INDUSTRIAL TRAINING REPORT

Company name: Indian Oil Corporation Limited (IOCL)

Branch: Nashik (Ambad MIDC)

Name of the student: Suyash S Saundankar / Samruddha S Kulkarni

College Name: D.J. Sanghavi C.O.E. / SVIT Chincholi

Guide Name: 1) Mr. R.K.SHARMA SIR

2) Mr.Sandesh Petare Sir
3) Mr.Ganesh Barahate Sir
 Company introduction

IOCL is an Indian government owned Petroleum Company. It mainly produces oil

and natural gas.
Its business includes entire hydrocarbon value chain, including refinery, pipeline
of crude oil, and transportation of petroleum products exploration and production of
crude oil, natural gas and petrochemicals.
IOCL becomes India’s most profitable state owned company for second
consecutive year in 2018.
 Departments

The work is divided into different major departments according to is function. Each
department is well organized. The mutual coordination between departments is very
good.
The major departments of IOCL, BG (Cryogenics) are:
1. Marketing and sales.
2. Design.
3. Materials.
4. Production.
5. Quality Control
 Products and Services provided

Indian oil accounts India’s half of the petroleum product market share.
IOCL owns and operates 11 out of 23 petroleum refineries in India. Indian oil has its sub
branches in other countries like Sri Lanka Middle East countries Etc.

IOCL Nashik branch

IOCL Nashik branch is located in the Ambad MIDC region in Nashik. This
branch is well known as Indian Oil Business Group Cryogenics. This industry is one of
the prominent industries in Nashik MIDC.

They are leading manufacturer of cryocans, reaction vessels and other products with
lots of experience in design and production of state art vacuum super insulated
cryogenics storage and transport vessels.
 Products of IOCL Nashik

1) Cryobiology container
2) Cryovessels
3) Industrial application containers
4) Liquefied natural gas container (LNG)
5) Special projects

Brief information about the following products is as follows:

1) Cryobiology container: These products are needed for storage of biological material at
cryogenic temp. Right from semen to cell stem both in liquid and vapour nitrogen phases.

2) Cryobiology container:
Wide mouth container of 340 to 1200 liter capacity is available for bulk preservation of
materials. Each Cryovessels is manufacture by top class technology and raw materials
under supervision of top class officers in the industry.
3) Industrial application container:

Catering the requirements of storage and transportation of industrial gases such as oxygen
nitrogen etc.
Various container are manufactured as per requirement
Examples are:
1) Vertical storage container
2) Horizontal storage container
3) Transport container mounted on vehicles
4) Custom bill solutions

4) Liquefied natural gas container (LNG):

LNG is future and green fuel.
Various industries now use LNG a green fuel as a main fuel in their industries.
Here IOCL cryogenics is manufacturing containers on low key basis to provide
operational LNG storage and transport facility.
5) SPECIAL PROJECTS:
pressure vessel for refineries ,fertilizer plants and cryogenic systems for defense related
projects are provided by company We also supports to scientific and research institutes
like ISRO , BARC etc .
 Manufacturing process of cryocans

Cryocans are manufacture in industry by following steps

Flow Chart for Cryocans

Top dish

Pre treatment of surfaces for bonding

Bonding

Inner welding

MSLD (mass spectrometer leak detector)

Insulation

Bounding outer top

Outer welding

MSLD (mass spectrometer leak detector)

Evacuation
 Performance testing

Painting

Assembling and packing

 Process description

1) Bonding: 2types are used in bonding of pressure vessels

Hardener (glue) and RAISINS for packing of upper and lower tubes. (Epoxy adhesive
+raisin mixture) adhesive used for bonding is known as epoxy adhesive.

2) Winding: - Winding of vessels is done by continuous winding of Al paper on vessels.

Then charcoal is used to absorb the any moisture available.

3) MSLD: - The checking of the vessel is done by the MSLD checking and they are
further displaced to evacuation treatment.
 Introduction to vessel design

The pressure vessel design or equipment design is the important perspective

for development of any chemical plant.

The basic stages of any chemical process are raw material storage, feed
preparation, various reactions, product separations, purifications, etc. For this processes
various equipments and vessels are required and it’s necessary to design them as per the
need.

There are different types of vessels are required like:

1) Storage vessel
2) Reaction vessel
 Pressure vessel

A pressure vessel is a container designed to hold gases or

liquids at a pressure substantially higher from the ambient pressure.
Pressure vessels can be dangerous, and fatal accidents have occurred in the
history of their development and operation. Consequently, pressure vessel design,
manufacture, and operation are regulated by engineering authorities backed by
legislation. For these reasons, the definition of a pressure vessel varies from country to
country.
Design involves parameters such as maximum safe operating pressure and
temperature, safety factor, corrosion allowance and minimum design temperature (for
brittle fracture). Construction is tested using nondestructive testing, such as ultrasonic
testing, radiography, and pressure tests. Hydrostatic tests use water, but pneumatic tests
use air or another gas. Hydrostatic testing is preferred, because it is a safer method, as
much less energy is released if a fracture occurs during the test (water does not rapidly
increase its volume when rapid depressurization occurs, unlike gases like air, which fail
explosively).
 Fabrication

Material identification

Shell rolling

Weld setup inspection

LS longitudinal seam & circumferential seam

(Welding)

Dish end forming

Dish end inspection

Dish end setup and welding

Nozzle marking and opening

Flanges to pipe welding and radiography

Dimension inspection –TPI

PWHT report verification

Hydro test

Surface rough and DFT of the paint

Packing and dispatch

 Pressure vessel codes

There are general rules and regulations advise for construction and
fabrication of pressure vessel.

There are many pressure vessel codes designed worldwide such as:

1) ASME Sec VIII Div 1 and Div 2

2) BS 5500
3) IS 2825
4) Ad Merk Blatter (German)
5) AFNOR (French)

But ASME is now accepted world wide as a standard pressure vessel code
designed by American Society of Mechanical Engineres

They regulate the design and construction of boiler and costruction of boiler and
pressure vessel.

IOCL also prefers ASME Sec VII Div 1 and Div 2 as a standard code to design
pressure vessels.
 SHELL
The shape of the process equipment is either cylindrical or spherical or some
composite of these. The majority of vessels are cylindrical because a cylinder has good
structural strength, easy to fabricate and install.

Types of the shell

1. Cylindrical shell

2. Spherical shell

Fig (a) fig (b)

 Heads / Enclosures’

Head is the part which closes the end opening of the cylinder shell
Types of the heads:
1. Hemispherical head
2. Elliptical head
3. Torispherical head
4. Conical head

Design of elliptical head under internal pressure

As per ASME sec-viii div-1, cl. ug-32.
For external design pressure,
Head to be design as per ASME sec-viii div-1 cl. ug-33
SINGLE PIECE DISHEND

TORISPHERICAL DISHEND

HEMISPHERICAL DISHEND
 Nozzles

Nozzles are the openings provided in the shell/ head for connecting the
external piping with vessel.

Types of the nozzles / connections

1. Pipe neck with flange connection

2. Forged neck with flange connection
Nozzle neck to be designed as per ASME sec 8 division cl. ug-45
RF pad for the nozzle to be designed as per ASME sec 8 division 1 cl. ug-36
Non std. flange to be designed as per ASME sec viii div I, appx-2 & STD flange to be
selected as per ug-44/ASME b16.5
 Supports for vessel

Supports are required for the installation of the vessel on the foundation.
The support system of pressure vessels depends upon the size
of the vessel. Large or tall vertical vessels are usually supported on skirts while
small to medium sized vertical vessels are usually supported on legs.

Type of supports

 1. LEG TYPE SUPPORT

 2. SKIRT TYPE SUPPORT (CYLINDRICAL/CONICAL)

 3 BRACKET TYPE SUPPORT

 4. SADDLE SUPPORT
 Solved Design Problem:

DATA:

Material: SA516 Gr 70
Max temp: 130°C or 266 °F
Allowable Stress(S): 20000psi = 1406 kg⁄ mm2
Radius: 300 mm
Weld joint efficiency (E): 1
Pressure (P): 6.5 *10-2 kg⁄mm2
Corrosion Allowance(C):6 mm
Stress calculation:
Thickness of shell under pressure (UG 27):

T= PR⁄ (SE- 0.6P)

T =1.39 + C
T= 1.39+ 6 ≈ 7.39mm
Therefore, thickness plate of 8mm thickness is used for shell design.

Head design (UG 31):

Ellipsoidal head design:

T= PR/ (2SE -0.2 P)

T= 1.38 + C
T= 7.38mm

Torispherical head design:

T = 0.885PL / (2SE -0.2P)

T= 2.46+ C
T= 8.46 mm

Hemispherical head:

T= PL/ (2SE- 0.2 P)

T= 1.39+6
T= 7.39mm
Therefore due to low in thickness of head and fabrication cost ellipsoidal head should be
used here.

NOZZLE THICKNESS :( UG 45)

LWN
1)O1 nozzle :

Di = 1.5 inch = 38.1mm

T= 14.33mm
Do = Di + 2T
= 66.7 mm
t = PR/ (SE- 0.6P)
t= 0.12mm +C=6.12mm

2) I1 nozzle:
Do = 4inch= 101.6mm
t= PRo/ (SE+ 0.4P)
t=0.33+C
t=6.33mm

3) UC1 and UC2 nozzle:

Di = 2inch = 50.8mm
t= PRi / (SE – 0.6P)
t= 0.16mm+C
t=6.16mm

PSV NOZZLE:
Do = 4inch =101.6mm
t= 6.33mm (fromI2 nozzle)

NOZZLE REINFORCEMENT:

For LWN nozzles:

Given data:
TR=7.39mm
T= 8mm
D=38.1mm
Tn= 8mm
Trn= 6.12mm

A= DTrF + 2TnTrF(1-Tr)
A= 38.1 (1*8-1*7.39)
A= 281.56mm2

A1= D (E1T – FTr)-2Tn(E1T-FTr)(1-Fr)

A1= 38.1(1*8-1*7.39)
A1=23.24mm2

A2=5(Tn-Trn)Fr2 T
A2=5*(8-6.12) 1*8
A2= 75.2mm2

A3= 0

A4= (leg)2Fr
A4= 10*10=100mm2

A>A1+A2+A3+A4+A3A4
Therefore, reinforcement should be added.

A5= (DP-D- 2Trn) Te*Fr4

A5=251.16mm

A1+A2+A3+A41+A42+A43+A5= 549.16mm2

Which is greater than A.

Therefore this reinforcement is added and accepted.