Winter internship Report

INDIAN OIL CORPORATION LIMITED (GUWAHATI refinery)

(20-12-2021 to 20-01-2022)

Approved By: Submitted By:

Mr. Aritra Pramanik BHASKARJYOTI HAZARIKA (129/19)
Assistant Manager(ML) Dhrubajyoti mudoi (133/19)
Sem-5th
Branch-Mechanical (Dibrugarh university)
 ACKNOWLEDGEMENT

Our indebtedness and gratitude 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
we must record our immense gratitude to those who helped us undergo this valuable
learning at IOCL Guwahati Refinery.
We are highly obliged to Training and Development Department for providing us this
opportunity to learn at IOCL.We have further more to thank our guide Sir Aritra Pramanik
for sharing his knowledge and time about mechanical equipment maintainance. It was
a really great opportunity for us via which we have accumulated practical experience
on pumps and heat exchangers which are usually hard to find in textbooks.
Since we belong to the same university ,we kindly request L&D centre to kindly accept
the same report for both of us

My special thanks to----

Mr. Aritra Pramanik (AM, ML)
Ms. Debanuja Borah (AM- L&D)
 IOCL: Indian Oil Corporation Limited
❖ The organisation was established on 30 June 1959, It is under Ministry of Petroleum and Natural
Gas, Government of India.
❖ It's headquarter is in New Delhi, Chairman is Shrikant Madhav Vaidya
❖ IOCL is the largest commercial oil company in the country, In 2019 - 2020 FY it's turnover was
566950 CRORE & Net profit was 1310 CRORE.
❖ Ranked 2nd in fortune India 500 list in 2020 & 151 in Fortune Global 500 list of world largest
companies in 2020. This organisation work in 7 divisions:
o Refineries, Pipeline, Marketing, R&D, Petrochemical, Exploration & Production, Explosive &
Cryogenics.
❖ Indian oil accounts for nearly half of India petroleum products market share & 35% national
refining capacity.
❖ On 19 Nov 2017, IOCL with OLA launched India's 1st electric charging station at it petrol-diesel
station in Nagpur.
❖ IOCL owns & operates 11 of India's 23 refineries & it's pipeline network for transport of crude oil
to refineries & finished product is 13000 KM.
 Refineries
❖ Barauni refinery, CPCL-Chennai, CPCL-Narimanam, Digboi refinery, Guwahati refinery, Haldia
refinery, Koyali refinery, Mathura refinery, Panipat refinery, Paradip refinery, Bongaigaon
refinery.

SUBSIDIARIES
❖ Indian Oil (Mauritius) Limited, IOC middle East FZE - UAE, Panna IOC PLC- Sri Lanka,IOC
Sweden AB-Sweden, IOCL (USA) Inc - USA, IndOil Global B.V - Netherlands, IOCL Singapore
Ltd. Ltd.

COMPETITION
❖ There is two major domestic competitors - Bharat petroleum & Hindustan petroleum both are
government owner organisation.

AWARDS
❖ National CSR Award on 29 OCT 2019,
❖ Indian oil wins BEST PSU/CORPORATE HOUSE for promotion of Sport's on 14 January 2020,
❖ Outstanding PSU of the year at AIMA Managing India Awards on 8 April 2019,
❖ PRSI AWARD on 21 FEB 2021
 GUWAHATI REFINERY-GANGOTRI OF IOCL

 Guwahati Refinery was set up at Noonmati in Guwahati on 1 January 1962. Guwahati

Refinery is the first Public Sector refinery of India and belongs to Indian Oil
Corporation Limited. The refinery was inaugurated by Late Pandit Jawahar Lal Nehru,
the first Prime Minister of independent India. The refinery was built
with Romanian Collaboration and has a capacity of 1.0 million metric tonnes per
annum. This refinery process crude oil from Upper Assam Oil Fields, India and helps
cater energy need of the region. Major Products of this refinery are:
➢ LPG,
➢ Motor Spirit (Petrol),
➢ Aviation Turbine Fuel (ATF),
➢ Kerosene,
➢ High Speed Diesel,
➢ Light Diesel Oil and
➢ Raw Petroleum Coke.
 Stamp of India – 1962
- Collect 142019
- Inauguration Guwahati Refinery

❖ With growing environmental consciousness, Guwahati Refinery, Indian Oil

Corporation Limited has also ventured into ecologically friendly fuel and
subsequently installed 3 new units: the ISOSIV, the Hydrotreater and the INDMAX.
❖ The ISOSIV unit produces Lead Free Petrol by the Molecular Sieve Technology, which
separates Octane rich MS components from feed naphtha.
❖ The Hydrotreater Unit (HDT) enables the Refinery to produce High Speed Diesel of
very low sulphur and cetane number conforming to BIS specifications. The HDT also
produces ATF, Superior Kerosene Oil with high smoke point and low sulphur. The
Indane Maximization (INDMAX) technology developed by R&D Centre of Indian Oil
installed at the Refinery is designed to achieve LPG yield as high as 44% through
Fluidized Catalytic Cracking of residual feed stocks like Reduced Crude Oil, Coker
Fuel Oil and Coker Gasolene. The INDMAX unit also enables Guwahati Refinery to
upgrade all its residual products to high value distillate products and make it a zero
residue Refinery
A glimpse of Guwahati Refinery
 Role of mechanical engineers in IOCL

❖ Mechanical equipment maintenance- Mechanical engineers carry out planned

or unplanned maintenance and repair activities on a wide range of equipment e.g.
pumps, heat exchangers, compressors etc. Typical Day Duties: Fault-finding and
repair of plant, systems and equipment.
❖ Engineering services-Engineering services is a design department for modification
of different mechanical equipments based on some critical observation or RCA or
failure during expansion of the refinery. Modification can be in an existing system or
buying a new system.
❖ Material procurement and contract line up- There are many mechanical
equipments which are in need of spare parts .Accordingly mechanical engineers
undertake engineering, procurement, and construction (EPC) contracts (a type of
turnkey contract) , a form of contract to undertake construction works by the private
sector on large-scale and complex infrastructure projects.
 Important mechanical equipments used in GHY Refinery.

Pumps

A pump is a device that is used for lifting the liquid from ground sources to the upper top
surface or from one place to another place. Pumps are operated by the mechanism that is
rotary, reciprocating and it consumes electrical energy while performing mechanical work
which is moving fluid from one place to another. This can be operated by many energy
resources which include manual operation, electricity, engine, wind power and many more,
day to day life to industrial applications.
 Types of Pumps

 Positive displacement pump

A positive displacement (PD) pump moves a fluid by repeatedly
enclosing a fixed volume and moving it mechanically through the
system. The pumping action is cyclic and can be driven by pistons,
screws, gears, rollers, diaphragms or vanes. Although there are a wide
variety of pump designs, the majority can be placed into two
categories: reciprocating and rotary.

 Types of positive displacement pumps

❖ Reciprocating pump
❖ Rotary pump
 Reciprocating Pump
 A Reciprocating Positive Displacement pump works by the repeated back-and-forth
movement (strokes) of either a piston, plunger or diaphragm (Figure 1). These cycles are
called reciprocation.
➢ Types with their working principle:
 In a piston pump, the first stroke of the piston creates a vacuum, opens an inlet valve,
closes the outlet valve and draws fluid into the piston chamber (the suction phase). As
the motion of the piston reverses, the inlet valve, now under pressure, is closed and the
outlet valve opens allowing the fluid contained in the piston chamber to be discharged
(the compression phase). The bicycle pump is a simple example. Piston pumps can also
be double acting with inlet and outlet valves on both sides of the piston. While the piston
is in suction on one side, it is in compression on the other. More complex, radial versions
are often used in industrial applications.
 Plunger pumps operate in a similar way. The volume of fluid moved by a piston pump
depends on the cylinder volume; in a plunger pump it depends on the plunger size. The
seal around the piston or plunger is important to maintain the pumping action and to
avoid leaks. In general, a plunger pump seal is easier to maintain since it is stationary at
the top of the pump cylinder whereas the seal around a piston is repeatedly moving up
and down inside the pump chamber.
 A diaphragm pump uses a flexible membrane instead of a piston or plunger to move
fluid. By expanding the diaphragm, the volume of the pumping chamber is increased
and fluid is drawn into the pump. Compressing the diaphragm decreases the volume
and expels some fluid. Diaphragm pumps have the advantage of being hermetically
sealed systems making them ideal for pumping hazardous fluids.
 Rotary pump
 Rotary positive displacement pumps use the actions of rotating cogs or gears to
transfer fluids, rather than the backwards and forwards motion of reciprocating
pumps. (Fig 2)
➢ Types with their working principle:
 External gear pump: consists of two interlocking gears supported by separate
shafts (one or both of these shafts may be driven). Rotation of the gears traps the
fluid between the teeth moving it from the inlet, to the discharge, around the
casing. No fluid is transferred back through the centre, between the gears,
because they are interlocked. Close tolerances between the gears and the
casing allow the pump to develop suction at the inlet and prevent fluid from
leaking back from the discharge side. Leakage or “slippage” is more likely with
low viscosity liquids.
 Internal gear pump: operates on the same principle but the two interlocking
gears are of different sizes with one rotating inside the other. The cavities
between the two gears are filled with fluid at the inlet and transported around to
the discharge port, where it is expelled by the action of the smaller gear.
 Lobe pump: the rotating elements are lobes instead of gears.
 Vane pumps: use a set of moveable vanes (either spring-loaded, under hydraulic
pressure, or flexible) mounted in an off-centre rotor. The vanes maintain a close
seal against the casing wall and trapped fluid is transported to the discharge
port.
 Centrifugal pump

 A Centrifugal pump is a mechanical machine that pumps the fluids by converting

the mechanical power (rotational energy) into the pressure energy of the fluid flow.
This mechanical power generally supplies by the electric motor or engine. A
centrifugal pump uses a centrifugal force to pump the fluids. Therefore, it is known as
a centrifugal pump.
 Working Principle of Centrifugal Pump

 The centrifugal pump working principle is according to the basic principle of

the angular momentum principle which states that the change in the angular
momentum of a revolving element is equivalent to the applied force. It represents,
when a specific quantity of the fluid rotates due to an external force (force provide by
an electrical motor or a turbine), a centrifugal force appears on the fluid, which further
converts the fluid speed into pressure. Some part of this energy converts into the fluids’
kinetic energy.
 Main Parts of a Centrifugal Pump

 Casing: The casing is a narrow air passage around the impeller. The casing
includes in the major components of the centrifugal pump. It is designed in
such a shape that it converts the kinetic energy of the fluid discharged by the
impeller outlet into pressure energy before the fluid exits the casing and goes
into the discharge pipe. Centrifugal pumps may have volute casing
(mostly),vortex casing or guide blades casing.
 Impeller: The impeller imparts kinetic energy to the fluid via the centrifugal
action acting on the fluid .It is the most pivotal component of the centrifugal
pump. It can be an open impeller ,closed impeller or semi-open impeller.
 Suction Pipe: The bottom side of the suction pipe immerses in the water to that
we want to lift while other side connects with the inlet of the centrifugal pump.
This part of the centrifugal pump has a foot and strainer valve at its bottom
end. The role of these valves is to remove debris like sands, leaves, and allow
the water to flow upwards.
 Delivery Pipe: This part of the centrifugal pump is used to lift fluid to the
required area. One end of the delivery pipe connects with the outlet of the
pump, and the other end connects with the height where we want to transfer
fluid.
 Diffuser: The diffuser is an important element of a compressor or pump. Its purpose
is to reduce the velocity of the flow leaving the impeller resulting in an increase in
pressure. The diffuser can be simply depicted as a nonrotating channel whose flow
area increases in the direction of flow.
 Shaft (Rotor). The impeller is mounted on a shaft. A shaft is a mechanical
component for transmitting torque from the motor to the impeller.
 Shaft sealing. Centrifugal pumps are provided with packing rings or mechanical
seal, which helps prevent the leakage of the pumped liquid.
 Bearings. Bearings constrain the relative motion of the shaft (rotor) and reduce
friction between the rotating shaft and the stator. There are at least 5 common
types of bearing, each of which operates on different principles:
1. Plain bearing
2. Rolling-element bearing
3. Jewel bearing
4. Fluid bearing
5. Magnetic bearing
 NPSH (Net Positive Suction Head)
❖ NPSH stands for Net Positive Suction Head and is a measure of the pressure
experienced by a fluid on the suction side of a centrifugal pump. It is quoted
as a Head (in feet or metres) rather than as an actual pressure (lb/in2 , psi or
Pa) because ‘head’ is a fluid-independent property: a pump will lift different
fluids to the same height irrespective of their densities.

❖ NPSH is defined as the total head of fluid at the centre line of the impeller less
the fluid’s vapour pressure. The purpose of NPSH is to identify and avoid the
operating conditions which lead to vaporisation of the fluid as it enters the
pump – a condition known as flashing. In a centrifugal pump, the fluid’s
pressure is at a minimum at the eye of the impeller. If the pressure here is
below the vapour pressure of the fluid, bubbles are formed which pass on
through the impeller vanes towards the discharge port. As the bubbles of
vapour are transported into this higher pressure region, they can
spontaneously collapse in a damaging process called cavitation (Figure 1).
The repeated shock waves produced by this process can be a significant
cause of wear and metal fatigue on impellers and pump cases.
When to use +ve displacement pump vs Centrifugal pump

When Head Flow

Positive Displacement Pump

When Head Flow

Centrifugal Pump

In refineries we generally have very large pipelines ,so flow is more and
head requirement isn’t much.

Hence , in refineries we mostly see Centrifugal Pumps as compared to

positive displacement pumps.
 Heat Exchangers

❖ A heat exchanger is a device that facilitates the process of heat exchange

between two fluids that are at different temperatures.
❖ Heat exchangers are used in many engineering applications, such as
refrigeration, heating and air conditioning systems, power plants, chemical
processing systems, food processing systems, automobile radiators, and
waste heat recovery units.
❖ Air preheaters, economizers, evaporators, super heaters, condensers, and
cooling towers used in a power plant are a few examples of heat
exchangers.
 Shell and Tube Heat Exchanger
 A shell and tube type heat exchanger ,in simple words ,is a type of heat
exchanger where the working fluids exchange heat with the help of ,as the
name suggests, tubes and a shell.
❖ One of this is called the tube side fluid and the other is known as the shell type
fluid.
❖ The tubes are encompassed in a cylindrical shell which exists at a temperature
different from the network of tubes mounted inside it.
❖ It is obvious by the laws of thermodynamics that a heat exchange will take
place due to said temperature difference between the two parts.
The Three types of Shell and tube heat exchangers are as follows :
❖ Fixed Tubesheet - this heat exchanger type has straight tubes through the shell
and are fixed at both ends.
❖ U-Tube - as the name describes, the tube bundle in this heat exchanger is U
shaped. The tubes start in the top part of the tube sheet, make a U, and come
back to the bottom part of the tube sheet.
❖ Floating Head -This heat exchanger type has one end of the tube fixed in the
tube sheet while the other end is kept free to expand.
 Floating Head Heat Exchanger
 The most commonly used heat exchanger in petrochemical industries is
floating head type heat exchanger . As shown in the name of it, in this
design, one end of the tube sheet is fixed to the shell, while the other one
can “float” freely inside the shell. Generally, both the shell and tube bundle
are free of expansion, this permits no thermal stress is produced between
shell and tube bundle, when the temperature difference of two medium is
large.
 The different parts of Floating Head Heat Exchanger are as follows :
❖ Shell
❖ Tube
❖ Tube sheet
❖ Tube bundle
❖ Channel head
❖ Floating Head
❖ Shell cover/dome cover
❖ Baffles
❖ Tie Rods and Spacers
❖ Support saddles
Other important components of FLOATING HEAD HEAT EXCHANGER

❖ Flanges- A Flange is a protruded ridge, lip or rim, either external or internal, that serves to
increase strength (as the flange of an iron beam such as an I-beam or a T-beam); for easy
attachment/transfer of contact force with another object (as the flange on the end of
a pipe, steam cylinder, etc.); or for stabilizing and guiding the movements of a machine or
its parts (as the inside flange of a rail car or tram wheel, which keep the wheels from running
off the rails).
❖ The ASME B16.5 and ASME B16.47 norms mention a few different types of flange faces:
• Flat face flange (FF)
• Raised face flange (RF)
• Ring joint flange (RTJ)
• Lap joint flange
• Male and female flange (M&F)
• Large and small tongue-and-groove flange (T&G)
 Raised face flange Flat face flange

Gasket area is positioned above the Gasket area is positioned collinear

bolting line of flange with the bolting line of flange

Ring joint flange Lap joint flange

Circular groove to accommodate a

A flat face to simply host the stub end
ring joint gasket (oval, or rectangular)
 Tongue and Groove Flange Male and Female Flange

One flange has an area extended

beyond its face area, the male flange,
T&G perfectly fit one into the other: one
the other flange has a matching
flange has a raised ring, the other a
depression machined on the facing
groove
surface, the female flange.
 ❖ Gasket- The gasket is a key component in a flange assembly. As known, flanges are
composed of three sub-components. The complex interaction between these sub-
components under bolting up and operating conditions determines the successful
operation of the flange. However, it is through the gasket that any leakage occurs and
for this reason it receives most attention.
❖ A wide range of gasket materials and types are used, most of them to national
standards which specify quality and dimensions. They are as follows:

Rubber gasket CAF gasket

This was the most common material used for

Natural rubber was the first material low pressure service. The gasket consists of
used; synthetic rubbers now is widely asbestos fiber bound together with an
available in many grades elastomeric binder, sometimes with a steel
mesh, and can be used up to 550°C.
 CSF gasket Graphite gasket

This new range of gasket materials The material comprises almost 100% graphite
utilize Kevlar,TM a registered trademark of Du laminated to a metal core to give it strength
Pont, and glass fibre with elastomeric binders for handling and service. It has a wide
and is an attempt to replace CAF. temperature range.
 Metal jacketed asbestos gasket
A popular gasket for exchangers as it can be
manufactured with integral pass partition
bars for multipass heads. A section is shown
in Figure and shows the asbestos millboard
core surrounded with a metal jacket which
can be produced in a wide range of
materials.
Spiral wound gasket
These gaskets are made from stainless steel
or high alloy metal wound in a spiral
formation with a nonmetallic filler. These are
suitable for high integrity gaskets and can be
produced in a wide range of materials.
 Solid metal joint gasket

Used for high pressure applications, they are

available in a range of sections, e.g., flat or
octagonal, or as proprietary designs. The
flange surface finish is critical in achieving a
leak free gasket. The finish should be
selected to suit the particular gasket used,
and the gasket supplier involved if
necessary. A "gramophone" finish is one of
the most useful finishes.
 Floating Head Heat Exchanger Design

❑ According to different requirements, the floating head on a floating head heat

exchanger can be designed into various types, in addition to consider that the
tube bundle can move freely within the device, we must also take into the
convenience of maintenance, installation, and cleaning for the heat exchanger.

❑ Generally, there are four basic types of floating head heat exchanger – outside
packed stuffing box (TEMA P), outside packed lantern ring (TEMA W), the floating
head with backing device (TEMA S), and pull through (TEMA T) designs.
ANSON can manufacturer various kinds of floating head heat exchangers
accordance with the TEMA, API660, and JISB8249. Other special requirements are
also available.
Pull Through Floating Head Heat Exchanger (TEMA T)

Pull Through Floating Head Heat Exchanger (TEMA S)

TEMA Designations for Shell and Tube type Heat Exchanger
Heat exchanger process data sheet
 Some important specifications observed

❖ Type of Heat exchanger

❖ Type of Shell and Tube fluids

❖ Maximum design temperature

❖ Maximum operating temperature

❖ Maximum design pressure

❖ Maximum operating pressure

❖ Heat capacity
 Case study : Hydrotest of heat exchangers

❖ Hydro test is the maintenance procedure to find out any leakage in the
heat exchanger.
❖ Hydro test is basically done in 2 steps :
1. Shell test – to find out leakage in shell of heat exchanger
2. Tube test – to find out leakage in tubes of heat exchanger
❖ Procedure of Shell test
1. Insert tube bundle in shell.
2. Install floating head side test ring with gasket.
3. Install blinds in shell's inlet and outlet .
4. Install pressure gauge in shell inlet and outlet with the help of fitting.
5. Fill the shell by water from bottom side and vent should be opened during
water filling
6. Now raise the pressure up to value given by the inspection team with the
help of hydro test pump
7. Now check leakage from the tubes and tube sheet (since the shell fluid is
pressurised ,if there is any leakage in the tubes fluid shall enter the tubes and we
shall be able to identify the defective tube)
Basically shell test gives us information about the leakage of any tube too.
Tapered plugs are generally used to seal the leaking tubes in heat exchangers.
Tapered plugs offer low cost maintenance and are highly efficient .
The plugs are made of different materials as per requirement .

Plugs of different materials

After completion of shell test ,we shall perform tube test.

❖ Procedure of Tube Test
1. Remove test ring and gasket from back side ,then install floating head with
split ring with gasket and then tight nut bolt .
2. In front side if channel side is already available then install channel cover with
gasket but here we have distributer so we need to remove test ring and
gasket and install distributer with new gasket
3. Now install blinds in distributer’s inlet and outlet .
4. Install pressure gauge with the help of flitting, in distributer top and bottom
side.
5. Connect water hose and fill the water from bottom side.
6. Now connect hydro test pump and raise the pressure upto given pressure by
inspection.

Here tube test is competed .

It basically gives us information about leakage of tubes.
 A Glimpse of our Site Visit

During our winter internship, we went to site visit for a number of times. A brief
account of such a visit is as follows: Under the guidance and mentorship of Mr.
Aritra Pramanik (AM-ML) , we started our visit from central workshop where we
learnt about the maintenance , modification and testing of pressure safety
valves via the testing bench. Then we made our way to DCU unit and
physically witnessed rotating systems like centrifugal pumps and its different
components ,positive displacement pump like gear pump and its different
parts and reciprocating air compressors.

In the pump section sir also showed us different types of valves like pressure
safety valves and one way valve like foot valve(non return valve) .We saw
Heat exchangers primarily Floating head heat exchangers (kettle type reboiler
and one pass shell) ,its main components and other important components
like gaskets, flanges and nozzles.
Sir was very friendly throughout our entire discussion and we also discussed
about cooling towers (TPU unit) .

We had also discussed in brief about the static systems like Columns, Pressure
Vessels and Tanks . We also understood the separation of different components
of crude oil in columns, its maintenance and storage of these components
under high pressure in pressure vessels and comparatively low pressure in
tanks.
Bibliography

❖ https://archive.mu.ac.in/4.66%20heat_exchanger_databook%20Mechanic
al.pdf
❖ https://www.thermopedia.com/content/805/
❖ https://learnmechanical.com/pump/
❖ https://www.wermac.org/flanges/flanges_raised-face_flat-face_ring-type-
joint.html