Panipat Refinery(PR)

VOCATIONAL TRAINING REPORT

(Duration: 8/08/2022-09/05/2022)

Submitted By:
Nirmit Madaan
Btech(Mechanical Eng.)
DCRUST, Murthal
 Preface

Industrial training plays a vital role in gaining the practical knowledge that one
cannot gain by only running through the learning from books during the theory
examinations.

The experience gained doing this short period was much needed. It was an
excellent feeling to observe the operation of different equipment and processes
which I have studied before in theory. It was amazing for me to notice how such a
big refinery petrochemical complex is being monitored and operated with proper
coordination to obtain desired results and how the security related stuff is handled
by the CISF Officers and being done the training in mechanical management
department I get to know that for every single small to large work done in the
refinery there is a need of a permit from the respective authority for the work to be
done. For example, for repairing any leakage inside any pump in a plant, the permit
has to be taken just to transfer the respective pump from the plant to the
Workshop.

During this timeline I realized how the theory we studied during the past Semesters
is being practically used in the Industry for performing a particular Operation and I
hope so that the knowledge I gained in this period will be much helpful in my
Future Endeveours.
 ACKNOWLEDGEMENT

I am thankful 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 PANIPAT.

I am highly obliged to Training and Development Department for providing

me this opportunity to learn at IOCL I thank Mr. Shashank and his
colleagues , for guiding me through the whole training period. I express my
heartiest thanks to respective unit heads, for sharing their deep
knowledge about various equipments in plants/workshop.

Last but not the least I am thankful to Almighty God, my parents, my family
and friends and their immense support and cooperation throughout the
training period.
 Introduction:

Petroleum is derived from two words – “petro” means rock and

“oleum” means oil. Thus the word “petroleum” means rock oil.
This is a mixture of hydrocarbons; hence it cannot be used
directly and has got to be refined. Petroleum is refined in
petroleum refinery.
Indian Oil Corporation Ltd. (IOC) is the flagship national oil
company in the downstream sector. The Indian Oil Group of
companies owns and operates 10 of India's 19 refineries with a
combined refining capacity of 1.2 million barrels per day. These
include two refineries of subsidiary Chennai Petroleum
Corporation Ltd. (CPCL) and one of Bongaigaon Refinery and
Petrochemicals Limited (BRPL). The 10 refineries are located at
Guwahati, Barauni, Koyali, Haldia, Mathura,
Digboi, Panipat, Chennai, Narimanam, and Bongaigaon.
Indian Oil's cross-country crude oil and product pipelines
network span over 9,300 km. It operates the largest and the
widest network of petrol & diesel stations in the country,
numbering around 16455.
Indian Oil Corporation Ltd. (Indian Oil) was formed in 1964
through the merger of Indian Oil Company Ltd and Indian
Refineries Ltd. Indian
Refineries Ltd was formed in 1958, with Feroze Gandhi as
Chairman and Indian Oil Company Ltd. was established on 30th
June 1959 with Mr S. Nijalingappa as the first Chairman.
Fire & Safety Trainings + Documentation
The First day at the Oil Refinery was basically for the Fire & Safety Trainings and the
Drills which every single person who has to work at the refinery, has to undergo
either it’s a worker or a trainee for vocational training purpose. In the Fire & Safety
Training, a documentary based on the Oil Refinery and Petrochemical Complex was
shown, the documentary included the Safety Equipments used while entering in
the Refinery Gate which are Helmet, Safety Shoes, Hand Gloves, Ear Buds and IFR
Suits, Goggles. The Documentary was also consisted of information about the
Assembly Points, MCB’s and the Emergency Numbers. In the Panipat Naptha
Cracker (PNC), there were 12 Assembly Points which are the places at which the
people gather at the time of any emergency. The MCB’s are placed in every 50-100
meter range of the Oil Refinery which has to be used for communicating about any
Emergency Situation. At least two MCB’s have to be used at a time to remove the
chances of any technical issue in communication. The Emergency Numbers were
told in the Documentary which are useful in case of any Fire - 6333, 6666 and for
any Health related issue – 8053.

Additionally, The Causes related to any accident in the PNC were also told which
was Gas Leak as there were many toxic gases (such as H2S, NH3), Fire or Flames,
and the Chemicals used in the PNC. The Last Accident which was unfortunately
occurred in the Oil Refinery on 22nd January 2018, which was around 1200 safety
days ago from current day.

Further, the process of Documentation was covered on the day which was related
to the Gate Pass as the Security of the Oil Refinery was in the hands of the CISF
Cadets. The Gate Pass of the Oil Refinery and the Petrochemical Complex includes
the Signatory of the Head of the CISF Officer of the Oil Refinery which was to be
done after the Completion of the Fire & Safety Trainings.
 Heat Exchangers
A heat exchanger is a device which transfers heat from one medium to another, a
Hydraulic Oil Cooler or example will remove heat from hot oil by using cold water
or air. Alternatively a Swimming Pool Heat Exchanger uses hot water from a boiler
or solar heated water circuit to heat the pool water. Heat is transferred by
conduction through the exchanger materials which separate the mediums being
used. A shell and tube heat exchanger passes fluids through and over tubes, where
as an air cooled heat exchanger passes cool air through a core of fins to cool a
liquid.

Types of Heat Exchanger:

There are many different types of heat exchanger available, the three main
types are:

 Shell and Tube:

Shell and Tube Heat Exchangers consist of a large number of small tubes
which are located within a cylindrical shell. The tubes are positioned into the
cylinder using a tube bundle or "tube stack" which can either have fixed tube
plates or, in the case of Thermex Heat Exchangers a floating tube stack which
allows the tube bundle to expand and contract with varying heat conditions as
well as allowing the tube bundle to be easily removed for servicing and
maintenance.
 Plate Type:

 Plate Heat Exchangers operate in very much the same way as a shell
and tube heat exchanger, using a series of stacked plates rather than tubes.
Plate heat exchangers are usually brazed or gasketed depending on the
application and fluids being used. Their compact stainless steel construction
makes them an ideal choice for use with refrigerants or in food and beverage
processing.

 Air Cooled;
Air Cooled Heat Exchangers are commonly used in vehicles or other
mobile applications where no permanent cool water source is available.
Thermex designs and supplies combination cooling packs (or combi-coolers)
which combine an engine jacket water cooler, oil cooler and charge air cooler
into a single unit reducing space requirements and improving efficiency. Cool air
is provided either by a fan or by air flow caused by the movement of the vehicle.
Heat Exchanger “Pass”
A Heat Exchanger Pass refers to the movement of a fluid from one end of the heat
exchanger to the other. For example, when referring to the "through tubes" circuit
 Single Pass – Fluid enters one end of the heat exchanger, and exits at the
other end.
 Double Pass – Fluid enters and exists the heat exchanger at the same end.
 Triple Pass – Fluid travels the length of the heat exchanger body three times
before exiting.
Single Pass (1 pass)

Double Pass (2 pass)

 Triple Pass (3 pass)

 A greater number of passes increases the amount of heat transfer available,

but can also lead to high pressure loss and high velocity.
 The number of passes on the primary circuit can also be adjusted to optimise
thermal performance and efficiency by changing the baffle quantity and
pitch.

Fouling is the formation of unwanted material deposits on heat transfer surfaces

during process heating and cooling. It occurs in all industries and most heat
exchanger designs, with impacts ranging from heat transfer degradation to flow
resistance and pressure drops.
Mechanical Seals:
Mechanical seals are critical components in centrifugal pump systems. These
devices preserve the integrity of the pump systems by preventing fluid leaks and
keeping contaminants out. Mechanical seal systems are used on various seal
designs to detect leakage, control the seal environment and lubricate secondary
seals.

Depending on the pump type and the process variables, there are various
mechanical seal types to choose from. Each seal variant has its unique design and
characteristics which make it suitable for a specific application.

Different Types of Mechanical Seals:

Mechanical seal types vary in design, arrangement, and how they disperse

the hydraulic forces acting at their faces. The most common seal types

include the following:

 Balanced seals

 Unbalanced seals

 Pusher seals

 Non-pusher seals

 Conventional seals

 Cartridge seals
Mechanical Seal Plans
 PUMPS
A pump is a device that moves fluids 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 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.

Common Pumps Used In IOCL

1. Centrifugal Pumps:
A centrifugal pump is a pump that consists of a fixed impeller on a rotating shaft
that is enclosed in a casing, with an inlet and a discharge connection. As the
rotating impeller swirls the liquid around, centrifugal force builds up enough
pressure to force the water through the discharge outlet. This type of pump
operates on the basis of an energy transfer, and has certain definite
characteristics which make it unique. The amount of energy which can be
transferred to the liquid is limited by the type and size of the impeller, the type of
material being pumped, and the total head of the system through which the liquid
is moving.
Centrifugal pumps are designed to be used as a portable pump, and are often
referred to as a trash pump. It is named so because the water that is being
pumped is not clean water. It is most often water containing soap or detergents,
grease and oil, and also solids of various sizes that are suspended in the water.

The major types of centrifugal pumps used in the refinery are:

1. Vertical Cantilever Pump

It is a specialized type of vertical sump pump designed to be installed in a tank or
sump but with no bearing located in the lower part of the pump. Thus, the
impeller is cantilevered from the motor, rather than supported by the lower
bearings. A cantilever pump is considered a centrifugal pump configured with the
impeller submerged in the fluid to be pumped. But unlike a traditional vertical
column sump pump, there are no bearings below the motor supporting the
impeller and shaft. The cantilever pump has a much larger diameter shaft, since it
has no lower sleeve bearings that act to support the impeller and shaft.
In general, cantilever pumps are best for relatively shallow sumps, usually around
8 to 10 feet maximum. This is because the deeper the sump, the larger the shaft
diameter that is required to cantilever the impeller.
2. Split Case Pumps
This type of pump has a split casing at the suction side. It prevents the turbulence
and formation of eddies at inlet. Split Case pumps are designed to pump clean
water or low viscosity clean liquids at moderate heads more economically, which
is widely used for liquid transfer and circulation of clean or slightly polluted water.
And the typical applications are Municipal water supply, Power plants, Industrial
plants, Boiler feed and condensate systems, Irrigation and dewatering and marine
service.

Applications of Centrifugal Pump in Panipat Refinery

 For circulation of cooling water

 For pump the fluid (crude oil, VGO, diesel etc.) in reactors,coulombs etc.
with high pressure.
 In liquid storage tanks
Lathe Machine
Lathe Machine is a machine tool that uses a cutting tool for removing the material
from the surface of the workpiece which is held in the chuck for holding the
workpiece and feed was provided by the tool on to the workpiece for the removal
of material. It is the most versatile and widely used machine in industries,
institutions, etc.

Line Diagram of Lathe Machine:

Parts of Lathe Machine:
The Parts of the lathe machine are as follows.

 Bed
 Lead Screw
 Guideways
 Prime mover
 Transmission system
 Headstock
 Spindle
 Chuck
 Feed Gearbox
 Thread Chasing Dial
 Split nut
 Carriage
 Slideways with saddle
 Compound rest
 Toolpost
 Tailstock
Bed:

 It should be rigid enough to withstand for the forces acting during machining
and self-weight of the workpiece.
 It should have high damping qualities i.e. it can absorb the vibrations induces
during machining.
 It should act as a house for keeping some of the parts in a machine tool like
Prime mover of a machine, gearbox, coolant tank, etc.

Material:
Grey C.I: It is used for manufacturing of bed of the machine because it has high
damping qualities and rigid qualities.

Manufacturing Method:
Casting is a manufacturing method because it gives high damping qualities.

Shape:
The shape of the bed is selected such that the reduction in the rigidity of machine
tool should be minimum and it should provide the maximum amount of the space.

Lead Screw:

 It is used for converting rotational movement into linear movement.

 The material of the lead screw must be selected such that it should have high
wear resistance
 Due to this, the best preferable material for the manufacturing of lead screw
is the brass.
 Because of the sagging problem, the maximum length of the brass lead screw
will be 2 meters only.
 The type of threads used on the lead screw is square thread because it gives
the highest efficiency of power transmission. For example, Buttress Thread.

Guideways:

 They are guiding the moving parts in a machine tool. They act as a mediator
for transmitting forces to the bed of a machine tool.
 The material used for the manufacturing of guideways should possess High
wear resistance, high damping qualities, and low ductility.
Prime Mover:

 Whatever the energy required for performing the machining operation is

obtained from Prime mover.
 The very first Prime mover used in machining is IC engine but because of
noise pollution and result of the reciprocating parts after the invention of
electrical Motors, the electrical Motors are used as a prime mover in the
machine tools.
 Whenever the power supply is given to the induction motor, it always starts
rotating at only one particular rpm i.e. designed rpm.

Transmission System:

 Even though prime mover is rotating at only one particular RPM, to get the
different RPM of the spindle on a job during machining of different sizes of
the components at different velocities, it is required to use mechanical
transmission system between the prime mover and the spindle.
 The most commonly used mechanical transmission system is the belt drive
with stepped pulley because during machining operation any sudden
increase Inf forces will cost to split the belt but no failure is taking place.

Head Stock:

The headstock is acting as a house for keeping some of the parts like transmission
system, Prime mover, etc. and it also acts as a support for supporting the
components at one side.

Spindle:

 It is the hollow shaft used for transmitting power from the transmission
system to the workpiece.
 It also supports the longer length of the workpiece during machining.

Chuck:

It is a work holding device used for holding the workpiece at one end.

Chuck Is classified into two types:

 3-Jaw chuck: It is used for cylindrical and circular shape jobs 

 4-Jaw chuck: It is used for non-circular jobs.
Feed Gear Box:

It is used for transmitting power from spindle to the lead screw at different speeds.

Thread Chasing Dial (TCD):

It is used in thread cutting operation for reducing multiples start of the thread with
multiple cuts.

Split nut:

Split nut with the lead screw will be used for converting rotational movement into
linear movement.

Carriage:

The carriage is the device used for carrying a moving part in a lathe machine
globally.

Slideways with Saddle:

It is used for moving the tool locally.

Compound Rest:

It is used for rotating the tool to perform the taper turning operation.

Tool Post:

It is the device which is used for holding the tool.

Tailstock:

It is used for supporting the workpiece at the other end.

Quill:

For localized movement of the Dead Centre, Quill will be used.

Some Images Shot During the Training Duration: