acidic water from the cation exchange unit is sprayed from top by using spray pipe or
trays and diffuse with low pressure air entering from the bottom of the tower. Air is
blown at the bottom, rises counter current to the downward trickling water. The spray
tubes or tray divide water into droplets or thin film exposing new surface to gas
phase. Tray agitates the water by splashing thereby allowing dissolved gasses to
leave water readily. Agitation overcome tendency of water to retain gas bubbles
through surface tension and viscosity. The unit removes carbonic acid and the water
is then pumped using a degasser pump to the strong base anion vessel containing
anion resins.
STRONG BASE ANION (SBA-A AND SBA-B)

This is the anion exchange unit. It contains weak base anion or strong base anion.
The anion resins have a positive functional group and attract the negatively
charged ion. The strong base anion exchange unit removes weakly dissociated
and the strongly dissociated acids. The water is then sent to the Mixed Bed
vessel.
Quality of SBA treated water
pH: 7.5 to 9.5
Conductivity: lees than
10uS/cm
Silica, SiO2 : less than
0.15 ppm

MIXED BED (MB-A and MB-B)

The mixed bed is a single pressure vessel containing a mix of cation and anion
resin. Here the ions that are further present are deionised and then stored in the
three demineralised tanks .
Capacity of Chain C = 1250m3/60m3 per hour
The water from the water treatment plant is first received in the Dual Media
Filter (DMF) tank.
MB outlet water quality
pH: 6.5 to 7.2
Conductivity: 1.0 uS/cm
Total Silica:
0.0Sppm

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Feed:

 Reduced Crude Oil (RCO) (Density: 950 kg/m3 &

CCR: 5.5-6.0%)
 Clarified Oil (CLO) ex INDMAX
 Refinery Slop oil (as vapor line quench medium)

MACHINERIES AND EQUIPMENTS

8.1. Pumps : -

Main Components of a Pump:

1. Impeller: It is the rotating part that moves fluid by converting rotational kinetic
energy to hydrodynamic energy.
2. Casing: It is the outer shell that houses the impeller and directs the flow of
fluid.
3. Shaft: It is the component that transmits power from the motor to the impeller.
4. Bearings: It supports the shaft and reduce friction between moving parts.
5. Seals: It prevents fluid leakage along the shaft and casing and is considered
the most crucial component of a pump.
6. Motor/Driver: It provides the mechanical energy required to drive the pump.
7. Suction and Discharge Ports: It is the inlet and outlet points for the fluid
being pumped.

33
There are four main types of pump used in a refinery : -

Rotary Pump:

A rotary pump is a type of positive displacement pump where the fluid is moved by
the mechanical action of rotating components, such as gears, screws, or vanes.
These pumps are known for their ability to handle viscous fluids and provide a
steady, pulse-free flow. They are commonly used in applications requiring high
pressure and low flow rates.

Lobe Pump:

A lobe pump is a type of positive displacement pump that uses two or more lobed
rotors that rotate in opposite directions to move fluid. The lobes do not make contact
with each other but create cavities that trap and transfer fluid from the inlet to the
outlet. Lobe pumps are ideal for handling shear-sensitive fluids, slurries, and viscous
materials, often used in food processing, pharmaceuticals, and chemical industries.

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Between Bearings Pump:

A between bearings pump, also known as a BB pump, has its impeller(s) mounted
on a shaft supported by bearings on both ends. This design enhances stability and
allows the pump to handle high pressures and flow rates. They are typically used in
large-scale industrial applications such as water supply, petrochemicals, and power
generation.

Vertical Pump:

A vertical pump is a type of centrifugal pump with a vertically oriented shaft,

designed to fit in narrow spaces or sumps. These pumps are commonly used in
applications where space is limited or where the liquid source is below ground level,
such as in wastewater treatment, drainage, and sump pumping.

35
In summary, these types of pumps and their main components play a crucial role in
various industrial applications, ensuring efficient fluid handling and transfer in
processes at the IOCL Guwahati Refinery.

8.2. Compressors : -

Reciprocating Compressors

Single-Stage Reciprocating Compressor: A single-stage reciprocating

compressor compresses air or gas in one step. The gas is drawn into a cylinder and
compressed by a single piston stroke, then discharged at the desired pressure.
These compressors are commonly used for low to medium pressure applications,
such as in small workshops or for general industrial use. It is mainly seen in units like
INDAdeptG, K-3, HDT-RGC.

Multi-Stage Reciprocating Compressor: A multi-stage reciprocating compressor

compresses air or gas in multiple steps to achieve higher pressures. The gas is first
compressed in one cylinder, then cooled in an intercooler before entering a second
cylinder for further compression. This process can repeat through additional stages
depending on the required pressure. Multi-stage compressors are efficient for high-
pressure applications and are often used in industries like oil and gas, chemical
processing, and manufacturing. It is mainly seen in units like LRU, INDMax, MSQ,
TPS, HDT-MUG.

Centrifugal Compressors

Single-Stage Centrifugal Compressor: A single-stage centrifugal compressor uses

one impeller to accelerate the air or gas, converting kinetic energy into pressure
energy in a diffuser. These compressors are ideal for applications requiring
moderate pressure and high flow rates, such as in HVAC systems, small gas
turbines, and refrigeration.

Multi-Stage Centrifugal Compressor: A multi-stage centrifugal compressor uses

multiple impellers (stages) arranged in series to incrementally increase the pressure
of the air or gas. Each stage consists of an impeller followed by a diffuser, where the
kinetic energy is converted into pressure. Multi-stage centrifugal compressors are
used for applications requiring very high pressures and large flow rates, such as in
natural gas processing, petrochemical plants, and large industrial processes.

Main Components of Compressors:

1. Cylinders (for reciprocating): Houses the pistons and provides the space for
compression.
2. Pistons (for reciprocating): Move back and forth within the cylinders to
compress the gas.
3. Impellers (for centrifugal): Rotating blades that accelerate the gas.

36
 4. Diffusers (for centrifugal): Convert the kinetic energy from the impellers into
pressure energy.
5. Intercoolers (for multi-stage): Cool the gas between stages to increase
efficiency and reduce the work required for further compression.
6. Valves (for reciprocating): Control the intake and discharge of gas in and
out of the cylinders.
7. Casings: Enclose and support the internal components.
8. Shafts: Transmit power from the motor to the pistons or impellers.
9. Bearings: Support the shaft and reduce friction.
10. Seals: Prevent gas leakage.

In summary, both reciprocating and centrifugal compressors, whether single or multi-

stage, play essential roles in industrial applications at the IOCL Guwahati Refinery,
providing the necessary compression of gases for various processes and operations.

8.3. Heat Exchangers : -

Shell and Tube Heat Exchangers:

37
Shell and tube heat exchangers are a type of heat exchanger design commonly used
in various industries for efficient heat transfer between two fluids. They consist of a
series of tubes, one set of which carries the hot fluid, while the other set carries the
cold fluid. The tubes are enclosed within a larger cylindrical shell.

Components:

1. Tubes: The smaller diameter tubes that carry one of the fluids. These tubes
can be arranged in various configurations, such as straight or U-shaped.
2. Shell: The larger outer cylinder that encloses the tubes and contains the
second fluid.
3. Tube Sheets: Plates that hold the tubes in place at each end of the shell.
4. Baffles: Internal components that direct the fluid flow across the tubes,
increasing heat transfer efficiency.
5. End Caps/Heads: Enclosures at both ends of the shell that direct the fluid
into and out of the tube bundle.

Working Principle: Hot fluid flows through the tubes, while the cold fluid flows over
the tubes within the shell, or vice versa. The heat is transferred through the walls of
the tubes from the hotter fluid to the cooler fluid. The use of baffles ensures that the
fluid flows in a zigzag pattern, enhancing the heat transfer efficiency.

Plate Heat Exchangers:

38
Plate heat exchangers use a series of thin, corrugated metal plates stacked together
to create channels for the hot and cold fluids. The fluids flow through alternate
channels, and heat is transferred through the plates.

Components:

1. Plates: Thin metal sheets, typically made of stainless steel, with a corrugated
surface to increase surface area and turbulence.
2. Gaskets: Seals that direct the flow of fluids through alternate channels and
prevent leakage.
3. Frame: The structure that holds the plates together and applies pressure to
ensure a tight seal.
4. End Plates: The outermost plates that support the stack of heat exchange
plates.

Working Principle: Hot and cold fluids flow in alternate channels created by the
plates. The heat transfers from the hot fluid to the cold fluid through the plate
surfaces. The corrugated design of the plates creates turbulence, which improves
heat transfer efficiency.

8.4. ID Fan & FD Fan : -

ID Fan (Induced Draft Fan):

An ID fan, or induced draft fan, is a type of fan used in power plants and industrial
facilities to create a negative pressure or suction in a system. It is typically positioned
downstream of the boiler or process equipment and is responsible for drawing
exhaust gases or flue gases from the system and expelling them into the
atmosphere or further processing units.

39
Components and Working Principle:

1. Impeller: The rotating component of the fan that accelerates air or gas.
2. Casing: Encloses the impeller and directs the airflow.
3. Inlet and Outlet Ducts: Channels that guide the gases into and out of the
fan.
4. Motor: Drives the impeller to create airflow.
5. Bearings and Shaft: Support and transmit rotational energy to the impeller.

The ID fan operates by creating a negative pressure zone in the system it serves.
This negative pressure draws gases, typically hot flue gases, through the system
and expels them into the atmosphere through a chimney or stack. The fan's
performance is critical for maintaining proper combustion and ensuring efficient
operation of boilers and other combustion equipment.

FD Fan (Forced Draft Fan):

An FD fan, or forced draft fan, is another type of fan used in industrial processes,
especially in power plants and boilers, to provide positive pressure or forced airflow
into a system. Unlike ID fans that handle exhaust gases, FD fans are positioned
before the combustion chamber or furnace and supply air necessary for combustion.

Components and Working Principle:

1. Impeller: Similar to ID fans, FD fans have impellers that accelerate air.

40
 2. Casing: Encloses the impeller and directs the airflow towards the combustion
chamber.
3. Inlet and Outlet Ducts: Channels that guide the air into and out of the fan.
4. Motor: Drives the impeller to create airflow.
5. Bearings and Shaft: Support and transmit rotational energy to the impeller.

The FD fan operates by generating positive pressure, which forces air into the
combustion chamber or furnace. This airflow ensures proper mixing of fuel and air
for combustion, maintaining optimal combustion efficiency and reducing emissions.
FD fans are crucial for controlling combustion processes and ensuring stable
operation of boilers and furnaces.

Summary:

ID fans and FD fans are essential components in industrial settings, particularly in

power generation and boiler systems. ID fans handle exhaust gases, creating
negative pressure to expel gases from the system, while FD fans supply air under
positive pressure to facilitate combustion. Both fans play critical roles in maintaining
efficient and safe operations in industrial processes at facilities like the IOCL
Guwahati Refinery, ensuring proper airflow management for combustion and
exhaust handling.

8.5. Valves : -

 Plate Valve:

Plate valves are designed with a flat plate that slides across the flow path
to control the flow of fluids or gases. They offer reliable shut-off
capabilities and are commonly used in applications where tight sealing
and minimal flow restriction are critical, such as in pipelines and industrial
processes. There are two further division of plate valve metallic valve
used in LRU, INDMax and non – metallic valve used in INDAdeptG in the
refinery.

41
  Magnum Valve:

Magnum valves are known for their robust construction and high
performance in severe service applications. They typically feature a large
diameter and heavy-duty components to withstand high pressures,
corrosive environments, and abrasive materials, making them suitable for
oil and gas, chemical processing, and refining industries. They are used in
hydrogen generation unit and HDT in the refinery.

MAINTENANCE PROCESSES

Maintenance processes are the ways to maintain the machines to increase the life
span and yield of a machinery. There are three main requirements for a industry to
run manpower, machines and materials.

Therefore to continuously run a industry all the 3Ms must be in their best condition
due to which maintenance is crucial in any industry. There are mainly fie types : -

9.1. Breakdown Maintenance

It is a reactive approach where equipment is repaired or replaced after a
failure occurs, aiming to minimize downtime and restore functionality quickly,
albeit at potentially higher costs and with no proactive prevention.

9.2. Preventive Maintenance

Reactive approach where equipment is repaired or replaced after a failure
occurs, aiming to minimize downtime and restore functionality quickly, albeit at
potentially higher costs and with no proactive prevention. The first country to
advocate this type of maintenance was Japan by Total Productive
Maintenance(TPM) by CLITA which stands for : -
 C  Cleaning

42
  L  Lubricating
 I  Inspection
 T  Tightening
 A  Assembling

This all must be followed according to the machine manual by a individual

carrying out preventive maintenance.

9.3. Predictive Maintenance

Uses data analysis and monitoring techniques to predict equipment failures
before they occur, optimizing maintenance schedules and reducing downtime
by addressing issues at the earliest signs of deterioration.

9.4. Shutdown Maintnance

Also known as corrective maintenance, involves repairs performed on
equipment after a breakdown, aiming to restore operational status quickly but
often leading to unplanned downtime and higher emergency repair costs.

9.5. Proactive Maintainance

Focuses on continuous improvement and efficiency gains by identifying and
addressing root causes of equipment issues, implementing design
improvements, and optimizing maintenance strategies based on real-time
data and feedback.

CONCLUSION

In conclusion, the industrial training experience at Indian Oil Corp. Ltd. has been
invaluable in providing practical insights into the Refinery Processes and
Maintenance. Throughout the training period, I gained hands-on experience in all
aspects, which has significantly enhanced my understanding of industrial processes
and operations.

I am grateful for the guidance and mentorship received from supervisors, mentors
and colleagues, whose support has been instrumental in my professional
development during this training. The practical experience gained here will
undoubtedly contribute to my academic growth and future endeavors in the refinery
sector.

Overall, this industrial training has been a transformative experience, equipping me

with the skills and confidence needed to excel in a Refinery. I look forward to
applying the knowledge and experiences gained here as I continue to pursue my
career aspirations.

43
I extend my sincere thanks to everyone at IOCL, Noonmati for providing me with this
opportunity and for their continuous support throughout the training period.

44