PROJECT REPORT OF INDUSTRIAL TRAINING AT

IOCL BONGAIGAON REFINERY

TRAINING PERIOD: 06/06/2023 – 17/07/2023

SUBMITTED BY:

SUMAN SUTRADHAR (2014008)

Student of B.Tech (Electronics and Communication Engineering)

National Institute of Technology Silchar

 DECLARATION

I, Suman Sutradhar, Roll No. 2014008, a full time bonafide student of Bachelor of
Technology (B.Tech) Programme, Batch (2020-24) of Department of Electronics
and Communication Engineering, National Institute of Technology Silchar,
hereby certify that this summer training carried out by me at Indian Oil
Corporation Limited (IOCL), Bongaigaon Refinery and the report submitted in
partial fulfillment of the requirements of the programme is an original work of
mine under the guidance of the industry mentors Mr. Abhijit Barman, ITM
(Instrumentation Department), Mr. Deepak Kr Jain, AMEL (Telephone
Exchange) and Mr. B C Sarkar, CM (Information System) and is not based or
reproduced from any existing work of any other person or on any earlier work
undertaken at my other time or for any other purpose, and has not been submitted
anywhere else at any time.

(Student's Signature)

Date:
 ACKNOWLEDGEMENT

My indebtedness and gratitude to many individuals who have helped me to shape

this report in its present form can not be adequately conveyed in just a few
sentences. Yet I must record my immense gratitude to those who helped me
undergo valuable learning at IOCL Bongaigaon Refinery.

I am highly obliged to Training and Placement Cell of our institute for providing
me this opportunity to learn at IOCL Bongaigaon Refinery.

I would like to thank Mr. Janardan Deka, Manager (L&D) sir for briefing us on
orientation and his helpful words on fire and safety.

My sincere gratitude goes to Mr. Abhijit Barman, ITM (Instrumentation

Department), Mr. Deepak Kr Jain, AMEL (Telephone Exchange) and Mr. B C
Sarkar, CM (Information System) sir for their valuable guidance.

I would also like to express my special thanks to Mr. Abinash Deka and Mr.
Ravindra Kumar Mahawar sir, who shared their knowledge to improve my
theoretical knowledge in actual works.

Last but not the least, we are grateful to everyone who guided me in the field
work.

Name of the Training Officers Name of the Student

Mr. Abhijit Barman, ITM Suman Sutradhar

Mr. Deepak Kr Jain, AMEL

Mr. B C Sarkar, CM (IS)

 PREFACE

Industrial training plays a vital role in the progress of future engineers. Not only
does it provide insights about the future concerned, it also bridges the gap
between theory and practical knowledge. I was fortunate that I was provided with
an opportunity of undergoing industrial training at Indian Oil Corporation
Limited, Bongaigaon Refinery. The experience gained this short period was
fascinating to say the least. It was tremendous feeling to observe the different
units and processes. It was overwhelming for us to notice how such a big refinery
is being monitored and operated with proper coordination to achieve desired
results. During my training I realized that in order to be a successful engineer one
needs to put his/her concepts into action. Thus, I hope that this training serves as a
stepping stone for me in future and help me carve a niche for myself in this field.
 TABLE OF CONTENTS
TITLE PAGE NUMBER
DECLARATION......................................................................................................i
ACKNOWLEDGEMENT.......................................................................................ii
PREFACE...............................................................................................................iii
CHAPTER 1: Introduction.......................................................................................1
1.1 History and location..................................................................................1
1.2 Capacity of the Refinery...........................................................................1
1.3 Major Products.........................................................................................1
CHAPTER 2: Fire and Safety Department Overview.............................................1
2.1 Safety Measures........................................................................................1
2.2 Types of Siren...........................................................................................2
CHAPTER 3: Instrumentation Department Overview............................................2
3.1.1 Distributed control system (DCS)................................................2
3.1.2 Programmable logic controller (PLC)..........................................3
3.2 Instruments used in Refinery....................................................................3
3.2.1 Temperature measurement...........................................................3
3.2.2 Flow measurement.......................................................................4
3.2.3 Pressure measurement..................................................................4
3.2.4 Level measurement......................................................................4
3.2.5 Control Valves.............................................................................5
Figure 3.8 Schematic diagram of control valve....................................6
3.2.6 Analyzers......................................................................................6
CHAPTER 4: Telephone Exchange Department Overview....................................7
4.1 EPABX telephone system........................................................................7
4.2 Air Raid Protection (ARP) system...........................................................7
4.3 Main Distribution Frame (MDF)..............................................................7
4.4 Different Wireless Equipments................................................................8
 4.4.1 Walkie-talkie................................................................................8
Classification of walkie-talkie...............................................................8
4.4.2 Base station..................................................................................8
Advantages of base stations over walkie-talkies:..................................9
4.4.3 Repeater........................................................................................9
CHAPTER 5: Information System Department Overview......................................9
5.1 Difference between Internet and Intranet...............................................10
5.1.1 Internet.......................................................................................10
5.1.2 Intranet.......................................................................................10
5.2 Computer Networking............................................................................11
5.2.1 Local Area Network (LAN).......................................................11
5.2.2 Wide Area Network (WAN)......................................................11
5.3 Important Terminologies in Computer Network....................................11
5.3.1 Server.........................................................................................11
5.3.2 Router.........................................................................................12
5.3.3 Switch.........................................................................................12
5.3.4 Optical fiber...............................................................................12
5.3.5 Category 6 cable.........................................................................13
5.3.6 RJ45 connector...........................................................................13
METHODOLOGY.................................................................................................14
CONCLUSION......................................................................................................15
 CHAPTER 1: Introduction

1.1 History and location

Bongaigaon Refinery & Petrochemicals Limited (BRPL) was incorporated in 1974 as a
Government Company. Situated amidst its spectacular beauty in the Chirang district of
Assam, it is about 200 km west from the state capital Guwahati. Amalgamation of
Bongaigaon Refinery & Petrochemicals Limited (BRPL) with Indian Oil happened in 2009
and the refinery today is part of Indian Oil and is known as Bongaigaon Refinery.

1.2 Capacity of the Refinery

The first CDU with a capacity of 1.0 MMTPA was commissioned in 1979, which was later
on de-bottlenecked to 1.35 MMTPA in 1986. The Refinery Expansion Project was
commissioned in 1995 with which the overall capacity was increased to 2.35 MMTPA. It
comprises two Crude Distillation Units (CDU), two Delayed Coker Units (DCU), DHDT unit
including HGU & SRU and CRU/MSQ units. Further two projects 'Indmax Project' and 'BS
VI' was implemented to comply BS VI fuel norms. INDMAX project along with increase in
crude processing from 2.35 to 2.7 MMTPA was completed in 2020.

1.3 Major Products

The major products of this refinery are: Liquefied Petroleum Gas (LPG), High Speed Diesel
(HSD), Naphtha, Motor Spirit, Ethanol Blended Motor Spirit (EBMS), Superior Kerosene
Oil, Aviation Turbine Fuel (ATF), Light Diesel Oil (LDO), Sulphur, Raw Petroleum Coke
(RPC).

CHAPTER 2: Fire and Safety Department Overview

2.1 Safety Measures

Different safety measures are taken to reduce the chances of hazard. Mobiles, laptops, pen
drives etc. all electronics are prohibited inside the battery area. Cars which are allowed to
enter the battery area are provided with spark arrestors. Cigarette, alcohol and other
inflammable objects are not allowed inside the battery area. Fire alarms and Fire
Extinguishers are present within a considerable distance inside the refinery. Workers are
always advised to use their Personal Protective Equipments (PPEs). Different safety
equipments that are used in the refinery are safety shoes, helmet, face shield, hand gloves,
IFR (or boiler) suit, safety goggles etc.

2.2 Types of Siren

The major types of siren codes are:
 A continuous test siren is sounded every morning at 8am for 2 minutes
 Major fire: a wailing siren for 2 minutes
 Disaster: 3 times wailing siren for 2 minutes at intervals of 1 minutes in between (8
minutes in total)

CHAPTER 3: Instrumentation Department Overview

Instrumentation is used to monitor and control the process plant in the oil, gas and
petrochemical industries. Instrumentation ensures that the plant operates within defined
parameters to produce materials of consistent quality and within the required specifications. It
also ensures that the plant is operated safely and acts to correct out of tolerance operation and
to automatically shut down the plant to prevent hazardous conditions from occurring.
Instrumentation comprises sensor elements, signal transmitters, controllers, indicators and
alarms, actuated valves, logic circuits and operator interfaces. There are two types of
controllers which are being used in Bongaigaon refinery. They are discussed below.

3.1.1 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. It provides real time measurement value of a transmitter and
its control located at field. The response time is slow in DCS and also it operates on both
analog and digital I/O. It is used for normal control operations in industries. A DCS is used
for continuous, complex controls. The DCS has a number of predefined functions that come
ready to customize and deploy for various applications. The DCS is a process-oriented
system that uses closed-loop control.
3.1.2 Programmable logic controller (PLC)
A Programmable Logic Controller or PLC is simply a special computer that is programmed
to control certain processes in industries like petroleum, Steel or automotive. Every PLC is
composed of three main parts: Input, CPU and Output. We have to write a program on
computer for an operation and then download it to the CPU. The CPU will process the data
received and send the result to the output. PLC is a digital computer used for automation of
electromechanical processes, such as control of machinery on factory. Unlike general-
purpose computers, the PLC is designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and
impact. PLC is known as emergency shutdown system (ESD). The response time of PLC is
very high and it always operates on digital logic.
The communication between the field instruments and DCS/PLC is shown below.

Figure 3.1 Block diagram for the communication between the field instruments and DCS/PLC

3.2 Instruments used in Refinery

There are various instruments which are used for the measurement of different parameters.
Out of which, the major parameters that are: temperature measurement, flow measurement,
pressure measurement, flow measurement.

3.2.1 Temperature measurement

Measurement of temperature is done with the help of various devices. The devices which are
being used in IOCL Bongaigaon for the measurement of temperature are temperature gauge,
thermocouple, RTD etc.
Figure 3.2 Resistance temperature detector (RTD) Figure 3.3 A temperature gauge

3.2.2 Flow measurement

Flow measurement is done with the help of various flow meters such as: Orifice flow meter,
Venturi meter, Ultrasonic.

3.2.3 Pressure measurement

Measurement of pressure is done with the help of various devices. But pressure gauge is
mainly used in IOCL Bongaigaon for the measurement of pressure.

Figure 3.4 Pressure gauge Figure 3.5 Schematic diagram of bourdon tube pressure gauge

3.2.4 Level measurement

Level measurement is done with the help of various level meters such as: level gauge, radar
level transmitter, differential pressure transmitter.
Figure 3.6 Magnetic level gauge Figure 3.7 Radar level transmitter

3.2.5 Control Valves

Control Valves are mechanical devices used to regulate flow by opening or closing or
partially obstructing the passage based on signal from controller. Valves manipulate a
flowing fluid such as gas, steam, water or chemical compounds to keep process variables
such as pressure, flow, level or temperature within a required range. The control valve, or
more exactly the control valve assembly, consists of the valve body, the internal trim parts, an
actuator to provide the force to operate the valve and a variety of additional valve accessories,
such as positioner.

A control valve is a power-operated device used to regulate or manipulate the flow of fluids,
such as gas, oil, water and steam. A control valve can be operated electrically, pneumatically,
or hydraulically. A control valve receives a signal from a controller such as a PLC in order
for it to move resulting in a change in flow. A control valve has two separate components: the
valve and the actuator. The actuator is the device connected to the valve through the valve
stem that provides the force required to move the valve. The most common and the most
reliable is the "Pneumatic Actuator". The control valve receives a signal from a controller
such as a PLC or a DCS in order to operate. The controller compares the actual flow rate to
the desired flow value called the setpoint. The controller will produce an output to move the
valve to bring the flow rate to the setpoint value.
 Figure 3.8 Schematic diagram of control valve

3.2.6 Analyzers
Analyzers are devices that measures and transmit information about chemical composition,
physical properties or chemical properties of the sample. The analyzers in use in IOCL
Bongaigaon refinery are gas detector, oxygen analyzer, pH meter, SOX analyzer, NOX
analyzer, CO analyzer.

Figure 3.9 Infrared gas detector Figure 3.10 NOX analyzer

 CHAPTER 4: Telephone Exchange Department Overview
The various communication facilities available at IOCL Bongaigaon Refinery are walkie-
talkie (wireless) system, loud speaker announcing system, EPABX telephone system, Air
Raid Protection (ARP) system, spark free mobile/cellular phones, fire alarm system (siren).

4.1 EPABX telephone system

EPABX stands for electronic private automatic branch exchange. It is of 3000 lines and is
installed at the administrative building of refinery equipped with the Level DID (Direct
Inward Dialing) facility. The number of various departments of the refinery consists of four
digit numbers starting from 3001 to 5999.

4.2 Air Raid Protection (ARP) system

Air Raid Protection is an emergency management system. This is used in emergency situation
like fire in refinery. In case of emergency situation the "FIRE AND SAFETY
DEPARTMENT" record and store the emergency message 5 times by bailing the 139 through
the intercom and then the emergency management system conveys the message to all the
DGMs, HODs at the same time.

4.3 Main Distribution Frame (MDF)

In telephony, a main distribution frame (MDF or main frame) is a signal distribution frame
for connecting equipment (inside plant) to cables and subscriber carrier equipment (outside
plant). The MDF is a termination point within the local telephone exchange where exchange
equipment and terminations of local loops are connected by jumper wires at the MDF. With
disciplined administration the MDF can hold over a hundred thousand jumpers, with dozens
changed every day, for decades without tangling.

Figure 4.1 Main Distribution Frame (MDF)

4.4 Different Wireless Equipments

4.4.1 Walkie-talkie
A walkie-talkie is a hand-held portable, two ways radio transceiver. The major characteristics
include a half duplex channel (only one radio transmits at a time though any number can
listen) and push to talk switch that starts transmission. Typical walkie-talkie resembles a
telephone handset, possibly slightly larger but still a single unit, with an antenna sticking out
on the top. Where a phone's earpiece is only loud enough to be heard by the user, walkie-
talkie's built in speaker can be heard by the user and those in the immediate vicinity.

Classification of walkie-talkie
 Fixed walkie-talkie: Walkies positioned at a central site like an office or
headquarters where the manager can maintain contact with the field staff. The
equipment at such a site termed as base station.
 Mobile walkie-talkie: Walkies installed in vehicles are referred to as mobile
walkie.

Figure 4.2 Walkie-talkie

4.4.2 Base station

Base station systems are used to provide instantaneous one-to-one or one-to-many
communication. Base station can be on the form of stationary base stations or they can be
mounted on moving vehicles for maximum flexibility and reach. Its operation is like a
walkie-talkie. The wireless system works with the help of walkie-talkie sets. These are also
called portable radios.
 Figure 4.3 Base station

Advantages of base stations over walkie-talkies:

In some locations (mainly control rooms), where walkie-talkie does not work properly, since
control rooms are air tight and RF signal can not pass through the signal to these control
rooms, base stations are used along with GP antenna for reliable communication. The antenna
of the base station can accept signals over a very large area.

4.4.3 Repeater
In digital communication systems, a repeater is a device that receives a digital signal on an
electromagnetic or optical transmission medium and regenerates the signal along the next leg
of the medium. In electromagnetic media, repeaters overcome the attenuation caused by free-
space electromagnetic field divergence or cable loss. A series of repeaters make possible the
extension of a signal over the distance. A repeater when strategically located on top of a high
building or a mountain can greatly enhance the performance of a wireless network by
allowing communication over distance much greater than would be possible without it.

CHAPTER 5: Information System Department Overview

In all but the smallest of firms, the information systems department is the formal
organizational unit responsible for information technology services. The information systems
department is responsible for maintaining the hardware, software, data storage, and networks
that comprise the firm's IT infrastructure.
5.1 Difference between Internet and Intranet

5.1.1 Internet
Internet is used to connect the different networks of computers simultaneously. It is a public
network therefore anyone can access the internet. On the internet, there are multiple users and
it provides an unlimited of information to the users.

5.1.2 Intranet
Intranet is the type of internet that is used privately. It is a private network therefore anyone
can’t access the intranet. On the intranet, there is a limited number of users and it provides a
piece of limited information to its users.

Table 6.1 Difference between internet and internet

Serial
Internet Intranet
No.

1. The Internet is a global network that An intranet is a private network that

connects millions of devices and computers connects devices and computers within an
worldwide. organization.
2. On the internet, there are multiple users. On an intranet, there are limited users.

3. Internet is unsafe. Intranet is safe.

4. Internet is a public network. Intranet is a private network.

5. Anyone can access the Internet. In this, anyone can’t access the Intranet.

6. The Internet provides unlimited Intranet provides limited information.

information
7. It is open to everyone and allows access to An intranet is only accessible to
public information, such as websites and authorized users within the organization.
online services.
8. Users can access the Internet from any Access to an intranet is restricted to
location with an Internet connection and a authorized users within the organization
compatible device. and is typically limited to specific devices
and locations.
5.2 Computer Networking
Multiple computers are connected together to form a network where they can share resources
and information. Networking devices like cables, routers and switches and protocols found in
the OSI model make computer networking realizable.

5.2.1 Local Area Network (LAN)

A local area network (LAN) is a group of computers and associated devices that share a
common communications line within a distinct geographic area such as an office or a
commercial establishment. A local area network may serve as few as two or three users (for
example, in a small-office network) or several hundred users in a larger office. LAN
networking comprises of cables, switches, routers and other components that let users
connect to internal servers, websites and other LANs via wide area networks.

Ethernet and Wi-Fi are the two primary ways to enable LAN connections. Ethernet is a
specification that enables computers to communicate with each other. Wi-Fi uses radio waves
to connect computers to the LAN.

5.2.2 Wide Area Network (WAN)

A wide area network connects more than one LAN and is used for larger geographical areas.
A WAN works in a similar fashion to a LAN, just on a larger scale. Typically, TCP/IP is the
protocol used for a WAN in combination with devices such as routers, switches, firewalls and
modems.

5.3 Important Terminologies in Computer Network

5.3.1 Server
A server is a device that provides functionality for called clients which are other programs or
devices. This architecture is called the client–server model. A single overall computation is
distributed across multiple processes or devices. Servers can provide various functionalities
called services. These services include sharing data or resources among multiple clients, or
performing computation for a client. Multiple clients can be served by a single server, and a
single client can use multiple servers. It can also connect over a network to a server to run on
a different device. Example of servers may include database servers, mail servers, print
servers, file servers, web servers, application servers, and game servers.
5.3.2 Router
Router is a networking device which works at the network layer i.e., third layer of the ISO-
OSI model and are the multiport devices. It establishes a simple connection between the
networks in order to provide the data flow between the networks. Router transfers data in the
form of packet is used in LAN as well as MAN. It works on the network layer 3 and used in
LAN (Local Area Network), MAN (Metropolitan Area Network) and WAN (Wide Area
Network). It stores IP address and maintains address on its own.

5.3.3 Switch
It is a point to point communication device. Basically, it is a kind of bridge that provides
better connections. It is a kind of devices that set up and stop the connections according to the
requirements needed at that time. It comes up with many features such as flooding, filtering
and frame transmission.

5.3.4 Optical fiber

A fiber optic cable is made of glass or plastic and transmits signals in the structure of light
signals. The structure of an optical fiber cable is displayed in the figure. It involves an inner
glass core surrounded by a glass cladding that reflects the light into the core. Each fiber is
encircled by a plastic jacket. It works on the principle of total internal reflection (TIR) that
the ray get internally reflected when it passes from a denser medium to rarer medium
provided angle of incidence is greater than critical angle. Optical fibers are used for
transmission of data as they provide high speed data transmission facility (10Gbps).

Figure 5.1 Construction of optical fiber

The advantages of fiber optic cable are as follows:

 Speed: The bandwidth provided by a fiber optic cable is generally high

compared to a copper twisted pair cable.
  Longer distances: Fiber optic cables are created to carry signals over much
higher distances than traditional cabling as they provide low power loss.
 High-level security
 Flexibility: An optical fiber has more accurate strength than copper or steel
fibers of equal diameter.

5.3.5 Category 6 cable

Category 6 is an Ethernet cable standard defined by the Electronic Industries Association and
Telecommunications Industry Association. Cat 6 is the sixth generation of twisted pair
Ethernet cabling that is used in home and business networks. Cat 6 cabling is backward
compatible with the Cat 5 and Cat 5e standards that preceded it.

Figure 5.2 Category 6 ethernet cable

5.3.6 RJ45 connector

RJ45 is a well-known ethernet connectivity connector that allows users to connect through
wired internet. There are other ports also which do the same, but RJ45 is widely used and
most common in wired internet connection interfaces. It is an ethernet cable consisting of 8
wires (4 pairs of wires). These cables follow a specific color code with respect to the
arrangements of the wires.

Figure 5.3 RJ45 connector

 METHODOLOGY

We studied about different types of controllers used for automation such as Programmable
Logic Controller (PLC) and Distributed Control System (DCS). Also we have studied about
the instruments which are used for pressure measurement, temperature measurement, flow
measurement and level measurement. We have gain the knowledge of different analyzers
used like NOX analyzer, SOX analyzer etc. Then we visited the Telephone Exchange
department and studied about different types of communications used in the refinery like
telephonic communication, walkie-talkie, spark free mobile etc. At last, we have visited the
Information System Department and studied about the internet and intranet, server, router,
local area network (LAN) etc. This document is all about what I studied during the Internship
days in the summer.
 CONCLUSION

Indian Oil Corporation Limited, Bongaigaon Refinery is well known for its achievements
during the last 49 years and all together. IOCL always holds the reputation of best PSU
(Public Sector Unit) in India.

After the completion of industrial training, I enhanced competencies and competitiveness in

our respective area of specialization. I tried to relate the experience in the workplace with
knowledge learned in the institute and applied on the job under supervision.

Here, I gained the experience and knowledge that can be used for suitable job without delay
after studies.

I learned to hone soft skills appropriate to the work environment. Also get improvised in
communication skills. I assessed carrier ability, knowledge and confidence as well as
enhanced my marketability to be more competitive.

With experience, knowledge and skills acquired during industrial training, I will be better
prepared to face working world.