SUMMER INTERNSHIP REPORT

SUBMITTED BY:-
NAME -PRITAM JYOTI DEKA
BRANCH-BTECH MECHANICAL ENGINEERING
YEAR/SEM- 3rd YEAR/6th SEM
COLLEGE- NATIONAL INSTITUTE OF TECHNOLOGY, SILCHAR
DUARTION OF INTERNSHIP- 2nd JUNE-17th JULY,2025

UNDER THE SUPERVISION OF-

Mr SAGAR KUMAR(MECHANICAL ENGINEER AT IOCL, GR)
 DECLARATION
This is to declare that the Summer Industrial Training report, submitted by Pritam
Jyoti Deka, an intern from National Institute of Technology, Silchar, for the fulfillment
of the B.Tech course, is the record of the candidate’s work carried out under my
supervision. This report thereof has not been submitted elsewhere for any degree or
any other purpose previously. I wish him a successful career and a prosperous life
ahead.

Mr Sagar Kumar
(Mechanical engineer, IOCL GR)
 PREFACE
This report is a comprehensive summary of my summer internship at Indian
Oil Corporation Limited (IOCL), Guwahati Refinery, undertaken as a part
of my academic curriculum. The internship was pursued during the summer
internship period from 2nd June – 17th July, 2025, with the aim of gaining hands-
on exposure to industrial processes and real-world applications of engineering
concepts.

Guwahati Refinery, being the first public sector refinery in India, provided an
excellent platform to observe and understand various operations related to crude
oil refining, plant maintenance, and process control systems. The internship
experience helped bridge the gap between classroom knowledge and practical
implementation, enriching my understanding of technical, operational, and
safety aspects within a large-scale industrial environment.

This report encapsulates the insights gained during the internship, departments
visited, equipment and systems observed, along with key learnings and personal
reflections. Efforts have been made to present the content in a structured and
concise manner.

I sincerely hope that this report proves informative and useful to readers who
seek to understand the working environment of a major refinery like IOCL
Guwahati.
 ACKNOWLEDGEMENT
I would like to express my heartfelt gratitude to the Indian Oil Corporation Ltd,
Guwahati Refinery, for granting me the opportunity to intern at their
esteemed organization. I am thankful to our allotted guides, Mr. Sagar Kumar
(mechanical engineer, IOCL GR). Mr. Avinash Kumar (Assistant Manager,
Mechanical Workshop ), Mr Raju Kumar, Mr Rohan Shaw, Mr Satvik Pandey,
Mr Sachin Kumar/ Mr PP Bharti, Mr Surendra Pradhan Sir for their invaluable
guidance throughout the internship duration. They were really helpful in
providing us with the necessary knowledge about the refinery and its
production unit. Also, thank you to the Fire& Safety department for providing
awareness of the necessary precautions and measures to mitigate any
potential hazards.
 TABLE OF CONTENTS
CONTENTS
SL. PAGE
NO NO.
Certificate
i. 02
Preface
ii. 03
Acknowledgement
iii. 04
Table of contents
iv. 05 -06
Introduction 07-13
v.
1. About the internship
2. Overview of Guwahati Refinery
i) Establishment year
ii) Major Units of Guwahati refinery
iii) Products of the Guwahati refinery
iv) Type of Crude processed
v) Flow of the refinery process

14-15
vi. Hydrogen Generation Unit/Hydrotreating Unit
INDMAX/SRU 15-16
vii.
MSQ\Nitrogen 16-17
viii.
Workshop 17-19
ix.
Delayed Coker Unit (DCU) 20 -22
x.
Crude Distillation Unit(CDU) 22-23
xi.
Thermal Power Station(TPS) 24-26
xii.
1). Boilers and their details
 2) Steam turbines and their details in the refinery

Heat Exchanger 27-29

xiii.
DM Plant 29-31
xiv.
xv. Cooling Towers 31-34
xvi. Health, Safety & Environment 35-37
xvii. Conclusion 38
xviii. References 39
 INTRODUCTION
This report presents a concise overview of the summer internship undertaken at
Indian Oil Corporation Limited (IOCL), Guwahati Refinery, as a part of the
academic curriculum for my Bachelor of Technology in Mechanical
Engineering. The internship was carried out during the period of [2nd June-17th
July], offering valuable exposure to industrial mechanical systems and real-
world engineering applications within a refinery setting.

IOCL is India's largest public sector oil and gas company, playing a key role in
refining, transportation, and distribution of petroleum products. Among its
network of refineries, Guwahati Refinery holds historical importance as it was
the first public sector refinery in India, commissioned in 1962 with Romanian
collaboration. Located at Noonmati, Guwahati, the refinery primarily
processes Assam crude oil, known for its high wax and sulfur content.

As a mechanical engineering intern, I was involved in observing and

understanding the operation and maintenance of mechanical equipment,
including pumps, heat exchangers, boilers, compressors, and mechanical
handling systems. I also gained insights into maintenance protocols, pipeline
systems, utility services, and the importance of safety and reliability in
continuous plant operations.

This report highlights the mechanical engineering-specific learnings,

departmental exposure, and the overall experience gained during the internship,
which contributed significantly to bridging the gap between academic
knowledge and industrial practice.
OVERVIEW
Indian Oil Corporation Limited (IOCL) is India’s largest commercial enterprise
and a global energy major, operating across the entire hydrocarbon value chain.
Among its extensive network of refineries, Guwahati Refinery holds a place of
historic significance as the first public sector oil refinery in India.

Established in 1962, Guwahati Refinery was set up in collaboration with

Romania and marked a milestone in India’s journey toward energy self-
sufficiency. Located at Noonmati in Guwahati, Assam, the refinery was
commissioned with an initial capacity of 0.75 million metric tonnes per
annum (MMTPA), which has since been upgraded over the decades to
improve efficiency, meet growing demands, and adhere to modern

environmental standards. Guwahati Refinery plays a crucial role in refining and

processing Assam crude oil, which is known for its high wax and sulfur
content.

MAJOR UNITS OF REFINERY

The refinery includes several major units such as:

• Crude Distillation Unit (CDU)

• Vacuum Distillation Unit (VDU)
• Delayed Coking Unit (DCU)
• Hydrotreating Units
• Utilities and Offsite Facilities

The refinery also has facilities for producing BS-VI grade fuels, aligning with
India’s clean fuel vision. It produces a variety of petroleum products, including
LPG, Naphtha, Kerosene, Diesel, and Fuel Oil, catering to both domestic and
industrial consumers across the Northeast and beyond.

As a pioneer in Indian refining history, IOCL Guwahati Refinery is not just an

industrial facility but a symbol of technological progress, operational
excellence, and sustainable practices. It has consistently adapted to the latest
advancements in refinery operations and continues to contribute significantly to
the region’s socio-economic development.

This internship provided a unique opportunity to observe and understand the

refinery's complex operations, safety protocols, and maintenance strategies, and
offered invaluable insights into how such a large-scale plant is managed and

Fig-Guwahati Refinery
PRODUCTS OF REFINERY
The refinery was inaugurated by the Late Pandit Jawaharlal 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 crude
processes oil from Upper Assam oil fields, India, and helps cater energy needs of the
region. Major Products of this refinery are[1]

1. LPG,
2. Motor Spirit (Petrol),
3. Aviation Turbine Fuel (ATF),
4. Kerosene,
5. High Speed Diesel,
6. Light Diesel Oil and
7. Raw Petroleum Coke.
With growing environmental consciousness, Guwahati Refinery, Indian Oil
Corporation Limited, has also ventured into ecologically friendly fuel and subsequently
installed three 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 a high smoke point and low sulphur. The
Indane Maximization (INDMAX) technology developed by the 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 feedstock like Reduced Crude Oil, Coker
Fuel Oil, and Coker Gasolene. The INDMAX unit also enables the Guwahati Refinery

TYPE OF CRUDE PROCESSED

The IOCL Guwahati Refinery primarily processes:

Assam Crude Oil

This includes crude oils extracted from various oil fields in Assam such as:

• Naharkatiya
• Rudrasagar
• Lakwa
• Geleki
 Characteristics of Assam Crude:

1. High Wax Content: Makes it more viscous and difficult to transport

without heating.

2. High Sulfur Content: Requires special processing and desulfurization

units.

3. Low API Gravity: Generally heavier, requiring thermal and catalytic

cracking for processing.

Processing Challenges:

1. Requires specialized treatment units like hydrotreaters and delayed

coking units.

2. Higher maintenance and operational demands due to wax deposition

and sulfur corrosion.

This crude type is unique compared to other lighter, sweeter crudes processed in
coastal refineries and has shaped Guwahati Refinery’s configuration and
technological upgrades.
 REFINERY FLOW PROCESS

Fig- Flow chart of refinery process

REFINERY FLOW PROCESS OVERVIEW

The refinery process at IOCL Guwahati Refinery follows a systematic and integrated flow
of operations, starting from crude oil reception to the production of finished petroleum
products. The process is designed to maximize efficiency, safety, and product quality.

1. Crude Oil Reception and Pre-treatment

• Crude oil is received through pipelines and stored in large tanks.

 • Pre-treatment involves desalting to remove water and salts that could corrode
equipment.

2. Atmospheric and Vacuum Distillation

• The crude is heated and sent to the Crude Distillation Unit (CDU) where it is
separated into different fractions (LPG, naphtha, kerosene, diesel, etc.).
• Heavier residues go to the Vacuum Distillation Unit (VDU) for further separation
under reduced pressure.

3. Secondary Processing

• Involves cracking and reforming to improve fuel quality and yield.

• Includes units like the Delayed Coking Unit (DCU) and Hydrotreating Units,
which break down heavy fractions and remove sulfur.

4. Treatment and Blending

• Fuel components are treated using hydrotreaters to produce BS-VI compliant fuels.
• Blending systems mix various streams to meet product specifications.

5. Storage and Dispatch

• Final products are stored in floating-roof tanks or fixed-roof tanks.

• Products are dispatched via pipelines, tankers, and rail wagons to regional depots
and consumers.
 Production Unit visited / Work Allocation

List of Production Units we were assigned to:

1) HGU/HDT(Hydrogen generation unit/Hydro treating Unit)

2) INDMAX/SRU
3) MSQ/NITROGEN
4) WORKSHOP
5) DCU(Delayed Coker Unit)
6) CDU(Crude Distillation Unit)
7) TPS(Thermal Power Station)

1)Hydrogen Generation Unit (HGU) – Brief Overview

The Hydrogen Generation Unit (HGU) at Guwahati Refinery produces high-purity

hydrogen gas essential for various refining processes.

Hydrotreating Unit (HDT) – Brief Overview

The Hydrotreating Unit (HDT) in a refinery is used to remove impurities such as sulfur,
nitrogen, oxygen, metals, and unsaturated hydrocarbons from petroleum fractions like
diesel, kerosene, or naphtha.

The Hydrotreating Unit with a capacity of 0.6 MMTPA produces High Speed Diesel (HSD), Aviation
Turbine Fuel (ATF), and Pipeline Compliant Kerosene (PCK) in blocked out mode of operation. In HSD
mode of operation, the Sulfur content of diesel components ex CDU, DCU, and Indmax unit is
removed, and the Cetane number is boosted. The smoke point of the Straight Run Kerosene
component is improved in ATF and PCK modes along with desulfurization. Hydrogen required for
Hydrotreating is produced in the Hydrogen Generation Unit based on Steam Reforming technology.
Importance in Guwahati Refinery:

• Guwahati Refinery operates HDT units for diesel and kerosene (ATF).
• Helps in achieving low sulfur content, improved smoke point (for ATF), and better
cetane number (for diesel).

2) INDMAX technology- INDMAX Unit, in-house technology developed by the R&D Centre of
IndianOil, was installed for increased production of LPG and gasoline from heavy ends like
Reduced Crude Oil and Coker Fuel Oil. Indmax unit works on the Fluidized Catalytic Cracking
process, similar to other Fluidized Catalytic Cracking Units. The first commercial unit based on
INDMAX technology was installed at Guwahati Refinery with a capacity of 0.1 MMTPA, and the
capacity was subsequently enhanced to 0.15 MMTPA. Besides its function of maximizing LPG, it
enables the Refinery to upgrade its residual products to high-value distillate products.

PROCESS DESCRIPTION

INDMAX employs a circulating fluidized bed Riser-Reactor-Stripper configuration similar

to conventional FCC technology, along with a single-stage full combustion Regenerator
system. The catalyst system and operating conditions employed in the INDMAX process are
tailor-made and different from the conventional FCC technology. The specially designed
catalyst of the INDMAX process consists of various synergistic components for upgradation
of heavy molecules, maximising conversion with higher light olefins selectivity.

Advantages :

1)Highly attractive yields of light olefins (ethylene, propylene, and butylenes), Toluene and
Xylene for integration with Petrochemical complexes.

2) Higher octane of gasoline (RON > 96).

3) Capability to handle a wide range of feed stocks, starting from hydrotreated VGO to
residue of 10 wt% CCR.

The Sulphur Recovery Unit (SRU)(5 TPD) in the Refinery takes care of the sour off gases from
the various units for the removal of Hydrogen Sulphide. This is done by Amine treatment, after
which H2S is converted to sulphur through the Claus process.
3)MOTOR SPIRIT QUALITY UNIT(MSQ)

The MSQ unit is responsible for improving the quality of motor spirit (gasoline) to meet
market specifications. This unit typically involves processes like reforming,
isomerization, and blending to enhance the octane number and reduce impurities,
ensuring the fuel meets environmental and performance standards.

The Motor Spirit Quality Unit (MSQU) at Indian Oil’s Guwahati Refinery is a dedicated
facility that enhances the quality of petrol (Motor Spirit, MS) to meet government-mandated
standards (BS-III, then BS-IV, now BS-VI).

Purpose & Impact

• Enables Guwahati Refinery to produce lead-free, low-sulfur, eco-friendly petrol

complying with evolving Indian Auto Fuel Policies, from Euro-III through BS-VI
• Supports the production of cleaner fuels critical for Northeast India's air quality and
vehicular emissions standards.
• Improved petrol quality secures regulatory compliance and meets consumer
expectations for performance and environmental safety.

3) WORKSHOP

1) Centri-fugal pump( Sundyne pump)

In workshop, we generally learnt about the centrifugal pump(centrifugal pump) , its types,
and its parts.
Parts of a Centrifugal Pump

The different parts of the centrifugal pump are listed below.

1. Shaft and shaft sleeve

2. Impeller
3. Casing
4. Suction Pipe with a foot valve and strainer
5. Delivery Pipe & valve

Shafts and shaft sleeves

• Simple design
• Less vibration and noise
•

Impeller- The impeller is fixed onto the pump shaft, which is housed in a pump casing
and backplate

• The impeller transfers energy from the motor to the fluid that is to be pumped.
• Due to the rotation of the impeller, fluid gets accelerated and
• increases velocity as well as kinematic energy.
Impellers have a lot of vanes. These vanes help the liquid to flow from the centre to the
outer edge of the impeller. There are three basic impeller designs:-
Casing- The Centrifugal pump casing is simply an airtight passage. This houses
the pump impeller and helps to convert the kinetic energy of the impeller into
the pressure head. There are three different kinds of centrifugal pump casings:

• Volute casing
• Vortex casing
• Casing with guide blade

Suction pipe

Suction Pipe with a foot valve and strainer

The suction pipe means the pipe at the suction side. It connects the pump-
enclosed area and the water sump. One end of this pipe is connected to the
centre of the impeller or the inlet of the pump, which is known as the eye, and the
other end dips into the water that is to be lifted.

Delivery pipe

Delivery pipe & Valve

The delivery pipe helps the pump to deliver liquid from the pump outlet to the
required level.

• It makes the connection between the pump outlet to the deliver point
 • A valve is provided near the outlet of the pump on the delivery pipe to
control the controls the flow from the pump.
• The non-return valve is a type of delivery valve.

Types of pumps
Centrifugal pumps are classified into many types. But here I will only include the
ones that are present in the refinery:-

Single-stage centrifugal pump

A single-stage pump means a single impeller in the pump.

• This pump has the simplest design

• Maintenance is very easy
• Suitable for low-pressure and large flow rate applications.
Two-stage centrifugal pump

• A two-stage pump means two impellers in the pump.

• In the case of medium head applications, these two-stage pumps are widely used.

Multi-stage centrifugal pump

• A multi-stage pump means three or more impellers in a pump.

• These are mainly used for high head services.
• In this case, many impellers are connected in series to get the required head.
Delayed coker unit(DCU):
DGU, GR is the First Delayed Coker of IOCL. It was commissioned in 1962 with Romanian
technical assistance. Initial Capacity: 0.33 MMTPA. Revamped capacity:
0.44MMTPA,1320MT/Day with a recycle ratio of 0.73 (Revamp in
2000). Maximum achieved T’put: 0.447 MMT (2010-11).Highest Heater On-stream days: 623
days (2008-10).

Process description: Delayed Coking Unit is a secondary processing unit designed and
installed to process the low-value heavy stock to upgrade it to more valuable lighter and
middle distillates with petroleum coke as a byproduct. The feed is to be processed in
the unit is Reduced Crude Oil obtained from the bottom of the fractionating column of the
CDU, and the process used is Thermal Cracking.

The delayed coker unit of Guwahati Refinery is a secondary process unit to crack RCO
(Reduced Crude Oil from the bottom of the CDU fractionating column. The cracked RCO is
distilled into different products, and coke is obtained as by byproduct.RCO from CDU or
from OM&S tank is pumped by DCU primary feed pump (03-P-1/03-P-1A/03-P-1B) through a
series of preheat exchangers to the main fractionator column(03-CL-2). The preheat
temperature obtained is around 250°C. At the bottom part of the fractionator, RCO(primary
feed) exchanges heat with incoming cracked vapors coming from the coke drum. A part of
the cracked vapors condenses upon contact with the primary feed and forms recycle.
Exchange of heat between primary feed and cracked vapors causes the column bottom
temperature to be maintained at 365°C. The column bottoms or secondary feed (fresh RCO
plus recycle) is pumped by the secondary feed pump (03-9-2/03-P-2A) to the DCU furnace.
The temperature of the secondary feed is increased to around 498°C at the outlet of the
furnace. At this high temperature, it enters one of the coke drums, which are in line
alternately for 24 24-hour cycle. Thermal cracking of the secondary feed takes place in the
coke drum. The vapors generated by the cracking of the feed exit the coke drum at 430°C
and pass through a quench column (03-CL-1) before
entering the main fractionator. In the quench column, the vapor temperature reduces to
422°C, and any coke fines entrained by the vapor is washed off by the quench stream.
The vapors are separated in the main fractionator to produce streams Coker Gasoline, Coker
Kerosene, Coker Gas Oil, and Coker Fuel Oil. Gases from the column overhead at 90°C
are cooled in overhead condensers to 30°C and enter the overhead separator vessel (03-V-
1).
 Fig- Flow diagram of DCU

PROCESS CHEMISTRY OF COKING

The coking process, therefore, involves two types of reactions.

• Primary Reaction

• Secondary Reaction

PRIMARY REACTION:
In this reaction, the heavier hydrocarbon molecules decompose into smaller ones. This
reaction is known as cracking.

SECONDARY REACTION:
In this reaction, the smaller reactive molecules combine to produce heavy, tarry materials.
This reaction is called Polymerization. Polymerization of heavier reactive
molecules take place in reaction chambers, forming coke in an alternate production time of
24 hours. The coke chamber provides a residence time of 24 hours for the cracking and
polymerization reaction to take place. For this lengthening
During the time of liquid phase cracking and polymerization, the reaction takes place. For
this lengthening of the time of liquid phase cracking and polymerization, the whole process
of cracking is known as Delayed Coking. The two types of chemical reactions that take place
during thermal cracking operation may be represented by the chemical reaction shown
below:

DECOMPOSITION OF HEAVIER MOLECULES

CH3. CH2. CH2. CH3. = CH4 + CH3 CH = CH2
N-Butane = Methane + Propene
CH3. CH2. CH2. CH3. = CH3. CH3 + CH2 = CH2
N-Butane = Ethane + Ethylene
At high temperature, the first of these appears to proceed to the extent of about 55% and
the second to 40%. Dehydrogenation reactions, as given below, appear to represent less
than 5 % of the total. The tendency to dehydrogenate, leaving an olefin with the same
number of carbon atoms as the original paraffin hydrocarbon, rapidly diminishes as the
series is ascended. Thus, the production of large amounts of hydrogen
Cracking gas oil stocks should not be expected.

SECONDARY REACTION
2C2 H4 = C4 H8
3C3 H6 = C9 H18
C4 H8 + C9 H18 = C13 H26
CH3 CH2 CH=CH2=CH2 = CH3 CH2 CH2 CH3 CH2
CH=CH2

FEED AND PRODUCTS

Feed:
1) Reduced Crude Oil (RCO) (Density: 950 kg/m3 & CCR:
5.5-6.0%)
2) Clarified Oil (CLO) ex INDMAX
3) Refinery Slop oil (as vapor line quench medium)

CDU(Crude Distillation Unit): Crude distillation is the first step in processing crude oil into
its different end products, including gasoline, kerosene, diesel, jet fuel, asphalt, and more.
Crude stills are the oldest means for processing oil. The purpose of crude distillation is to
recover the light materials from the oil. This process begins with a fractional distillation
column, which separates the various components of the crude oil by their size, weight, and
boiling point.

The crude oil mixture is heated using high-pressure steam. The vapors from this liquid rise
up into the fractional distillation column, which contains several trays. Each tray is
designated for a different kind of oil. The tray captures its designated vapor as it is
separated from the other vapors according to their individual boiling points. So the
substance with the lowest boiling point (car gasoline) will condense at the highest point in
the column, and the substance with the highest boiling point will condense lower down in
the column.
 Fig- Chemical process of crude oil distillation

The Crude Oil Distillation Unit (CDU) at Guwahati Refinery serves as the fundamental
backbone of the refining process, where the primary separation of crude oil into various
valuable petroleum fractions takes place. Operating efficiently and reliably, the CDU ensures
a consistent supply of essential feedstock to downstream processing units such as naphtha
hydrotreater, catalytic reformer, and diesel hydrotreater. The unit’s design and integration
with modern control systems highlight IOCL’s commitment to operational excellence, safety,
and environmental compliance. As the first public sector refinery in India, Guwahati Refinery
continues to play a significant role in meeting regional energy demands, with the CDU
standing at the heart of its refining operations.

THERMAL POWER STATION(TPS): The Thermal Power Station (TPS) of Guwahati

Refinery was
commissioned in 1962 with the collaboration of the Romanian Government.
The thermal power station meets Guwahati Refinery’s power needs with three
steam turbo-generators operating in complete island mode. Facility for
synchronization with Assam State Electricity Board (ASEB) grid connection is
also available. However state grid generally supplies power to non-essential
loads, intake, and as a standby supply in TPS.
The Thermal Power Station has an installed capacity of 28 MW. It has two
turbo-generators (TG 3 & TG 4) of 8 MW capacity each and one turbogenerator
TG 5 of 12 MW capacity. TG-3 is a BHEL-made 8 MW turbogenerator
with conventional DC generator exciter excitation, whereas TG-4 is
Also, BHEL made an 8 MW TG with static excitation.TG-5 is a BHEL-made 12MW
capacity TG with brushless excitation. The power system in Guwahati Refinery is an
unearthed system with a generation voltage of 6.3KV. There are 2 earthing transformers
in the outgoing feeders to the intake and the New unit HT substation to neutralise
charging current in long cables and easy
detection of earth faults. There are two home service transformers and two TPS
auxiliary transformers to fulfill the 0.4 KV supply requirements of the powerhouse. The
lightning and auxiliary equipment’s Power supply is given from home service and TPS
Aux substations. The 6.3 KV generation bus in TPS via the 6.3KV distribution. PMCC
takes care of power distribution to other substations in the refinery. TPS also has a DM
plan to supply DM water to the boilers and various units of the refinery. For the steam
generation, TPS has five boilers, two Romanian-made BLR #3 and BLR #4 of 20 Tons/hr
capacity each. One IJT-made boiler, BLR #5, with 40 Tons/hr capacity and two
Thermax-made boilers, BLR #6 and BLR #7, with 50 Tons/hr capacity each. Steam
generator from these boilers is also used as process steam apart from the power
generator.

MAJOR EQUIPMENTS DETAILS

1)Boilers:
2×20 TPH Romanian Boilers (Boilers #3, #4).
1×40 TPH IJT boiler (Boiler#5).
2×50 TPH Thermax Boilers (Boilers #6, #7)
Total installed capacity: 180 TPH

TYPES OF TURBINES IN REFINERY

2)Steam Turbine:
There are three steam turbines in the Guwahati Refinery Thermal Power
Station,
namely STG-3, STG-4 and STG-5. All three STGs are BHEL-made. Input to
the
steam turbine is HP steam at 37 kg/cm2 and 4350C. Total installed capacity
is 28
MW. The breakups are:

1) STG 3 has a capacity of 8 MW (0.8 pf lag), and it was commissioned in

1985.

2) STG 4 has a capacity of 8 MW (0.8 pf lag), and it was commissioned in

1998.
3) STG 5 has capacity of 12 MW, (0.8 pf lag) and it was commissioned in
2006.

Overview of Steam Turbines in Refineries

Steam turbines in refineries play a critical role in generating electricity and
driving mechanical equipment by utilizing high-pressure steam produced
in the
boilers. These turbines convert thermal energy from the steam into
mechanical
energy, which can then be used to generate electrical power or drive
pumps and
compressors.

Components of Steam Turbines

1. Turbine Blades: Convert the thermal energy of steam into kinetic energy.
2. Rotor: Holds the turbine blades and converts the kinetic energy into
rotational energy.
3. Stator: Contains fixed blades that direct the flow of steam onto the
turbine blades.
4. Casing: Encloses the turbine, providing structural support and containing
the steam pressure.
5. Governor: Controls the turbine speed by regulating the steam flow.
6. Bearings: Support the rotor and reduce friction during rotation.
7. Condensers: Convert exhaust steam back into water for reuse.

Working Principle
The high-pressure (HP) steam at 37 kg/cm² and 435°C enters the turbine
and
expands across multiple stages of blades, transferring its energy to the
rotor.
The rotor, in turn, drives a generator to produce electricity or mechanical
equipment.

Types of Steam Turbines

1. Impulse Turbines: Steam hits the turbine blades at high velocity,
causing impulse forces that rotate the blades.
2. Reaction Turbines: Steam expands as it passes through the blades,
causing a reaction force that rotates the blades.

Details of Guwahati Refinery Steam Turbines

The Guwahati Refinery Thermal Power Station has three BHEL-
manufactured steam turbines, each serving a specific capacity and role in
the refinery's power generation process. Here’s a detailed look at each:

1. STG-3
Capacity: 8 MW
Power Factor: 0.8 (lag)
Commissioned: 1985
Features: As one of the older turbines, STG-3 may have undergone
Several upgrades to maintain efficiency. It is likely equipped with older
generation control systems and may require more maintenance compared
to newer units.

2. STG-4
Capacity: 8 MW
Power Factor: 0.8 (lag)
Commissioned: 1998
Features: This turbine, being relatively newer than STG-3, may
incorporate more modern design features and control systems,
contributing to improved efficiency and reliability.

3. STG-5
Capacity: 12 MW
Power Factor: 0.8 (lag)
Commissioned: 2006
Features: The newest of the three turbines, STG-5, likely features the
latest technological advancements in turbine design and control, offering
Higher efficiency and better performance. With a higher capacity, it plays
a critical role in meeting the refinery's power demands.
 HEAT EXCHANGER
Heat exchangers are devices that are used to transfer thermal energy from
one fluid to another without mixing the two fluids. The fluids are usually
separated by a solid wall (with high thermal conductivity) to prevent mixing, or
they may
be in direct contact. The classic example of a heat exchanger is found in an
Internal combustion engine, in which an engine coolant flows through radiator
coils and air flows
past the coils, which cools the coolant and heats the incoming air. In power
engineering, common applications of heat exchangers include steam
generators, fan coolers, cooling water heat exchangers, and condensers. For
example, a steam generator is used to convert feedwater into steam from
heat produced in a nuclear reactor Core. The steam produced drives the
turbine. Heat transfer in a heat exchanger usually involves convection in each
fluid and thermal conduction through the wall separating the two fluids. In the
analysis of heat exchangers, it is often convenient to work with an overall
heat transfer coefficient, known as a U-factor. The U-factor is defined by an
expression analogous to Newton's law of cooling.

Parallel-flow arrangement: In the parallel-flow arrangement, the hot and cold

fluids enter at the same end, flow in the same direction, and leave at the same
end.

Counter•flow arrangement- In the counter-flow arrangement, the fluids enter

at opposite ends, flow in opposite directions, and leave at opposite ends.
The Figure shows the directions of fluid flow in the parallel and counterflow
exchangers. Under comparable conditions, more heat is transferred in
a counter-flow arrangement than in a parallel flow heat exchanger. The
temperature profiles of the two heat exchangers indicate two major
disadvantages in the parallel-flow design.
• The large temperature difference at the ends causes large thermal
stresses.
• The temperature of the cold fluid exiting the heat exchanger never
exceeds the lowest temperature of the hot fluid

Shell and tube heat exchanger

A heat exchanger is a device that, as the name suggests, helps in the process of
exchanging or transferring energy in the form of heat. It is usually used for the
transmission of heat energy from one working fluid to another, which can be
either a liquid or a gas, and is one of the most efficient ways for the transfer of
heat.

• One of these is called the tube side fluid, and the other is known as the
shell side 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 basic laws of thermodynamics, a heat exchange will
take place due to said temperature difference between the two parts.
It is most commonly used in massive chemical processes such as oil refineries
because it is very well suited for applications that require a high-pressure
environment.

This is because of the fact that they can be used for a wide range of temperature
and pressure conditions, their uncomplicated design, and low maintenance
requirements.
Demineralization (DM) Plant

Introduction

Demineralization is the process of removing dissolved salts and minerals from

raw water using the ion exchange method. This process is widely used in power
generation, machinery operations, and in refinery units like distillation and
reforming.
In the IOCL Guwahati Refinery, water for the DM plant is sourced from the
Brahmaputra River. The untreated river water first passes through several
purification stages to become high-quality demineralized water.

Water Source and Initial Treatment:

a. River Intake: Water is collected from the Brahmaputra and sent to the
Water Treatment Plant.
b. Suspended Impurities: River water contains mud, sand, clay, and dissolved
minerals like:

c. Cations: Ca²⁺, Mg²⁺, Na⁺, NH₄⁺, Fe²⁺, Mn²⁺

d. Anions: Cl⁻, SO₄²⁻, HCO₃⁻, SiO₄⁴⁻, NO₃⁻, PO₄³⁻

River water parameters

e. pH: 6.5–8.5
f. Conductivity: 50 to 1500 μS/cm

Process Flow in Chain A and B

1. Pressure Sand Filters (PF-A & PF-B)

Removes suspended solids, clay, colloidal matter, and microorganisms.
Filter media include pebbles and sand layers.
Protects downstream equipment from fouling.

2. Strong Acid Cation Unit (SAC-A & SAC-B)

Removes positive ions (cations) like Ca²⁺, Mg²⁺, Na⁺.
Resin replaces these cations with H⁺ ions.

3. Degasser
1. Removes carbonic acid (H₂CO₃) formed after cation exchange.
2. Works by spraying acidic water over trays while blowing low-pressure air
from the bottom, releasing dissolved gases.

4. Strong Base Anion Unit (SBA-A & SBA-B)

1. Removes negative ions (anions) such as Cl⁻, SO₄²⁻, and NO₃⁻.
2. Resin replaces anions with OH⁻ ions.
3. Water Quality after SBA:
pH: 7.5–9.5
Conductivity: <10 μS/cm
Silica (SiO₂): <0.15 ppm
5. Mixed Bed Unit (MB-A & MB-B)
Contains both cation and anion resins mixed together.
Final polishing stage to remove trace ions.
Water Quality after MB:
pH: 6.5–7.2
Conductivity: ~1.0 μS/cm
Silica: <0.05 ppm
Chain C Special Setup
Capacity: 1250 m³
Dual Media Filter (DMF): Removes suspended matter using a
combination of coarse and fine media.
Activated Carbon Filter (ACF): Removes free chlorine, oil, and grease.
Water then passes through:

SAC → Degasser → SBA → Mixed Bed → Stored in 1450 m³ DM tank.

Additional Systems
Condensate Recovery System (only in Chain C): Recovers and reuses ~110
m³/day of unit condensate.
Chemical Storage: For acid (HCl) and alkali (NaOH) used in regeneration.
Effluent Disposal: Safe discharge of wastewater from the process.

Regeneration Process
Ion exchange resins lose their capacity over time. To restore them, regeneration
is done using acid or alkali:
Steps:
1. Backwash: Water is pumped in reverse to remove settled particles and
clear flow paths.
2. Dosing: SAC unit is dosed with 5% HCl; SBA unit with 5% NaOH.
Dosed water flows out until the effluent strength matches 5% solution.
3. Rinsing: Fresh water flows through until specific gravity = 1 (indicating
clean resin bed.

Demineralization (DM) Plant Capacities

Component Details
Chain A & B Capacity 612 m³
Chain C Capacity 1250 m³
DM Water Storage Tanks 2 × 800 m³ + 1 × 1450 m³
Total DM Water Storage 3050 m³.

Summary
The DM plant ensures the supply of high-purity water free from salts and minerals
using a combination of filtration, ion exchange, degassing, and chemical
regeneration. This treated water is essential for critical refinery operations,
Reducing scale formation, corrosion, and improving equipment efficiency.

Cooling Towers
A cooling tower is a heat removal device used in power plants to cool down the
hot water discharged from the condenser. This cooled water is then recirculated
back to the condenser, reducing the cooling water demand of the plant and
maintaining the plant's operational efficiency.

Types of Cooling Towers:

a. Natural Draft Cooling Towers: These towers use a large concrete
chimney to induce airflow through the tower. They are typically used for
very large water flow rates. The temperature range is 0.5 to 1℃
b. Mechanical Draft Cooling Towers: These towers use fans to force or draw
air through the tower. They are more common than natural draft towers and

They are categorized into forced draft (fans at the air inlet) and induced draft (fans
at the air outlet). The temperature range is 5 to 6°C.
Key Components:

a. FillMedia: Provides a large surface area for water and air contact in wet
cooling towers.
b. Air Inlet: Allows air to enter the cooling tower.
c. Water Distribution System: Distributes warm water over the fill media in
wet cooling towers.
d. Fan (in mechanical draft towers): Creates airflow for heat transfer.
e. Drift Eliminators: Prevent water droplets from being carried out of the
tower by the airflow.
f. Basin: Collects the cooled water.

Importance:
Cooling towers are crucial for the efficient operation of thermal power
plants. They help to:
a. Reduce water consumption: By recirculating cooled water.
b. Maintain plant efficiency: By ensuring the condenser operates at optimal
temperatures.
c. Prevent equipment damage: By dissipating excess heat.

Cooling Tower
In the Guwahati Refinery, there are three cooling towers:
1. TPS cooling tower
2. Unit cooling tower
3. Process cooling tower

TPS Cooling Tower:

Purpose and Function:

Cooling towers in thermal power stations are critical components used to

remove excess heat from the water used in the cooling process. This water is
essential for cooling various systems, including the condenser, which condenses
exhaust steam from the steam turbine back into water. Cooling towers ensure
the thermal power station operates efficiently by maintaining optimal
temperatures.
Components:

1. Fill Media: Increases the surface area for water-air interaction, enhancing
heat transfer.
2. Distribution System: Sprays or distributes hot water evenly over the fill
media.
3. Drift Eliminators: Minimize water loss by capturing water droplets
entrained in the airflow.
4. Cold Water Basin: Collects cooled water at the bottom of the tower.

5. Fans (Mechanical Draft Towers): Induce or force airflow through the

tower.
6. Air Inlets: Allow ambient air to enter the tower.
Working Principle
1. Hot Water Entry: Hot water from the power station's condenser is pumped
to the top of the cooling tower.
2. Water Distribution: The hot water is distributed over the fill media through
nozzles or spray systems.
3. Air Flow: Air enters the tower either naturally (natural draft) or via fans
(mechanical draft).
4. Heat Transfer: As the hot water flows over the fill media, it transfers heat
to the air through evaporation and convective heat exchange.
5. Cooling: The cooled water collects at the bottom of the tower in the cold
water basin.
6. Water Return: The cooled water is pumped back to the condenser or other
cooling systems in the power station.

Cooling Process:

1. Evaporative Cooling: A small portion of the water evaporates, removing

heat from the remaining water.
2. Convective Cooling: Heat is transferred from the water to the air through
direct contact.

Efficiency and Performance:

1. Wet Bulb Temperature: The efficiency of a cooling tower is significantly

affected by the ambient wet bulb temperature, which indicates the
potential for evaporative cooling.

2. Approach: The difference between the temperature of the cooled water

and the ambient wet bulb temperature. A smaller approach indicates better
performance.

3. Range: The difference between the hot water temperature entering the
cooling tower and the cooled water temperature leaving the tower.

Maintenance and Operational Considerations:

1. Water Treatment: Prevents scaling, corrosion, and biological growth,

ensuring efficient heat transfer and longevity of the system.

2. Inspection and Cleaning: Regular inspections and cleaning of the fill

media, basins, and nozzles to prevent clogging and maintain efficiency.
3. Fan and Motor Maintenance: For mechanical draft towers, regular
Maintenance of fans and motors is essential to ensure proper airflow and
operation.

Importance in Refineries:

1. Thermal Efficiency: By effectively cooling the water used in the

condenser and other systems, cooling towers help maintain the thermal
efficiency of the power plant.
2. Environmental Impact: Properly designed and maintained cooling
Towers reduce thermal pollution by preventing the discharge of hot water
into natural water bodies.
3. Resource Conservation: Cooling towers recycle water, minimizing the
need for fresh water intake and reducing operational costs.

The sump level should be maintained between 76% to 81%

Otherwise pump will not work.
o Inlet temp in cooling tower = 316K
o Outlet temp in cooling tower = 306K
o TPS Cooling tower is of counterflow type, and in this, air and
Water makes an angle of 180 degrees.
Heath, Safety & Environment: The three pillars to ensure safe
communities and happy stakeholders

At IndianOil, we believe that it is possible to fuel the energy needs of the Nation while also
protecting people and the environment. We are committed to conducting business in a manner
that is compatible with the environmental and economic needs of the communities in which we
operate, and that protects the safety and health of our employees, those involved with our
operations, our customers, and the public.
IndianOil accords topmost priority to conducting its business with a strong environmental
conscience, ensuring sustainable development, safe workplaces, and enrichment of the quality of
life of its employees, customers, and community at large. All refineries are certified to ISO:14064
standards for sustainable development as well as for the Occupational Health & Safety
Management System (OHSMS/OHSAS18001), besides having fully equipped occupational health
centres. Compliance with safety systems, procedures, and environmental laws is monitored at
the unit, division and corporate levels.
As India's leading oil & gas corporation, IndianOil remains steadfast in its commitment to
excellence in Health, Safety and Environmental (H, S&E) performance. This publication showcases
how IndianOil people are relentlessly pursuing multiple commitments - at the operations, social
and environmental levels - to fully realize IndianOil’s potential as the prime mover of a resurgent
India.
Safety Management at IndianOil
IndianOil is committed to safety and demonstrated leadership in the field of Health, Safety, and
Environment. The Health, Safety and Environmental (H, S&E) policy of IndianOil demonstrates this
commitment. IndianOil has a well-defined Health, Safety and Environmental (H, S&E) Policy that
gives direction for various safety, occupational health, and environment protection-related
activities. The safety & fire protection measures at IndianOil encompass a well-sensitised
Management, a focus on imparting regular training, and a culture of safety throughout the
Company.

Well-sensitised Management:
• Employee Participation: To boost safety consciousness, all the employees and
others related to our operation are involved in the safety culture. Safety Committees
play a vital role in this regard. Representatives of the workmen and officers work
together in the Location Safety Committees. Safety awareness is enhanced by
observance of Safety Day every month, and safety performance is encouraged
through safety awards.
• Safety is reviewed in the Local Management Committee Meetings, chaired by the
Unit Head/Installation Head. Functional Directors on the Board of IndianOil review
safety performance in the monthly Performance Review Meetings.
• The Board of Directors is apprised on safety performance with regard to the
implementation of recommendations of the External Safety Audit (ESA) on a regular
basis. Major incidents and corrective actions taken are also reported to the Board.
Culture of Safety
• Process hazards are reviewed at all phases of project life by multidisciplinary teams.
Hazard and Operability (HAZOP) study and Risk Analysis are carried out to identify,
assess and control process hazards. Quantitative Risk Analysis (QRA) is carried out
for new unit or facilities, and actions are taken to mitigate or minimize the hazards.
• For new projects, pre-commissioning checks and audits are carried out by multi-
disciplinary teams and deviations, if any, are corrected before start-up. Also pre-
commissioning audit is carried out by the Oil Industry Safety Directorate (OISD) for
new units/ installations.
• Mechanical integrity of equipment/ system is ensured through condition monitoring,
periodic inspection, and preventive/predictive maintenance for reliable and safe
operation.
• Operating manuals are updated periodically to ensure integrity of procedure. Use of
proper Personal Protective Equipment (PPE) is enforced. Strict supervision is
maintained by Fire & Safety Personnel/site supervisors regarding compliance of
permit conditions and use of PPE.

Keen focus on training

IndianOil has a keen focus on training. Regular training is imparted not only to company
employees but also to contract workers and security personnel in various locations by experts.
Considering the socio-economic conditions and high turnover of contractor personnel, major
thrust is given to train contractor personnel.

Contractor Commitment towards Safety

• Before awarding any job, a commitment is taken from the contractor to comply with
all HSE parameters during the execution of any work.
• Inclusion of guidelines on safety in the tendering stage itself, like General Conditions
of Contract (G.C.C)/ Special Conditions of Contract (S.C.C) ensures safety standards
during the execution of the contract.
• It is ensured that the contractor provides adequate means and establishes a suitable
programme on safety & health for workers, consistent with National/State laws and
regulations. OISD guideline OISD-GDN-192 on Safety Practices during Construction
forms a part of the tender document.
•
Incident Investigation
• All incidents are investigated with the objective of learning and to avoid repetitive
shortcomings. Recommendations are implemented in time bound manner. All jobs in
the plants are carried out through a systematic Work Permit System to ensure that
safety precautions are taken in line with the norms of Oil Industry Safety Directorate
(OISD).
 •
Fire-fighting
• IndianOil has an elaborate fixed as well as mobile firefighting system backed by a
dedicated firefighting crew to take care of emergencies/eventualities. A well-
structured Emergency Management Plan at each location is in place to meet these
requirements. System effectiveness is ensured through regular mock drills.
• Fire fighting/ protection facilities are designed as per Oil Industry Safety Directorate
(OISD) norms which are based on reputed international codes like American
Petroleum Institute (API), USA, National Fire Protection Association (NFPA), USA,
Institute of Petroleum (IP), UK etc as well the industry experience.
• Water spray system/ sprinklers are provided in vulnerable areas like storage tanks,
columns and hot pumps. Semi-fixed foam system has also been provided in storage
tanks storing crude/petroleum products. Hydrocarbon detectors are provided in
vulnerable areas of all installations including LPG locations for early leak detection.
• Emergency Response Disaster Management Plans (ERDMP) as per PNGRB guidelines
are in place for all installations. Agreements are in place with neighbouring industries
and District Authorities for Mutual Aid. On-site and Off-site Disaster drills are
conducted as per the calendar.
• To ensure the effectiveness of all the components of our safety system and activities,
the following audit systems are in place:
o Internal Safety Audit by multi-disciplinary teams
o External Safety Audit by OISD
o Surprise Safety Check by OISD.
o Surprise Inspection by Senior Indian Oil officials
 CONCLUSION
The summer training period at the IOCL-Guwahati Refinery has been an
exceptionally gratifying experience for us. This immersive opportunity not
only allowed us to become integral members of the refinery but also provided
a unique platform to bridge the gap between theoretical knowledge and
practical application. During this period, we had the privilege of visiting
various units, gaining valuable insights into the entire refinery infrastructure.
Although the duration was limited, the exposure to different facets of the
refinery proved to be immensely beneficial for our understanding as
mechanical engineering students. The hands-on experience not only enhanced
our practical skills but also strengthened the theoretical foundations of our
academic pursuits. This tenure was not only memorable and interesting but also
served as a crucial building block for our future endeavors in the dynamic field
of mechanical engineering.
 REFERENCES

1. https://iocl.com/pages/guwahati-refinery
2.https://en.m.wikipedia.org/wiki/Guwahati_Refinery
3. Iocl pocket manuals
4.www.mechstudies.com
5. iasacademy.in
6. iocl.com › safety