Rishabh Rajan completed a vocational training program at Indian Oil Corporation's Barauni Refinery in Bihar, India. He thanks the refinery managers and staff for their guidance and support during the program. The report provides an overview of Indian Oil Corporation and details of the Barauni Refinery. It describes the refinery's process control and monitoring systems, including distributed control systems, programmable logic controllers, vibration analysis and plant resource management software. Field instruments for measuring pressure, temperature, magnetic flow, and level are also outlined. The training enhanced Rishabh's practical knowledge of industrial processes and challenges.

1. Indian Oil Corporation Limited
Barauni Refinery, Bihar
Report on Vocational Training
July 31
2014
Submitted By:
Name: Rishabh Rajan
Semester: VIIth Sem.
Roll: 11EMTEC093
Electronic & Communication Engineering
M.A.I.E.T. Jaipur / R.T.U. Kota (Raj.)
Vocational Training at IOCL (June 16, 2013 to July 31,
2014 )

2. Acknowledgement
I would like to thank Mr. A.B. Minz, Chief Manager
(Training & Development) for giving me an
opportunity to explore my ideas and interact with
experts of the industry at Barauni (Bihar) Refinery. I
extend my heartiest thanks to Mr. Abhijeet Sir, Dy.
Manager (Inst.) and Mr. Nishant, Sr. Inst. Engineer
(BXP Unit) for their inspiration and kind support. This
training would have not been so fruitful without their
guidance.
I would also like to thank all officers and staff of the
company for their support and cooperation. Finally I
would like to express my sincere gratitude to my
parents, for helping me to undertake this training and
constantly encouraging me to interact with the experts
and make the best use of the immense opportunities
available at the refinery.

3. CONTENTS

4. 1. OVERVIEW
Indian Oil Corporation Ltd
 Indian Oil, is an Indian state-owned oil and gas
corporation with its headquarters in New Delhi,
India.
 Indian Oil and its subsidiaries account for a 49%
share in the petroleum products market, 31%
share in refining capacity and 67% downstream
sector pipelines capacity in India.
 Indian Oil operates the largest and the widest
network of fuel stations in the country, numbering
about 20,575 (16,350 regular ROs & 4,225 Kisan
Seva Kendra).
 It supplies Indane cooking gas to over 66.8
million households through a network of 5,934

5. REFINERIES
 Barauni Refinery, in Bihar. It was commissioned
in 1964 with a capacity of 1 MMTPA. Its capacity
today is 6 MMTPA.
 Gujarat Refinery, at Koyali (near Vadodara) in
Gujarat in Western India, is Indian Oil’s 2nd largest
refinery.
 Panipat Refinery is the 7th and largest refinery of
Indian Oil. The original refinery with 6 MMTPA
capacity was built and commissioned in 1998.
 Haldia Refinery is the only coastal refinery of the
Corporation. It was commissioned in 1975 with a
capacity of 2.5 MMTPA, which has since been
increased to 7.5 MMTPA.

6. Barauni Refinery
 Barauni Refinery, in Bihar. It was commissioned
in 1964 with a capacity of 1 MMTPA. Its capacity
today is 6 MMTPA.
 Barauni Refinery in the Bihar state of India was
built in collaboration with the Soviet Union at a
cost of Rs.49.4 crores and went on stream in July,
1964.
 Barauni Refinery was built in collaboration with
Russia and Romania. It is situated 125 kilometres
from Patna.
 Barauni Refinery receives crude oil by pipeline
from Paradip on the east coast via Haldia.

7. Highlights of Barauni Refinery:
 The establishment of a totally electronic-based
communication system within the refinery.
 The presence of four ambient air monitoring
stations that were in place well before the refinery
was in use.
 It is an eco-friendly refinery, as indicated by a
green belt outside it.
 Zero discharge of effluent gases.
 It has the lowest manpower of all refineries in the
region with similar capacities.

8. 2. Field Instruments
> Pressure Measurement :
 Instruments used to measure pressure are called
pressure gauges or vacuum gauges.
 Pressure gauge performs the mathematical
operation of subtraction through mechanical
means, obviating the need for an operator or
control system to watch two separate gauges and
determine the difference in readings.

9. .
1. Bourdan pressure gauges
2. Diaphragm
pressure gauges

10. Types of Pressure Gauge
 Barometer Pressure gauge : It has a glass tube
closed at one end, with an open mercury-filled
reservoir at the base.
 Monometer Pressure gauge : This is the most
simple and precise device used for the measurement
of pressure.
 Capacitive: This is applied measurement of low
pressure.
 Electromagnetic: It measures the displacement of a
changes in inductance, Hall Effect, or eddy current
principle.
 Piezoelectric: It uses the piezoelectric effect in
certain materials such as quartz to measure the strain
upon the sensing mechanism due to pressure. This

11. > Temperature Measurement :
 Thermocouples: It consists of two dissimilar
conductors in contact, which will produce a
voltage when heated. Conductor will experience
the temperature gradient, and develop a voltage
of its own.

12.  Thermistors: It is a resistor whose resistance
varies significantly with temperature. These are
used as in rush current limiters & temperature
sensors.
Fig:
Thermistors
 Pyrometer: A pyrometer has an optical system
and a detector.

13. > Magnetic Flow Meter :
 The magnetic flow meter A mass flow meter is a
device that measures mass flow rate of a fluid
traveling through a tube. It requires a conducting
fluid and a non-conducting pipe liner. The
electrodes must not corrode in contact with the
process fluid.

14. > Level Measurement :
 Radar : Radar is an object detection system which
uses radio waves to determine the range, altitude,
direction, or speed of objects. It is mounted on the
top of the vessel.
 Ultrasonic : In this method ultrasonic sound
waves are used in place of radio waves. It also
works on the basis of Doppler Effect for level
measurement.

15.  Capacitive : In this method, the property of a
capacitor is used that the capacitance of the
capacitor changes when a dielectric material
(medium) is introduced between its two plates. The
capacitance of the capacitor is directly proportional
to the level in the vessel.

16. > Control Valves:
 A valve is a device that regulates, directs or
controls the flow of a fluid (gases, liquids,
fluidized solids, or slurries) by opening, closing
various passageways.
 Valves are found in every industrial process,
including water & sewage processing, mining,
power generation, processing of oil, gas &
petroleum, food manufacturing, chemical &
plastic manufacturing and many other fields.

17. Components of Control Valves:
 Air Filter Regulator (AFR): It filters the air &
removes the small unwanted dust particles. The
filtered air can also be regulated with the help of
AFR.

18.  Positioner: This is used for position control. It
receives air from AFR & it also receives a signal
from control room. Positioner supplies that amount
of air to the valve which fulfills the control room
demand.

19. 3. Process Control & Monitoring:
> Distributed Control System (DCS):
 DCS (Distributed Control System) is a
computerized control system used to control the
production line in the industry. The entire system of
controllers is connected by networks for
communication and monitoring.
 A DCS typically uses custom designed processors
as controllers and uses both proprietary
interconnections and communications protocol for
communication.
 DCSs are connected to sensors and actuators and
use set point control to control the flow of material
through the plant.

20.  DCSs may employ one or more workstations
(FCS or HIS) and can be configured at the
workstation or by an off-line personal computer.

21. >Programmable Logic Controller
(PLC):
 A Programmable Logic Controller, PLC is a digital
computer used for automation of
electromechanical processes.PLC is designed for
multiple inputs and output arrangements.
 It is also called Programmable Controller.
 It performs sequential relay control, motion
control, process control, distributed control
systems and networking.
Allen Bradley PLC :

22. > Vibration Analysis :
 Vibration Analysis is monitoring instrumentation
company, providing services for sensors, systems,
and monitoring machinery vibration.
Vibration Analysis

23. >Plant Resource Manager (PRM):
 Plant Resource Manager (PRM) is a plant asset
management (PAM)software tool that works with
production control systems CENTUM.
 PRM can monitor the condition of plant assets
remotely.
 Typical applications:
1. Impulse line blocking diagnostics for differential
pressure
transmitters.
2. Heat trace diagnostics for a group of pressure
transmitters.
3. Diagnostics for magnetic flow meters.
4. For control valves
5. Valve health monitoring

24. Alarm & Shutdown System
 All the important equipment are provided with
alarm and shutdown devices for critical operating
parameters.
 All the storage devices are provided with high
level alarms.
 Emergency shutdown switch is provided in
control room to shutdown the plant in any case of
emergency.
 Remote shutdown switches are provided in the
local panels of two most important equipment-inlet
gas compressor and expander compressor.
 Status monitoring is done round the clock through
DCS work stations. Operation tested during
running condition, planned and non-planned
shutdown of the plant.

25. Conclusion
 The vocational training enhanced our 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.
 Nevertheless , we did enjoy the training to the
fullest and are very sure that this training will help
us in our future endeavors.

26. T H A N K I N G __ Y O
U