VISVESVARAYA TECHNOLOGICAL UNIVERSITY,

BELAGAVI

VIII Sem B.E. (Mechanical Engineering) Internship Report

INDIAN OIL CORPORATION LIMITED

By

ABHINAV AGRAWAL

1MV17ME002

Supervisor – Sampath Kumar L

DEPARTMENT OF MECHANICAL ENGINEERING

SIR M VISVESVARAYA INSTITUTE OF TECHNOLOGY, BENGALURU

Academic year: 2020-21

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 SIR M. VISVESVARAYA INSTITUTE OF
TECHNOLOGY,

BENGALURU
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that Mr. Abhinav Agrawal, USN: 1MV17ME002 a

student of VIII Semester B.E. in Department of Mechanical Engineering
of Sir M. Visvesvaraya Institute of Technology has successfully
completed the internship at “Indian Oil Corporation Limited” and has
submitted the report to fulfil the academic requirement of
Internship(17ME84.)

Mr Sampath Kumar L Dr K S Shanmukharadhya Dr V R

Manjunath
Faculty Supervisor HOD Mechanical Principal

Name of Examiners Signature with date

1 .………………. …………………

2 ……………….. ...……………….

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 ACKNOWLEDGEMENT

As a part of the course of B.E. in Sir M Visvesvaraya Institute of Technology, I Abhinav

Agrawal, underwent an industrial Training at the Bottling Plant of Indian Oil
Corporation Limited. I am extremely grateful to IOCL for providing me the opportunity.

I express my deepest thanks to Mr. Ankit Kumar for taking part in useful decision &
giving necessary advices and guidance. I choose this moment to acknowledge his
contribution gratefully. It is because of his invaluable guidance and support that made the
experience possible and made my internship highly informative.

I am highly obliged to Training and Development Department for providing me this

opportunity to learn at IOCL. I have further more to thank the officers of production for
sharing their knowledge about the plant and production process. It is really great
opportunity for me by which I have learned here many practical knowledge which are
usually hard to find in textbooks.

I am thankful to Mr. Adarsh Sachan for giving me valuable information regarding his
concern. 

I would also like to thank my internship coordinator Mr. Sampath Kumar L for helping
and guiding me through the process.

ABHINAV AGRAWAL (1MV17ME002)

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 ABSTRACT

Indian Oil Corporation Limited (IOCL), Indian Oil, is an Indian government-

owned oil and gas corporation. It is under the ownership of Ministry of Petroleum and
Natural Gas.LPG bottling plant is a plant where LPG is put into bottles (mounded
bullets) for storage. The plant has the facility to receive bulk LPG by pipeline from a
reliable source or any area. This is the safest and the cheapest way of transporting
bulk LPG. A 6 weeks internship was carried out at the bottling plant conducted by the
Engineering department. The training was mainly about the functioning of the bottling
plant and the core applications of the concepts of Mechanical Engineering.

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 LIST OF CONTENTS

CHAPTER Page No.

1) Introduction to Indian oil

1.1) About IOCL

1.2) Vision

2) Introduction to Amausi bottling plant

2.1) Working of Bottling Plant

2.2) Properties of LPG

3. Detailed working

3.1) Equipment used for Bullets

3.2) Transferring of LPG

3.3) Filling process

4. Conclusion

5. References

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 1.INRODUCTION TO INDIAN OIL

1.1 About IOCL

Indian Oil Corporation (Indian Oil) is India's largest commercial enterprise, with a sales
turnover of Rs. 4,38,710 core (USD 65,391 million) and profits of Rs. 19,106 crore (USD
2,848 million) for the year 2016-17. The improvement in operational and financial
performance for FY 2016-17 reflected in the market capitalization of the Company,
which grew two-fold, from Rs. 95,564 crores as on 31st March 2016 to Rs. 1,87,948
crores as on 31st March 2017. In view of its rising share price and market capitalization,
Indian Oil was included in the Nifty50 index (NSE benchmark index of 50 best
performing corporate). Indian Oil is ranked 161st among the world's largest corporates
(and first among Indian enterprises) in the prestigious Fortune ‘Global 500’ listing for the
year 2016. As India's flagship national oil company, with a 33,000-strong work-force
currently, Indian Oil has been meeting India’s energy demands for over half a century.
With a corporate vision to be 'The Energy of India' and to become 'A globally admired
company,' Indian Oil’s business interests straddle the entire hydrocarbon value-chain –
from refining, pipeline transportation and marketing of petroleum products to exploration
& production of crude oil & gas, marketing of natural gas and petrochemicals, besides
forays into alternative energy and globalization of downstream operations. Having set up
subsidiaries in Sri Lanka, Mauritius and the UAE, the Corporation is simultaneously
scouting for new business opportunities in the energy markets of Asia and Africa. It has
also formed about 20 joint ventures with reputed business partners from India and abroad
to pursue diverse business interests.

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1.2 VISION

Indian Oil’s ‘Vision with Values’ encompasses the Corporation’s new aspirations – to
broaden its horizons, to expand across new vistas, and to infuse new-age dynamism
among its employees. Adopted in the company’s Golden Jubilee year (2009), as a ‘shared
vision’ of Indian Oil People and other stakeholders, it is a matrix of six cornerstones that
would together facilitate the Corporation’s endeavours to be ‘The Energy of India’ and to
become ‘A globally admired company.’ More importantly, the Vision is infused with the
core values of Care, Innovation, Passion and Trust, which embody the collective
conscience of the company and its people, and have helped it to grow and achieve new
heights of success year after year.

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2.INTRODUCTION TO AMAUSI BOTTLING PLANT

LPG was first marketed in India in the mid-fifties by the multi-national oil companies,
which were having marketing operations in India. The bottling operations were, then,
mainly confined to Refinery plants and marketing operations limited to nearby areas.
Though IOC, under Public Sector, started functioning in the year 1959, it actually started
marketing of LPG in the year 1965 with the brand name of "Indane" through its only
bottling plant at Barauni Refinery, which had very limited bottling capacity.
Bulk LPG is packed in LPG cylinders only in safe and secure environment. IOCL has
currently 89 bottling plants in the country to do such bottling. Amausi is one of them.

2.1 Working of Bottling Plant

Amausi bottling plant currently has 4 bullets of 600 MT each, i.e. A total of 2400MT
storage capacity and has progress of 2 mounted storage bullets of 900MT each. This
expansion will increase the bulk storage capacity of plant from 2400MT to 4200MT.

In a bottling plant, bulk LPG is received from the sources through pipelines, by road or
by rail. This is then stored in the vessels and then filled in cylinders using sophisticated
filling machines called Carousals. IOC is now having electronic Carousals with minimum
manual intervention for accurate and safe filing. After filling the cylinder body, valve is
checked for any leaks and the weight is checked on 100% of cylinders.
Good, Safe and Correct weight cylinders are sent to the distributor godowns after sealing
them.

The main operation of this bottling plant is to receive bulk LPG, store into mounded
storage vessels, and bottle in cylinders and dispatch the same to distributors in Lucknow
and adjoining districts.

There are mainly two operations:

 Shed operation
 TLD (Tank Lorry Decantation) operation

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Shed operation is divided into following:
 Filling operation (filling of LPG).
 Evacuation operation (evacuation of defective cylinders received from Market).
 Degassing operation (degassing of defective cylinders).
 Statuary testing of outdated cylinder.

In TLD operation we receive product i.e., LPG from tank truck and transfer into
Mounded storage vessels (MSV)

Physical operations within the LPG plants covering:

 Receipt (bulk / packed)

 Storage (bulk / packed)
 Filling (bulk / packed)
 Deliveries (bulk / packed)

IOC markets LPG in bulk as well as packed supplies as under:

 Bulk supplies to all Industrial customers through bulk tank trucks ex – MI supply
basis.
 Packed supplies to all domestic users through a network of LPG Distributors.
 Packed supplies to commercial installations through LPG Distributors
(E.g. Hotels) and also directly.
 Auto LPG supply to Auto LPG Dispensing Stations (ALDS)

All IOC plants conform to OISD (Oil Industry Safety Directorate) norms and PESO
(Petroleum and Explosives Safety Organization) regulations. Plants have very high safety
standards with state of art firefighting facilities. Plants are notified as prohibited areas and
visits from others who do not have any business with the plants are not permitted.
The plant is provided with an elaborate fire protection system in view of the high hazard
potential of LPG.

The fire protection system is designed as per the guidelines of OSID 144 and its salient
features are given below:

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  The storage capacity is equal to 4 hrs combined capacity of all the fire engines- as
per OISD 144
 Water storage: above ground 2 MS tanks-capacity (3700 KL each)
 Pump size and pressure: 5 nos. diesel operated pumps of 410 m3 /hr capacity
 Manual/auto: Auto mode

2.2 Properties of LPG

 LPG mainly consists of the following: Commercial Butane, Commercial Propane,

A mixture of commercial Butane and Propane.
 Like air, LPG is colourless; therefore, it cannot be seen. However, when liquid
LPG is released from a container or a pipe it vaporizes almost immediately. This
produces a cooling effect in the surrounding air and may cause water vapor in the
air to condense, freeze and become visible. In this way, LPG leak may be
detected even though the gas itself is invisible.

 LPG by nature is odourless. However, it is distinctively odorized to give warning

in case of leakage. LPG is generally odorized by adding ethyl mercaptan in the
approximate proportion of 0.45kg/37.9 m3

 LPG vapour is tasteless and non-toxic. Therefore, the presence of LPG vapour in
the atmosphere cannot be sensed by taste.

 DENSITY OF LIQUIDS
Since the density of water is 1 gm/cm3 or 1000 kg/m3, and the density of liquid
LPG is about 0.55 gm/cm3, the latter is about ½ as heavy as water. The density of
the liquid is approximately half that of water and ranges from 0.510 to 0.580
gm/cm3 at 15 0C. The liquid density of LPG is important to determine the safe
level to which the containers can be filled i.e., to calculate the maximum
permissible filling capacity.

 DENSITY OF VAPOURS
Relative density is used to indicate the density of the gas in relation to that of air
at the same temperature and pressure. If the relative density is greater than unity,

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 the gas is heavier than air. LPG vapor is about 1 ½ to 2 times as heavy as air. As
a result of this property, any leakage of LPG tends to settle down at the floor level
particularly in depressions, pits, drains, etc. Floor level ventilation to disperse the
gas and thereby prevent accumulation are, therefore, most important.

 The melting point for propane and butane (the main constituents of LPG) are –187
0
C and – 137 0C respectively. It is such a low temperature that it cannot encounter
in normal operations/handling and, therefore, does not have any practical
significance.

 The boiling point of LPG presently marketed is in the range of 0 0C to -180 0C. At
temperatures nearer to 0 0C or at sub-zero temperatures, the pressure inside the
container will be almost the same as atmospheric pressure.

 Vapor pressure plays an important part in the manufacture of LPG containers as

they are designed to withstand the maximum vapor pressure likely to arise in
actual use. In India, LPG Cylinders are designed for vapor pressure of 16.87
kgf/cm2 at the assessed temperature of 65 0C whereas un-insulated storage
(spheres/bullets) and transport vessels (tank trucks and tank wagons) are designed
for maximum temperature and vapor pressure of 55 0C and 15.85 kgf/cm2
respectively.

 The flammable mixture of LPG vapor and air will not ignite or explode unless the
ignition source is present. The source may be spark, flame or heated material
possessing sufficient heat to equalize or exceed the required ignition temperature,
which is in the range of 410 0 C to 580 0C depending upon the proportion in which
propane and butane are mixed together. The auto ignition temperature for propane
and butane is 4660 C and 4300 C respectively.
 The calorific value of LPG is very high and uniform which makes it an ideal fuel.
It is nearly 10900 -11000 K cal/Kg at 25 0C.
 LPG has low Absolute or Dynamic viscosity approx. 0.15 cP at 15 0C (Centipoise)
which is much less than that of water which is unity. 1 cP= .001 Pa-s.

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 3. DETAILED WORKING

3.1 EQUIPMENTS USED FOR BULLETS

3.1.1 SERVO GAUGE

Servo Gauge is a microprocessor based electronic level gauging instrument, which uses
digital technology for accurate measurement of product level interface, density and
temperature (with external temperature sensors). It has facility for reading at the gauge as
well as at a remote location.

The Servo tank gauging system is based on the principle of displacement measurement. A
small displacer is accurately positioned in the liquid medium using a servo motor. The
displacer is suspended on a measuring wire that is wound onto finely grooved drum
housing within the instrument.
The drum is driven via coupling magnets, which are completely separated by the drum
housing. Outer magnets are connected to the wire drum whilst the inner magnets are
connected to the drive motor. As the magnets turn, the magnetic attraction causes the
outer magnets to turn as well, resulting in turning the entire drum assembly. The weight
of the displacer on the wire creates a torque on the outer magnets generating the change
of magnetic flux. These changes generated between the drum assemblies are detected by a
unique electromagnetic transducer on the inner magnet. The drive motor is actuated to
balance the voltage generated by the variations of magnetic flux to equal the reference
voltage defined by the operating command.
When the displacer is lowered and touches the liquid, the weight of the displacer is
reduced because of the buoyant force of the liquid. As a result, the torque in the magnetic
coupling is changed and this change is measured usng Hall sensor, which are temperature
compensated. The signal, an indication of the position of the displacer, is sent to the
motor control circuit. As the liquid level rises and falls, the position of the displacer is
adjusted by the drive motor. The rotation of the wire drum is precisely evaluated to
determine the level value, which is accurate to an outstanding +/‐ 0.7 mm.

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3.1.2 RADAR GAUGE

The Radar Gauge is mounted on top of the tank on a suitable nozzle having extended
steel well pipe going inside the vessel. The head of the gauge sends radar signals which
bounce back from the liquid level surface. The time taken for the signals to travel is
translated into the actual height of the level from the tank bottom. Measurement can be
taken even under boiling and turbulent conditions, as this gauge has no moving parts and
has no contact with the liquid.

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3.1.3 HIGH LEVEL ALARM

The high level alarm is provided to allow pre-determined minimum vapor space. It is
independent of the mechanical level gauging devices. It transmits an audio & visual
signal at the desired place when predetermined level of the liquid LPG is reached. One
signal is also taken for closure of liquid ROV of the vessel.

Simple buoyancy and magnetic field are the underlying principles of this instrument.
This instrument has a float (called displacer), which is suspended across a spring. When
the vessel is filled with liquid, the displacer is submerged below the surface of the liquid.
When this happens, the buoyancy causes the spring to contract. This longitudinal
movement displaces a drive magnet, which then attracts a follower magnet, provided on
the outside of the lead pipe. This actuates a micro switch, which gives an output signal.
This output signal is fed to an audio-visual alarm located at any convenient place. This
output signal is also used to close the ROV on the liquid line of the vessel.

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3.1.4 PRESSURE TRANSMITTER

pressure applied to capacitive cells will produce a change in the capacitance of the sensor.
This change will affect the oscillator frequency, and the pressure transmitter will detect
this change. Then the transmitter translates this data into a standard output signal that we
can read.

3.1.5 MULTISPOT TEMPERATURE SENSOR

Measures temperature with one to sixteen Pt-100 spot elements placed at different heights
to provide a tank temperature profile and an average temperature. The calculated average
liquid temperature, based on fully immersed elements, is used as an input for accurate
volume calculations in storage tanks. The temperature sensor is easily installed on the
tank nozzle, and is then connected either directly to the multi-input temperature
transmitter or via cable. The sensor is mounted with a flange or a thread at the top of the
tank. The spot elements are placed in a flexible gas-tight protection tube, made from
convoluted stainless steel, for easier handling during installation. All spot elements are
attached to a wire, which runs from the top to the bottom of the sensor. An anchor weight
can be hung at the bottom, or the tube can be fixed to the bottom to keep the sensor
vertical and avoid floating when the tank is filled.

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3.1.6 ROV (Remote Operated Valve)

The system is provided for closing shut-off valves (Remote Operated valves- ROVs)
quickly on liquid lines in the event of an emergency. The system is operated
pneumatically. The valves connected to the system get closed automatically when the air
pressure in the pneumatic system is reduced through bleeder valves provided at various
points in the plant for quick access. The shut-off ROVs are normally located on the
storage vessel outlets, pipe lines leading to tank wagon gantry, and tank truck bays and
pipe lines leading to the filling shed. Whenever the bleeder valve is opened to actuate
closure of the valves, the system gives automatic audio/visual alarm and also a signal to
the control room, if provided with EP System. All ROVs to be provided with manual air
drain valves for closure of ROV from safe distance. Each ROV shall also be provided
with prominent open-close indicators.

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3.2 TRANSFERING OF LPG

3.2.1 TRANSFER THROUGH LPG COMPRESSOR.

This method involves withdrawing vapor from the receiving vessel, compressing the
vapor and discharging the compressed vapor into the ullage space of the delivering
vessel. The method of pressure differential is well suited for unloading operations.
An important additional advantage of compressor over liquid pump is their ability to
recover vapor from the delivering vessel. The vapor recovery can be achieved from the
discharge vessel by reversing the compressor connections at the end of the discharge
operation.
Differential vapor pressure of 1.5 to 2.0 kg/cm 2 is usual for most of the unloading
operations.

3.2.2 TRANSFER THROUGH LPG PUMP

Transfers LPG from bullet to filling station by pressurizing liquid by suction method.

3.3 FILLING PROCESS

Incoming cylinders fall into following categories:

 New cylinders from the manufactures.
 Cylinders in circulation from the distributors (empty, under-filled, defective).
 Cylinders received from the statutory testing plants, duly tested.
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  Hot repaired cylinders received from the approved repairers.

3.3.1 SEQUENCE OF OPERATIONS

 Unloading
 Segregation
 Washing
 Drying
 Regenerator (measures tear weight)
 Filling machine
 Check scale
 Valve leak detector
 Oaring checking
 Water bath
 Hot air sealing
 loading

3.3.2 CONVEYOR SYSTEM

The function of a conveyor system, in bottling plants, is to convey and distribute the
cylinders mechanically, thereby reducing the manual handling and faster movement of
cylinders to the various on-line facilities.
Power operated chain conveyers are widely used in the filling plants due to the chain type
conveyors that are found to be most suitable for the size and type of cylinders that are
being handled at IOC’s filling plants. The special shape and surface of the chain permit
LPG cylinders to accumulate anywhere on the conveyor. Thus, LPG cylinders may be
retained for different working operations while the chain moves uninterrupted.
The chain can run at different velocities on different sections when provided with
suitable drive units, giving considerable flexibility to adapt to different working
requirements.
All the on-line equipment with wide range of special purpose utilities can
be incorporated in the system.

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CONTROL OF CYLINDER MOVEMENT ON THE CONVEYORS -
COMPONENTS

 Pusher: It is intended for automatic diversion of LPG cylinders to the required

direction and conveyor sections. The same are operated pneumatically actuated by
pneumatic/Electro pneumatic signals.

 Pneumatic-cylinder-stop-device: It can be placed at desired locations on the chain

conveyor and is intended for stopping, retaining or releasing LPG cylinders at
designed intervals. The same are operated pneumatically actuated by pneumatic /
Electro pneumatic signals.

 Diverter/Converge: It is intended for diverting movement of cylinders to

different conveyer sections by means of pneumatic device.

 Stopper: This is a pneumatic device to stop the movement of cylinders by manual

or automatic actuation

3.3.3 DRIVING UNITS

The chain conveyors are driven by the drive units. Drive unit consists of worm reduction
gear box coupled to flame proof electric motors. Transmission of power is made by the
transmission chain from the sprocket of the gear box (or directly through the sprocket
assembly of planetary gear box) to the sprocket of conveyer drive section.

The number and specific dimensions of the driving units are adopted based on the
anticipated load and the desired velocity of conveyance. The driving units are provided
with tensioning device for the conveyor chain. Soap water trays are provided at suitable
locations on the system, where the chain gets cleaned and efficiently lubricated during its
continuous passage through the solution.

3.3.4 PRE-FILLING FACILITIES

a. Purging unit
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The unit consists of Vacuum pump with gauge and a manifold with sets of adopters for
removal of air from the new empty cylinders and filling of LPG vapor into these
cylinders. The unit is installed and operated on line and designed for automatic &
semiautomatic operations. To ensure removal of air up to 0.35 kg/cm2 (absolute )/
(-)494 mm of Hg (g)/(-)0.65 kg/cm2 (g), pressure based purging cut-off has been
provided.

b. Cylinder washing / Drying unit

This unit is installed on line for the cylinder washing and subsequent drying of empty
Cylinders prior to filling. The unit consists of continuous water rinsing section with
rinsing nozzles and water tank with filter, centrifugal pump & air blower.

On line check facilities for market return cylinders. The facilities consist of check
weighing scale along to check the weight of defectives returned by the distributors.

c. Foot Ring Straighter

The cylinders segregated on account of bent VP Ring/Stay Plate / foot ring but without
break in welding, should be repaired at this machine before being sent to carousel for
filling.

d. Weighing arrangement for new cylinders

A weighing scale is provided to check and verify the tare weight of the new, statutory
tested and hot repaired cylinders. Minimum 10% of the cylinders received should be
checked at random for the correctness of the tare weight. The paint thickness (67
microns) should also be verified at random by using Elcometer to check whether the
minimum thickness of the paint is maintained as per specification, for ST tested cylinder.

3.3.5 FILLING METHOD- GROSS WEIGHT SYSTEM

Gross weight system is adopted for filling operation in all plants. In this case, the
machine is provided with individual adjustments for ‘Tare-Weight’ and ‘Net-Weight’.
Once the weight of the product to be filled is pre-set as ‘Net-weight” which remains
constant, the only adjustment required is that of ‘Tare-Weight’. Once the set ‘Gross-

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Weight’ (arithmetical sum of pre-set ‘Net-Weight’ and the ‘Tare-Weight’ set) is reached,
the product flow is cut off automatically. So the accuracy of the filling relates to the
accuracy of ‘Tare-Weight Marking’ on the cylinders and the tare weight set on the
machine. It is, therefore, essential that the ‘Tare-Weight’ marked on the cylinders is
accurate and legible.

3.3.6 FILLING MACHINE

Filling carousel

The filling carousel is intended for filling of large number of LPG cylinders at major /
mini bottling plants. It consists of a carousel frame with running wheel and corresponding
running rail, a central column for gas and air and hydraulic driving unit, which by means
of anti-static V-Belts / Tyre rotates the carousel frame around the central column. The
speed of the driving unit is variable so that the rotation of the carousel can be adjusted to
various filling times and capacities.

From the central column, gas and air are distributed through distributing pipes to circular
pipes behind the filling machines and through gas-stop valves and anti-static hoses. A
filling machine can thus be shut-off for repairs without affecting the operation on the
other machines. The LPG liquid line from the pump house is provided with a by-pass
arrangement with DP (Differential Pressure) Valve near the carousal. The DP valve is a
spring-loaded valve, which automatically allows the flow of LPG through a by-pass line,
whenever LPG pressure in the pipeline exceeds the set limit.

The filling pressure shall not exceed max. working pressure of the cylinder i.e. 16.9
Kgf/sq cm at 65 Degree centigrade.

While selecting the size of the carousel (6/12/18/24 machine capacity) not only the
immediate requirement but also future requirement of filling capacity is considered. The
carousel frame chosen can then be equipped with a number of filling machines covering
the present demand. Further, machines can subsequently be augmented as and when the
demand increases.

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 The filling carousel is provided with equipment for automatic introduction and also
ejection of cylinders. Using automatic Introduction and ejection units, smooth transfer of
cylinders, to and from the carousel to conveyer is achieved.

3.3.7 POST FILLING FACILITIES

a. ON LINE CHECK SCALES

The function of the equipment is to check the correctness of the quantity filled in the LPG
cylinder on filling machines. Check scales consist of weighing scale suitably
modified for the operation. The least count of the scale should not be more than 10 grams.
They are installed on line on the conveyor section to check the correctness of the weight
of the filled cylinders on a continuous basis after they come out of filling machines.

The check scale consists of electronic weighing scale with load cell and digital display
and the net weight (14.2 Kg, 19 Kg etc) is tared or fixed and the check scale shows only
the variation in weight of the cylinder and cylinders with weight variation higher than the
pre-set values are automatically rejected into a different loop.

In majority of the Plants, the check-scale is integrated with carousel and the tare weight
of the cylinders is automatically transferred to check scale. The check-scale gets the input
tare weight data from tare punching station and compare the actual weight of the
cylinders with tare weight as received from punching station plus net weight of the
cylinder and If found within range, it allows the cylinder on main stream else it transfers
the cylinder on the correction loop.

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In some of the Plants, stand-alone check scales are still available. In this type of check
scale, tare weight of the cylinder is punched by an operator as it approaches the check
scale. Check scale after comparison automatically accepts or rejects the cylinder as the
case may be.

The scales of capacity 1200cyls/hr, 1400 cylinders/hr, 1600 cylinders /hr are available
and are provided with anti-jam sensors to stop the operation in case of accumulation of
cylinders down the stream or on the rejection conveyor.

Maximum permissible errors in deficiency against the declared weight should be within
+75 gm & -75 gm (+/- 1.5%) in case of 5 Kg cylinders & +/150 gm in case of 14.2 Kg
cylinders, in accordance with the Legal Metrology (Packaged Commodities) Rules 2011.
However, as per the corporation norms maximum acceptable variation in net weight for
14.2 Kg Cylinders is + 200 gm and -100 gm. However, it must be borne in mind that as
per Legal Metrology Rules, the average net weight of cylinders in a lot should be equal to
or greater than the declared net weight.

b. WEIGHT CORRECTION UNIT

Over filled / under filled cylinders rejected from the check scale are manually corrected
at this unit. The unit consists of weighing scale and one filling head (common for filling
and evacuation) with a stopper, lifting mechanism, tilting mechanism for evacuating
excess quantity of over filled cylinders. The under filled cylinders are corrected by
topping up with the required quantity and the overfilled cylinders are evacuated to the net
quantity by tilting the cylinder on the frame of the machine. The system operates on the
same gross weight method similar to the filling, where the operation cuts off once the
total weight of cylinder reaches the gross weight of cylinder.
The cylinders after correction are checked again in the check scale for the correct net
weight.

c. AUTOMATIC WEIGHT REDUCTION UNIT

At many of the plant, since the rejection from electronic carousal is very low, Automatic
Weight Reduction Unit has been provided in place of Integrated Weight Correction Unit.
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The cylinders rejected from check scale are fed to this machine, wherein 3 to 4 Kg of gas
is removed (by evacuating the gas for a fixed time from all the cylinders. These cylinders
are then sent back to the carousal for refilling.

d. COMPACT VALVE TESTER (CVT)

The CVT is used for checking the ‘O’ ring condition and the valve leak. CVT is
designed to detect the leakage of 0.5 gm per hour and above. It consists of a detecting
head with a central air capillary connected to the top chamber filled with kerosene. When
the head is connected to the cylinder valve, it clamps the valve and probe air is supplied
around valve ‘O’ ring. For any damage in the ‘O’ ring, the air passes through the ‘O’ ring
to the top chamber through air capillary. Bubbles in the kerosene chamber shall indicate
the damaged “O” ring or the valve leak. If the bubble continues to persist, when the probe
air is cut off, it indicates the valve leak and if not, defective ‘O’ ring. The working of
CVT should be verified by using CVT verifier. Now days, CVT is being used only at
RQC loop at most of the Plants.

e. AUTOMATIC ELECTRONIC ‘O’ RING LEAK DETECTORS

The unit consists of testing head with auto centring and cylinder clamping/lifting facility.
When the cylinder enters the unit, the cylinder is clamped and lifted simultaneously. The
testing head lowers and is clamped to the cylinder valve, probe air is supplied around
Valve “O” ring. For any damage in the “O” ring, the air passes through the central
capillary and taken to the pressure transmitter. The pressure transmitter produces an
electrical signal (4-20 milliamps) proportionate to the quantum of air leak. As per the
preset values set in the PLC panel, the cylinder will be sorted out according to the
magnitude of the electrical signal. The cylinder valve with defective ‘O’ ring shall be
rejected automatically by a pusher to the rejection conveyer. The online MIS is also
generated as the unit is integrated to the PC.
The detector has the capacity to check 1200 to 2200 cylinders /hr with single/ double
head. The unit is totally automated and does not require manning.

f. AUTOMATIC ELECTRONIC VALVE LEAK AND BUNG LEAK

DETECTOR

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The unit consists of single / multi sensing head with auto centring & lifting facility. The
equipment is also provided with a gas analyser and a control panel. When the cylinder
enters the unit, the cylinder is lifted and centred automatically. The sensing head is
automatically lowered covering and sealing the valve and bung portion of the cylinder.
Clean air is supplied to the sealed cavity of the sensor head. In case of a leaky cylinder,
mixture of air and LPG is formed within the sealed cavity of sensor head. This mixture of
air and LPG from the sensor head cavity is transferred through a tube to the gas analyser,
which intern actuates the control panel to give a signal for auto rejection of the cylinder.

The gas analyser is calibrated to detect leakage of LPG of 0.5 gm/hr or more. The
detector has the capacity to check 1200 to 2200cylinders per hour. The on-line MIS also
is generated as the unit is integrated to the PC.

The unit is totally automated one and does not require manning. The cylinders segregated
from this unit are either valve leak or bung leak. These segregated cylinders are sent for
valve change after evacuation. OK valves fitted on Bung leak cylinders can later be
retrieved through valve retrieval machine/system.

g. AUTOMATIC VALVE TESTING MACHINE

Automatic valve testing machine is an on-line automatic valve leak and damaged ‘O’
ring testing equipment. The cylinder detected for the valve leak / ‘O’ ring damage is also
rejected by this equipment automatically to either a common rejection loop conveyer or
separate loop conveyors for valve leak and O-ring leak cylinders.

Operation: The cylinder enters into the unit on the conveyor and is automatically
positioned under the testing head. The testing head lowers on to the cylinder valve and
test starts as soon as head is engaged to the cylinder valve fully. In case there is no
leakage the head lifts off after pre-set time and cylinder is released for further operation.
In case of leak either
from the valve seat or damaged valve ‘O’ ring the head lifts up. For any leakage, the
air/LPG vapor passes through the central capillary and taken to the pressure transmitter.
The pressure transmitter produces an electrical signal (4-20 milliamps) proportionate to
the quantum of leak. As per the preset values set in the PLC panel, the cylinder will be
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sorted out according to the magnitude of the electrical signal and pusher of the unit ejects
the cylinder to the rejection conveyer loop for further identification of the type of leakage
and necessary operation thereof.

h. SAFETY CAP MALLETING UNIT

This unit consists of pneumatically operated PVC head and it taps on the top of the safety
cap placed on the valve. This unit is installed before the in line bath to ensure that
capping of the cylinder is done before entering into water bath.

i. IN-LINE WATER BATH

The filled cylinders are passed through the in-line water bath, dipped up to the bung level
to determine the leakage from the bung and the body. The facility consists of a water
bath made of sheet metal having chain conveyer for the movement of cylinders inside the
bath.

Periodical painting of the interior surface of the water bath with white paint or cleaning
of the white tiles, provision of sufficient lighting arrangement and periodical changing of
water are required to ensure that it is kept clean for easy detection of the leaks.

j. HOT AIR SEALING

The cylinder sealing is done by means of PVC seal using hot air. The PVC seals are
placed on the safety caps over which hot air or steam jet is forced on. The PVC seals
shrink and effectively cover the safety cap as a seal. Portable hot air sealing unit may be
provided at plants, in addition to fixed hot air sealing unit to ensure 100% sealing of
sound filled cylinders before dispatch.

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 CONCLUSION
The vocational training enhanced my practical knowledge. Most importantly, we were
oriented to the industrial scenario and its many challenges and subtleties. The smooth
functioning of an industry depends to a large extent on the mutual co-operation among its
different wings. We also learnt about the core applications of Mechanical Engineering.
Nevertheless, I did enjoy the training to the fullest and am very sure that this training will
help me in our future endeavours.

Thanking You

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 REFERENCES
1. IOCL LPG MANUAL

2. www.iocl.com

3. www.wikipedia.com

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