PROJECT REPORT OF INDUSTRIAL TRAINING AT

INDIAN OIL CORPORATION LIMITED

BONGAIGAON REFINERY

TRAINING PERIOD: 15/06/2024 – 17/07/2024

SUBMITTED BY : SANDEEP SAHA (2115015)

Department of Electronics and Instrumentation Engineering

NATIONAL INSTITUTE OF TECHNOLOGY SILCHAR
DECLARATION

I, Sandeep Saha, Roll No. 2115015, a full time bonafide student of Bachelor of
Technology (B.Tech) Programme, Batch (2021-2025) of Department of
Electronics and Instrumentation 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. Mr. P. P Gogoi, CITM
(Instrumentation Department), Mr. Rahul Shareen, MNM(EL) (Telephone
Exchange) and Mr. Dinesh Daimary, DGM (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:

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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 the Training and Placement Cell of our institute for
providing me this opportunity to learn at IOCL Bongaigaon Refinery.

My sincere gratitude goes to Mr. P. P Gogoi, CITM (Instrumentation Department),

Mr. Rahul Shareen, MNM(EL) (Telephone Exchange) and Mr. Dinesh Daimary,
DGM (Information System) sir for their valuable guidance.

I would also like to express my special thanks to Mr. Saddam Hussain 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. P. P Gogoi, CITM Sandeep Saha

Mr. Rahul Shareen, MNM(EL)

Mr. Dinesh Daimary, DGM

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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 in this short period was
fascinating to say the least. It was a 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 helps me carve a niche for myself in this field.

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 TABLE OF CONTENTS

TITLE PAGE NUMBER

DECLARATION 1

ACKNOWLEDGEMENT 2

PREFACE 3

CHAPTER 1: Introduction 6

1.1 History and location 6

1.2 Capacity of the Refinery 6

1.3 Major Products 6

CHAPTER 2: Fire and Safety Department Overview 7

2.1 Safety Measures 7

2.2 Types of Siren 7

CHAPTER 3: Instrumentation Department Overview 7

3.1.1 Distributed control system (DCS) 8

3.1.2 Programmable logic controller (PLC) 8

3.2 Instruments used in Refinery 9

3.2.1 Temperature measurement 9

3.2.2 Flow measurement 9

3.2.3 Pressure measurement 9

3.2.4 Level measurement 10

3.2.5 Control Valves 10

Figure 3.8 Schematic diagram of control valve 10

3.2.6 Analyzers 12

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CHAPTER 4: Telephone Exchange Department Overview 13

4.1 EPABX telephone system 13

4.2 Air Raid Protection (ARP) system 13

4.3 Main Distribution Frame (MDF) 13

4.4 Different Wireless Equipments 14

4.4.1 Walkie-talkie 14

Classification of walkie-talkie 14

4.4.2 Base station 14

Advantages of base stations over walkie-talkies: 15

4.4.3 Repeater 15

CHAPTER 5: Information System Department Overview 16

5.1 Difference between Internet and Intranet 16

5.1.1 Internet 16

5.1.2 Intranet 16

5.2 Computer Networking 17

5.2.1 Local Area Network (LAN) 17
5.2.2 Wide Area Network (WAN) 17
5.3 Important Terminologies in Computer Network 18
5.3.1 Server 18
5.3.2 Router 18
5.3.3 Switch 18
5.3.4 Optical fiber 18
5.3.5 Category 6 cable 19
5.3.6 RJ45 connector 20

METHODOLOGY 20

CONCLUSION 21

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 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' were implemented to comply
with BS VI fuel norms. The INDMAX project along with an 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).

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 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.
Cigarettes, 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 Equipment (PPEs). Different safety equipment 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 the Bongaigaon refinery. They are discussed below.

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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 the 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 the 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 in factories. 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 an 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.

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 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 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.

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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

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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.

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 Figure 3.8 Schematic diagram of control valve

3.2.6 Analyzers
Analyzers are devices that measure 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

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 CHAPTER 4: Telephone Exchange Department
Overview
The various communication facilities available at IOCL Bongaigaon Refinery are
walkie-talkie (wireless) system, loudspeaker announcement 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 the 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 situations like fire in a 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.

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 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 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 is termed as a 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 stations can be in the form of stationary base stations or

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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 signals can not pass through the
signal to these control rooms, base stations are used along with GP antennas 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.

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 CHAPTER 5: Information System Department

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

3. The Internet is unsafe. The Intranet is safe.

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

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

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 6. The Internet provides unlimited Intranet provides limited information.
information
7. It is open to everyone and allows access An intranet is only accessible to
to public information, such as websites authorized users within the
and online services. organization.
8. Users can access the Internet from any Access to an intranet is restricted to
location with an Internet connection and authorized users within the
a compatible device. organization 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 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.

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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. Examples 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 is used in LAN (Local Area Network),
MAN (Metropolitan Area Network) and WAN (Wide Area Network). It stores IP
addresses and maintains addresses 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 device that sets up and stops 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

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from a denser medium to a rarer medium provided angle of incidence is greater
than critical angle. Optical fibers are used for transmission of data as they provide
a 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.

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 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 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 gained 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 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.

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 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 a 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 the working world.

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