WINTER TRAINING REPORT

INDIAN OIL CORPORATION LTD. BARAUNI

PERIOD OF TRAINING (01.01.2020 – 15.01.2020)

REPORT BY:

 ABHISHEK GUPTA

SUBMITTED TO
MRS.KRISHNA KUMARI
L& D Department
 CONTENTS
SI.NO TITLE PAGE
1. ACKNOWLEDGEMENT
2. Introduction
3. History
4. Barauni Refinery
5. MISSION
6. THE SAFETY CELL
7. ATMOSPHERIC AND
VACUUM UNIT-1&2
8. COKER UNIT

9. MOTOR SPIRIT QUALITY

UNIT(MSQ)
10. CATALYTIC REFINING
UNIT(CRU)
11. BARAUNI EXPANSION
PROJECT(BXP)
12. BIBLIOGRAPHY

13. CONCLUSION
 ACKNOWLEDGEMENT
I would like to express my gratitude to all those who were a part of this huge
experience, I want to thank the department of training and development of
Barauni Refinery for granting me the permission to pursue this training. I
would further like to thank the officers of the Production department who
gave me the knowledge about the plant, production process, and products in
depth. The learning process was a total different perspective altogether
because everything was solid and practical, And the environment surrounding
the workplace was very helpful in accelerating the whole process. I am
deeply indebted to Barauni Refinery for providing such opportunity to
students that they can explore their curiosity to its full extent on various skills
from team work, time management to most importantly their confidence
level. I would like to give credit and express my generous gratitude to the
concerned officers of different units who were there all along guiding and
directing me at every step. Following are the names with respective units:
AVU-1 & 2:
COKER:
MSQ:
CRU:
BXP:
Lastly but not the least I would like to thank each and every employee of the
production department who gave me directions, ideas and advices in a whole
new place from the first day and making me feel guided throughout. I would
like to thank AKS sir professor of Heritage Institute of Technology, Kolkata
for permitting me to undergo this vocational training.
 INTRODUCTION
IOCL is the India’s largest downstream company tasked with handing
crudes imported from Arabian countries transported by ship Indian Oil
Corporation Ltd. (IOC) is the flagship national oil Company in the
downstream sector. It is one of the most advanced plants in India for oil
refining and has been using American, Japanese & Russian technology.
The Indian oil group of companies owns and operates 9 refineries
directly of India’s 24 refineries and 2 more with some shares, with a
combined refining capacity of 1.2 million barrels per day. These two
refineries of subsidiary Chennai Petroleum Corporation Ltd. (CPCL) and
one of the Bongaigaon Refinery and petrochemicals Limited (BRPL).
The 9 refineries are located at:

• Guwahati(Assam)

• Barauni (Bihar)

• Koyali, Baroda(Gujarat)

• Haldia(W.B.)

• Mathura(U.P.)

• Panipat (Hr.)

• Paradweep (Orissa)

• Bongaigaon(Assam)

• Digboi(Assam)
Barauni Refinery is the sound oil refinery in the public sector and forms an
important part in Indian petrochemical industry. Barauni refinery was built in
collaboration with Russia and Romania situated 125 km from Patna. Barauni
refinery was commissioned in 1964 with a refinery capacity of 1 million
metric ton per annum. (MMTPA) It was dedicated to the nation by the union
minister of petroleum, Prof. HUMAYUN KABIR in January 1965. With
various revised and expansion projects at Barauni refinery, capability for
processing high-sulphur crude has been added, thereby increasing not only
the capacity but also the profitability of the refinery. Barauni refinery was
initially designed to proces low sulphur crude and (sweet crude) of Assam.
After establishment of other refineries in the north-east, Assam crude is
unavailable for this refinery. Hence, sweet crude in being sourced from
Africa, East Asian and Middle East countries. The refinery receives crude oil
by pipeline from Paradip on the east coast via Haldia. There are 3 AVU units
from which AVU-3 is designed for high-sulphur crude and producing
Bitumen. Matching secondary processing facilities such Residues Fluidized
Catalytic Cracking Unit (RFCCU), diesel hydrotreater (DHDT), sulphur
recovery unit (SRU) have been added. These state of the art eco-friendly
technologies have enabled the refinery to produce green fuels company with
international standards. The third reactor has been installed in the DHDT unit
to produce diesel that complies with the Bharat Stage-III auto fuel emission
norms. The MS quality up gradation project has been newly added to remove
benzene and some sulphur thus increasing octane number also.
THE VARIOUS PRODUCTS OBTAINED AT BARAUNI REFINERY
ARE: 1.LPG 2.Motor spirit (petrol) 3.Naphtha 4.Kerosene 5.Diesel 6.Sulphur
7.Raw petroleum coke 7.Bitumen 8.LCO (light cycle oil) 9.HCO (heavy
cycle oil).

Crude oil is separated into fractions by fractional distillation. The

fractionating column is cooler at the top than at the bottom because the
fractions at the top have lower boiling points than the fractions at the bottom.
The heavier fractions that emerge from the bottom of the fractionating
column are often broken up cracked to make more useful products. All of the
fractions are subsequently routed to other refining units for further
processing. Raw oil or unprocessed oil is not very useful in the form it comes
in out of the ground. Although “light, sweet” (low viscosity, low sulphur) oil
has been used directly as a burner fuel for steam vessel propulsion, the lighter
elements form explosive vapor in the fuel tanks and so it is quite dangerous,
especially so in warships. For this and many other uses, the oil needs to be
separated into parts and refined before used in fuels and lubricants, and
before some of the byproducts could be used in petrochemical processes to
form materials such as plastics, and foam. Petroleum fossil fuels are used in
ship, automobile and aircraft engines. These different hydrocarbons have
different boiling points, which can they can be separated by distillation. Since
the lighter liquid elements are in great demand for use in internal combustion
engines, a modern refinery will convert heavy hydrocarbons and lighter
gaseous elements into higher valve products using complex and energy
intensive processes. Oil can be used in so many various ways because it
contains hydrocarbons of varying molecular masses, forms and lengths such
as paraffins, aromatics, naphthenes (or haloalkanes), alkenes, dienes &
alkynes. Hydrocarbons are molecules of varying length and complexity made
of only hydrogen and carbon atoms. Their various structures give them their
different properties and thereby uses. The trick in the oil refinement process
is separating and purifying these.
PRODUCTION UNITS OF BARAUNI
REFINERY
Process Units

AVU-I : ATMOSPHERIC & VACUUM UNIT-1

AVU-II : ATMOSPHERIC & VACUUM UNIT-2

AVU-III : ATMOSPHERIC & VACUUM UNIT-3

PEU : PHENOL EXTRACTION UNIT

SDU : SOLVENT DEWAXING UNIT

CCU : COKE CALCINATION UNIT

NSU : NAPTHA SPLITTER UNIT

CRU : CATALYTIC REFORMER UNIT

RFCCU : RESID FLUID CATALYTIC CRACKING UNIT

DHDT : DIESEL HYDROTREATER UNIT

HGU : HYDROGEN GENERATION UNIT

SRU : SULPHUR RECOVERY UNIT

ARU : AMINE REGENERATION UNIT

SWS : SOUR WATER STRIPPER

 FIRE AND SAFETY
DEPARTMENT
Fire safety refers to the precaution that are taken to prevent or reduce the
likelihood of a fire that may result in death, injury or property damage, alert
those in a structure to the presence of fire in the event one occurs, better
enable those threatened by a fire to survive, or to reduce the damage caused
by a fire. Fire safety measures include those that are planned during the
construction of a building or implemented in structures that are already
standing. Threats to fire safety are referred to as fire hazards. A fire hazard
may include a situation that increases the likelihood a fire may start or may
impede escape in the event a fire occurs.

Some common fire hazards are:

1. Electrical systems that are overload, resulting in hot wiring or connection.
2. Combustibles storage areas with insufficient protection.
3. Combustibles near equipment that generates heat, flame, or sparks.
4. Candles, Flammable liquids and Smoking (Cigarattes, cigars, etc).
5. Fireplace chimneys not properly or regularly cleaned.
6. Heating appliances – stoves, ovens, furnaces, boilers, heaters.
7. Electrical wiring in poor condition.
8. Batteries.

Barauni Refinery is very hazardous plant among all plants due to production
of all kinds of petroleum products that are highly inflammable. Therefore
safety is very essential for the refinery. It is the policy of the corporation that
every reasonable effort shall be made to provide and ensure safety inside the
plant. To ensure safety and to have a safe workplace the employees shall
follow safety regulations that are made by Fire and Safety Department of
IOCL, Barauni Refinery.
General Safety Rules of the Refinery:
1. Smoking is prohibited in the refinery.
2. All persons before entering the refinery must deposit lighters, matches,
mobile phones etc. at the refinery gate.
3. No person is allowed to enter the refinery without safety shoes. Use of
sleepers, sandals or sandal shoe is strictly prohibited.
4. All vehicles, mobile engine and generator sets inside the refinery must
have standard spark arrestors fitted to the exhaust.
5. Use of entertainment media inside the refinery is strictly prohibited, use of
public address system, VCP/VCR etc. will be permitted for official use
only with prior permission of competent authority.
6. Use of hydrant lime water for washing is strictly prohibited.
7. Any person entering an operating unit/ project site must wear safety
helmet and safety shoes.
8. Photography inside the refinery without prior permission is strictly
prohibited.
9. Speed limit for all vehicles inside the refinery should not exceed more than
20 km per hour and no overtaking is allowed except for fire tender and
ambulance in case of emergency only.
10. All should move to the specified assembly point in case of disaster.
11. Care should be taken that LPG doesn’t leak out while dispersing waster
from LPG bullet. A vapour cloud will form if the same happens.
12. Breathing analyser should be used while going to any confined space in
the refinery.
13. Various permits like hot permit, height permit, confined space entry
permit, evaporation permit should be maintained before initiating any
activity.
 ATMOSPHERIC AND VACUUM
DISTILLATION UNIT
(AVU-I/II)
Introduction:

There are two Atmospheric and Vacuum Distillation Units in Barauni

Refinery numbered as AVU-I and AVU-II, each were designed for 1
MMT/year crude processing. Subsequently another distillation unit without
vacuum distillation facility was added. This unit was designed for 1
MMT/year of crude and known as AU-3. Crude Processing capacity
of both units AVU-I & AVU-II was increased to 1.6 MMT/year by HETO
project (Heat Exchanger Train optimization) in 1990. The above modification
(HETO project job was designed by EIL (Engineer's India Limited) and
fabrication/erection job was completed by M/s. Pethon Engg. Ltd, Mumbai.
The units were again revamped in 1998 (M & I) when the capacity was
expanded to 2.1 MMT/year of each of the two units. Through these units
were designed on the basis of evaluation data of Naharkatiya crude, presently
the units have switched on to imported crude due to none availability of
Assam crude.

Process Description:

Crude oil (imported) is received from Haldia by pipeline and is pumped from
tanks through Heat Exchangers after exchanging heat with various hot
stream, the crude streams attain a temperature of approx. 393K to 403K.
After attaining temperature about 393K to 403K the two crude flows combine
together and enter in desalter for separation and removal
of water and salt.Bi electric desalter is having two energised electrodes.
A distributor head splits crude between the upper and lower pair of
electrodes. Crude oil separated from water between the centre and lower
electrodes passes through the upper electrode in a converging countercurrent
flow with the separating water from upper set of electrodes. This creates a
second washing zone for half of the feed in a strong electrical field thereby
causing maximum salt removal efficiency. The two desalter in AVU-I &II are
PETRECO BIELECTRIC type which were commissioned in the year 2001.
Post Desalter
At the outlet of Desalter there are two booster pumps which boost up the
crude at discharge pressure around 15 kg/km.Pre-topping column has 20
Trays (All valve trays with a bed of packing between 9th & 10th tray) and
operates on operating conditions.

Pretopped crude stream passes through heat exchangers. After exchanging

heat with various hot products the pretopped crude flows combine and it is
segregated again near furnace in two pass flows before entering the
atmospheric heater for further heating and finally fed to 6th tray of main
column through two entry nozzles at 340oC. The Furnace is provided with
Air Preheater. Main Fractionating Column has 43 double pass valve trays.
Following are the operating parameters of the main column.
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