TRAINING REPORT

SUPERVISOR: By:
Mr. Pramod Kumar Bhardwaj Uday Umakant
SPM, IOCL
Mathura

1
 INDEX

1. Acknowledgement
2. Synopsis
3. Brief Overview of IOCL
4. Overview of Mathura Refinery
5. Fire Risk Management Philosophy
6. Once-through Hydro Cracking Unit
7. New Hydrogen Generation Unit (NHGU)
8. Diesel Hydro Desulfurization Unit (DHDS)
9. Diesel Hydro-Treatment Unit (DHDT)
10. Jindal Coating Unit Report
11. References

2
 ACKNOWLEDGMENT

We feel immense pleasure and privilege to express our deep sense of gratitude, indebtedness
and thankfulness towards MR. PRAMOD KUMAR & MR. SUSHANT ACHARYA who generously helped
us color the mosaic of this training with their knowledge, expertise and memories. We shall remain
ever grateful to all the persons of I.O.C.L, who have helped, inspired and encouraged us and above all
made us an ever more experienced person.

For their invaluable guidance, kind cooperation, inspiration and encouragement during all the
stages of our training, we would like to thank MR. GAURAV BAJAJ who has been of immense help
during our training period and thousands of other I.O.C.L employees whose name we could not
mention just for the lack of space. Last but not least, we would like to convey our hearty and blossom
thanks to my friends and fellow mates who have directly or indirectly helped me in the compilation of
this report.

After the completion of the training program, we found it to be of immense help, not only in
supplementing the theoretical knowledge, but also by gaining highly practical knowledge regarding
the actual work carried out in a Refinery Plant. At the end, we again express our gratitude to all those
who helped us in any way to complete our project work successfully.

June 2013

I.O.C.L. Mathura

3
 Overview of Indian Oil

I.O.C.L: AN OVERVIEW
Introduction

Indian Oil Company Limited, a wholly owned Government company was incorporated on 30 June, 1959 to undertake
marketing functions of petroleum products. Later, Indian Oil Corporation Limited (IOC) was set up on 1 st September,
1964 by amalgamating the Indian Refineries Limited (started in August, 1958) with the Indian Oil Company Ltd., for
better coordination between refineries and marketing.

4
Indian Oil Corporation Limited or IOC is Indias largest commercial enterprise and the only Indian company to be
among the worlds top 200 corporations according to Fortune magazine. It is also among the 20 largest petroleum
companies in the world.

It was established in 1959 as Indian Oil Company Limited which was merged with Indian Refineries Limited in 1964 to
form IOC as it is today.

Indian Oil Corporation has four divisions:

Marketing Division with Headquarters at Bombay;

Refineries and Pipelines Division with Headquarters at New Delhi;
Assam Oil Division with Headquarters at Digboi; and
Research and Development Centre at Faridabad.

The Assam Oil Division was established on 14th October, 1981 on taking over the refining and marketing operations of
Assam Oil Company Limited.

The Company wholly owns a subsidiary Company viz. Indian Oil Blending Limited, which is engaged in the manufacture
of lubricants and greases. The products of the subsidiary Company are also marketed by the Company.

Objectives

The objectives of the Company as approved (June, 1984) by Government are as follows:

To serve the national interests in the oil and related sectors in accordance and consistent with Government policies.
To ensure and maintain continuous and smooth supplies of petroleum products by way of crude refining,
transportation and marketing activities and to provide appropriate assistance to the consumer to conserve and use
petroleum products most efficiently.
To earn a reasonable rate of return on investment.
To work towards the achievement of self-sufficiency in the field of oil refining, by setting up adequate domestic
capacity and to build up expertise for pipe laying for crude/petroleum products.
To create a strong research and development base in the field of oil refining and stimulate the development of new
petroleum products formulations with a view to eliminate their imports, if any and
To make use of the existing facilities in order to improve efficiency and increase productivity.
5
Decentralisation of Imports And Exports

Earlier, import of crude oil and import as well as export of almost all petroleum products were done through the
Company. In the wake of economic liberalisation, the Government has decentralised a number of petroleum products
starting from July, 1991. The Govt. of India amended (July, 1994) Export and Import Policy 1992 -1997, thereby enabling
the users to import ATF (Aviation Turbine Fuel) against special import licence. The Company assisted (October, 1994) the
airlines in importing the ATF. But with imposition (March, 1995) of a cost and freight surcharge by Government with
retrospective effect, the Company stopped such imports as these were no longer beneficial. By September, 1995 as
many as 9 products, including LPG and Kerosene, which are being marketed in parallel by joint as well as private sector,
have been decentralised and custom duties on them have also been successively reduced. A chronology of major events
in the decentralisation of marketing of petroleum products is given at Annexure-I.

However, the Company continues to import LPG and Kerosene for meeting the countrys demand and for sale through
public distribution system at administered and centralized prices.

Organizational Set-Up and Network of Marketing Division

The Marketing Division, with its headquarters at Bombay and headed by Director (Marketing), has four regional offices
located at Bombay, Delhi, Calcutta and Madras. All regional offices are headed by either Executive Directors or General
Managers. There are 44 Divisional Offices, including two of the Assam Oil Division. As on 31 March, 1995, the Company
had 39 bulk storage installations (including 3 of AOD) and 117 storage depots, which fed 5995 retail outlets. In addition,
there were 2898 kerosene/light diesel oil dealers who also move these products from the depots to 4379 consumer
outlets for sale. The Company had a total product tankage of 3.93 million kilo liters at its installations and depots.

Being the major producer and distributor of LPG to various types of consumers in India, the Company has 32 area offices
to deal with LPG marketing. As on 31 March, 1995, the Company had 33 LPG bottling plants with a total bottling capacity
of 11.92 lakh tones per annum. Indane cooking gas (LPG) is distributed to 12 million households.

Indian Oil markets nearly 66.8 percent of the countrys aviation fuel (68.2% in 1992-93), meeting the needs of 59
international airlines besides the domestic carriers and the defence services. Of the 117 aviation fuel stations in the
country, Indian Oil operates 93.

6
Products

Auto LPG
Aviation Turbine Fuel (ATF)
Bitumen
High Speed Fuel
Industrial Fuels
Liquefied Petroleum Gas
Lubricants and Greases
Marine Fuels
MS/Gasoline
Petrochemicals
Services

Refining
Pipelines
Marketing
Training
Research & Development

7
Location of various I.O.C Refineries

IOC Refineries - Overview

Refinery Year of Initial Capacity, TMTPA
Commissioning Capacity As on 01.04.06
TMTPA
Digboi 1901 28 650
Guwahati 1961 750 1000
Barauni 1964 2000 6000
Gujarat 1965 2000 13700
Haldia 1975 2500 6000
Mathura 1982 6000 8000
Panipat 1998 6000 6000
IOC's Total 41350
IOC Associates 12850
IOC+Associates 54200
Total Industry 132470
% Share (IOC) 41%

IOCL Refineries

Oil India Crude

KBPL Conversion Pipeline
Panipat: 6.0
BRPL:2.35
SMPL Mathura: 8.0 Digboi 0.65
Sanganer
Chaksu
Sidhpur
Viramgam Barauni : 6.0
Mundra Guwahati 1.0
Kandla
Salaya Koyali :13.7
HBCPL Haldia : 6.0

Paradip : 15.0

IOC Refineries
IOC Associates
CPCL-M :9.5
IOCs Proposed Refinery
New Crude PL
CBR : 1.0
Refinery Capacity in MMTPA

8
 Mathura Refinery: An Overview
Introduction

Mathura refinery was commissioned in 1982 as the sixth refinery in the fold of IndianOil and with an original capacity of
6.0 MMTPA. Located strategically between the historic cities of Delhi and Agra, the Refinery at Mathura is situated in the
mythical and mystical land of Lord Krishna. Later the capacity of Mathura refinery was increased to 7.5 MMTPA by
systematically debottlenecking and revamping. With its Fluid Catalytic Cracking Units (FCCU), the refinery mainly
produces middle distillates for Northern India supplied though a 760km long product pipeline to Jalandhar in Punjab via
Delhi (MJPL) and 100km long Mathura Tundla Pipeline (MTPL). A Vis-breaking unit was commissioned in 1982 and
Soaker drum technology was implemented in VBU in the year 1993. The two-stage desalter was commissioned in 1998
in order to improve the on-stream availability of the crude distillation unit. In the same year new Continuous Catalytic
Reformer Unit (CCRU) for production of unleaded gasoline was added.

The First hydrogen generation unit (HGU-I) commissioned in 1999 along with first Diesel Hydro-desulfurisation unit
(DHDS) for production of HSD with a low Sulfur content of 0.25% wt (max). A once through Hydro-cracker unit was
commissioned in July 2000 for increased middle distillates production. For supplying EURO-III grade auto fuels, viz,
EURO-III HSD and EURO-III MS to National Capital Territory (NCT) and National Capital Region (NCR), a Diesel Hydro-
treating unit (DHDT) and MS quality up gradation unit consists of NHDT and PENEX along with FCCU Gasoline splitter and
2nd Hydrogen generation unit (HGU-II) commissioned in 2005. The present capacity of the refinery is 8.0 MMTPA and
regularly receives crude oil through the 1870 km long Salaya Mathura Pipeline (SMPL). Over the years Mathura Refinery
has systematically synchronized technology with ecology with constant care for the surrounding environment. Its close
proximity to the magnificent wonder TajMahal adds to the responsibility towards a cleaner Environment.

Salient Features :-

1. The Refinery processes low sulphur crudes from Bombay High, Nigeria, and high sulphur crudes from Middle
East Countries. The process configuration of the Refinery employs the state-of-the-art technologies with minimal
impact on the environment.

Various steps have been taken by Mathura Refinery to monitor and control the emission of Sulphur Dioxide.
Mathura Refinery is the only refinery in the country to have set up the concern of community and archeological

9
 sites. These Ambient Air Monitoring Stations were commissioned before commissioning of the Refinery in
1981 and being continuously operated thereafter.
2. Mathura Refinery has taken many initiatives to produce more and more clean fuels in stages in the interest of
environment, public health and preservation of national monuments around. Its noteworthy efforts are stage-
wise implementation of various projects like Catalytic Reforming Unit, Diesel Hydro-desulphurisation Unit and
Hydrocracker for quality upgradation of automobile fuels.

3. The Refinery has full-fledged ETP comprising of physical, chemical and biological treatment facilities. The treated
effluent from the Refinery fully meets the MINAS(Minimal National Standards), the prescribes effluent discharge
standards

4. For the protection of the land environment, Mathura Refinery has initiated biodegradation of oily sludge
through "Oilivorous-S", an oily sludge degrading bacterial consortium developed by IOCL(R&D) in collaboration
with Tata Energy Research Institute.

5. The Refinery has full-fledged ETP comprising of physical, chemical and biological treatment facilities. The treated
effluent from the Refinery fully meets the MINAS(Minimal National Standards), the prescribes effluent discharge
standards

6. A beautiful ecological park has been developed in an area of 4.45 acres. During the recent survey, the experts
from the BNHS (Bombay Natural History Society) have identified 96 species of birds of which 30 migratory ones
in the park giving a testimony of richness of life in the ecosystem.

7. Mathura Refinery has done extensive tree plantation in and around Refinery. The Refinery has also taken extra-
ordinary initiatives to provide green cover to the archeological heritage sites especially the TajMahal by planting
1,15,000 trees in the Taj region.

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 Awards/Accolades:-

Safety:

Mathura Refinery received the prestigious Oil Industry Safety Award 2008-09 for Best Overall Safety Performance
among Refineries. Shri J.P. Guharay, ED Mathura Refinery received the award from Shri Murli Deora, Minister of
Petroleum and Natural Gas at a glittering function held in Oct 09 at Delhi.

Mathura Refinery received Gold Award in Petroleum Refinery sector from Greentech Foundation, New Delhi, for
outstanding achievement in Safety Management in 2008. The award was presented by Shri R.K. Srivastava,
Director General, Ministry of Health & Family Welfare, Govt. of India, New Delhi on 4th May 2009 at Goa.

Received British Safety Council Award08 in May09 for excellence in Health, Safety and Environment
Management.

Received Safety Innovation Commendation-2009 award from Institution of Engineers in Sep09 for innovation in
Safety for 2008-09.

Security:

Received Best Corporate Security Trophy (Refinery Category) for two consecutive years i.e. 2008 & 2009.

Energy Conservation:

Mathura Refinery received First Prize of 'Oil and Gas Conservation Fortnight -2009' for lowest Steam
Consumption Performance amongst Refineries having steam consumption <= 0.5 MT/MT and same was
received by ED, MR during 15th RTM at Mahabalipuram on 5th Nov.09.

Received 'Jawharlal Nehru Centenary Award 2008-09' - second prize for Specific Energy Consumption
Performance amongst all refineries in the public sector. ED, MR received coveted award during 15th RTM held
at Mahabalipuram on 5th Nov-09.

Environment:

Received Gold Award-2009 from Greentech Foundation for outstanding achievement in Environment
Management in Oct09.

11
Financial:

Received the SammaanPatra for the year 2009-10 in the category of Large Scale Units, by Central Excise Deptt,
Lucknow Circle in recognition of the highest levels of compliance with regard to Indirect Taxes apart from
contribution to the exchequer. The trophy was received by GM(F)-MR at Lucknow on 24th February, 2010.

TPM:

Mathura Refinery TPM health checkup was carried out by CII on 23rd December09 thereby approving the
nomination of Mathura Refinery for final audit on Excellency Certification in TPM activities by JIPM.

Propylene bulk truck loading facility completely shifted to new location outside refinery premises at Marketing
Terminal in Oct09.

In land matters, the search certificates as well as Non-encumbrance Certificates for 1199.49 acres of land of
Mathura Refinery received from District Revenue Officer. The UP Govt has also provided the NOC for 1199.49
acres of land enabling appropriate mortgage with State Bank of India.

70 cases with Customs were settled and refund of Rs 55.12 crores received from Customs Department in
Mar10.

Various PFIs of Business Improvement Program with M/s Shell Global were successfully implemented.

Major facilities commissioned:-

PRIME-G unit: PRIME-G unit for FCC gasoline desulphurization was successfully commissioned on 20th Feb 2010.

BBU Revamp: Biturox Technology was implemented in BBU in Oct 09. The capacity of the Bitumen unit was
increased from 0.5 MMTPA to 0.75 MMTPA.

ATF Tank: New 10000 KL capacity ATF tank was mechanically completed and commissioned in March. This
additional tank will facilitate supplying higher ATF parcel size and will help in tapping additional ATF production
potential.

NG as HGU Feed: Facilities (2.4 Km 10 line, Knock out Drum, LP steam heater, associated control valve and
piping) for use of high pressure Natural Gas feed to HGUs were completed at refinery end.

Simultaneous pumping of HSD in MJPL & MTPL: A dedicated header for simultaneous pumping BS-III HSD in
MTPL and BS-IV HSD in MJPL was commissioned in Mar10.

12
 Additional DM plant chain: Fourth chain of DM plant was mechanically completed. Commissioning of additional
chain will ensure sustainable and reliable operation of DM plant.

Process Schemes for Euro-IV preparedness: Six nos of process schemes were implemented to ensure availability
of Euro-IV products as per schedule.

Units :

PROCESSING UNITS OF MATHURA REFINERY

S.No. Name of Processing Units

1 Atmospheric & Vacuum Distillation Unit(AVU )

2 Visbreaker Unit (VBU)

3 Fluidized Catalytic Cracking Unit (FCCU)

4 Continuous Catalytic Reforming Unit (CCRU)

5 Propylene Recovery Unit (PRU)

6 Hydrogen Generation Unit ( HGU )

7 Once Through Hydrocracker Unit (OHCU)

8 Sulphur Recovery Unit (SRU)

9 Bitumen Blowing Unit (BBU)

10 Diesel Hydro Desulphurization Unit (DHDS)

11 Merox (Mercaptan Oxidation)

The refinery runs on a large number of predominantly Middle East crude. For refinery producing lube oil base
stacks, it is highly unusual to run so large number of crude because the operation of the lube oil process is highly crude
specific. It is more usual for a lube refinery to operate on a handful of selected feed stacks and to operate the lube units
based upon the known processing characteristics and response of the crude oil. This is not possible at MATHURA

13
refinery due to the large number of crudes handled and on the constraints on the size of the crude percels that can be
handled through the port.

Products:

Finished products from this refinery cover both fuel oil products as well as lube oil base stocks.

1. Liquid Petroleum Gas (LPG)

2. Fuel Oil Products:
Motor Spirit (MS)
Mineral Turpentine Oil (MTO)
Superior Kerosene (SK)
Aviation Turbine Fuel (ATF)
Russian Turbine Fuel (RTF)
High Speed Diesel (HSD)
Jute Batching Oil (JBO)
Furnace Oil (FO)
Naphtha
Gasoline
3. Lube Oil Products:
Inter Neutral, Heavy Neutral & Bright Neutral HVI Grades
4. Other Products:
Slack Wax
Carbon Black Feed Stock
Bitumen
Sulphur
Future:

With Indian oils achievement of a high degree self-reliance defining technology, Mathura refinery is poised for a bright
future. All out action have taken for capacity augmentation, increase in distillate production, value addition, cost
reduction for obtaining higher margins and improving productivity. All environmental friendly products with latest
technology is being incorporated to meet the challenge of change. Mathura refinery will continue to play a significant
role in meeting the vital needs of petroleum products in the country.

14
 Fire Risk Management Philosophy
Petroleum refinery which stores and handles large quantity of flammable materials pose threat to the surrounding
in addition to its own safety. It therefore, necessitates the introduction of inbuilt fire prevention & fire protection
facilities.
It is impractical and prohibitively costly to design fire protection facilities to control all catastrophic fires. Usual
requirement of a good system is to prevent emergencies from developing into major threat to the installations and
surroundings.
Fire

Fire is a rapid, self-sustained oxidation process accompanied by the release of energy in the form of heat and light of
varying intensity.

Fire results from the combination of fuel, heat and oxygen. When a substance is heated to a certain temperature called
the ignition temperature the material will ignite and continue to burn as long as there is fuel, the proper temperature
and a supply of oxygen (air).

Fire Triangle

Three elements are necessary for initiation of fire:

1. Fuel in the form of vapour, liquid or solid.

2. A source of ignition sufficient to initiate & propagate the fire.
3. Oxygen in sufficient proportion to form a combustible mixture.
Combustion process is observed in two modes.

For flaming combustion to occur, solid or liquid fuel must be converted into a vapor, which then mixes air and reacts
with oxygen.

Smoldering combustion, on the other hand, involves a reaction between oxygen and the surface of the fuel: this is a
complex process and in general occurs with solid fuels which char on heating.

15
 FIRE TRIANGLE

OXYGEN HEAT

FUEL

Classification of Fire

An Indian standard IS: 2190 classifies the fire in four categories according to the type of material burning.

Class A: Fires involving ordinary combustible material like wood, paper, textiles etc. where the cooling effect of water is
essential for extinguishments of fire.

Extinguishing media- water

Class B: Fires in flammable liquids like oils, solvents, petroleum products, paints etc. where a blanketing effect is
essential to extinguish the fire.

Extinguishing media- foam, carbon dioxide, dry chemical powder.

16
Class C: Fires involving gases or liquefied gases in the form of a liquid spillage, or a liquid or gas leak. Here it is necessary
to dilute the burning gas at a very fast rate with an inert gas or powder.

Extinguishing media - carbon dioxide, dry chemical powder. The best way to extinguish such fires is by stopping the flow
of fuel gas to fire. Container is kept cool with water spray.

Class D: Fires involving metals like magnesium, aluminum, zinc, potassium etc. Where the burning metal is reactive to
water and which require special extinguishing media.

Extinguishing media- Special dry powder.

Electrical fire : Electrical fires are not treated as a class of their own, since any fire involving, or started by, electrical
equipment must, in fact, fall into one of the other categories.

The normal procedure for dealing with an electrical fire is to cut off electricity and use an extinguishing media
appropriate to what is burning.

Classification of Petroleum Products

Class A: Liquid which have flash point below 23oC.

Class B: Liquids which have flash point of 23oC and above but below 65oC

Class C: Liquid which have flash point of 65oC and above but below 93oC

Excluded Petroleum: Liquid which have flash point of 93oC and above.

Note: LPG do not fall under this classification but form separate category.

Definitions:

Hazard: Situation with a potential for damage to men, machines and environment.

Ex : Fire / explosion in LPG storage

: Toxicity in chlorine storage

Risk : Combination of hazard consequence and its probability of occurrence.

Ex : likely death of two persons in 100 years due to loading hose failure.

17
Flash point: The flash point of a liquid is the lowest temperature at which sufficient vapour given off to flash on the
application of flame in the presence of air.

Auto ignition: The lowest temperature to which a solid, liquid or gas requires to be raised to cause self-sustained
combustion without initiation by a spark or flame.

Explosive limits: Explosive limits are those concentrations of a vapor or gas in air below or above which propagation of a
flame does not occur on contact with a source of ignition.

The lower explosive limit is the minimum concentration below which the vapor air mixture is too lean to burn or
explode.

The upper explosive limit is the maximum concentration above which the vapor air mixture is too rich to burn or
explode.

Methods of Extinguishments of Fire

1. Starvation : Elimination of fuel

2. Smothering : Limiting of oxygen
3. Cooling : Limiting temperature
Starvation: Starvation is accomplished by removing combustibles from the neighbourhood of the fire or by removing fire
form the mass of combustible materials. It is also achieved by subdividing burning materials to small isolated pockets of
fire.

Smothering: Smothering is accomplished by eliminating or diluting the available oxygen with inert gas or covering the
fuel surface by a smothering agent like foam.

Cooling: If the rate at which heat is generated by combustion is less than the rate at which it is getting dissipated then
the combustion cannot persist. Application of water jet or spray to a fire results in its extinguishments by this
fundamental principle

18
CLASS DESCRIPTION EXTINGUISHING MEDIUM INDIAN
OF FIRE STANDARD

A Fire involving ordinary Water 934-1976

combustible materials like
wood, paper, textiles, etc. 940-1976
Where the cooling effect of 6234-1971
water is essential for the
extinction of fires

B Fire inflammable liquids like Foam * carbon dioxide dry 933-1976

oils, solvents, petroleum chemical powder. Not suitable
products, varnishes, paints etc. for alcohol and other water 2878-1976
where a blanketing effect is miscible flammable liquids 2171-1976
essential
(4308)-1982

C Fires involving gaseous Carbon dioxide dry chemical 2878-1976

substances under pressure
where it is necessary to dilute
the burning gas at a very fast
rate with an inert gas or
powder.
powder. The best way to
extinguish such fires is by 2171-1976
stopping the flow of fuel gas to (4308)-1982
the fire. Container is kept cool
with water spray

D Fires involving metals like Special dry powder 2171-1976

magnesium, aluminum, zinc,
potassium etc. where the (4861) 1968
burning metal is reactive to
water and which require
special extinguisher media.

19
 Source of Ignition

It is necessary to understand the sources of ignition and to eliminate them to prevent fires/explosions in the refinery.

SOURCES OF IGNITION EXAMPLE PREVENTIVE MEASURES

Electrical equipment Sparks from motors, switches, 1. Use of approved

lamps, hot elements and equipment
electrical defects 2. Follow nation electrical
codes
3. Proper maintenance.

Friction Hot bearings, misaligned or Preventive maintenance

broken M/C parts, chocking,
jamming of material, poor and proper lubrication
adjustment

Open flames Cutting and welding torches Strict compliance of

gas & oil burners precautions stipulated in the
fire permit for hot jobs.

Smoking as ignition Smoking booths in area where 1. Smoking only in areas

combustible are used permitted.
2. Use of prescribed
receptacles for cigarette
butts

Spontaneous ignition Pyrophoric iron, hot oil Keep pyrophoric iron wet at
leakage the time when it is taken out.

Hot surfaces Contact of combustible Provide proper insulation and

material without surfaces, air circulation.
heated lines

20
Spark from engine exhaust POL trucks / DG set Spark arrestor on exhaust

Static electricity During splash loading and 1. Proper earthing of

loading at high velocities equipment.
2. Loading velocity should be
controlled

Lightening Thunderstorm cloud burst Proper lighting arrestor and

earth continuity.

Fire Risk Management

Fire risk is the chance / possibility of loss due to fire. Three aspects to deal with fire risk management are:

Fire prevention
Fire protection
Fire fighting
Fire Prevention

Objective: To eliminate the occurrence of fire

Regulations for the prevention of fire

Fire & explosion contribute a serious hazard to hydrocarbon processing industry like a petroleum refinery. The following
regulations should be strictly followed for prevention of fire.

Regulation 1:

Fire or naked light, matches, petrol or other lighters, cellular phone or any apparatus which is capable of causing ignition
is not permitted to be taken within the battery area by any person.

Regulation 2

No fires shall be lit and no matches ignited in any part of the battery area unless a valid hot work permit has been
obtained from the authorised fire permit signatories of the area and registered at the fire station
21
Regulation-3

Smoking is prohibited in all parts of the battery area except in the smoking booths/locations duly approved for this
purpose.

Regulation 4

Cycle lamps, other than dynamo operated, are not allowed in the refinery battery limits. The cyclist will switch off
even the dynamo as soon as he enters the plant area.
Ordinary torches will not be used within the battery area. Flame proof torches/lamps of approved manufacturers as
supplied by the refinery, shall only be used.
Regulation-5

All vehicles entering / transporting petroleum products from the refinery must be fitted only with approved type of
spark arrestors.

Regulation-6

Persons entering the refinery battery limit shall deposit match boxes, lighters, mobiles etc with the security at the main
entrance gate of the refinery.

Fire Protection

Objective: To contain the spread of fire

Fire protection philosophy:

Fire protection philosophy is based on loss prevention & control. Because of the inherent hazard a refinery carries. No
plant is absolutely safe. A fire in one part/section of a plant can endanger other sections of plant as well.

Types:

Active Fire Protection System

Passive Fire Protection System
Following fire protection facilities shall be provided depending on the nature of the installation and risk involved:

Fire Water System

Foam System

22
 Clean Agent System
CO2 System
DCP Extinguishing System
Detection And Alarm System
Communication System
Fire Fighting

Objective: To extinguish the fire with minimum loss

It is the last line of the defense. It comes into force when there is actual fire. Main purpose is to extinguish the fire with
suitable equipment and materials with an aim to reduce damage due to fire

Portable fire fighting equipment

Mobile fire fighting equipment
Fixed fire fighting system
Mobile Fire Fighting Equipment

DCP tenders
Foam nurser
Trailer fire pump
Trolley mounted monitors
Fire fighting hose & other accessories like foam branch, nozzles etc.
Fire fighting chemicals like foam compound, dry chemical powder etc.

NEED FOR SAFETY

ECONOMIC LEGAL HUMAN SOCIAL

ASPECTS ASPECTS ASPECTS ASPECTS
LOSS OF (STATUTORY PHYSICAL GENETIC
PRODUCTION INJURY
OBLIGATION) ECOLOGICAL
LOSS OF REPARATION
LOSS TO NATION
CAPITAL ON FAMILY
POLLUTION OF
LOSS OF MORAL LOSS
STREAM AND
MANPOW ER
AIR
MEDICAL
COMPENSATION
COST OF
TRAINING
LOSS OF WAGES
BUSINESS
INTERRUPTIONS

23
Safety Aspects

Safety, Health & Environment (S, H&E) Policy

Indian Oil Corporation is committed to conduct business with strong environment conscience ensuring sustainable
development, safe workplaces and enrichment of quality of life of employees, customers and the community. We at
Indian Oil believe that good safety, health & environment performance is integral part of efficient andprofitable business
management.

We shall:

Establish and maintain good standards for safety of the people, the processes and the assets.
Comply with all rules and regulations on safety, occupational health and environment protection.
Plan, design, operate and maintain all facilities, processes and procedures to secure sustained safety, health and
environmental protection.
Remain trained, equipped and ready for effective and prompt response to accidents and emergencies.
Welcome audit of our safety, health & environment conduct by external body, so that stakeholder confidence is
safeguarded.
Adopt and promote industry best practices to avert accidents and improve our safety, health & environment
performance.
Remain committed to be a leader in safety, occupational health and environment protection through continuing
improvement.
Make efforts to preserve ecological balance and heritage.
General Loss Control Rules

No match box/ lighter / mobile is allowed in refinery.

No smoking is allowed in refinery except at designated places.
No vehicle is allowed inside battery area without spark arrestor.
No body is allowed to enter the refinery without shoes.
No outsider is allowed inside any operational plant / unit area without permission of area in charge.
No debris/obstacles allowed on roads.
No photography / videography is allowed without permission.
No maintenance work should be started without valid permit & clearance.
Never enter work area without helmet with chin strap in place.

24
 No climbing/working allowed without safety belt above 2 metre height.
Do not walk on pipelines or false ceilings.
Do not stand under suspended loads.
Do not tamper with fire fighting equipment or fire hydrants.
Do not exceed speed limit of 25 kmph within the refinery premises.
Report all accidents/incidents to area incharge and fire & safety.

25
 Once-through Hydro Cracking Unit
Basic Details

Design capacity 1.2 MMTPA

Turn down capacity 50% of design
Licensor CHEVRON Research and Technology

Purpose of Unit:-

MR from its inception in 1981 has been proceeding the crude oil which are classified primarily in two categories.

i. Low sulphur crude oil

ii. High sulphur crude oil

Residue up gradation into middle distillates and light distillates is currently being done in MR primarily by employing
FCC process, and visbreaking.
Visbreaking is adopted to reduce the viscosity of residues thereby making it marketable. Viscosity of products
obtained from FCC and Visbreaker are relatively poor in quality w.r.t. stability, and sulphur have to be blended with
other straight run product to be able market them.

Hydrocracker Technology:-

It is an extremely versatile catalytic process in which feed ranging from naphtha to vacuum residue can be
processed in presence of H2 and catalyst to produce desire products lighter than the feed. Thus if the feed is naphtha it
can be converted to LPG. In MR VGO (vacuum gas oil) is feed and products are LPG, naphtha, ATF, diesel and FCCU feed.
Feed to the unit consists of VGO from AVU (Atmospheric Vacuum distillation Unit) containing 70% high sulphur and 30%
low sulphur.

Hydrocracker unit consists of four following section

Make up H2 compression section

Reaction section

Fractionation section

Light end recovery section

Primary products from OHCU:-

LPG: - It is separated from light naphtha from stabilizer located in the light end section of the unit. LPG is treated
with caustic to remove H2S and free water to meet sales specifications.

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 Stabilized light naphtha:- It is the bottom product of stabilizer with nominal true boiling point(TBP) cut point
range for light naphtha used in this design is C5-1080C, stabilized light naphtha sent to tankage after cooling.
Heavy naphtha:-It is recovered as the first side cut of atmospheric fractionator. This draw is sent to heavy
naphtha side cut stripper. The nominal TBP cut point range for heavy naphtha is 108-1270C. After leaving the
side cut stripper heavy naphtha is sent to either tankage off plot or blended into diesel product upto 38 0C in
diesel flash point specification.
ATF/Superior Kerosene: - It is recovered as the second side cut of atmospheric fractionator. This draw is sent to
kerosene side cut stripper. The nominal TBP cut point range of Kerosene is 127-2570C. After leaving the side cut
stripper kerosene is cooled and may either sent to tankage or blended into diesel products.
High speed diesel (HSD):-It is recovered as the third draw of product fractionator. This draw is split between
pump around liquid and feed to diesel side stripper. The diesel pump around stream provides rebioling for heavy
naphtha and kerosene side stripper and the de-ethaniser and stabilizer. The nominal TBP is 257-3000C. The
diesel product from side cut stripper is first cooled and blended with heavy naphtha and kerosene to meet
product requirement.
FCC feed:-It is the bottom product of atmospheric fractionator.

In reactor section feed is combined with H2 at high T & P and this is catalytically converted into Higher transportation
feed. The makeup H2 compression section provides H2 to reactor section. The reaction products are separated and
cooled in the H2 rich recycle gas is scrubbed using DEA in H2S absorber to remove H2S.

HCU operates under two different catalytic conditions:-

i. Start of Run(SOR)

ii. End of Run(EOR)

When the catalyst is new or freshly regenerated, it is start of run condition. The catalyst gets deactivated due to coke
deposition and requires regeneration to operate under design stipulations. The operating condition just before the
regeneration is called EOR operation.

Catalyst type:-

The lead and the main reactor contains ICR 126, a highly active and stable catalyst at high conversion levels. ICR 126 is
an amorphous catalyst with a small % of zeolite.(middle distillate yield is not overly sacrificed)

ICR 114L is loaded in the bottom bed of the main reactor for merceptane control. With cracking catalysts, there is
equilibrium between intermediaries in the cracking reaction on H2S to form merceptanes. It is relatively inactive for
conversion, it only desulphurises. Thus ICR 114L shifts merceptanes formed by cracking catalyst to desulphurise HC and
H2S.

ICR 114ZF is used in the bottom of each bed of both reactors. It is not cracking catalyst and much larger in size than the
cracking catalysts.

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Effect of condition:-

S.No. Variable Change Effect on catalyst life

1 Feed Rate Increase Decrease

2 Conversion Increase Decrease

3 H2 partial pressure Increase Increase

4 Make up gas purity Increase Increase

5 Reactor pressure Increase Increase

6 Recycle gas rate Increase Increase

7 Recycle gas purity Increase Increase

Process Description:-

In hydrocracker, the VGO feed is subjected to cracking in a reactor over catalyst bed in presence of H 2 at pressure of 185
kg/cm2 and temperature ranging from 365-445 0C. Cracks products are separated in fractionator. Light ends are
recovered in de-butaniser column. The process removes almost all sulphur and nitrogen from feed by converting into
H2S and NH3 except from mild caustic wash for LPG, post treatment is not required for other products. The unit consists
of four sections

Hydrocracker is made up of four sections:-

i. Reactor section:- Feed stoke is mixed with H2 at high temperature and pressure in the presence of catalyst,
converted to lighter transportation fuel. It consists of two reactors in series, lead reactor (3 catalyst bed,
pressure 189 kg/cm2) and main reactor (2 catalyst bed), due to high weight of catalyst (400MT).

The hydro treating and hydro cracking reaction taking place in reaction stage at high T & P. The high
partial pressure of H2 taken to prevent coking of catalyst and excess H2 is recirculated in reactor top for cooling
and to promote hydro cracking reaction. In the lead and the main reactor fresh feed is partially converted to
mild distillates and lighter products. S & N are almost completely removed or aromatic content is reduced. The
reaction section contains additional equipment for separation of H2 rich gas from reactor effluents which is
compressed and recycles back to the high pressure reactor loop. The recycle gas contains H2 by product
generated from hydro cracking reaction, H2S and NH3. Nearly all ammonia and some of the H2S are removed in
form of ammonium bi sulphite by water that is injected upstream of the cold high pressure separator. H 2S is
removed from reactor section in liquid form.

ii. Make Hydrogen compression section:-Provides H2 to reactor section. The H2 rich recycle gas is scrubbed with Di
Ethyl Amine (DEA) in H2S absorber to remove H2S. It consists of three parallel compressor trains each with 3
stage compression. Normally two train compressors are used to compress H2 form PSA to reactor section. They
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 are also used to compress the mixture of N2 and air during catalyst regeneration. The compressed make up H2 is
combined with H2 recycle gas in the reactor section to form reactor feed gas.

iii. Fractionation section:-The purpose of this section is to separate the reactor section products into sour gas,
unstabilised liquid naphtha, heavy naphtha, kerosene and diesel. Bottoms containing and converted products
are fed to FCC unit. The sour gas and unstabilised naphtha sent to light end section to make flue gas, LPG, light
naphtha.

iv. Light end recovery section:-Liquid naphtha from fractionation section is sent to de-ethaniser, where H2S is
absorbed in amine and the H2S free fuel gas is sent to fuel gas system. The rich amine is sent to ARU (Amine
Regeneration Unit) in Sulphur Recovery Unit (SRU) block. The de-ethaniser bottom is sent to de-butaniser for
recovery of LPG. LPG is taken out from the top of de-butaniser and sent to treating section where it is washed
with caustic for removal of H2S.

The three main functions of this section are:-

Remove light ends and H2O from light naphtha

Separate LPG and treat LPG to desired specification

Sweeten the sour gas for further uses as fuel gas

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 New Hydrogen Generation Unit (NHGU)
TECHNOLOGY : Technip,France

CAPACITY : 65000 MTPA

INTRODUCTION :

A New Hydrogen Generation Unit of 65000 metric tones per annum of Hydrogen producing is recently included in the
secondary processing facilities. The primary objective of the Hydrogen Generation Unit is to produce hydrogen to meet
the entire hydrogen requirement of Hydrocracker,Diesel Hydro Desulphurization Unit,Diesel Hydrotreatment Unit & the
new upcoming project Motor Spirit Quality Upgradation Unit.

PROCESS DESCRIPTION :
1. FEED PRE-DESULPHURIZATION :

The feed contains unsaturated components as well as high amount of organic sulphur. Sulphur would act as a poison for
the downstream process catalysts and needs to be removed. The bulk of the sulphur can be removed by conversion
(hydrogenation) of the organic sulphur components to H2S and subsequent stripping.The feed to the unit is the straight
run naptha which is passed through filters & collected in the sour naptha feed surge drum.The feed is mixed with
hydrogen recycled from PSA & fed into the furnace through a series of heat exchangers.The temperature of the mixture
is raised to 310-330 oC so the naptha gets vaporized.The superheated sour naphtha / H2 mixture is fed to the
hydrogenation reactor which consists of two layers of catalysts, with the top layer consisting of Nickel Molybdenum and
the bottom layer consisting of Cobalt Molybdenum catalyst. In this reactor, the olefinic compounds in the feed naphtha
get saturated and the sulphur in the naphtha gets converted to H2S. The chlorine present in the feed gets converted to
HCI.The mixture coming from the reactor is cooled in heat exchangers & water coolers & sent to a separator having a
pressure of 19 kg/cm2.The liquid naptha from the separator drum contains dissolved H2S is heated to 125 oC & sent in
the stripper where the H2S is stripped off & naptha is taken as the bottom product.

RSH + H2 RH + H2S
RCI + H2 RH + HCI
R=R + H2 R-R

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2. FEED DESULPHURIZATION :
The sweet naphtha, collected in the sweet naphtha surge drum. This naphtha is pumped by the sweet naphtha feed
pumps to a pressure of approximately 39 kg/cm2g.The feedstock is mixed with hydrogen under ratio control and
preheated to about 120C in the heat recovery section.This feed is vapourized by HT shift effluent in the feed naphtha
vaporizer and is superheated to about 380 C to 400 C in the convection coil.
This is now fed to the hydrogenation reactor to convert any residual organic sulphur to H2S.This reactor contains 4.5 m3
of CoMOx or any other equivalent catalyst.The recycle hydrogen is mixed to provide a mole ratio of 0.25 to provide the
necessary amount of hydrogen for conversion of sulphur in the hydrogenation reactor.The hydrogenated feedstock is
then passed through the feed desulphurizers A/B containing the chlorine guard and zinc oxide catalyst.Reactor A
consists of a bed of 4.1 m3 of Chlorine guard Al2O3 followed by reactor B having 2.2 m3 of ZnO.H2S & HCl are absorbed
according to the reactions given below.
Hydrogenation reactor :

RSH + H2 RH + H2S

Reactor A :

Al2O3 + 6HCI 2AlCl3 + 3H2O

Reactor B :

ZnO + H2S ZnS + H2O

3. PREREFORMER :
The desulphurized feed is mixed with a controlled quantity of steam based on the calculated hydrocarbon weight flow
and the required steam to feed ratio. There are two prereformers, one in operation and the second on standby. Each
reformer is designed for a life of 12 months operation and consists of 5.9 m3 of Katalco 65-3R (Ni based catalyst).

After heating to required temperature of 460C in the pre-reformer preheat coil 3, the gas is passed through the
prereformer A/B which is operated adiabatically and will convert the naphtha to methane, carbon dioxide, carbon
monoxide and hydrogen.This results in a feed, which can be further preheated to minimize the reformer duty. The
steam to feed ratio varies from 3.0 to 2.4 to enable additional temperature control for inlet to the prereformer.The feed
in the presence of steam reacts to a mixture of methane, carbon dioxide, carbon monoxide and hydrogen over a nickel
based catalyst. These reactions take place in both the pre-reformer as well as the reformer. The principle reactions are:

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 CnHm + nH2O nCO + (m + n) H2 - Heat

CO + H2O CO2 + H2 + Heat

The CO formed from these higher hydrocarbons will be partly converted to methane. For n=1 and m=4; this reaction is
referred to as the steam methane reforming reaction, the reverse reaction is generally referred to as methanation
reaction. The reversible conversion of methane with steam to CO and hydrogen is strongly favoured by a high
temperature, low pressure and high steam quantity which is maintained in the reformer.
4. REFORMER :
In order to achieve a higher hydrogen yield from the feedstock, after the prereformer the methane is further converted
in the reformer, which operates at a higher temperature.The reaction in the reformer is strongly endothermic so
burners are provided in the reformer.Before superheating in the mixed preheat coil , additional steam is added to meet
the required steam to carbon for the steam methane reformer which consists of 204 tubes, 12.2 m heated length
arranged in 6 lanes each of 34 tubes. Each tube is filled with Katalco 25-4 and Katalco 57-4(Ni based catalyst) in the ratio
of 40% : 60% of the heated tube length.The reformer is designed to operate at a steam to carbon of 2.75 mol/mol,
which is achieved, by an overall steam to feed of 3.25 kg/kg.The steam to carbon ratio will be increased at lower
capacities.The normal reformer inlet temperature is around 650 - 665 at 10. The gas is distributed over the reformer
tubes where the reforming reactions take place and an outlet temperature of 880 - 885C is reached.Coking is prevented
using excess of steam.
5. SHIFT REACTOR :
The gas mixture, which leaves the reformer, is essentially at equilibrium of the shift reaction. Since the equilibrium of
the reaction shifts with the temperature, shift conversion will be applied at comparatively lower temperatures to further
convert carbon monoxide to hydrogen. There are two temperature levels at which the reactors are operated. The first
stage reactor is the High Temperature Shift Reactor and the other, Low Temperature Shift Reactor. The principle
reaction is

CO + H2 CO2 + H2

Reactor inlet temperature of 327C fo. In order to increase the hydrogen content in the syngas from the reformer, the
bulk of the carbon monoxide is converted by steam to hydrogen and carbon dioxide in the high temperature shift
reactor 302-R-14 filled with 25.6 m3 of Katalco 71-5 catalyst. The reformer effluent is cooled to the required inlet
temperature for the high temperature shift reactor in the process gas boiler.The effluent from the HT Shift Reactor is at
a high temperature. After sufficient heat recovery the effluent is sent to the 2nd shift reactor for more hydrogen
recovery. The effluent is cooled in series of heat exchangers,water cooler & air cooler & sent for hydrogen purification.

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6. HYDROGEN PURIFICATION :
In the Pressure Swing Adsorbtion Unit, the hydrogen is hydrogen leaving with a purity of more than 99.99 vol% and the
rest of the process gas is purge gas and serves as primary fuel for the reformer. PSA technology is used to remove the
impurities from the reformed gas. This is achieved by molecular sieves, which adsorb the contaminants at high pressure
and allow the hydrogen to pass. To regenerate the molecular sieves the adsorber is depressurized. This releases the
contaminants and after pressurization the adsorber is ready for reuse. The contaminants, which are released at low
pressure, are collected in the purge gas drum and are used to meet part of the heat demand of the reformer. There are
12 vessels containing the adsorbent, out of which three are used for adsorbtion, others are used for desorption &
maintaining the pressure. This is a automatic process each vessel having a cycle of 60 seconds.

33
 Diesel Hydro Desulfurization Unit (DHDS):
DHDS (Diesel hydro desulphurization unit) is set up for the following purposes:
A step towards pollution control
To produce low sulphur diesel (0.25 w/w %) as per govt. directive w.e.f. Oct. 1999.

Feed consists of different proportion of straight run LGO, HGO, LVGO and TCO. Mainly two proportions are used:
74% SR LGO, 21% SR HGO, 5% SR LVGO
48% SR LGO, 24% SR HGO, 8% SR LVGO, 20% TCO

The DHDS unit treats different gas oils from various origins, straight run or cracked products. The feed is a mixture of
products containing unsaturated components (diolefins, olefins), Aromatics, Sulfur compounds and Nitrogen
compounds. Sulfur and nitrogen contents are dependent upon the crude.
The purpose of DHDS Unit is to hydro-treat a blend of straight run gas oil and cracked gas oil (TCO) for production of HSD
of sulfur content less than 500 ppm wt.
The Hydrodesulphurization reaction releases H2S in gaseous hydrocarbon effluents. This H2S removal is achieved by
means of a continuous absorption process using a 25% wt. DEA solution.
In addition to the desulphurization, the diolefins and olefins will be saturated and a denitrification will occur.
Denitrification improves the product stability. The hydrogen is supplied from the hydrogen unit. Lean amine for
absorption operation is available from Amine Regeneration Unit (ARU). Rich Amine containing absorbed H2S is sent to
ARU for amine regeneration.

CATALYSTS
Catalysts used for this process are HR-945 and HR-348/448.The HR-945 is a mixture of nickel and molybdenum oxides on
a special support. Nickel has been selected because it boosts the hydrogenating activity. The HR-348 and HR-448 are
desulphurization catalysts; it consists of cobalt and molybdenum oxides dispersed on an active alumna. Its fine
granulometry and large surface area allow a deep desulphurization rate.
Different catalysts based on Nickel and Molybdenum Oxide are used to enhance the rate of reactions.

Products Yields:

Sl. No. Products wt%

1 Off-Gas 1.36
2 Wild-naptha 1.04
3 Diesel 97.1

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 Diesel Hydro-Treatment Unit (DHDT):
Objective : To meet the EURO-III/IV diesel quality requirement (<350/50 ppmS)
Feed : Straight run diesel / FCC diesel component/ Coker and Visbreaker diesel components.
Catalyst : Ni-Mo oxides
Products Yields:

Sl. No. Products wt%

1 Off-Gas 2.65
2 wild-naphtha 2.8
3 Diesel 96.1

Wild naphtha feed from existing DHDS unit is processed along with DHDT wild naphtha in a stabilizer located inside
DHDT battery limits for producing single naphtha product.

Processes in DHDT:

Refining & hydrogenation:

Removal of heteroatom (S, N2, O2) Saturation of olefins and dioelfins.

Hydrodesulfurization:

Hydrodesulfurization reactions are fast and take place in single step.

Mercaptans: R-SH + H2 R-H + H2S

Sulfides: R-S-R + 2H2 2R-H + H2S

Hydrogenation:

Aromatic saturation & denitrification of heterocyclic compounds.

Hydrocracking:

Hydroisomerisation & then cracking into lighter isoparaffins.

Metal removal
Coking

35
TRAINING REPORT
@

36
Introduction:

Corrosion is a natural phenomenon which if left unattended can cause large economic losses. Many methods like paints,
coatings of Zinc, Polymers and others are used for preventing corrosion. With pipelines becoming an integrated
transportation mechanism for fluids as well as solids in some cases the protection of these pipes from corrosion is
important to increase their life.
This report deals with three important coating techniques and their laboratory quality inspection. Fusion Bonded Epoxy,
Dual Fusion Bonded Epoxy, 3 LPE and 3LPP. The procedure of application of these coating involve similar steps. In FBE
coating there is one layer of epoxy; in double FPE two layers; in 3LPE, one layer of epoxy, one layer of adhesive and one
layer of Poly ethylene; in 3LPP, one layer of epoxy, one layer of adhesive and one layer of Poly propylene.

Fusion Bonded Epoxy:-

Fusion bonded epoxies are thermosetting epoxy coatings designed as a corrosion prevention coating for use on
underground pipelines. These coatings are capable of operating in ranges from -100 up to 230F depending on which
grade is chosen, soil type, moisture content, thickness, temperature and other conditions. The values below are for a
range of FBE types and specific product information should be obtained from the manufacturers technical data sheet.

History

Fusion bonded epoxy (FBE) has been one of the premier coatings of choice on pipelines for many years due to its
durability, corrosion protection properties and ease of application. Starting in the mid 1970s FBE was used on the girth
weld area as a field joint coating and since that time millions of girth welds have been coated utilizing this product. In
the mid 1980s FBEs were utilized to coat induction bends, flanges, valves, tees and other fittings used in a pipeline
system allowing the owner companies to have a high quality corrosion protection coating from start to destination of
their pipelines. Technological advances in the application techniques allow for a low cost, high production process for
battling corrosion on the weld areas of pipelines.

Definition

Fusion bonded epoxies are a one part, heat curable, thermosetting epoxy utilized for corrosion protection. FBEs are
applied to heated parts in a powder form that rapidly gels from liquid to a solid and have remarkable adhesion to the
steel surface. FBEs are also are very resilient coatings that resist damage during handling. FBEs are environmentally
friendly containing no volatile organic compounds (VOCs). Societies for Protective Coatings (SSPC), NACE International
(NACE), and the International Standards Organization (ISO) have developed standards for surface preparation and
application of FBE

Storage Temperature of Raw Epoxy : Below 27 C

For sea submerged pipes Concrete Coating is done on the top of the Epoxy Coating to counter the buoyancy, so rough
outer finishing of the epoxy coating required to grip the concrete to prevent the slippage of the concrete during
installation of the pipes.

The thickness of epoxy coating is 300 to 400 micron

37
Dual Fusion Bonded Epoxy:-

All conditions similar to FB Epoxy coating but two layers of FB Epoxy is applied to provide extra mechanical strength.

Three Layered Poly Ethylene:-

4 3 2 1

1 Steel Pipe

2 Epoxy Layer (0.2 mm)

3 Adhesive (0.2 mm)

4 Poly Ethylene/ Poly Propylene Layer (2-5 mm)

1 Steel Pipe
The steel pipes are charged and the temperature of the pipe is increased. The coating is applied using electrostatic spray
and due to positively charged surface and negatively charged particles the epoxy gets applied and due to the
temperature the polymerization occurs and the coat is formed. After the application of the coat the pipe is kept for
curing for some time.

Curing of the coating after the application may be equally important as the application itself depending on the use.
Curing means allowing for the solvent to evaporate and leave back the coating particles to coalesce and for a solid
coating

38
2 Epoxy Layer
Above is the structure of the epoxy, the epoxy layer is hard and provides for excellent corrosion resistance. The epoxy
application may in done in two ways, electrostatic spraying of powdered epoxy or application of liquid epoxy. I case of
liquid epoxy the epoxy and the catalyst are mixed at the application site and the reaction occurs on spot to form the
coating. Generally liquid epoxy is used in coating of internal surface as it is easier to apply using spray technology. But it
is also used in external coating depending on the specifications from the client. . The suppliers of the powder epoxy are
3M, Vulspar, DuPont, BASF. The suppliers of the liquid Epoxy are 3M, Henspel, Exonovel.

3 Adhesive
The adhesive layer is used to create the necessary bond between the epoxy and the Poly ethylene/ Poly propylene layer.
The adhesive has two end one polar and other non-polar. The Polyethylene has polar ends and the epoxy non polar
ends. To bond these two layers the adhesive is required. The suppliers of the adhesive are DuPont, Borogue, Hyndai

4 Poly Ethylene
The poly ethylene layer or the poly propylene layer is added to increase the mechanical strength of the coating.
Polyethylene is generally black in color due to presence of carbon black in it whereas polypropylene is white due to
presence of Titanium oxide in it. . The suppliers of the Poly Ethylene are Bassel, Borogue, Hyndai

APPLICATION PROCESS (3 LPE Coating )

A. INLET INSPECTION
The pipe is visually inspected for any transit defects and other manufacturing errors. It is also checked for
oil and grease which may have got applied on the surface during transit.

B. ENVIRONMENTAL CONDITION MONITIRING

The environmental conditions are very important for preparation of the surface for coating. The surface
must be moisture free.
S.No. Pipe Temperature Ambience Relative Dew Point
Temperature Humidity
1 28 C 27 C 70 % 23 C
2 27 C 28 C >85 % 27 C

In case of 1 the pipe temperature is greater than the Dew point so the condensation of the moisture on the
pipe surface is negligible.
But if the moisture content is high in the environment generally above 85% the Dew point increases as in
case 2. In this case the moisture condenses on the pipe surface creating problems during coating
application.
Thus to remove this moisture the pipe is generally heated to 65 C 85 C depending on the requirement of
the client.
39
C. FIRST STAGE BLASTING
The surface of the pipes generally have the deposits of rust, mill scales. The major part of the surface
preparation includes blasting the surface of the pipes with the shots and grits of steel as shown in the
figure. The surface if blasted creates roughness and increases the surface area available for bonding. The
Anchor like structure created on the surface helps in holding the coating as shown.
The steel shots have the radius of 0.85 mm and when due to the abrasion the radius falls below 0.3 mm the
shots are discarded. The angular steel shots are used for creating roughness using the peen action.
Initially 70% Grits and 30% shots are mixed but with time the grits get converted to spherical structures
and thus in later stages only the angular grits are added to compensate the depletion of shots

40
41
 The action of steel grits

The increased bond with the coating due to increased surface area due to blasting

42
 Steel Shot : By contrast, the action of the steel shot is one of impact alone. Results are similar to striking
the surface with ball peen hammer. Shot will peen and hammer the surface, which is an advantage when
heavy brittle deposits (i.e. mill scale ) must be removed from the surface. The energy of the heavy metal
hitting the surface effectively cracks and pops the heavy brittle rust and mill scale from the surface. It is
not, however as efficient in removing surface residues since these may be pounded into the surface by the
peening action. The peening action on the metal both compresses the surface and stretches the meta, so
that care must be taken in shot blasting the sheet metal. The stretching of the metal surface can cause
excessive deformation and warpage.
Shot blasting is usually more effective on heavier steel plate and shapes as they can absorb the impact of
the shot and the surface compression without excessive warpage.

Steel Grits : In blasting action because of the sharp edges it creates a cutting action. The sharp edges cut
into steel forming sharp peaks and valleys which increases the adhesion potential.

D. PHOSPHORIC ACID WASH/ HIGH PRESSURE WATER WASH

The usual cold phosphate pretreatment is combination of phosphoric acid to water soluble solvent such as
butyl alcohol. Treatment with phosphoric acid can inhibit the rusting of the surface for a considerable
period of time. The phosphate wash is followed by high pressure water wash. This is used to remove the
chlorides, sulphides and dust on the surface which could cause problems in the coating.
Properties of the Phosphoric Acid Wash
H3PO4 + Organic Surfactant -> 80%
Other additives -> 20%
The above mixture is diluted 10 1% v/v
The pH of the solution is around 1-2
The volumetric flow rate of the Phosphoric wash is 1 L/min
Manufacturer- Chemital Rai (Germany )
Properties of the Water Wash
De ionized water is used.
Pressure > 1000 psi
Flow Rate = 19 L/min
pH = 6-8

E. SURFACE INSPECTION
The surface of the pipe is checked for Slivers1, Lamination and other defects.

F. SECOND STAGE BLASTING:

Pre Heating at 60-85 C and then blasting operation as described in section C

1
Slivers are elongated pieces of metal attached to the base metal at one end only. They normally have
been hot worked into the surface and are common to low strength grades which are easily torn, especially
grades with high sulfur, lead and copper.- AISI Technical Committee on Rod and Bar Mills, Detection,
Classification, and Elimination of Rod and Bar Surface Defects

43
G. QUALITY INSPECTION AFTER BLASTING
a. Degree of cleanliness on the basis of the ISO 8501-1 standards
b. Roughness Profile2 : Generally the specification of the roughness is about 40-100 Micrometer. The
observed value during field visit was 54.66 micrometer.

c. Salt Contamination Level : Maximum Specified Value 2 microgram/cm2. The observed value during
field visit was 0.4 microgram. 1.6 ml of distilled water is absorbed in a filter paper and is then
placed on the pipe for some time, it absorbs the salt on the pipe surface and then it is kept in the
instrument which works on the principle of conductivity and the salt concentration is determined.
d. Residual Dust Level ISO 8502-3
The procedure include application of a special adhesive tape to the surface and on removal the dust
particles get stuck to the surface of the tape and on comparison with the standard the level of
contamination is determined and if above level 2 the surface is unacceptable. There are a maximum
of 5 levels

H. CHROMATE APPLICATION
A thin layer of Cr2(SO4)3 is applied on the surface to make the surface more adhesive to the epoxy which
will be applied in subsequent stages. The application of the chromate layer improvises the adhesive
properties of the surface but if the Thickness of the layer > 2 micrometer then a brittle layer over the pipe
undermines the surface properties.
The inspection for proper application of the chromate layer involves visual inspection of the layer. The
colour must be between light yellow and light brown.
Manufacturer- Chemital Rai (Germany )

2
1. Rz: Rz is the arithmetic mean value of the single roughness depths of consecutive sampling lengths. Z is the sum
of the height of the highest peaks and the lowest valley depth within a sampling length.

44
 I. INDUCTION HEATING :
Induction Heaters provide alternating current to an electric coil. The electric coil induces the current in the
pipe and due to resistance and hysteresis losses the pipe gets heated.

The pipe is heated to

S.No. Type of Coating Temperature Range

1 3 LPE 180-220 C
2 3LPP 200 230 C
3 FBE/DFBE 230 250 C

45
 J. EPOXY POWDER SPRAY :

Using the electrostatic spraying technique

The feed inlet is 2 Kg/ m2 and the particles of epoxy get negatively charged when they get in interaction with
the nozzle and due to 70 KV voltage applications the surrounding region of the nozzle gets negatively charged and this
region is called CORONA. The particle of epoxy gets attached to the positively charged pipe.

The key parameters that control the thickness of epoxy coating are
V = 72 KV, Pressure : 6.00 Kg/cm2, % = 35 %

The observed flow rate of epoxy is 30 kg/hr.

FUSION BONDED EPOXY

When the Epoxy powder is sprayed on the pipe the powder goes through five stages to form the coating

a. Fusion of the particles : The epoxy particles get fused with each other due to high temperature of the pipe.
b. Coalescence: The fused epoxy particles coalesce with each other to form big droplets.
c. Flow : When the droplets are big enough they flow around the pipe. The above three processes generally take
10 seconds to get completed.

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 d. Film Formation : With increasing droplets the drops join together to form the film of epoxy
e. Curing : The coating is given some time to get cured, after getting cured to about 30% to 70% it is quenched.

The curing time is different for different coatings. In LPE, LPP due to application of a further hotter layer above the epoxy
the epoxy layer gets cured faster as compared to a single layer epoxy coat.

Before the application of the second coat first coat must be between 30 70 % cured as it helps in proper bond
formation if the curing is less than 70 %. If the layer gets more cured the bonding between the epoxy and the adhesive
becomes weaker.

The epoxy which doesnt adhere to the substrate falls down, it is recycled back.

ADHESIVE: The adhesive is applied at 222 C

POLYETHYLENE: The raw polyethylene is in granulated form, it is first hot air dried to remove the moisture which could
cause the irregularities in the Polyethylene coat layer. It is then passed through an extruder and the polyethylene passed
through a die to form a layer which gets applied to the top of the adhesive layer. The extruder is of screw type. The
temperature of application of the polyethylene is around 234 C.

K. QUENCHING
After application of the coating the pipe is given a residual period of 3 minutes in case of FBE coating and 10
seconds in case of 3LPE coating for curing. The pipe is to be cooled after the curing is completed. The pipe is
quenched with running water. The wash is done for 180-240 seconds.

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 Continuous flow of water should be maintained, if drop wise application occurs the surface becomes uneven
resulting in bad quality.

L. THICKNESS, VISUAL :-
The thickness of the coating is immediately checked after quenching to avoid any production discrepancies in
the subsequent coatings. The visual appearance is also checked for any defects.

M. END CLEANING/ END BRUSHING

When the pipes will be laid in the field it will be welded with other pipes. To enable this welding there is a
provision of cut back of coating from 12510 mm from the ends. To avoid any corrosion to the pipes during the
storage, a toe of epoxy coating measuring 10 mm is left. The bevel angle of the toe is generally 30-45 degree.

N. HOLIDAY DETECTION (NACE 0274)

The pipe is passed through a ring surrounded by flexible conducting rubber which are in contact with the pipe.
The speed of the pipe is 0.3 m/sec and so it takes around 40 seconds for a pipe to get checked. In this method
the pipe is earthed and a voltage of 25,000 V is applied to the pipe using the below equipment and the above
shown structure

If the coating has any defects the circuit will get completed and it will give rise to a buzzer. If there is a major holiday
defect the pipe is rejected, if small holiday defect is there it is sent for repairs.

O. INLINE INSPECTION AND TESTS

Visual, Thickness, Holiday, Cut Back Dimension, Repair are checked for if any they are sent for repairs.
Also the Peel Test, Impact Test, Residual Magnetism test is done.
Peel Test : The adhesion of the coating is tested using the peel test
Impact Test: The impact test is done to check the resistance of the coating to small mechanical damages it can
face during laying.
Magnetism: Due to induction heating some residual magnetism may be present in the pipe, if the magnetism is
above 3 mTesla, then the pipe is sent to demagnetizer.

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P. STENCIL AND MARKING
The stencil is used to mark the batch no. and other details on the pipe. Also special color codes are used to mark
the diameters of the pipe which could make it easier to handle.

Q. QUALITY TESTING LABORATORY

The final product is sent to the quality testing laboratory to check for the features which will be described later
in the report.

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50
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 References
1. Manuals of :-
OHCU, NHGU, DHDS, DHDT,
2. Corrosion Prevention by Protective Coating by C.G. Munger
3. Notes obtained during training.

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