Content

Preface 2

Acknowledgement 3

Areas covered 4

Introduction 5

Overview Of Haldia Refinery 6

Fire And Safety Rules 7

LOB 8

OHCU 11

OM&S Off-Site 12

Workshop 13

Conclusion 20

Summer Vocational Training, IOCL HALDIA REFINERY 1

PREFACE
Industrial training plays a vital role in the progress of future engineers. Not only does it
provide insights about the industry concerned, it also bridges the gap between theory and
practical knowledge. We were fortunate that we were provided with an opportunity of
undergoing Industrial training at INDIAN OIL CORPORATION Ltd., Haldia, one of the
leading refineries in India.

The experience gained during this short period was fascinating to say the least. It
was a tremendous feeling to observe the operation of different equipment and
processes. It was overwhelming for us to notice how such a big refinery is being monitored
and operated with proper coordination to obtain desired results.

During our training we realized that in order to be a successful Instrumentation engineer

one needs to possess a sound theoretical base along with the acumen for effective
practical application of the theory. Thus, we hope that this industrial training serves as a
stepping-stone for us and helps to be successful in future.

Summer Vocational Training, IOCL HALDIA REFINERY 2

ACKNOWLEDGEMENT
Here I would like to take this opportunity to thank all those who have been instrumental in
providing me an enriching experience in this esteemed company. I can say that I have picked
up some valuable skills that would surely help me adapt better to the industry. Something that
specifically appealed to me was that how different the industry is when compared tour theory.
I have learnt about turbines, pumps etc. as a part of my course material and I was perfectly
happy with the theoretical aspects until I saw what happens in the real world. Here I was
shown how those basics that I learnt at college have to be applied in actual industry, I was
taught quite a few thumb rules that industrial experts rely on to do their jobs correctly. I was
also imparted with the skills of handling industrial problems at mammoth scales. My
theoretical problems involved machinery primarily on a lab scale, however here I was taught
what other considerations come into effect when the scale becomes roughly a thousand times
or more of the laboratory size.
A lot of assumptions that I was used to making earlier do not hold in real life and I understood
the importance of being precise and accurate. Lastly, I realised what it meant to be an
engineer. I saw what engineers do for the nation, though people might not realise it, engineers
sacrifice a lot for our nation, they build our nation, they silently work behind the scenes and
turn our dreams into reality, the steel, the roads, the aircrafts, the cars, the power plants,
everything in this whole wide world has a touch of engineering in it and some engineer’s hard
work behind it. I am really happy and proud that I chose this noble profession. Hence, I can
sum up by saying that I gained a lot in this limited time and I would want to thank my guide
cum mentors, Mr. N C Baruah (Workshop), Mr. Vipul Vinay (OHCU), Mr. P S Gole (LOB), for
giving me this great opportunity and supporting me throughout the period of my stay.
We would like to mention a great word of gratitude to Mr. P. Sandilya Chari, O (L&D)who
provided us full support throughout the training.

Summer Vocational Training, IOCL HALDIA REFINERY 3

AREAS COVERED

SL No. Areas Covered Site Officer Period

21.06.2019
1 LOB Mr. P S Gole To
26.06.2019

27.06.2019
2 OHCU Mr. Vipul Vinay To
03.07.2019

04.07.2019
OM&S
3 Mr. Tapomay Das To
OFF-SITE(LPG) 09.07.2019

10.07.2019
4 Workshop Mr. N C Baruah To
13.07.2019

Summer Vocational Training, IOCL HALDIA REFINERY 4

INTRODUCTION
Indian Oil Corporation Ltd. (IOC) is the flagship national oil company in the
downstream sector. The Indian Oil Group of companies owns and operates 11 of India's
19 refineries with a combined refining capacity of 1.2 million barrels per day. These
include two refineries of subsidiary Chennai Petroleum Corporation Ltd. (CPCL) and
one of Bongaigaon Refinery and Petrochemicals Limited (BRPL). The 11 refineries
are located at
 Guwahati
 Barauni
 Koyali
 Haldia
 Mathura
 Digboi
 Panipat
 Chennai
 Narimanam
 Bongaigaon

Paradweep has also recently added to this list.

Indian Oil's cross-country crude oil and product pipelines network span over 9,300 km. It
operates the largest and the widest network of petrol & diesel stations in the country.
Indian Oil Corporation Ltd. (Indian Oil) was formed in 1964 through the merger of Indian
Oil Company Ltd and Indian Refineries Ltd. Indian Refineries Ltd was formed in 1958,
with Feroze Gandhi as Chairman and Indian Oil Company Ltd. was established on 30th
June 1959 with Mr. S. Nijalingappa as the first Chairman. In 1964, Indian Oil
commissioned Barauni Refinery and the first petroleum product pipeline from Guwahati.
In 1965, Gujarat Refinery was inaugurated. In 1967, Haldia Barauni Pipeline (HBPL) was
commissioned. In 1972, Indian Oil launched SERVO, the first indigenous lubricant. In
1974, Indian Oil Blending Ltd. (IOBL) became the wholly owned subsidiary of Indian Oil.
In 1975, Haldia Refinery was commissioned. In 1981, Digboi Refinery and Assam Oil
Company's (AOC) marketing operations came under the control of Indian Oil. In 1982,
Mathura Refinery and Mathura-Jalandhar Pipeline (MJPL) were commissioned. In 1994,
India's First Hydrocracker Unit was commissioned at Gujarat Refinery. In 1995, 1,443
km. long Kandla-Bhatinda Pipeline (KBPL) was commissioned at Sanganer. In 1998,
Panipat Refinery was commissioned. In the same year, Haldia, Barauni Crude Oil
Pipeline (HBCPL) was completed. In 2000, Indian Oil crossed the turnover of Rs l00,000
crore and became the first Corporate in India to do so. In the same year Indian Oil
entered into Exploration & Production (E&P) with the award of two exploration blocks to
Indian Oil and ONGC consortium under NELP-I. In 2003, Lanka IOC Pvt. Ltd. (LIOC)
was launched in Sri Lanka. In 2005, Indian Oil's Mathura Refinery became the first
refinery in India to attain the capability of producing entire quantity of Euro-III compliant
diesel.

Summer Vocational Training, IOCL HALDIA REFINERY 5

OVERVIEW OF HALDIA REFINERY
Haldia Refinery, one of the seven operating refineries of Indian Oil, was commissioned
in January 1975. It is situated 136 km downstream of Kolkata in the district of Purba
Medinipur, West Bengal, near the confluence of river Hooghly and Haldia. Petroleum
products from this refinery are supplied mainly to eastern India through two product
pipelines 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, 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, refinery is producing BS-II and Euro-III equivalent HSD (part
quantity) at present. Resid Fluidised Catalytic Cracking Unit (RFCCU) was
commissioned in 2001 in order to increase the distillate yield of the refinery as well as to
meet the growing demand of LPG, MS and HSD. Refinery also produces eco friendly
Bitumen emulsion and Microcrystalline Wax. A Catalytic Iso Dewaxing Unit (CIDWU)
was installed and commissioned in the year 2003 for production of high quality Lube Oil
Base Stocks (LOBS), meeting the API Gr-II standard of LOBS. Finished products from
this refinery cover both fuel oil products as well as lube oil products

Fuel oil products include:

 LPG
 Naphtha
 Motor spirit (MS)
 Mineral Turbine Oil (MTO)
 Superior Kerosene (SK)
 Aviation Turbine Fuel (ATF)
 Russian Turbine Fuel (RTF)
 High Speed Diesel (HSD)
 Jute Batching Oil (JBO)
 Furnace Oil (FO)

Besides the above, slack wax, carbon black feed stock (CBFS), Bitumen and Sulphur
are the other products of this refinery.

The main units in this refinery are:

1. Fuel Oil Block (FOB)

2. Lube Oil Block (LOB)
3. Diesel Hydro De- Sulphurisation Unit (DHDS)
4. Oil Movement & Storage Unit (OM&S)
5. Fluid catalytic cracking (FCC)
6. Thermal power station (TPS) and Gas Turbine (GT)
7. Once through Hydrocracker Unit (OHCU)

Summer Vocational Training, IOCL HALDIA REFINERY 6

FIRE AND SAFETY RULES

1. Before entering the battery area, mobile phones and camera have to be
deposited.

2. Matches and lighters were strictly prohibited inside the battery area.

3. Smoking inside the factory was prohibited, except at the smoking booth.

4. Loose garments are not permitted near moving machinery inside plants.

5. Use of PPE (Personal Protective Equipments) was must in plant area.

These included safety helmet, gloves, welding glasses etc.
The trainees were each assigned a safety helmet each along with a
safety card.

6. The process area must be entered escorted by site personnel.

7. Speed limit of vehicle inside the factory is 25 Km/hr.

8. In case of any emergency, the employees and trainees had to assemble at

the nearest Emergency Assembly Point

Summer Vocational Training, IOCL HALDIA REFINERY 7

LUBE OIL BLOCK (LOB)

In lube oil block, the reduced crude oil from the Atmospheric Distillation Unit (ADU) is processed
to produce lube base stock, slack wax, transfer oil feed stock (TOFS), etc. LOB contains the
following 8 units:

1. Vacuum Distillation Unit

2. Propane De-Asphalting Unit
3. Furfural Extraction Unit
4. Solvent De-Waxing Unit
5. Hydro Finishing Unit
6. Bitumen treatment Unit
7. Visbreaking Unit
8. N – Methyl Pyrrolidine (NMP) Extraction Unit
9. Micro Crystalline Wax Unit
10. Catalytic Iso De-Waxing Unit

In LOB we were allowed to visit DCS Control Room And look through the control panel
that how the signal system works, how the field system communicate with the control
room.

DIGITAL CONTROL SYSTEM

Control device that makes control computation with digital values using a Processor
(processing unit).

Again digital control systems are of two types:-

 Centralized control system

 Distributed control system

Summer Vocational Training, IOCL HALDIA REFINERY 8

GRADUAL EVOLUTION TO DCS:-
-Single Loop Controllers

-ECS (Electronic control system) be used to monitor and regulate remote relays within
the refinery.

-SCADA (supervisory control and data acquisition) generally refers to industrial control
systems (ICS): computer systems that monitor and control industrial, infrastructure, or
facility-based processes.

-However, the SCADA systems have many security vulnerabilities. Any attacks or
damages of the SCADA systems can affect to the society severely.

-Finally DCS comes into scene.

INTRODUCTION TO DCS:-
A DCS typically uses custom designed processors as controllers and uses both
proprietary interconnections and communications protocol for communication. Input and
output modules form component parts of the DCS. The processor receives information
from input modules and sends information to output modules. The input modules receive
information from input instruments in the process (or field) and transmit instructions to
the output instruments in the field. Computer buses or electrical buses connect the
processor and modules through multiplexer or demultiplexers.

Basic architecture:
There are 4 parts incorporated in one DCS.

 FCS(field control station)

 Engineering station
 HIS(Human interface station)
 Gateway

All these are confined in one network named Domain. One domain can accommodate at
max 64 stations. There must be one engineering unit through which programs
downloaded /modified to CPU.

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No of HIS are up to user’s choice. HIS can function as Engineering Station if
engineering keyboard is there.

Field Control Station (FCS)

– Main controller of Centum CS 3000 system

– All control strategies implemented in FCS
– Two types
 FIO (Field network I/O)
 RIO (Remote I/O)
 Field network I/O (FIO)

– FIO use ESB & ER Bus to connect with FCS

– ESB bus (Extended Serial Backboard bus) is a communication bus for
local nodes, Max. 10m
– ER bus (Enhanced Remote bus) is a communication bus for remote
nodes, Max. 2 Km using Optical fiber repeaters
– Dual redundant
– Remote I/O (RIO)
– RIO use RIO bus to connect with FCS
– I/O nodes can be mounted remotely
– 750m with twisted pair cable
– 20 Km with Optical fiber

Engineering Station (ENG)

– Engineering and maintenance functions

– General purpose PC as HIS
– Can be used HIS

Human Interface Station (HIS)

– Mainly used for Operation and monitoring

– Window for Process, alarms
– Uses a general purpose PC.
– Has both engineering keyboard and operational keyboard.

Summer Vocational Training, IOCL HALDIA REFINERY 10

ONCE THROUGH HYDROCRACKER UNIT (OHCU)
Cracking is the breakdown of a large alkane into smaller, more useful alkanes and an
alkene. Oil refinery cracking processes allow the production of "light" products such as
liquefied petroleum gas (LPG) and gasoline from heavier crude oil distillation fractions
such as gas oils and residues. Fluid catalytic cracking produces a high yield of gasoline
and LPG, while hydro cracking is a major source of jet fuel, diesel, naphtha, and LPG.

Thermal cracking is currently used to "upgrade" very heavy fractions (also called
"visbreaking"), or to produce light fractions or distillates, burner fuel and/or petroleum
coke. Two extremes of the thermal cracking in terms of product range are represented
by the high-temperature process called "steam cracking" or pyrolysis (ca. 750 °C to 900
°C or more) which produces valuable ethylene and other feedstock for the petrochemical
industry.

Indian Oil has commissioned the Once-through Hydro Cracker Unit (OHCU) project at
Haldia refinery.

The OHCU project consists of the hydrogen generation unit, the nitrogen plant, and the
hydrocracking unit.

During the visit, we were shown around the unit by Mr. Vipul Vinay.

Some of the field instruments shown in OHCU are written below:

For level measurement DP, Displacer type, Radar level gauges and Hydrastep are
majorly used. Magnetic type and Gauge glass are used for local indication of level. Level
switching is done using Ultrasonic Level Switches.

Temperature is measured using RTDs, T/Cs and pyrometers. Temperature scanners of

upto 24 time-multiplexed channels are used for filed indication and are sent to PLC to
trip thus reducing the cabling to the control room.

Flow measurement is done using Orifice type, Venturimeter, Coriolis Mass flowmeter,
Annular, Ultrasonic flowmeter and Variable area Rotameter.

For pressure measurement, pressure gauges and DP cell are used. Most of the
instruments were of the latest models and HART compatible.

Strainers are used in the path before the gas enters the compressor to trap foreign
particles. When the differential pressure across the strainer increases indicating choke, it
is cleared manually or sent to flare in case of hazardous gases.5 valve transmitter
manifold systems are used for periodic removal and maintenance of the pressure
transmitters. Loops are used in hotline to absorb expansion and avoid cracking.

Explosion proof protection PLCs are used in the plant area to prevent spread of fire in
hazardous areas. The analyzer shelters in the plant are equipped with smoke detectors,
IS switches, Hydrocarbon and Hydrogen detectors, O2, SOx NOx analyzers.

Summer Vocational Training, IOCL HALDIA REFINERY 11

Heat tracing of wire bundles are done to prevent condensation of gases in line. Gases
are diluted to prevent choking due to high percentage of H2S.Instrument air is provided
by absorbing moisture using dessecants.

UV flame detector is used in the furnace to monitor fuel oil combustion.

OM&S Off-site:

This section of the plant deals with the logistical challenge of moving crude oil to the
plant for refining and also distributing the refined products to consumers. There are
several storage tanks which maintain a large inventory of crude oil and finished products
like Aviation Turbine Fuel, Motor Spirit, Bitumen, Diesel, etc. Apart from several storage
tanks, this unit has the following main sections:
 Wagon Loading Gantry
 Truck and Tank Loading station
 Bitumen Filling Station

LPG:
LPG is a blend of Butane and Propane readily liquefied under moderate pressure. LPG
vapour is heavier than air; thus it normally settles down in low-lying places. Since LPG
has only a faint scent, a mercaptan odorant is added to help in its detection. In the ev-
ent of an LPG leak, the vaporization of liquid cools the atmosphere and condenses the
water vapour contained in it to form a whitish fog, which is easy to observe. LPG in fairly
large concentrations displaces oxygen leading to a nauseous or suffocating feeling.

CHARACTERISTICS OF LIQUIFIED PETROLEUM GAS (LPG) :

a) It contains mainly C3 & C4 and unsaturated hydrocarbons like propylene and

butylenes.
b) It has a typical vapour pressure of 7-8 kg/cm2 at 380C and density 0.54 gm/cc to
0.55 gm/cc.
c) At normal atmospheric pressure LPG exists as vapour, where it is in liquid state
when stored under pressure in LPG storage vessels and cylinders.
d) In case of leakage to atmosphere the LPG vaporizes rapidly. This is a potentially
dangerous situation as the spilling LPG vapour can get ignited from any source of
ignition. In case liquid LPG spills out of container it vaporizes into very large
volume i.e. over 250 times.
e) While evaporation, liquid LPG picks up heat from the surroundings and cools
down; moisture present around it condenses.
f) LPG is heavier than air.
g) It is colourless in liquid and in vapour phase and practically odourless. For easy
leak detection Ethyl Marcaptan an odorant is added.

Summer Vocational Training, IOCL HALDIA REFINERY 12

WORKSHOP
We were allowed to explore the workshop. We got to see a number of spare
instruments. Instrumentation is all about Measuring, Controlling, Analyzing and
recording. And to do so you have different kinds of instruments which are capable of it. It
is almost used in every industry where there is a need for some kind of measurement
and control which might be very essential for the smooth functioning of the process.

Some of the instruments we saw are:

 Temperature measurement: RTD, thermocouple, radiation pyrometer

 Level measurement: DP transmitter, glass gauge, remote seal diaphragms
 Pressure measurement: DP transmitter, pressure gauge, bellows
 Flow measurement: Orifice plate
 Control valves
 I to P convertor

TEMPERATURE MEASUREMENT:
Resistive Temperature Detectors (RTDs): RTDs are sensors
used to measure temperature by correlating the resistance of
the RTD element with temperature. Most RTD elements consist
of a length of fine coiled wire wrapped around a ceramic or
glass core. The element is usually quite fragile, so it is often
placed inside a sheathed probe to protect it. The RTD element
is made from a pure material whose resistance at various
temperatures has been documented. The material has a
predictable change in resistance as the temperature changes; it
is this predictable change that is used to determine temperature.
As they are almost invariably made of platinum, they are often
called Platinum resistance thermometers (PRTs). PRTs
which have 100Ω resistance at 00C are called Pt-100 RTDs.
The relation between temperature and resistance is given by the Callendar-Van Dusen
equation:
RT = R0 [ 1 + AT + BT2 ] ( 00C <= T < 8500C )

Here, RT is the resistance at temperature T, R0 is the resistance at 0 °C, and the

constants (for an alpha=0.00385 platinum RTD) are
A = 3.9083 X 10-3 0C-1
B = -5.775 X 10-7 0C-2
C = -4.183 X 10-12 0C-4
Since the B and C coefficients are relatively small for elements like platinum, the
resistance changes almost linearly with the temperature, and hence can be used as
resistive element in RTD.

Summer Vocational Training, IOCL HALDIA REFINERY 13

Thermocouple: A thermocouple is a device consisting of two different conductors
(usually metal alloys) that produce a voltage proportional to a temperature difference
between either ends of the two conductors.
Thermocouples are self powered and require no
external form of excitation. The main limitation with
thermocouples is accuracy and system errors of
less than one degree Celsius (C) can be difficult to
achieve.
Any junction of dissimilar metals will produce an
electric potential related to temperature. This is
known as Seebeck effect. Thermocouples for
practical measurement of temperature are junctions
of specific alloys which have a predictable and
repeatable relationship between temperature and
voltage

Cold junction compensation: Thermocouples

measure the temperature difference between two
points, not absolute temperature. To measure a
single temperature one of the junctions—normally
the cold junction—is maintained at a known
reference temperature, and the other junction is at
the temperature to be sensed.
Having a junction of known temperature, while useful for laboratory calibration, is not
convenient for most measurement and control applications. Instead, they incorporate an
artificial cold junction using a thermally sensitive device such as a thermistor or
diode to measure the temperature of the input connections at the instrument, with
special care being taken to minimize any temperature gradient between terminals.
Hence, the voltage from a known cold junction can be simulated, and the appropriate
correction applied. This is known as cold junction compensation.

Thermocouples reference tables: Since the outputs of the thermocouple are not linear
with temperature difference, NIST (National Institute of Standards and Technology,
United States) have determined the output mV of all type thermocouples, at all
temperatures, within their range.

Summer Vocational Training, IOCL HALDIA REFINERY 14

 Table:- Types & Characteristics Of Thermocouple

Radiation Pyrometer: A pyrometer is any temperature-measuring device that includes

a sensor and a readout. A radiation pyrometer is a noncontact temperature sensor that
infers the temperature of an object by detecting its naturally emitted thermal radiation.
Principle of Operation: A pyrometer has an
optical system and a detector. The optical
system focuses the thermal radiation onto
the detector. The output signal of the
detector (temperature T) is related to the
thermal radiation or irradiance j* of the target
object through the Stefan–Boltzmann law,
the constant of proportionality σ, called the
Stefan-Boltzmann constant and the
emissivity ε of the object.
This output is used to infer the object's temperature. Thus, there is no need for direct
contact between the pyrometer and the object, as there is with thermocouples and
resistance temperature detectors (RTDs).

PRESSURE MEASUREMENT:
Bourdon Tube:
Bourdon tube is an elastic transducer which is fixed and open at one end to receive the
pressure which is to be measured. The other end of the bourdon tube is free and closed.
The cross-section of the bourdon tube is elliptical. The bourdon tube is in a bent form to
look like a circular arc. To the free end of the bourdon tube is attached an adjustable
link, which is inturn connected to a sector and pinion as shown in diagram.

Summer Vocational Training, IOCL HALDIA REFINERY 15

To the shaft of the pinion is connected a pointer which sweeps over a pressure
calibrated scale. The pressure to be measured
is connected to the fixed open end of the
bourdon tube. The applied pressure acts on the
inner walls of the bourdon tube. Due to the
applied pressure, the bourdon tube tends to
change in cross – section from elliptical to
circular. This tends to straighten the bourdon
tube causing a displacement of the free end of
the bourdon tube. This displacement of the free
closed end of the bourdon tube is proportional
to the applied pressure. As the free end of the
bourdon tube is connected to a link – section –
pinion arrangement, the displacement is
amplified and converted to a rotary motion of
the pinion. As the pinion rotates, it makes the
pointer to assume a new position on a pressure
calibrated scale to indicate the applied pressure directly. As the pressure in the case
containing the bourdon tube is usually atmospheric, the pointer indicates gauge
pressure.

CONTROL VALVE:
The control action in any control loop system is
executed by the final control element. The most
common type of final control element used in
chemical and other process control is the control
valve. A control valve is normally driven by a
diaphragm type pneumatic actuator that throttles the
flow of the manipulating variable for obtaining the
desired control action. A control valve essentially
consists of a plug and a stem. The stem can be
raised or lowered by air pressure and the plug
changes the effective area of an orifice in the flow
path The control valve assembly typically consists of
the valve body, the internal trim parts, an actuator to provide the motive power to
operate the valve, and a variety of additional valve accessories, which can include
positioners, transducers, supply pressure regulators, manual operators, snubbers, or
limit switches.

Current to Pressure Convertor: The I/P converter uses an electromagnetic force

balance principle to change electrical signals into pneumatic signals. Typically, a 4 –
20mA input is converted into a 3 – 15 psi output. The operating principle of the I/P
transducer is shown below:

Summer Vocational Training, IOCL HALDIA REFINERY 16

 As shown above, a coil produces the
magnetic field. Within the coil is a
deflector motor with a flapper valve
attached that operates against a
precision nozzle to create a
backpressure on the servo diaphragm of
a booster relay. The input current flows
in the coil and produces a force between
the coil and the flapper valve, which
controls the servo pressure and the output pressure

Positioner: A valve positioner is a device used to increase or decrease the air pressure
(from the I/P) operating the control valve actuator. Positioners usually
mount to the control valve actuator and connect mechanically to the
valve stem for position indication.
A positioner is a type of air relay, which acts to overcome hysteresis,
packing box friction, and effects of pressure drop across the valve. It
assures exact positioning of the valve stem and provides finer control.
There are many types of positioners. The basic principles of operation
are similar for all types.
The instrument pressure (from an I/P, for example) acts on the input module, which
controls the flapper-nozzle system of the relay. Supply pressure applies to the relay and
the output pressure of the relay goes to the control valve actuator.
.

LEVEL MEASUREMENT:
Differential Pressure Transmitter: Differential pressure level measurement is an
inferential level measurement technique. When hydrostatic pressure exerted by a liquid
column is measured using a pressure transmitter and the level of the liquid is inferred
from the measurement assuming that the density of the liquid is known and constant.

Differential pressure level measurement technique makes

use of a differential pressure detector which is installed at
the bottom of the tank whose level is to be detected. The
liquid inside the tank creates pressure which is comparatively
higher than the reference atmospheric pressure. This
pressure comparison is performed via the Differential
pressure detector.
In case of open tanks i.e. tanks which are open to the
atmosphere, only high pressure ends of the DP transmitter is
needed to be connected whereas the low pressure end of the
DP transmitter is expelled into the atmosphere. Hence, the differential pressure happens
to be the hydrostatic head or weight of the fluid contained in the tank.
The highest level detected by the differential pressure transmitter usually depends upon
the maximum height of fluid above the transmitter, whereas the lowest level detected is
based upon the position where the transmitter is attached to the tank or vessel.

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Now, in cases where tanks or vessels are not open to the atmosphere i.e. in
pressurized tanks, both the high and low pressure ends of the differential pressure
detector are required to be connected. These tanks are entirely covered in order to avoid
release of vapors or steam outside. Due to this, the liquid inside the tank gets
pressurized.

Displacer Level Sensors: Displacer level sensors use

Archimedes’ Principle to detect liquid level by
continuously measuring the weight of a displacer rod
immersed in the process liquid. The displacer is
cylindrical in shape with a constant cross-sectional area
and made long or short as required. Standard heights
range from 14 inches to 120 inches. As liquid level
increases, the displacer rod experiences a greater
buoyant force, making it appear lighter to the sensing
instrument, which interprets the loss of weight as an
increase in level and transmits a proportional output
signal. As liquid level decreases, the buoyant force
on the displacer rod decreases with a
corresponding weight increase which is interpreted
as decreasing level by the level sensor which then
give a corresponding signal output. The torque
tube assembly is the most common method of
constructing displacer type level transmitter.
A torque tube is a hollow tube that acts as a torsion
spring. One end is clamped to a rigid support and
the other end is connected to the displacer via a
torque arm and mounted as shown. Apparent
weight of displacer multiplied by the length of the
torque arm results in a torque acting on torque tube, causing the end connected to the
displacer to be subjected to a torsion θ = Torque/K, where K is the torsional stiffness.
The torque tube is designed to twist a specific amount for each increment in apparent
weight of the displacer. The angular deflection of the displacer is converted to a current
signal using a strain gauge connected to a Wheatstone bridge.

Ultrasonic Level Switch: Ultrasonic sound waves are greatly

attenuated when transmitted through air. Conversely, when
liquid is present, transmission of the sound waves is greatly
enhanced. The electronic control unit generates electrical
signals that are converted to bursts of ultrasonic energy at the
sensor. The ultrasonic bursts are transmitted across the liquid
sensing gap. Upon receipt of a valid signal, the solid-state
electronics generate a data enable condition, indicating liquid
is present. This signal energizes a relay and provides an
output condition.

Summer Vocational Training, IOCL HALDIA REFINERY 18

FLOW MEASUREMENT:
Differential Pressure Flow Measurement:
ORIFICE TYPE: An orifice plate and DP transmitter is the
most widely used flow measuring device in process
industries. An orifice plate, in its most commonly used
form, is a circular disc, usually made of stainless steel
and provided with a circular bore. An orifice plate is
usually mounted in a pipeline between a pair of flanges.

When fluid flow through the pipe is zero, the pressure

before and after the orifice is essentially identical. As
soon as the fluid begins to flow the velocity near the
orifice increases significantly due to the restriction in
the cross section. At the same time, the static
pressure at this region decreases. A differential
pressure is developed across the orifice as shown.
Pressure taps are located upstream and downstream
of the orifice plate to allow measurement of the
developed DP with a DP cell.
The disadvantage of orifice DP flowmeter is that the
abrupt change in cross section causes pressure losses and turbulent flow.

VENTURI FLOWMETER: The venture flow meter is

installed as a section of pipe or tubing and is used to
measure the flow of fluids, either gaseous or liquid. The
meter consists of a converging inlet section, a short
straight throat section, and a diverging section. As the
fluid enters the converging section, its velocity begins to
increase, reaching a maximum value at the throat. The
diverging section then slows the fluid to approximately its
original value. At the point of maximum velocity, the static
pressure has decreased to a value less than the inlet static pressure. The difference
between these two pressures along with the inlet pressure and temperature is an
extremely accurate and simple indication of the mass rate of flow through the instrument.

Summer Vocational Training, IOCL HALDIA REFINERY 19

CONCLUSION:
From the vocational training, we have come to acquire a considerable knowledge of the
working of the industry. There are numerous applications of Instrumentation and Control
in Indian Oil Corporation. We were able to see those field instruments in operation which
we had read in our curriculum. Also, we have seen how remote monitoring of a system
by Distributed Control System (DCS) and Programmable Logic Controller (PLC) how is
possible. In addition, interaction with several professional Instrumentation Engineers has
given us an exposure which is very valuable to us. Altogether, it can be said that the
practical knowledge acquired during this training will stand us in good stead. It has been
a great opportunity for us to get to know-how of the things from such a reputed industry.
I am grateful to all the employees of IOCL, Haldia, who guided us throughout the
training.

Summer Vocational Training, IOCL HALDIA REFINERY 20