IOCL MAthura

TRAINING REPORT

@

SUPERVISOR: Mr. Pramod Kumar SPM, IOCL Mathura

By: Bhardwaj Uday Umakant

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INDEX

1. Acknowledgement 2. Synopsis 3. Brief Overview of IOCL 4. Overview of Mathura Refinery 5. Fire Risk Management Philosophy 6. Once-through Hydro Cracking Unit 7. New Hydrogen Generation Unit (NHGU) 8. Diesel Hydro Desulfurization Unit (DHDS) 9. Diesel Hydro-Treatment Unit (DHDT) 10. Jindal Coating Unit Report 11. References

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ACKNOWLEDGMENT We feel immense pleasure and privilege to express our deep sense of gratitude, indebtedness and thankfulness towards MR. PRAMOD KUMAR & MR. SUSHANT ACHARYA who generously helped us color the mosaic of this training with their knowledge, expertise and memories. We shall remain ever grateful to all the persons of I.O.C.L, who have helped, inspired and encouraged us and above all made us an ever more experienced person. For their invaluable guidance, kind cooperation, inspiration and encouragement during all the stages of our training, we would like to thank MR. GAURAV BAJAJ who has been of immense help during our training period and thousands of other I.O.C.L employees whose name we could not mention just for the lack of space. Last but not least, we would like to convey our hearty and blossom thanks to my friends and fellow mates who have directly or indirectly helped me in the compilation of this report. After the completion of the training program, we found it to be of immense help, not only in supplementing the theoretical knowledge, but also by gaining highly practical knowledge regarding the actual work carried out in a Refinery Plant. At the end, we again express our gratitude to all those who helped us in any way to complete our project work successfully.

June 2013 I.O.C.L. Mathura

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Overview of Indian Oil

I.O.C.L: AN OVERVIEW Introduction Indian Oil Company Limited, a wholly owned Government company was incorporated on 30 June, 1959 to undertake marketing functions of petroleum products. Later, Indian Oil Corporation Limited (IOC) was set up on 1 st September, 1964 by amalgamating the Indian Refineries Limited (started in August, 1958) with the Indian Oil Company Ltd., for better coordination between refineries and marketing.

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Indian Oil Corporation Limited or IOC is India’s largest commercial enterprise and the only Indian company to be among the world’s top 200 corporations according to Fortune magazine. It is also among the 20 largest petroleum companies in the world. It was established in 1959 as Indian Oil Company Limited which was merged with Indian Refineries Limited in 1964 to form IOC as it is today. Indian Oil Corporation has four divisions: 

Marketing Division with Headquarters at Bombay;



Refineries and Pipelines Division with Headquarters at New Delhi;



Assam Oil Division with Headquarters at Digboi; and



Research and Development Centre at Faridabad.

The Assam Oil Division was established on 14th October, 1981 on taking over the refining and marketing operations of Assam Oil Company Limited. The Company wholly owns a subsidiary Company viz. Indian Oil Blending Limited, which is engaged in the manufacture of lubricants and greases. The products of the subsidiary Company are also marketed by the Company.

Objectives The objectives of the Company as approved (June, 1984) by Government are as follows: 

To serve the national interests in the oil and related sectors in accordance and consistent with Government policies.



To ensure and maintain continuous and smooth supplies of petroleum products by way of crude refining, transportation and marketing activities and to provide appropriate assistance to the consumer to conserve and use petroleum products most efficiently.



To earn a reasonable rate of return on investment.



To work towards the achievement of self-sufficiency in the field of oil refining, by setting up adequate domestic capacity and to build up expertise for pipe laying for crude/petroleum products.

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To create a strong research and development base in the field of oil refining and stimulate the development of new petroleum products formulations with a view to eliminate their imports, if any and



To make use of the existing facilities in order to improve efficiency and increase productivity. 5

Decentralisation of Imports And Exports Earlier, import of crude oil and import as well as export of almost all petroleum products were done through the Company. In the wake of economic liberalisation, the Government has decentralised a number of petroleum products starting from July, 1991. The Govt. of India amended (July, 1994) Export and Import Policy 1992 -1997, thereby enabling the users to import ATF (Aviation Turbine Fuel) against special import licence. The Company assisted (October, 1994) the airlines in importing the ATF. But with imposition (March, 1995) of a cost and freight surcharge by Government with retrospective effect, the Company stopped such imports as these were no longer beneficial. By September, 1995 as many as 9 products, including LPG and Kerosene, which are being marketed in parallel by joint as well as private sector, have been decentralised and custom duties on them have also been successively reduced. A chronology of major events in the decentralisation of marketing of petroleum products is given at Annexure-I. However, the Company continues to import LPG and Kerosene for meeting the country’s demand and for sale through public distribution system at administered and centralized prices.

Organizational Set-Up and Network of Marketing Division The Marketing Division, with its headquarters at Bombay and headed by Director (Marketing), has four regional offices located at Bombay, Delhi, Calcutta and Madras. All regional offices are headed by either Executive Directors or General Managers. There are 44 Divisional Offices, including two of the Assam Oil Division. As on 31 March, 1995, the Company had 39 bulk storage installations (including 3 of AOD) and 117 storage depots, which fed 5995 retail outlets. In addition, there were 2898 kerosene/light diesel oil dealers who also move these products from the depots to 4379 consumer outlets for sale. The Company had a total product tankage of 3.93 million kilo liters at its installations and depots. Being the major producer and distributor of LPG to various types of consumers in India, the Company has 32 area offices to deal with LPG marketing. As on 31 March, 1995, the Company had 33 LPG bottling plants with a total bottling capacity of 11.92 lakh tones per annum. Indane cooking gas (LPG) is distributed to 12 million households. Indian Oil markets nearly 66.8 percent of the country’s aviation fuel (68.2% in 1992-93), meeting the needs of 59 international airlines besides the domestic carriers and the defence services. Of the 117 aviation fuel stations in the country, Indian Oil operates 93.

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Products 

Auto LPG



Aviation Turbine Fuel (ATF)



Bitumen

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High Speed Fuel

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Industrial Fuels

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Liquefied Petroleum Gas

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Lubricants and Greases



Marine Fuels



MS/Gasoline



Petrochemicals

Services 

Refining

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Pipelines

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Marketing



Training

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Research & Development

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Location of various I.O.C Refineries

IOC Refineries - Overview Refinery

Year of Commissioning

Initial Capacity TMTPA

Capacity, TMTPA As on 01.04.06

Digboi

1901

28

650

Guwahati

1961

750

1000

Barauni

1964

2000

6000

Gujarat

1965

2000

13700

Haldia

1975

2500

6000

Mathura

1982

6000

8000

Panipat

1998

6000

6000

IOC's Total

41350

IOC Associates

12850

IOC+Associates

54200

Total Industry

132470

% Share (IOC)

41%

IOCL Refineries Oil India Crude Pipeline

KBPL Conversion Panipat: 6.0 SMPL

BRPL:2.35

Mathura: 8.0

Sanganer

Digboi 0.65

Chaksu Sidhpur

Viramgam Kandla Salaya

Barauni : 6.0

Mundra

Koyali :13.7

HBCPL

Guwahati 1.0

Haldia : 6.0 Paradip : 15.0

IOC Refineries CPCL-M :9.5

CBR : 1.0

IOC Associates IOC’s Proposed Refinery New Crude PL

Refinery Capacity in MMTPA

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Mathura Refinery: An Overview Introduction Mathura refinery was commissioned in 1982 as the sixth refinery in the fold of IndianOil and with an original capacity of 6.0 MMTPA. Located strategically between the historic cities of Delhi and Agra, the Refinery at Mathura is situated in the mythical and mystical land of Lord Krishna. Later the capacity of Mathura refinery was increased to 7.5 MMTPA by systematically debottlenecking and revamping. With its Fluid Catalytic Cracking Units (FCCU), the refinery mainly produces middle distillates for Northern India supplied though a 760km long product pipeline to Jalandhar in Punjab via Delhi (MJPL) and 100km long Mathura Tundla Pipeline (MTPL). A Vis-breaking unit was commissioned in 1982 and Soaker drum technology was implemented in VBU in the year 1993. The two-stage desalter was commissioned in 1998 in order to improve the on-stream availability of the crude distillation unit. In the same year new Continuous Catalytic Reformer Unit (CCRU) for production of unleaded gasoline was added.

The First hydrogen generation unit (HGU-I) commissioned in 1999 along with first Diesel Hydro-desulfurisation unit (DHDS) for production of HSD with a low Sulfur content of 0.25% wt (max). A once through Hydro-cracker unit was commissioned in July’ 2000 for increased middle distillates production. For supplying EURO-III grade auto fuels, viz, EURO-III HSD and EURO-III MS to National Capital Territory (NCT) and National Capital Region (NCR), a Diesel Hydrotreating unit (DHDT) and MS quality up gradation unit consists of NHDT and PENEX along with FCCU Gasoline splitter and 2nd Hydrogen generation unit (HGU-II) commissioned in 2005. The present capacity of the refinery is 8.0 MMTPA and regularly receives crude oil through the 1870 km long Salaya Mathura Pipeline (SMPL). Over the years Mathura Refinery has systematically synchronized technology with ecology with constant care for the surrounding environment. Its close proximity to the magnificent wonder TajMahal adds to the responsibility towards a cleaner Environment.

Salient Features :1. The Refinery processes low sulphur crudes from Bombay High, Nigeria, and high sulphur crudes from Middle East Countries. The process configuration of the Refinery employs the state-of-the-art technologies with minimal impact on the environment. Various steps have been taken by Mathura Refinery to monitor and control the emission of Sulphur Dioxide. Mathura Refinery is the only refinery in the country to have set up the concern of community and archeological 9

sites. These Ambient Air Monitoring Stations were commissioned before commissioning of the Refinery in 1981 and being continuously operated thereafter. 2. Mathura Refinery has taken many initiatives to produce more and more clean fuels in stages in the interest of environment, public health and preservation of national monuments around. Its noteworthy efforts are stagewise implementation of various projects like Catalytic Reforming Unit, Diesel Hydro-desulphurisation Unit and Hydrocracker for quality upgradation of automobile fuels. 3. The Refinery has full-fledged ETP comprising of physical, chemical and biological treatment facilities. The treated effluent from the Refinery fully meets the MINAS(Minimal National Standards), the prescribes effluent discharge standards 4. For the protection of the land environment, Mathura Refinery has initiated biodegradation of oily sludge through "Oilivorous-S", an oily sludge degrading bacterial consortium developed by IOCL(R&D) in collaboration with Tata Energy Research Institute. 5. The Refinery has full-fledged ETP comprising of physical, chemical and biological treatment facilities. The treated effluent from the Refinery fully meets the MINAS(Minimal National Standards), the prescribes effluent discharge standards 6. A beautiful ecological park has been developed in an area of 4.45 acres. During the recent survey, the experts from the BNHS (Bombay Natural History Society) have identified 96 species of birds of which 30 migratory ones in the park giving a testimony of richness of life in the ecosystem. 7. Mathura Refinery has done extensive tree plantation in and around Refinery. The Refinery has also taken extraordinary initiatives to provide green cover to the archeological heritage sites especially the TajMahal by planting 1,15,000 trees in the Taj region.

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Awards/Accolades:Safety: 

Mathura Refinery received the prestigious Oil Industry Safety Award 2008-09 for Best Overall Safety Performance among Refineries. Shri J.P. Guharay, ED Mathura Refinery received the award from Shri Murli Deora, Minister of Petroleum and Natural Gas at a glittering function held in Oct’ 09 at Delhi.



Mathura Refinery received Gold Award in Petroleum Refinery sector from Greentech Foundation, New Delhi, for outstanding achievement in Safety Management in 2008. The award was presented by Shri R.K. Srivastava, Director General, Ministry of Health & Family Welfare, Govt. of India, New Delhi on 4th May 2009 at Goa.



Received British Safety Council Award’08 in May’09 for excellence in Health, Safety and Environment Management.



Received Safety Innovation Commendation-2009 award from Institution of Engineers in Sep’09 for innovation in Safety for 2008-09.

Security: 

Received Best Corporate Security Trophy (Refinery Category) for two consecutive years i.e. 2008 & 2009.

Energy Conservation: 

Mathura Refinery received First Prize of 'Oil and Gas Conservation Fortnight -2009' for lowest Steam Consumption Performance amongst Refineries having steam consumption 80% Other additives -> 20% The above mixture is diluted 10 ± 1% v/v The pH of the solution is around 1-2 The volumetric flow rate of the Phosphoric wash is 1 L/min Manufacturer- Chemital Rai (Germany ) Properties of the Water Wash De ionized water is used. Pressure > 1000 psi Flow Rate = 19 L/min pH = 6-8 E. SURFACE INSPECTION The surface of the pipe is checked for Slivers1, Lamination and other defects. F. SECOND STAGE BLASTING: Pre Heating at 60-85 C and then blasting operation as described in section C 1

“Slivers are elongated pieces of metal attached to the base metal at one end only. They normally have

been hot worked into the surface and are common to low strength grades which are easily torn, especially grades with high sulfur, lead and copper.”- AISI Technical Committee on Rod and Bar Mills, Detection, Classification, and Elimination of Rod and Bar Surface Defects

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G. QUALITY INSPECTION AFTER BLASTING a. Degree of cleanliness on the basis of the ISO 8501-1 standards b. Roughness Profile2 : Generally the specification of the roughness is about 40-100 Micrometer. The observed value during field visit was 54.66 micrometer.

c. Salt Contamination Level : Maximum Specified Value 2 microgram/cm2. The observed value during field visit was 0.4 microgram. 1.6 ml of distilled water is absorbed in a filter paper and is then placed on the pipe for some time, it absorbs the salt on the pipe surface and then it is kept in the instrument which works on the principle of conductivity and the salt concentration is determined. d. Residual Dust Level – ISO 8502-3 The procedure include application of a special adhesive tape to the surface and on removal the dust particles get stuck to the surface of the tape and on comparison with the standard the level of contamination is determined and if above level 2 the surface is unacceptable. There are a maximum of 5 levels H. CHROMATE APPLICATION A thin layer of Cr2(SO4)3 is applied on the surface to make the surface more adhesive to the epoxy which will be applied in subsequent stages. The application of the chromate layer improvises the adhesive properties of the surface but if the Thickness of the layer > 2 micrometer then a brittle layer over the pipe undermines the surface properties. The inspection for proper application of the chromate layer involves visual inspection of the layer. The colour must be between light yellow and light brown. Manufacturer- Chemital Rai (Germany )

1.

2

Rz: Rz is the arithmetic mean value of the single roughness depths of consecutive sampling lengths. Z is the sum of the height of the highest peaks and the lowest valley depth within a sampling length.

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I.

INDUCTION HEATING : Induction Heaters provide alternating current to an electric coil. The electric coil induces the current in the pipe and due to resistance and hysteresis losses the pipe gets heated.

The pipe is heated to S.No. 1 2 3

Type of Coating 3 LPE 3LPP FBE/DFBE

Temperature Range 180-220 C 200 – 230 C 230 – 250 C

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J.

EPOXY POWDER SPRAY : Using the electrostatic spraying technique

The feed inlet is 2 Kg/ m2 and the particles of epoxy get negatively charged when they get in interaction with the nozzle and due to 70 KV voltage applications the surrounding region of the nozzle gets negatively charged and this region is called CORONA. The particle of epoxy gets attached to the positively charged pipe. The key parameters that V = 72 KV, Pressure : 6.00 Kg/cm2, % = 35 %

control

the

thickness

of

epoxy

coating

are

The observed flow rate of epoxy is 30 kg/hr.

FUSION BONDED EPOXY When the Epoxy powder is sprayed on the pipe the powder goes through five stages to form the coating a. Fusion of the particles : The epoxy particles get fused with each other due to high temperature of the pipe. b. Coalescence: The fused epoxy particles coalesce with each other to form big droplets. c. Flow : When the droplets are big enough they flow around the pipe. The above three processes generally take 10 seconds to get completed. 46

d. Film Formation : With increasing droplets the drops join together to form the film of epoxy e. Curing : The coating is given some time to get cured, after getting cured to about 30% to 70% it is quenched. The curing time is different for different coatings. In LPE, LPP due to application of a further hotter layer above the epoxy the epoxy layer gets cured faster as compared to a single layer epoxy coat.

Before the application of the second coat first coat must be between 30 – 70 % cured as it helps in proper bond formation if the curing is less than 70 %. If the layer gets more cured the bonding between the epoxy and the adhesive becomes weaker. The epoxy which doesn’t adhere to the substrate falls down, it is recycled back. ADHESIVE: The adhesive is applied at 222 C POLYETHYLENE: The raw polyethylene is in granulated form, it is first hot air dried to remove the moisture which could cause the irregularities in the Polyethylene coat layer. It is then passed through an extruder and the polyethylene passed through a die to form a layer which gets applied to the top of the adhesive layer. The extruder is of screw type. The temperature of application of the polyethylene is around 234 C. K. QUENCHING After application of the coating the pipe is given a residual period of 3 minutes in case of FBE coating and 10 seconds in case of 3LPE coating for curing. The pipe is to be cooled after the curing is completed. The pipe is quenched with running water. The wash is done for 180-240 seconds.

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Continuous flow of water should be maintained, if drop wise application occurs the surface becomes uneven resulting in bad quality.

L. THICKNESS, VISUAL :The thickness of the coating is immediately checked after quenching to avoid any production discrepancies in the subsequent coatings. The visual appearance is also checked for any defects. M. END CLEANING/ END BRUSHING When the pipes will be laid in the field it will be welded with other pipes. To enable this welding there is a provision of cut back of coating from 125±10 mm from the ends. To avoid any corrosion to the pipes during the storage, a toe of epoxy coating measuring 10 mm is left. The bevel angle of the toe is generally 30-45 degree.

N. HOLIDAY DETECTION (NACE 0274) The pipe is passed through a ring surrounded by flexible conducting rubber which are in contact with the pipe. The speed of the pipe is 0.3 m/sec and so it takes around 40 seconds for a pipe to get checked. In this method the pipe is earthed and a voltage of 25,000 V is applied to the pipe using the below equipment and the above shown structure If the coating has any defects the circuit will get completed and it will give rise to a buzzer. If there is a major holiday defect the pipe is rejected, if small holiday defect is there it is sent for repairs. O. INLINE INSPECTION AND TESTS Visual, Thickness, Holiday, Cut Back Dimension, Repair are checked for if any they are sent for repairs. Also the Peel Test, Impact Test, Residual Magnetism test is done. Peel Test : The adhesion of the coating is tested using the peel test Impact Test: The impact test is done to check the resistance of the coating to small mechanical damages it can face during laying. Magnetism: Due to induction heating some residual magnetism may be present in the pipe, if the magnetism is above 3 mTesla, then the pipe is sent to demagnetizer.

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P. STENCIL AND MARKING The stencil is used to mark the batch no. and other details on the pipe. Also special color codes are used to mark the diameters of the pipe which could make it easier to handle. Q. QUALITY TESTING LABORATORY The final product is sent to the quality testing laboratory to check for the features which will be described later in the report.

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References 1. Manuals of :OHCU, NHGU, DHDS, DHDT, 2. Corrosion Prevention by Protective Coating by C.G. Munger 3. Notes obtained during training.

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