BALAJI R

GRADUATE APRRENTICE TRAINEE

EMP ID :37412630
THREE MONTHS PROGRESSION REPORT
FROM 16-JAN TO 31 MAR 2019
SYNOPSIS:
 ABOUT HPCL
 ABOUT HPCL CHENNAI
NEW TERMINAL
 SAFETY TRAINING
 ABOUT GANTRY
 MY EXPERIENCE AS A
GANTRY OFFICER
 CALCULATION OF
SHORTAGE
ABOUT HPCL:
 HINDUSTAN PETROLEUM
CORPORATION LIMITED started as
STANVAC in 1952 and then in 1962
made merge with ESSO and further in
1974 made with lube india and caltex
oil.
 HPCL was incorporated in 1974 after
the takeover and merger of erstwhile
Esso Standard and Lube India Limited
by the Esso (Acquisition of
Undertakings in India) Act 1974.
Caltex Oil Refining (India) Ltd.
(CORIL) was taken over by the
Government of India in 1976 and
merged with HPCL in 1978 by
the CORIL-HPCL Amalgamation
Order, 1978. Kosan Gas Company was
merged with HPCL in 1979 by
the Kosangas Company Acquisition
Act, 1979.
 In 2003, following a petition by
the Centre for Public Interest
Litigation (CPIL), the Supreme Court
of India restrained the Central
government from privatising
Hindustan Petroleum and Bharat
Petroleum without the approval of
Parliament. As counsel for the
CPIL, Rajinder Sachar and Prashant
Bhushan said that the only way to
disinvest in the companies would be to
repeal or amend the Acts by which
they were nationalised in the 1970s. As
a result, the government would need a
majority in both houses to push
through any privatisation.[6]
 HPCL has been steadily growing over
the years. The refining capacity
increased from 5.5 million metric
tonnes (MMT) in 1984/85 to 14.80
million metric tonnes as of March
2013. On the financial front, the net
income from sales/operations grew
from ₹2687 crores in 1984–1985
 to ₹2,06,529 crores in financial year
2012–2013. During FY 2013-14, its
net profit was ₹1740 crores.
 It has Refineries,LPG bottling
plants,operation and distribution
terminal.

ABOUT HPCL CHENNAI NEW

TERMINAL:
 Chennai new terminal is vast area with
110 acres of land with the good looking
environment and one special about our
terminal we stood first among 91
terminal in all over india and received
an overall achievement award and now
lets discuss about special things about
our terminal
 It was opened on AUG 2013 and started
its operations
 The main function of our terminal is
Receipt,Storage,Distribution
 In our terminal totally there are 23
above ground tanks (3 –water tanks)and
8 underground tanks and total capacity
of our terminal is 1,45,000 lts
TANKS PRODUCT TANKS PRODUCT
1 MS 11 SKO
2 MS 12 SKO
3 MS 13 HSD
4 MS 14 MS
5 HSD 15 ATF
6 HSD 16 ATF
7 HSD 17 ATF
8 HSD 18 ATF
9 HSD 19 ETANOL
10 HSD 20 BIO
DIESEL

 There are 12 UG TANKS in our

terminal
 TANKS PRODUCT TANKS PRODUCT
1 HSD 7 MTO
2 BIO 8 HEXANE
DIESEL
3 MS 9 SLOP
4 SKO 10 SLOP
5 ETHANOL 11 HSD OWN
6 SOLVENT 12 ATF FAST
FLUSH

 In our terminal products are specifically

called by their some scientific names
1. PETROL-MS,MS-GASOHOL
2. DIESEL-HSD,TUBOJET
3. KEROSENE-SKO (IND, PSD)
4. JET A1-ATF
MS-MOTOR SPIRIT,HSD-HIGH SPEED
DIESEL,SKO-SUPERIOR KEROSENE
OIL,IND-INDUSTRIAL,PSD-PUBLIC
SYSTEM DISTRIBUTION,ATF-AVIATION
TURBINE FUEL,MTO-MINERAL
TURPENTINE OIL,FOOD GRADE
HEXANE
 We are also having additive pump house
where additives like petroplus,turbo
jet,blue dye will be stored in small tanks
each having two pumps for their
operations
 In our terminal safety will be given first
priority
 We take receipt directly from the ship
through PLT(Pipe Line Transfer) which
is 10 km pipline buried underground
 We are having three gantries (two TT
gantry and one TWG gantry)
 We are having 18-20 TTG pumps and
14 TWG pumps
 We are having 2 jockey pumps and 7
fire engines for our safety purpose
 We are having four teams in our
terminal i.e Combat team,Auxiliary
team,Rescue team,Communication team
 We are having separate helmets like
blue colour-employee,yellow color-
contractor,orange-visitor,red-fire chief.
 We are also having Engineering store
where spare parts will be available
 In our terminal there is solar yard and
where work is going on to operate it.
 There is a botanical garden in our
terminal in order to keep our
environment a healthier one.
 Our terminal consists of one entry
barrier and exit barrier gate and
emergency gate and wagon entry/exit
gate
 We have control room where we can do
all the operation and distributions
functions.
  We have separate electrical control
room for power supply purpose
 We have planning office where trucks
will be alloted accordingly.
 We have calibration shed to do the
calibration for trucks.
SAFETY TRAINING:
My first day of training started with Safety officer,my
first day started with knowing some things about
Chennai New Terminal and the products stored in our
terminal and then he taught me how to control fire in
tank farm by using HVLR (High Volume Long Range)
and I learnt of using how to carry the hose pipes and
then we gone on to the top of the tank and i have known
about various things like
 Rim seal fire protection system
 Hydro Carbon Detector
 Mobile expansion foam generator
 Hose pipes
 Emergency Shut down
 Manual Call point
 Pneumatically operated valve
 Motor operated valve
 Fire extinguisher
 AFFF(Aqueous flim forming solution)
 Sprinkler system
 Permit
 Fire Traingle
Now let us dicuss all those things in a brief manner
TYPES OF PRODUCTS BELONGS TO
CLASSES:
 Class A product(below 23 deg celsius)
 Class B product(23 to 65 deg celsius)
 Class C product(65 to 93 deg celsius)
 Unclassified product(above 93 deg
celsius)(excluded petroleum)

FIRE TRAINGLE:
Fire traingle involves three things fuel,oxygen,heat in
order to control fire if we reduce any of these things
we can control fire
 Stoppage of fuel (starvation method)
 Reduction of oxygen(smothering/blanketing
method)
 Controlling of heat(cooling method)

RIM SEAL FIRE PROTECTION SYSTEM:

The main purpose of Rim seal fire protection system
is to detect and discharge rim seal fire over the
floating roof tanks and alert the control room by
means of alarm,the main parts consists of tube type
dtection system,automatic foam based extinguishing
system,fire alarm panel
HYDRO CARBON DETECTOR:
The main purpose of this detector is to detect the
hydro carbons,toxic gases and asphyxiant,and in case
if detected alarm will be alarming in the control room.

MEDIUM EXPANSION FOAM GENERATOR:

Medium expansion foam generator which can be
moved from one place to another which can be used
in case of emergency, which consists of foam
generating nozzle to spray the foam in case of fire.
HOSE PIPES:
Hose pipes plays an important rule in safety because
without these we cant able to draw water from the
hydrant line,it consists of male and female couplings
and nozzle which is readily available in the fire hose
box and there are some methods of carrying the hose
pipes they are American method and UK method.

POV(PNEUMATICALLY OPERATED VALVE):

Pnematically operated valve that closes and opens the
tanks by means of automation and here air pressure is
maintained by compressor(5.45 bar) to operate the
tank POV,it is aslo called Remote Operated Shut
Off Valve(ROSOV).

MOTOR OPERATED VALVE:

Motor operated valves are used to open and close the
piplines coming from the tanks and these can be
operated in both remote and local condition and it can
a ball valve,gate valve or a butterfly valve.
EMERGENCY SHUT DOWN:
An emergency shut down is a like a sensor with a
glass fixed over it and if we break that glass entire
operation of the terminal will stop, automatically all
the ROSOV(Remote Operated Shut Off Valve will
close) i.e all tanks will close and it can reset by
placing a new class over it and everything will come
to normal.

MANUAL CALL POINT:

Manual call point is used to iniate a alarm signal in
case of fire,it consists of fire alarm switch and that
has to activated in case of fire over the terminal and
alarm will be alarming and it can done manually by
rotating the sirens kept inside the terminals.
FIRE EXTINGUISHER:
Fire extinguisher is an another important equipment
in safety practices and there are two types of fire
extinguishers DCP(dry chemical powder)(mono
ammoium phosphate) and CO2 extinguisher and their
type of usage depends upon the location and it may
vary but DCP is more safer when compared to CO2.
AQUEOUS FLIM FORMING SOLUTION:
The foam which is mixed with water to control fire
and in our terminal we use 3% and 6% AFFF which
means 97% and 96% water is mixed with this foam
and it completely controls the fire by covering over
the fire area and it is called blanketing or smothering
process that completely reduce level of oxygen in the
fire.

SPRINKLER SYSTEM:
A sprinkler system is kept around the tank for cooling
purpose and in case if any accidents has happen, the
tanks must be cooled by means of sprinkler system in
order to cool the tank.
 TYPES OF WORK PERMIT:
There are different types of work permit depending
upon the nature of the work,they are
 Hot work permit
 Cold work permit
 Height work permit
 Electrical work permit
Each permit have SOP (standard operating
procedure),JSA(job safety analysis)

ABOUT GANTRY:
Gantry, where filling of trucks will be taking place, in
our Chennai New Terminal totally there are two
gantires namely
 TT (TANK TRUCK)GANTRY
 TW(TANK WAGON) GANTRY
Now lets us see about TT GANTRY
TT GANTRY consists of totally three gantries
GANTRY-1,GANTRY-2,GANTRY-3 and each
gantries has eight bays and tottally there are 24 bays
and each loading points consists of DCV(Digital
Control Valve),NRV(Non Return valve),Mass flow
meter,BCU(Batch Control Unit),Pressure relief
valve,Ball valve,START/STOP button,Position
sensor,Strainer(Filter),Earthing point.
GANTRY-1 consists of totally Eight Bays and each
bay has two loading arms so totally 48 loading arms
are there in all three gantries.
There are some colors that indicates the product
coimng from the loading arm.

GANTRY-1
BAYS LOADING POINTS LOADING POINTS
1 HSD(BLUE ARM) MS(ORANGE
ARM)+gasohol
2 HSD MS+(gasohol)
3 HSD+(turbo jet) MS+(power)+gasohol
4 HSD MS+(gasohol)
5 HSD MS+(gasohol)
6 HSD+(turbo jet) MS+(power)+gasohol
7 HSD HSD
8 MS MS

GANTRY-2
BAYS LOADING POINTS LOADING POINTS
9 HSD(BLUE ARM) MS(ORANGE
ARM)+gasohol
10 HSD MS+(gasohol)
11 HSD MS+(power)+gasohol
12 HSD MS+(gasohol)
13 HSD MS+(gasohol)
14 HSD MS+(power)+gasohol
15 HSD MS+(gasohol)
16 HSD MS+(gasohol)
GANTRY-3
BAYS LOADING POINTS LOADING
POINTS
17 ATF(BLACK ARM) ATF
18 ATF ATF
19 ATF ATF
20 HEXANE(GREEN SOLVENT(RED
COLOR) COLOUR)
21 HSD HSD
22 HSD HSD
23 SKO(YELLOW ARM) SKO
24 SKO MTO(GREEN
ARM)

BATCH CONTROL UNIT:

A batch contro unit where we can all the information
including the truck number and also it contains
information about the flow rate,additives mixing,ratio
of blending,name of the product,loading point
number,etc,in next to it contains card reader where
the driver will be punching the card to fill the
product,and next one is the totaliser which will show
density and tempertaure of the product,total volume
of the product that has been filled.
POSITION SENSOR:
A position sensor that has been fixed on the loading
arm it senses whether the loading arm is in correct
position correct position to do the filling processand if
not the filling process will get stop.
PRESSURE RELIEF VALE:
A pressure relief valve valve is fixed on the top of
loading arm pipe where product will be coming with
high pressure in order to release that pressure
(air),pressure relief valve is there.

BALL VALVE:
A valve is one which restricts the flow of fliud and
this ball valve is used for shut down operation and
this valve contains a ball shaped valve which will
control the flow of product and also it will used for
stopping the flow of the product.
MASS FLOW METER:
A mass flow meter works on the principle of corolis
effect,it consists of two tubes which will be hidden
and it also consists of flow splitter which eual split
the fluid to flow into the tubes and it also consists of
drive coil magnets ,it works when the fliud flows
throrugh it the tude which will oscillate like one end
and the touching themselves producing sine waves
which will be useful for determing the mass flow rate
and the density.

DIGITAL CONTROL VALVE:

A valve that controls output from the loading arm for
example (out of 5000 lts 4998 ) is especially
controlled by digital control valve,it consists of
sloenid valve that controls the output by controlling
the flow for eg (for the first 200 lts flow rate will be
low and after that the flow will increase for the rest of
the flow and also the flow decrease ath the end of 200
ltrs),the piston and the diaphragam also plays a major
function.

STRAINER(FILTER):
A strainer or filter is used to strain away all the dust
particles coming from the tank ,it totally remove all
the foreign particles and make sure that good quality
product is under filling.
NRV(NON RETURN VALVE):
A valve that allows the fluid to flow in only one
direction is called non return valve,it make sure fluid
is flowing and leaving outside and it does not make
the fluid to return back.

EARTHING POINT:
The earth point is one of most important one in gantry
during filling process,it consists of crocodile clips that
has to connected over the trucks by means of a small
earth pit rod attached to the truck and when the clips
are not connected filling will not be taking place,the
main purpose is to transfer the voltage from the truck
to the ground because static electricity will be
produced on the surface of the tank during filling.
MY EXPERIENCE AS GANTRY
OFFICER:
 I had been given authority as a gantry officer to
sign the FAN(FILLING AUTHORITY NOTE)
slip from 16-jan-2019, FAN slip which contains
informations like truck no,load no,fan slip
no,entry and exit time of the truck,desination
where the truck has to be reached,type of product.
 My experience has an officer start with dip
checking and that dip rod consits of following
information like full length,oil level,proof
level,truck no,calibration date and renewal date
depending the truck capacity it may vary
accordingly and there is certificate that has to
maintained and it is called caibration certificate
which has to shown whenever asked.

 I always used to maintain a record called random

check list which consists of bay no that i had to
check the first batch of trucks and the same had to
be updated in the website
 Then we have to check density of the
product,density vary for the products and we will
be writing it on the density slip for every two
hours and it will be send to planning department
 who will update the density accordingly,density
will be checked by pouring the product in to glass
jar and with the help of denity meter and then we
will also check the temperature of the product for
e.g if density of MS is 735 and temp is 32 deg
celsius then we will check it with density at 15
deg celsius which is 748.7 is the density of the
product.
 As a gantry officer i will also ensure whether
MDG(Marketing Discipline Guidelines) taken
and kept in the sample room.
 As a gantry officer i will also be checking
whether any leakeges are there in the mainfold
box(gate valves),and if found any will
immediately tell to safety officer .
 As a gantry officer i will also be checking the
pass of the drivers and whether t hey are putting
the safety shoes and helmet.
 I will also inform the control room if there is any
problem regarding the product coming to the
gantry
 I also used to get the receipt (PLT) from the ship
and make sure that samples are taken.
  I had drawn P&ID diagram for gantry and i am
attaching it with this report and its a manual hand
drawn diagram
CALCULATION OF SHORTAGE:
 Shortage calculation will be done when any
trucks were coming to our terminal from longer
distance
 Depending on their invoice,it consists of date and
time of the product loaded ,their shipping
temperature,product coefficient factoretc
 For eg we are taking a load from Maharastra
means we will be doing the calculations below.
 In doing so we will first check the dip and note
the shortages,and then check the current
temperature of the product by using thermometer.
 Then we will do the calculations of shortages for
each compartments.
 For this also i am attaching a paper with proper
calculation