1 INTRODUCTION ABOUT IOCL, HALDIA REFINERY

1.1 General
Indian Oil Corporation Limited (IOCL) (NSE: IOC, BSE: 530965),
commonly known as IndianOil is an Indian state owned oil and gas company with
registered office at Mumbai and primarily headquartered in New Delhi. It is the
largest commercial enterprise in the country, with a net profit of ₹19,106 crores (USD
2,848 million) for the financial year 2016–17. It is ranked 1st in Fortune India 500 list
for year 2016 and 168th in Fortune's “Global 500” list of world's largest companies in
the year 2017. As of 31st March 2017, Indian Oil's employee strength is 33135, out of
which 16545 are in the officer cadre. Indian Oil's business interests overlap the entire
hydrocarbon value-chain, including refining, pipeline transportation, marketing of
petroleum products, exploration and production of crude oil, natural gas and
petrochemicals. Indian Oil has also ventured into alternative energy and globalization
of downstream operations. It has subsidiaries in Sri Lanka (Lanka IOC), Mauritius
(IndianOil (Mauritius) Ltd) and the Middle East (IOC Middle East FZE). Indian Oil is
scouting for new business opportunities in the energy markets across Asia and Africa.
It has also formed about 20 joint ventures with reputed business partners from India
and abroad to pursue diverse business interests. Indian Oil has its R&D Centre located
in Faridabad, Delhi NCR. May, 2018, IOC become India's most profitable state-
owned company for the second consecutive year, with a record profit of ₹21,346
crores in 2017-18, followed by Oil and Natural Gas Corporation, whose profit stood
at ₹19,945 crores.

Indian Oil Corporation Limited

Type Public
Traded as BSE: 530965
NSE: IOC
Industry Oil and gas
Predecessor Indian Refineries
Ltd. (1958)
Indian Oil Company
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 (1959)
Founded 1964; 54 years ago
Headquarters New Delhi, India
Area served India, Sri Lanka,
Middle East,
Mauritius
Key people Sanjiv Singh
(Chairman)
Products Petroleum, natural
gas, and other
petrochemicals
Revenue ₹4.214 trillion
(US$63 billion)
(2018)
Operating ₹274.4 billion
income (US$4.1 billion)
(2017)
Net income ₹198.5 billion
(US$3.0 billion)
(2017)
Total assets ₹2.735 trillion
(US$41 billion)
(2017)
Number of 34,999 (2017)
employees
Subsidiaries IndianOil
(Mauritius) Ltd.
Lanka IOC PLC
IOC Middle East
FZE
Indane
Website www.iocl.com

Table 1.1 Some Important Information about IOCL

The Haldia Refinery for processing 2.5 MMTPA of Middle East Crude was
commissioned in January, 1975 with two sectors - one for producing fuel products
and the other for Lube base stocks. The refinery is in Haldia near Kolkata (West
Bengal).The fuel sector was built with French collaboration and the Lube sector with
Romanian collaboration. The refining capacity of the Refinery was increased to 2.75
MMTPA in 1989 through debottlenecking measures. The refining capacity was
further expanded to 3.75 MMTPA with the commissioning of new crude distillation
unit of 1.0 MMTPA in March, 1997. The present refining capacity of this Refinery is
7.50 MMTPA.

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1.2 Introduction
Fourth in the chain of 10 operating Refineries of IndianOil, Haldia Refinery is
one of the two refineries of IndianOil Group Companies producing Lube Oil Base
Stocks (LOBS). The Refinery was commissioned in January 1975. It is situated 136
km downstream of Kolkata in the district of East Midnapore, West Bengal, near the
confluence of river Hooghly and Haldi.
From a fledgling Refinery in the 1970s to the first producer of Micro-Crystalline Wax
in India; from a technology absorber to a provider of technological knowledge in
Lube Oil Base Stock production, Maintenance in Oil Industry, and Motor Spirit
Quality Improvement Process - the journey is breathtaking.
Petroleum products from this refinery are supplied mainly to eastern India through
two product pipelines, namely Haldia-Mourigram-Rajband Pipeline (HMRBPL), and
Haldia-Barauni-Kanpur Pipeline (HBKPL), as well as through barges, tank wagons
and tank trucks. Products like MS, HSD and Bitumen are exported from this refinery.
Haldia Refinery is the only coastal refinery of the corporation and the lone lube
flagship amongst IndianOil Refineries, apart from being the sole producer of Jute
Batching Oil. Diesel Hydro Desulphurisation (DHDS) Unit was commissioned in
1999, for production of low Sulphur content (0.25% wt) High Speed Diesel (HSD).
With augmentation of this unit, Haldia Refinery is producing BS-IV and Euro-V
equivalent HSD (part quantity) at present. Haldia Refinery also produces eco-friendly
Bitumen emulsion and Microcrystalline Wax. A Catalytic Dewaxing Unit (CIDWU)
was installed and commissioned in 2003 for production of superior quality Lube Oil
Base Stocks (LOBS), meeting the API Gr-II standard of LOBS.
Spread over an area of 500 acres, Haldia Refinery consists of three blocks of process
units called the Fuel Oil Block, the Lube Oil Block, the OHCU Block and the
Additional Secondary Processing Block. The Oil Movement & Storage (OM&S) and
Utility sections cater to the storage and movement of crude oil and products along
with provision of generating and distributing steam, power, air and other utilities.

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 Fig. 1.1 Oil Refineries of India
1.3 Process Units
a. Fuel Oil Block (FOB): Fuel Oil Block, commissioned in 1975 in technical
collaboration with M/s. TECHNIP-ENSA of France, presently comprises
of two numbers of Atmospheric Distillation Units (CDU-I & II) along with
Naphtha Pre-treating (NHDT), Catalytic Reforming Unit (CRU), and Kero
Hydro De-sulphurisation Unit (KHDS).
The initial processing capacity of the Atmospheric/Crude Distillation Unit
was 2.5 MMTPA. It was increased to 2.75 MMTPA in April 1989 and
further scaled to 3.6 MMTPA through in-house de-bottlenecking in the
year 1996. In 1997 the second Crude Distillation Unit of 1 MMTPA was
added to increase the capacity to 4.6 MMTPA. The capacity of the second
Crude Distillation Unit was augmented to 2.4 MMTPA in 1999. With the
commissioning of the 2nd VDU in 2002 and secondary processing
facilities, the Refinery augmented its capacity to process 6 MMTPA of

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 crude oil. In 2010 the Refinery enhanced its capacity to 7.5 MMTPA with
the capacity expansion of CDU-II by 1.5 MMTPA.

b. Additional Secondary Processing Block:

1. Diesel-Hydro De-Sulphurisation & Affiliated Units: This
Block was commissioned in September 1999. The unit helps to
produce eco-friendly Diesel of Euro III quality for much
reduced sulphur dioxide in vehicular emissions minimizing the
impact of pollution in the environment.
The Block comprises of Hydrogen Unit (HGU), Diesel-Hydro-
De-Sulphurisation Unit (DHDS), Amine Absorption/
Regeneration Unit (AAU/ARU), Sour Water Stripper (SWS)
and other utilities. Besides, two numbers of high efficiency
Sulphur Recovery Units (SRU) ensures minimum sulphur
dioxide emission from the process blocks.
2. Fluidised Catalytic Cracking Unit (FCCU): The state-of-the-
art Fluidised Catalytic Cracking Unit, commissioned in 2003,
processes heavier feedstock, including a proportion of residue,
and produces value added products and contributes to improve
distillate yield from the Refinery.
3. Motor Spirit Quality Improvement Unit (MSQIU): The
MSQIU was commissioned in July 2005 to comply with the
national directive for supplying EURO-III petrol in select
cities.
4. Once Through Hydro-Cracker Unit (OHCU): OHCU
comprises Once-through Hydrocracker Unit (OHCU) of 1.7
MMTPA capacity, Hydrogen Generation Unit (HGU) of 75
TMTPA capacity, Sulphur Recovery Units (2 x 80 TPD),
Hydrogen Storage Facility, Air compressor, Air Driers, Heat
Recovery Steam generation (HRSG), LPG Mounded Bullets,
Effluent Treatment Plant (ETP), Tertiary Treatment Plant
(TTP) with R.O and mixed bed facilities, and Cooling Towers.
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2 INTRODUCTION ABOUT B&R

2.1 General
Bridge and Roof Company (India) Limited is a Central Public Sector
Enterprises (CPSE) of the Government of India, based in Kolkata, India. The
company began in 192 0. Bridge and Roof Co. (India) Ltd., is a construction
organization, encompassing industrial and infrastructure sectors in India as well as
abroad. It also undertakes EPC and Turnkey contracts. In fiscal 2016, the company
reported aggregated revenues of ₹17,101,700,000 (US$250 million). On the 9th of
February 2017, the Government of India approved the privatization of Bridge and
Roof Company.

2.2 Company Profile

a. Preamble:
Established in 1920, BRIDGE & ROOF CO. (INDIA) LTD. (B&R) has grown
into a premier multi-disciplinary Engineering and Construction organisation in the
country. The Company has been a major force in the field of construction for past
ninety-six years during which it has competently served almost all the major
Project Implementation Authorities in the country in both Public and Private
Sectors. With the present turnover of ₹ 2053.55 Crores during year 2017-18
(Unaudited Provisional), BRIDGE & ROOF is one of the leading and most
versatile construction organisations in the country with high degree of expertise
and substantial in-house resources comprising of dedicated man-power, modern
equipment and machineries for project work as well as sophisticated work shop
facilities at its Howrah Works in West Bengal.
b. Constitution:
 Inception in 1920 as a wholly owned subsidiary of Balmer Lawrie
& Co. Ltd., Kolkata.
 A Public Sector Undertaking since 1972 under the Ministry of
Petroleum & Natural Gas, Government of India.
 B&R came under the administrative control of DHI in 1986 (with
M/s. BYNL as holding company from 1987 to May’2008).

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  Presently under Ministry of Heavy Industries and Public
Enterprises, Department of Heavy Industry (DHI), Government of
India
c. Awards:
 B&R has been awarded ‘MINIRATNA’ Category-I status on 21st
September, 2010 by Government of India.
 B&R has been awarded ‘Turnaround CPSE Award 2010’ by
BRPSE on 10th March, 2011.
 B&R has been awarded ‘PSE Excellence Awards 2011’ by from
Department of Public Enterprises and Indian Chamber of
Commerce as the ‘Best Turnaround CPSE of the Year 2011’ on
19th September, 2011.
 B&R has been awarded ‘Best Vendor Award — 2012 (Boiler)’,
‘Best Vendor Award — 2010 (Civil)’ and ‘Best Vendor Award —
2014 (Civil)’ by Bharat Heavy Electricals Ltd. / Power Sector
Eastern Region.
 Bridge & Roof has been adjudged as the ‘Legend PSU of the Year
2013 for Operational Transparency’ by News Link Media and
Production (P) Ltd.
d. Major Work Groups & Areas of Operations:
I. Civil:
 Industrial Buildings, High-rise Buildings & Building Complex.
 All types of foundations
 Piling
 Well foundations for River Bridges
 Roads & Highways
 Prilling Towers & Chimneys
 Airport Terminal Building & Runways
 Storage Silos (Parabolic & Vertical)
 Rail & Road Bridges in RCC & Prestressed Concrete
 Composite Stadium cum Sports Complex & Swimming Pool
etc.

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 II. Mechanical:
 Light, Medium and Heavy Structural Steel Works
 Railway and Road Bridges
 All type of Storage Tanks
 Installation of Boiler with all associated activity for Power
Plant
 Laying of Cross Country Pipeline including HDD for Crossings
 Vessels, Heaters, Steel Chimneys
 Manufacturing of Pot Super Structure for Aluminium Smelters.
 All types of Piping and Equipment Erection Work in off—sites.
III. Turnkey:
 Coal Gas Storage and Handling Complex
 Non-ferrous Metal Plants
 Cooling Towers, Oil Storage & Handling Terminals
 Fire Protection System
 Refinery Heaters
 Process Plants / Units for Refineries & Petrochemicals
 Water Treatment Plant / Water Supply system
IV. Howrah Works:
 Manufacture of Railway Wagons, Bailey Type Unit Bridge,
Marine Freight Containers, Bunk Houses, etc.
 Manufacturing of Pot Shells for Aluminium Smelters
 Fabrication of Structural Steel Work, Railway Bridge Girders
 Design and detailing facilities
 Fabrication of pressure vessels & heat exchangers

e. Management System: In keeping with its modernisation scheme the company

has installed computer facilities and have developed the following EDP systems:
 Management information systems
 Planning & Monitoring of Project work through Primavera
Project Planner and Microsoft project
 Analysis of costs and estimates

8
  Market Information
 Personnel Data Bank
 Plant and Machinery Data Bank including control on
movement / deployment
 Financial Accounting, Budget Analysis etc.
 Structural Designing & Drawing using STAAD PRO & Auto
CAD.

Apart from networking facilities available at all

offices almost all project sites are also equipped with latest computers with
internet facilities.

For effective utilization of the resources,

Company has started to implement the Enterprise Resource Planning (ERP)
using the ORACLE — E-Business Suite across all Offices & Sites. The
Following ERP Modules have been already implemented:

 Accounts & Finance Module

 Payroll & HR Module
 Purchase & Inventory Module

f. Vision:
 To become a leader in integrated Project Management in the field of
construction and allied services with a high growth trajectory and
increase its market share.
 The mission of Bridge & Roof Co. (India) Ltd. is to thrive in the
competitive Indian construction industry and to position it to be India’s
leading Engineering and Turnkey Solution Company through quality
services and products with total commitment towards customer
satisfaction.
 Considering the present industrial scenario and modernisation required,
the company has taken in hand a number of diversification schemes
which are already in the process of implementation to cater for

9
 tomorrow's needs and priorities as well as to give the customer best
satisfaction and services.
 The company has developed a huge data base of various suppliers /
manufacturers / construction manpower. Suitable and resourceful sub-
agencies / associates for various activities have been developed for
increasing company’s business and areas of operation.

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3 SITE VISIT AT DYIP “AISHWARYA” PROJECT

3.1 General
DYIP “Aishwarya” Project is a Coker Unit Project which costs approximately
₹4190 crores. The major facilities envisaged are Delayed Coking Unit of 1.7 MMTPA
capacity along with Coker Gas Oil Treating Unit, Coker LPG Treating Unit, Sulphur
Recovery Unit, Amine Regeneration Unit, Sour Water Stripper and associated offsites
& Utilities. Project is being executed in hybrid mode and is in advanced stage of
construction.
The project aims to upgrade black oil mainly high sulphur furnace oil to
higher value products like diesel and LPG to improve the Gross Refinery Margin of
Haldia Refinery. It would also facilitate processing of high sulphur crude by the
refinery. This project also aims to produce 100% BS-IV quality auto fuels as a
measure towards environmental protection.

3.2 Coke

The table below illustrates the wide range of compositions for raw petroleum coke
(referred to as green coke) produced in a delayed Coker and the corresponding
compositions after the green coke has been calcined at 2375 °F (1302 °C):

Composition Of Coke From A Delayed Coker

Green coke Coke calcined

Component
as produced at 2375 °F

Fixed carbon, wt % 80 – 95 98.0 − 99.5

Hydrogen, wt % 3.0 − 4.5 0.1

Nitrogen, wt % 0.1 − 0.5 -

Sulphur, wt % 0.2 − 6.0 -

Volatile matter, wt % 5 – 15 0.2 − 0.8

Moisture, wt % 0.5 – 10 0.1

Ash, wt % 0.1 − 1.0 0.02 − 0.7

Density, g/cm3 1.2 − 1.6 1.9 − 2.1

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 Metals, ppm weight:

Aluminium 15 – 100 15 – 100

Boron 0.1 – 15 0.1 – 15

Calcium 25 – 500 25 – 500

Chromium 5 – 50 5 – 50

Cobalt 10 – 60 10 – 60

Iron 50 – 5000 50 – 5000

Manganese 2 – 100 2 – 100

Magnesium 10 – 250 10 – 250

Molybdenum 10 – 20 10 – 20

Nickel 10 – 500 10 – 500

Potassium 20 – 50 20 – 50

Silicon 50 – 600 50 – 600

Sodium 40 – 70 40 – 70

Titanium 2 – 60 2 – 60

Vanadium 5 – 500 5 – 500

Table 3.1 Composition of Coke

3.3 Uses of Petroleum Coke

The product coke from a delayed Coker has many commercial uses and
applications. The largest use is as a fuel.
The uses for green coke are:

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  As fuel for space heaters, large industrial steam generators,
fluidized bed combustions, Integrated Gasification Combined
Cycle (IGCC) units and cement kilns
 For producing blast furnace coke
 In silicon carbide foundries
The uses for calcined coke are:

 In the production of titanium dioxide

 As a carbon raiser in cast iron and steel making
 Producing graphite electrodes and other graphite products such as
graphite brushes used in electrical equipment
 In carbon structural materials
 As anodes in the production of aluminium

3.4 Processing Units

a. Coke Drum: A Coke Drum is a type of pressure vessel that uses heat and
pressure to refine complex hydrocarbons into lighter, more useful, products, such as
gasoline, diesel, and jet fuel. Coke drums are an integral part of Coker
units and serve as the final step in the cracking process. During this process, crude oil
is fed into a Coker, where it is first heated to cracking temperature in a furnace. It is
then sent through a transfer line to the coke drum for final processing. The coke drum
then separates lighter vapours out of the crude, including hydrocarbon gases, naphtha,
and light and heavy gas oils. The vapour is then removed for further refinement. The
leftover material is called coke and is physically similar to charcoal. This coke will
build up in the drum and once full, the drum must be taken offline and the coke is
removed using high pressure water cutters for either reclamation or
storage. Processing facilities often have delayed Coker units, which utilize at least
two coke drums working in tandem with each other and some have as many as eight
drums. This allows a facility to have one Coker online continuously, avoiding
unnecessary downtime.

Fig. 3.1 Coke Drum

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b. Delayed Coker Unit (DCU): A Delayed Coker is a type of coker whose process
consists of heating a residual oil feed to its thermal cracking temperature in a furnace
with multiple parallel passes. This cracks the heavy, long chain hydrocarbon
molecules of the residual oil into Coker gas oil and petroleum coke. Delayed coking is
one of the unit processes used in many oil refineries. The adjacent photograph depicts
a delayed coking unit with 4 drums. However, larger units have tandem pairs of
drums, some with as many as 8 drums, each of which may have diameters of up to 10
meters and overall heights of up to 43 meters. The yield of coke from the delayed
coking process ranges from about 18 to 30 percent by weight of the feedstock residual
oil, depending on the composition of the feedstock and the operating variables. Many
refineries worldwide produce as much as 2,000 to 3,000 tons per day of petroleum
coke and some produce even more.

c. Coke Mix: Petroleum coke, abbreviated coke or petcoke, is a final carbon-rich

solid material that derives from oil refining, and is one type of the group of fuels
referred to as cokes. Petcoke is the coke that, in particular, derives from a final
cracking process—a thermo-based chemical engineering process that splits long chain
hydrocarbons of petroleum into shorter chains—that takes place in units termed coker
units. (Other types of coke are derived from coal.) Stated succinctly, coke is the
"carbonization product of high-boiling hydrocarbon fractions obtained in petroleum
processing (heavy residues)." Petcoke is also produced in the production of synthetic
crude oil (syncrude) from bitumen extracted from Canada’s oil sands and from
Venezuela's Orinoco oil sands. In petroleum coker units, residual oils from other
distillation processes used in petroleum refining are treated at a high temperature and
pressure leaving the petcoke after driving off gases and volatiles, and separating off
remaining light and heavy oils. These processes are termed "coking processes", and
most typically employ chemical engineering plant operations for the specific process
of delayed coking. This coke can either be fuel grade (high in sulphur and metals) or
anode grade (low in sulphur and metals). The raw coke directly out of the coker is
often referred to as green coke. In this context, "green" means unprocessed. The
further processing of green coke by calcining in a rotary kiln removes residual volatile
hydrocarbons from the coke. The calcined petroleum coke can be further processed in
an anode baking oven in order to produce anode coke of the desired shape and
physical properties. The anodes are mainly used in the aluminium and steel industry.
Petcoke is over 90 percent carbon and emits 5 to 10 percent more carbon dioxide
(CO2) than coal on a per-unit-of-energy basis when it is burned. As petcoke has a
higher energy content, petcoke emits between 30 and 80 percent more CO2 than coal
per unit of weight. The difference between coal and coke in CO2 production per unit
of energy produced depends upon the moisture in the coal, which increases the CO2
14
per unit of energy – heat of combustion) and on the volatile hydrocarbons in coal and
coke, which decrease the CO2 per unit of energy. Petcoke is stored in a particular area
is known as Coke Mix.
d. Stockyard: Unused Coke is transferred into a zone via conveyor belt is known as
Stockyard.

Fig. 3.2 Stockyard Connection through Belt Conveyor

e. Heater/Furnace: An industrial furnace or direct fired heater is that equipment

which is used to provide heat for a process or can serve as reactor which provides
heats of reaction. Furnace designs vary as to its function, heating duty, type of fuel
and method of introducing combustion air. However, most process furnaces have
some common features. Fuel flows into the burner and is burnt with air provided from
an air blower. There can be more than one burner in a particular furnace which can be
arranged in cells which heat a particular set of tubes. Burners can also be floor
mounted, wall mounted or roof mounted depending on design. The flames heat up the
tubes, which in turn heat the fluid inside in the first part of the furnace known as the
radiant section or firebox. In this chamber where combustion takes place, the heat is
transferred mainly by radiation to tubes around the fire in the chamber.

15
 Fig. 3.3 Schematic Diagram of Furnace
f. Pipe Rack: Pipes are stored in the rack is known as Pipe Rack. Pipe Rack is of two
types:
i. Avoground: The pipes which are distributed in the Pipe Rack in the
Technical Structures (TS) are the Avoground Pipes.
ii. Underground: The pipes which are distributed in the Underground
Trenches are the Underground Pipes.
g. Technical Structures (TS): Technical Structures (TS) are the structures in which
the Avoground Pipes are stored.

Fig. 3.4 Pipes Along With Pipe Racks in TS

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h. Water Tank: A water tank is a container for storing water. Water tanks are used
to provide storage of water for use in many applications, drinking water, irrigation
agriculture, fire suppression, agricultural farming, both for plants and livestock,
chemical manufacturing, food preparation as well as many other uses. Water tank
parameters include the general design of the tank, and choice of construction
materials, linings. Various materials are used for making a water tank: plastics
(polyethylene, polypropylene), fibreglass, concrete, stone, steel (welded or bolted,
carbon, or stainless). Earthen pots also function as water storages. Water tanks are
an efficient way to help developing countries to store clean water.

Fig. 3.5 Water Tank

i. Compressor: A compressor is a mechanical device that increases the pressure of a

gas by reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and both can
transport the fluid through a pipe. As gases are compressible, the compressor also
reduces the volume of a gas. Liquids are relatively incompressible; while some can be
compressed, the main action of a pump is to pressurize and transport liquids. Here,
Electro-chemical Hydrogen Compressor is used.
 Electro-Chemical Hydrogen Compressor: An electrochemical hydrogen
compressor is a hydrogen compressor where hydrogen is supplied to the
anode, and compressed hydrogen is collected at the cathode with an energy
efficiency up to and even beyond 80% for pressures up to 10,000 psi or 700
bars.
 Applications: Electrochemical hydrogen compressors have been proposed for
use in hydrogen refuelling stations to pressurize hydrogen gas for storage.
They have also been applied into novel refrigeration systems to pressurize
hydrogen for absorption into metal hydrides or to pressurize other working
fluids (such as refrigerants) as demonstrated by winners of the global GE's
17
 Ecomagination awards for 2011. These electrochemical compressors are
noiseless, scalable, modular and highly efficient without the use of CFC's.

Fig. 3.6 Compressor

j. Cooking Gas Hydro Oil Treatment (CGOT): Catalytic Cracker feedstocks
(atmospheric gas oil, light vacuum gas oil, solvent de-asphalting gas oil) hydro treated
severely
 Sulphur Removal
 Openings of Aromatic Rings
 Removal of Heavy Metals
De-Sulphurisation of gas oil can be achieved with a relatively modest decomposition
of structures.
Gas oils can be contaminated with resins & asphaltenes
 Deposited in Hydro Treater
 Require catalyst replacement with a shorter run length than
determined by deactivation
 Guard chamber may be installed to prolong bed life
Nickel Molybdenum catalyst system is used for severe hydro treating.
Gas oil units more expensive because of more intensive hydrogenation
 Quench
 Multi Stage Flash
 More Complex Strippers

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4 SITE VISIT AT BS-VI (PRIME G+REVAMP)
4.1 General
Project Cost for all refineries are of ₹16,600 Crores. BS-VI programme envisages
revamps/installation of new units at Panipat, Mathura, Gujarat, Haldia, Paradip,
Guwahati, Bongaigaon and Digboi Refinery. Project Management Consultant has
been engaged for this project (except for Paradip and Guwahati ½which are in
progress). Process licensors selection and award of various contracts are in progress.
Site work has commenced. As per Govt. of India guidelines, productivity of 100%
BS-VI compliant auto fuel in the entire country w.e.f April 1, 2020.
4.2 Introduction
Bharat Stage Emission Standards (BSES) are emission standards instituted
by the Government of India to regulate the output of air pollutants from internal
combustion engines and Spark-ignition engines equipment, including motor vehicles.
The standards and the timeline for implementation are set by the Central Pollution
Control Board under the Ministry of Environment & Forests and climate change.
The standards, based on European regulations were first introduced in 2000.
Progressively stringent norms have been rolled out since then. All new vehicles
manufactured after the implementation of the norms have to be compliant with the
regulations. Since October 2010, Bharat Stage (BS) III norms have been enforced
across the country. In 13 major cities, Bharat Stage IV emission norms have been in
place since April 2010 and it has been enforced for entire country since April 2017. In
2016, the Indian government announced that the country would skip the BS-V norms
altogether and adopt BS-VI norms by 2020.
On November 15, 2017 The Petroleum Ministry of India in consultation with Public
Oil Marketing Companies decided to bring forward the date of BS-VI grade auto fuels
in NCT of Delhi with effect from April 1, 2018 instead of April 1, 2020. In fact,
Petroleum Ministry OMCs were asked to examine the possibility of introduction of
BS-VI auto fuels in the whole of NCR area from April 1, 2019. This huge step was
taken due the heavy problem of air pollution faced by Delhi, which became worse
around this year. The decision was met with disarray by the automobile companies as
they had planned the development according to roadmap for 2020.
The phasing out of 2-stroke engine for two wheelers, the cessation of production of
Maruti 800 & introduction of electronic controls have been due to the regulations
related to vehicular emissions.
While the norms help in bringing down pollution levels, it invariably results in
increased vehicle cost due to the improved technology & higher fuel prices. However,
this increase in private cost is offset by savings in health costs for the public, as there
is lesser amount of disease causing particulate matter and pollution in the air.
Exposure to air pollution can lead to respiratory and cardiovascular diseases, which is

19
 estimated to be the cause for 6.2 lakhs early deaths in 2010, and the health cost of air
pollution in India has been assessed at 3% of its GDP.
4.3 Processing Units
There are some processing units, those are:
a. Main Receiving Service Station (MRSS): A Service Station is a
part of an electrical generation, transmission, and distribution system.
Substations transform voltage from high to low, or the reverse, or
perform any of several other important functions. Between the
generating station and consumer, electric power may flow through
several substations at different voltage levels. A substation may
include transformers to change voltage levels between high
transmission voltages and lower distribution voltages, or at the
interconnection of two different transmission voltages.

Fig. 4.1 MRSS Building under Construction

b. Control Room: A Control Room, Operations Centre, or

Operations Control Centre (OCC) is a room serving as a central
space where a large physical facility or physically dispersed service
can be monitored and controlled. A control room will often be part of a
larger command centre. A control room's purpose is production
control, and serves as a central space where a large physical facility or
physically dispersed service can be monitored and controlled. Central
control rooms came into general use in factories during the 1920s.
Control rooms for vital facilities are typically tightly secured and
inaccessible to the general public. Multiple electronic displays and
control panels are usually present, and there may also be a large wall-

20
 sized display area visible from all locations within the space. Some
control rooms are themselves under continuous video surveillance and
recording, for security and personnel accountability purposes. Many
control rooms are manned on a "24/7/365" basis, and may have
multiple people on duty at all times (such as implementation of a "two-
man rule"), to ensure continuous vigilance.
Other special-purpose control room spaces may be temporarily set up
for special projects (such as an oceanographic exploration mission),
and closed or dismantled once the project is concluded.

Fig. 4.2 Control Room under Construction

c. Cooling Water Treatment Plant: A Cooling Tower is a heat

rejection device that rejects waste heat to the atmosphere through the
cooling of a water stream to a lower temperature. Cooling towers may
either use the evaporation of water to remove process heat and cool the
working fluid to near the wet-bulb air temperature or, in the case of
closed circuit dry cooling towers, rely solely on air to cool the working
fluid to near the dry-bulb air temperature.
Common applications include cooling the circulating water used in oil
refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is
based on the type of air induction into the tower: the main types of
cooling towers are natural draft and induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very large
hyperboloid structures (as in the adjacent image) that can be up to 200
metres (660 ft) tall and 100 metres (330 ft) in diameter, or rectangular
structures that can be over 40 metres (130 ft) tall and 80 metres (260 ft)
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 long. The hyperboloid cooling towers are often associated with nuclear
power plants, although they are also used in some coal-fired plants and
to some extent in some large chemical and other industrial plants.
Although these large towers are very prominent, the vast majority of
cooling towers are much smaller, including many units installed on or
near buildings to discharge heat from air conditioning.

Fig. 4.3 Cooling Tower Cell under Construction

d. Diesel Hydro-treating Technology (DHDT) Sub Station: This is a

distribution substation which transfers power from the transmission
system to the distribution system of an area. It is uneconomical to
directly connect electricity consumers to the main transmission
network, unless they use large amounts of power, so the distribution
station reduces voltage to a level suitable for local distribution.
The input for a distribution substation is typically at least two
transmission or sub-transmission lines. Input voltage may be, for
example, 115 kV, or whatever is common in the area. The output is a
number of feeders. Distribution voltages are typically medium voltage,
between 2.4 kV and 33 kV, depending on the size of the area served
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and the practices of the local utility. The feeders run along streets
overhead (or underground, in some cases) and power the distribution
transformers at or near the customer premises.
In addition to transforming voltage, distribution substations also isolate
faults in either the transmission or distribution systems. Distribution
substations are typically the points of voltage regulation, although on
long distribution circuits (of several miles/kilometres), voltage
regulation equipment may also be installed along the line.
The downtown areas of large cities feature complicated distribution
substations, with high-voltage switching, and switching and backup
systems on the low-voltage side. More typical distribution substations
have a switch, one transformer, and minimal facilities on the low-
voltage side.

Fig. 4.4 DHDT Sub Station under Construction

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5 PLANTS & MACHINERIES
5.1 General
Heavy equipment refers to heavy-duty vehicles, specially designed for
executing construction tasks, most frequently ones involving earthwork operations.
They are also known as heavy machines, heavy trucks, construction
equipment, engineering equipment, heavy vehicles, or heavy hydraulics. They usually
comprise five equipment systems: implement, traction, structure, power train,
control and information. Heavy equipment functions through the mechanical
advantage of a simple machine, the ratio between input force applied and force
exerted is multiplied. Some equipment uses hydraulic drives as a primary source of
motion.
5.2 Concrete Batching Plant
A concrete batching plant is a device that combines various ingredients to form
concrete. Some of these inputs includes sand, water, aggregates (fine and coarse)
admixtures and cement. A concrete plant can have a variety of parts and accessories
like mixtures (either tilt up or horizontal or in some cases both), cement batchers,
aggregate batchers, conveyors, radial stackers, aggregate bins, cement bins, heaters,
chillers, cement silos, batch plant controls etc.
There are two types of batching plant according to the process of mixing:
a. Ready Mix Plant: A ready mix plant combines all ingredients except for
water at the concrete plant. This mixture is then discharged into a ready mix
truck. Water is then added to the mix in the truck and mixed during transport to
the job site.
b. Central Mix Plant: A central mix plant combines some or all of the
above ingredients (including water) at a central location. The final product is then
transported to the job site. Central mix plants differ from ready mix plants in that
they offer the end user a much more consistent product, since all the ingredient
mixing is done in a central location and is computer-assisted to ensure uniformity
of product.
Modern concrete batching plants (both ready mix and central mix) employ computer
aided control to assist in fast, accurate measurement of input ingredients, as well as
tie together the various parts and accessories for coordinated and safe operation. With
concrete performance so dependent on accurate water measurement, systems will
often use moisture correction to measure the amount of water that is part of the
aggregate (sand or course) material while it is being weighed, and then automatically
compensate the mix design water target.
5.3 Components of Batching Plants
A batching plant consists of various accessories. These are:
a. Cement Silos: Cement silos are on-site storage containers used for the
storage and distribution of various types of cement mixtures. Silos of this
type come in a variety of sizes, making them ideal for use at many kinds of
construction sites. A cement silo can be a permanent structure, or a
portable model that can be relocated when necessary. Like many other
types of silos, the cement silo usually is equipped with some type of
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 blower to help expel the stored contents into a truck or other receptacle.
Generally, larger silos are permanent structures that cannot be moved.
These are likely to be found at concrete plant. It is not unusual for
construction companies to keep several portable cement silos available for
different building projects. These simple storage devices can usually be set
up in a matter of hours, then dismantled once the project is complete.
Storage of the portable cement silo is relatively easy, since the components
can be stored until the device is needed at another building site.
b. Hopper: A hopper is a container for bulk amount of aggregates (course
and fine). Typically one that tapers downward and is able to discharge its
content at the bottom. The lorries are waiting beneath the hopper to take its
discharges.
c. Conveyor: Conveyor is a continuous moving band metal used for
transporting objects from one place to another. In batching plant conveyor
belts are used to transport the aggregate through hopper to bin. These are
exposed to the atmosphere, so it should be effectively enclosed.
d. Aggregate Bin: This is a container that stores aggregate before it is send
to pan for mixing. It has four sections in it. These heavy-duty bins are
made of 3/16"–1/4" quality steel and welded construction. Reinforced
sections and I-beam supports make for long, dependable performance.
Choose from 10-ton capacity (water level) to 40-ton.
e. Skip: Skip is container that transfer the aggregates from bin to pan
mixture. It is also called skip bucket. It slides over a rail with the help of
ropes to transfer the aggregate to the pan mixture.
f. Pan Mixture: Pan mixture is used for mixing of concrete, mortar,
refractory and other material at ease in rugged site condition. It is a pan
type container. It serves the purpose of continuous mixing of concrete.
g. Chilling Plant: Chilling plants are installed to control the temperature of
the prepared concrete. These plants are very important for preparation of
concrete in summer season and hot areas. It cools the water that are added
to the concrete , thus controlling the temperature of concrete. It is not
advisable to use concrete having temperature of more than 29˚ C just after
it is from the pan mixture.

5.4 Working Principles of Concrete Batching Plant

Concrete batching plant is divided into four parts:
a. Sand feeding
b. Powder (cement, fly ash, bulking agent, etc.) feed
c. Water and additive feed
d. Transmission mixing and storage.
When mixer control system is power on, entering the interface of machine and man
dialogue, system start initialization processing, including formula number, concrete
grade, slump, production volume, etc. According to the weighing of each mixing tank,
test the weighing hopper, output material empty or material full signal, operating.
At site , we have three batching plant having capacity of 60 cubic meter per hour, 30
cubic meter per hour and 18 cubic meter per hour. The capacity of one silo is 90 tons.

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Chilling plant at site have three compressors having an overall capacity of 4000
litres/hour and maintains a minimum temperature of 13 to 14˚ Celsius.

5.5 Transit Mixer

Special concrete transport trucks (transit mixers) are made to transport and mix
concrete up to the construction site. The concrete mixing transport truck maintains the
material's liquid state through agitation, or turning of the drum, until delivery. The
interior of the drum on a concrete mixing

Fig. 5.1 Transit Mixer

Truck is fitted with a spiral blade. In clockwise rotational direction, the concrete is
pushed deeper into the drum. This is the direction the drum is rotated while the
concrete is being transported to the building site. This is known as "charging" the
mixer. When the drum rotates in the anticlockwise direction, it forces the concrete out
of the drum hence unloading is done.
At site, the capacity of transit mixer is 7 cubic meter.

5.6 Boom Placer

It is a construction machine used for transferring fresh concrete by pumping to the
required place .Boom pumps are used mostly in larger construction projects as they
are capable of pumping at very high volumes and because of the labour saving nature
of the placing boom. It is named so because it uses a remote controlled articulating
robotic arm called boom to place concrete accurately. Use of boom placers facilitates
faster completion of concreting and hence considerably reduces the time.

26
 Fig. 5.2 Boom Placer
Advantages of using Boom Placer

 Facilitates faster concreting in larger project

 Concrete can be placed in difficult position
 Reduces the time of job completion
 Reduces the manual work considerably

5.7 Bar Cutting & Bending Machine

As the reinforcement bars available in market are straight and are of specified length
that is 12m But it’s a fact that in almost all type of reinforced concrete structure
sometimes we need reinforcing bars of which either length would be less than 12m or
geometrical configuration would be other than straight. Hence to get the bars of
specified length (<12m) cutting machine is used and bending machine is used for
obtaining bent bars. They are also called bar cutters and bar benders.

Fig. 5.3 Bar Bending Machine (Left) & Bar Cutting Machine (Right)
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5.8 Concrete Pump
It is also an equipment that places concrete for mass concreting but it is less
efficient than boom placer.

Fig. 5.4 Use of Concrete Pump in Flooring

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6 HEALTH, SAFETY & ENVIRONMENTAL (HSE) POLICY

6.1 General
This policy ensures that impact of any project on the environment in its nearby area
would be minimum and the health of people either working in project or living near
project site will not get affected. It also ensures safety to all workers that are involved
in project. Nearly 50000+ people work at approximately 130+ construction sites
across the nation on any given day. The fatal injury rate for the construction industry
is higher than the national average in this category for all industries.

Potential Hazards for Workers in Construction includes:

 Falls (from Heights)

 Trench Collapse
 Scaffold Collapse
 Electric Shock & Arc Flash/Arc Blast
 Failure to use proper personal protective equipment
 Repetitive Motion Injuries
6.2 HSE Policy of B&R
B&R affirms its commitment to conserve the environment and provide a safe and
healthy workplace to its employees and stakeholders.
6.3 HSE Philosophy
All adverse environmental impacts and are preventable and no task is so important
that risk of injury to people or damage to environment is justified. The objectives of
this HSE Policy shall be achieved at our work places by:

 Incorporating HSE considerations in all business decisions

 Promoting a positive HSE culture
 Ensuring compliance to legal and other requirements
 Identifying & controlling HSE risks arising in the work place Imparting
structured training for employees and stakeholders Integrating HSE into every
operations of the company
 Employing contractors who aspire to adopt the same HSE standards in their
work
 Encourage communication, consultation & collaboration with all employees &
stakeholders

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7 QUALITY CONTROL
7.1 General

Quality Control (QC) for short is a process by which entities review the quality of all
factors involved in production. ISO 9000 defines quality control as "A part of quality
management focused on fulfilling quality requirements".
This approach places an emphasis on three aspects (enshrined in standards such as ISO
9001)

 Elements such as controls, job management, defined and well managed

processes, performance and integrity criteria, and identification of records
 Competence, such as knowledge, skills, experience, and qualifications
 Soft elements, such as personnel, integrity, confidence, organizational
culture, motivation, team spirit, and quality relationships.
Inspection is a major component of quality control, where physical product is
examined visually (or the end results of a service are analyzed). Product inspectors
will be provided with lists and descriptions of unacceptable product defects such as
cracks or surface blemishes for example.

7.2 Mix Design

It is a performance based mix where choice of ingredients and proportioning is left to
the designer to be decided. The user has to specify only the requirements of concrete
in fresh as well as hardened state. The requirements in fresh concrete are workability
and finishing characteristics, whereas in hardened concrete these are mainly the
compressive strength and durability. Mix design is done in the laboratory and samples
from each mix designed are tested for confirmation of result but before the mix design
process is started, the information about available materials, strength of concrete
required, workability, site conditions etc. are required to be known.

 Characteristic strength of concrete required: Characteristic strength is the

strength of concrete below which not more than 5% of test results of samples
are expected to fall. This can also be called as the grade of concrete required
for mix design. For example, for M20 grade concrete, the required concrete
compressive strength is 20 N/mm2 and characteristic strength is also the same.
 Workability requirement of concrete: The workability of concrete is
commonly measured by slump test. The slump value or workability
requirement of concrete is based on the type of concrete construction.

30
 Fig. 7.1 Workability of Concrete – Slump Test
For example, reinforced concrete construction with high percentage of steel
reinforcement, it will be difficult to compact the concrete with vibrators or other
equipment. In this case, the workability of concrete should be such that the concrete
flows to each and every part of the member. For concrete member, where it
is easy to compact the concrete, low workability concrete can also be used. It is also
known that with increase in workability of concrete, the strength of concrete reduces.
Thus, based on type of structure or structural member, the workability requirement of
concrete should be assumed and considered in the mix design. For pumped concrete,
it is essential to have high workability to transfer concrete to greater heights with
ease. This case also should be considered in the mix design.

 Quality control at site: The strength and durability of concrete depends on the
degree of quality control during construction operation at site. Nominal mixes of
concrete assumes the worst quality control at site based on past experiences. Thus, for
design mix concrete, it is essential to understand the quality control capability of
contractor and workmen at construction site in mixing, transporting, placing,
compacting and curing of concrete. Each step in concrete construction process affects
the strength and durability of concrete. The availability of workmen also affects
quality control of concrete. The more skilled workmen and supervision helps to
maintain good quality construction.
 Weather conditions: Weather impacts the setting time of concrete. In hot climate, the
concrete tends to set early due to loss in moisture, and in this case, the concrete need
to have higher water cement ratio or special admixtures to delay initial setting of
concrete. Recommendations for concrete cooling agents also required to be mentioned
in the mix design for very hot weather conditions. In cold climates, the initial setting
time of concrete increases as the moisture loss rate is very low. Due to this, water
cement ratio is considered appropriately. Admixtures should also be recommended to
prevent freezing of concrete in case of very cold climate.
 Batching and mixing methods: There are two types of batching method, i.e.
volumetric batching and batching by weight. These two conditions should be known
for concrete mix design calculations. Mixing methods include manual mixing,

31
 machine mixing, ready mix concrete etc. The quality control of concrete varies with
each type of mixing method.
 Quality of materials: Each construction material should have been tested in
laboratory before it is considered for mix design calculations. The type of material,
their moisture content, suitability for construction, and their chemical and physical
properties affects the mix design of concrete. Type of cement to be used for
construction, coarse and fine aggregates sources, their size and shape should be
considered.

Factors Affecting Concrete Mix Design Strength:

Factors that affect the concrete mix design strengths are as follows:

 Water/cement ratio
 Cement content
 Relative proportion of fine & coarse aggregates
 Use of admixtures
 Temperature

7.3 Quality Control Practice at Site

Quality control is the part of quality management that ensures products and services
comply with requirements. It is a work method that facilitates the measurement of
quality characteristic of a unit, compares them with the established standard, and
analyses the difference between the results obtained and the desired results in order to
make decision which will correct any differences.

Some important quality control test conducted at construction site are-

7.3.1 Fine Aggregate:

 Fineness Modulus: Fineness modulus is an empirical factor obtained by

adding the cumulative percentages of aggregate retained on each of the
standard sieves ranging from 4.75 mm to 150 micron and dividing this sum
by 100.Fineness modulus is generally used to get an idea of how coarse or
fine the aggregate is. More fineness modulus value indicates that the
aggregate is coarser and small value of fineness modulus indicates that the
aggregate is finer.
 PROCEDURE:

Sieve the aggregate using the appropriate sieves (4.75 mm, 2.36 mm, 1.18
mm, 600 micron, 300 micron & 150 micron) Record the weight of aggregate
retained on each sieve.

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  Calculate the cumulative weight of aggregate retained on each sieve.
 Calculate the cumulative percentage of aggregate retained.
 Add the cumulative weight of aggregate retained and divide the sum
by 100. This value is termed as fineness modulus.

7.3.2 COMPRESSIVE STRENGTH OF CONCRETE

Compressive strength of concrete is very important because it is primarily meant to

withstand the compressive stresses. At a given age under given curing conditions it is
assumed to depend mainly on water-cement ratio and degree of compaction

 PROCEDURE:

 Representative samples of concrete shall be taken and used for casting cubes
15 cm x 15 cm x 15 cm.
 The concrete shall be filled into the moulds in layers approximately 5 cm
deep. It would be distributed evenly and compacted either by vibration or by
hand tamping. After the top layer has been compacted, the surface of concrete
shall be finished level with the top of the mould using a trowel; and covered
with a glass plate to prevent evaporation.
 The specimen shall be stored at site for 24+ ½ h under damp matting or sack.
After that, the samples shall be stored in clean water at 27+20C; until the time
of test.
 Specimen shall be tested immediately on removal from water and while they
are still in SSD condition.
 The load shall be applied slowly without shock and increased continuously at
a rate of approximately 140 kg/sq.cm/min until the resistance of the specimen
to the increased load breaks down and no greater load can be sustained. The
maximum load applied to the specimen shall then be recorded and any unusual
features noted at the time of failure brought out in the report.

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8 BAR BENDING SCHEDULE
8.1 General

Bar Bending Schedule, commonly referred to as “BBS” is a comprehensive

list that describes the location, mark, type, size, length and number, and bending
details of each bar or fabric in a Reinforcement Drawing of a Structure. This process
of listing the location, type and size, number of and all other details is called
“Scheduling”. In context of Reinforcement bars, it is called bar scheduling. In short,
Bar Bending Schedule is a way of organizing rebars for each structural unit, giving
detailed reinforcement requirements.

8.2 Guidelines for Preparing BBS

 The bars should be grouped together for each structural unit, e.g. beam,
column, etc.
 In a building structure, the bars should be listed floor by floor.
 For cutting and bending purposes schedules should be provided as
separate A4 sheets and not as part of the detailed reinforcement
drawings.
 The form of bar and fabric schedule and the shapes of bar used should
be in accordance with BS 8666.
 It is preferable that bars should be listed in the schedule in numerical
order.
 It is essential that the bar mark reference on the label attached to a
bundle of bars refers uniquely to a particular group or set of bars of
defined length, size, shape and type used on the job.
 This is imperative as a bar mark reference can then point to a class of
bar characteristics. Also, this helps steel fixers and labourers keep track
of the type and number of bars needed to complete a certain work.

34
Fig. 8.1 BBS of PB-1 Site

35
 CONCLUSION OF THE PROJECT

We get a comprehensive idea regarding Indian Oil Corporation’s Terms &

Regulations; the difference between running plant area & under construction area, the
Distillate Yield Improvement “Aishwarya” Project (DYIP), BS-VI area where revamp works
as well as construction work is going around. We got comprehensive knowledge in regards to
the procedure of how it will be completed. We have also learned how they have created the
basic structures of the DYIP and BS-VI also including MRSS, Control Room, CWTP, DHDT
Sub Station, DCU, and CGUT etc. Here we have the opportunity to study the maps & realise
the structures. Throughout the training period we are developing our knowledge.

36
 ANNEXURE A: BIBLIOGRAPHY

 IOCL Documents, Haldia Refinery

 Bridge & Roof Co. (India) Ltd Documents

 www.iocl.com (dated 23.07.2018)

 www.bridgeroof.co.in (dated 23.07.2018)

 www.wikipedia.org (dated 15.07.2018)

 www.nptel.ac.in (dated 20.07.2018)

 www.civilblog.org (dated 19.07.2018)

 www.slideshare.net (dated 22.07.2018)

 www.theconstructor.org (dated 17.07.2018)

37