Report On Summer Training

At

Lube Blending Plant

Indian Oil Corporation Limited Paharpur

Project Guide: Mr. Pujan Kumar Maity, Dy. Plant Manager

Training period: 11 June, 2014 – 11 July, 2014

Submitted By

Sayan Roy

Department Of Mechanical Engineering (3rd

Year)

Future Institute of Engineering & Management

Kolkata

2

Sl.

No. Contents Page No.

1. Introduction 3

2. Map of the plant 4

3. Lubricant-Definition & Purpose 5 - 8

4. Classifications of lubricants 9 - 10

5. Process of the plant 11 -12

6. Base oil & Base oil storage tanks 13-15

7. Additive & additive storage tanks 16-17

8. Transfer Systems 17-20

9. Lube Blending & Blending Kettles 21-23

10. Inside blending kettle

Air Spanger

Agitator

Circulation

24-25

11. Boiler 26-27

12. Air Dryer 28-29

13. Lube Despatching Section

Barrel Filling

Manual Filling

Small can filling

30-34

14. Agro Spray section 35

15. Electra Plant (Transformer Oil) 36

16. Effluent Treatment Plant (ETP) 37-38

17. Quality Control Laboratory

Crackle test

Pour point test

Flash point test

Total Acid

Number(TAN)

39-42

18. Industrial Safety in Lube Blending Plant 43-51

19. Conclusion 52

3

INTRODUCTION The Lube Blending Plant of Indian Oil Corporation Limited

Location: Paharpur, Kolkata

Area: 13.59 acres

Production Capacity: 0.1 MMT/annum

Established on: 22nd March,1963

The Kolkata plant was commissioned in 1964.In 1973 the production of

‘SERVO’ lubricants started. In 1994, the plant was certified for ISO 9002:94

quality systems and in 2001, the plant was certified for ISO 14000:96

environment management systems. In 2003, SAP had been implemented in

Kolkata plant. In 2006, the plant has been certified for ISO 9001:2000.

More than 350 grades of lubricants are manufactured in this plant.

There are 28 base oil tanks having a total capacity of 30738 KL

There are 8 bulk additive tanks having a total capacity of 1365 KL

There are 14 blending kettles having a total capacity of 1712 KL

There are 2 diesel generator of 250 KVA and 350 KVA

2 Boilers of capacity 5 tons per hour

High capacity Effluent Treatment Plant (100KL &150 KL)

Integration of plant activities with all marketing network across the

organisation through SAP

Access control system is implemented in the plant

Quality Control laboratory which is equipped with instruments of latest

state of the art technology

4

Map of the Plant

Fig: Overview of the Lube Blending Plant, IOCL, Paharpur, Kolkata

5

Lubricant: Definition & Purpose

A lubricant is a substance introduced to reduce friction between moving

surfaces. It may also have the function of transporting foreign particles. The

property of reducing friction is known as lubricity (Slipperiness).

A good lubricant possesses the following characteristics:

High boiling point

Low freezing point

High viscosity index

Thermal stability

Hydraulic Stability

Demulsibility

Corrosion prevention

High resistance to oxidation

One of the single largest applications for lubricants, in the form of motor oil,

is protecting the internal combustion engines in motor vehicles and powered

equipment.

Typically lubricants contain 90% base oil (most often petroleum fractions,

called mineral oils) and less than 10% additives. Vegetable oils or synthetic

liquids such as hydrogenated polyolefin, esters, silicones, fluorocarbons and

many others are sometimes used as base oils. Additives deliver reduced

friction and wear, increased viscosity, improved viscosity index, resistance to

corrosion and oxidation, aging or contamination, etc.

Lubricants such as 2-cycle oil are added to fuels like gasoline which has low

lubricity. Sulphur impurities in fuels also provide some lubrication properties,

which have to be taken in account when switching to a low-sulphur diesel;

biodiesel is a popular diesel fuel additive providing additional lubricity.

6

Non-liquid lubricants include grease, powders (dry graphite, PTFE,

Molybdenum disulphide, tungsten disulphide, etc.), PTFE tape used in

plumbing, air cushion and others. Dry lubricants such as graphite,

molybdenum disulphide and tungsten disulphide also offer lubrication at

temperatures (up to 350 °C) higher than liquid and oil-based lubricants are

able to operate. Limited interest has been shown in low friction properties of

compacted oxide glaze layers formed at several hundred degrees Celsius in

metallic sliding systems, however, practical use is still many years away due to

their physically unstable nature.

Another approach to reducing friction and wear is to use bearings such as ball

bearings, roller bearings or air bearings, which in turn require internal

lubrication themselves, or to use sound, in the case of acoustic lubrication.

Purpose of Lubricant:

Lubricants perform the following key functions.

• Keep moving parts apart

• Reduce friction

• Transfer heat

• Carry away contaminants & debris

• Transmit power

• Protect against wear

• Prevent corrosion

• Seal for gases

• Stop the risk of smoke and fire of objects

• Prevent rust

Keep moving parts apart:

Lubricants are typically used to separate moving parts in a system. This has the

benefit of reducing friction and surface fatigue, together with reduced heat

generation, operating noise and vibrations. Lubricants achieve this by several

7

ways. The most common is by forming a physical barrier i.e., a thin layer of

lubricant separates the moving parts. This is analogous to hydroplaning, the

loss of friction observed when a car tire is separated from the road surface by

moving through standing water. This is termed hydrodynamic lubrication. In

cases of high surface pressures or temperatures, the fluid film is much thinner

and some of the forces are transmitted between the surfaces through the

lubricant.

Reduce friction:

Typically the lubricant-to-surface friction is much less than surface-to-surface

friction in a system without any lubrication. Thus use of a lubricant reduces

the overall system friction. Reduced friction has the benefit of reducing heat

generation and reduced formation of wear particles as well as improved

efficiency. Lubricants may contain additives known as friction modifiers that

chemically bind to metal surfaces to reduce surface friction even when there is

insufficient bulk lubricant present for hydrodynamic lubrication, e.g.

protecting the valve train in a car engine at start up.

Transfer heat:

Both gas and liquid lubricants can transfer heat. However, liquid lubricants are

much more effective on account of their high specific heat capacity. Typically

the liquid lubricant is constantly circulated to and from a cooler part of the

system, although lubricants may be used to warm as well as to cool when a

regulated temperature is required. This circulating flow also determines the

amount of heat that is carried away in any given unit of time. High flow

systems can carry away a lot of heat and have the additional benefit of

reducing the thermal stress on the lubricant. Thus lower cost liquid lubricants

may be used. The primary drawback is that high flows typically require larger

sumps and bigger cooling units. Turbochargers get red hot during operation

and the oil that is cooling them only survives as its residence time in the

system is very short i.e. high flow rate. If the system is shut down suddenly

(pulling into a service area after a high speed drive and stopping the engine)

the oil that is in the turbo charger immediately oxidizes and will clog the oil

ways with deposits.

8

Carry away contaminants and debris:

Lubricant circulation systems have the benefit of carrying away internally

generated debris and external contaminants that get introduced into the

system to a filter where they can be removed. Lubricants for machines that

regularly generate debris or contaminants such as automotive engines typically

contain detergent and dispersant additives to assist in debris and contaminant

transport to the filter and removal. Over time the filter will get clogged and

require cleaning or replacement, hence the recommendation to change a car's

oil filter at the same time as changing the oil. In closed systems such as gear

boxes the filter may be supplemented by a magnet to attract any iron fines that

get created.

Transmit power:

Lubricants known as hydraulic fluid are used as the working fluid in

hydrostatic power transmission. Hydraulic fluids comprise a large portion of

all lubricants produced in the world. The automatic transmission's torque

converter is another important application for power transmission with

lubricants.

Protect against wear:

Lubricants prevent wear by keeping the moving parts apart. Lubricants may

also contain anti-wear or extreme pressure additives to boost their

performance against wear and fatigue.

Prevent corrosion. Good quality lubricants are typically formulated with

additives that form chemical bonds with surfaces, or exclude moisture, to

prevent corrosion and rust.

9

Classification of Lubricant

The main types of lubricants are:

Automotive

Industrial

Specialty

Marine

Automotive Lubricants:

4 Stroke Engine Oil

2 Stroke Engine Oil

Multi-grade Engine Oil

Multi-grade Grease Oil

Transmission Fluid

Gas Engine Oil

Rail Road Oil

Industrial Lubricants:

Turbine Oil

System & Hydraulic System Oil

Knitting & Textile Oil

Circulating Oil

Vacuum Pump Oil

Steam Cylinder Oil

Heat Transfer Oil

Bearing Oil

Asphaltic Oil

Axle Oil

Gear Compound Oil etc.

10

Metal Working & Specialty Lubricants:

Soluble Cutting Oil

Neat Cutting Oil

Honing Oil

Aluminium Rolling Oil

Steel Rolling Oil

Quenching Oil

Rust Preventing Oil

Rubber Processing Oil

Agricultural Spray Oil

Glass Mould Oil etc.

Marine Lubricants:

Marine Crankshaft Oil

Marine Gear Oil

Marine Turbine Oil

Stern Tube Oil

11

Process of the plant

DISPATCHED TO REQUIRED LOCATIONS

BARGE/TANKER TRUCK WITH ADDITIVE BARREL

ADDITIVE STORAGE TANKS BASE OIL STORAGE TANKS

THROUGH MOTORS AND PUMPS

BLENDING KETTLE

TANK LORRY FILLING

SMALL CAN FILLING

BARREL FILLING

AGRO OIL BLENDING KETTLE

AGRO SPRAY

IN HDP CONTAINER

AND BUCKET

(1/5/6/7.5/10/12/20

LITRES)

BARREL (210 LITRES) TANK LORRY (2000) LITRES)

12

The base oil, also known as raw oil used for manufacturing

lubricating oil, is stored into the various storage tanks meant for

them. The base oil is brought by the tankers via sea route.

The oil is transferred to storage tanks by pipelines. The additives

which are to be mixed are brought by tank Lorries. Since the

amount of additive to be mixed to make a grade is quite small,

therefore the number of storage tanks for additives is much

smaller than the number of storage tanks. The additives and base

oil are stored in their respective storage tanks.

While making a specific grade of lubricating oil, certain amount

of base oil and additives are taken into the blending kettle. There

both are mixed by various pre-determined processes to

manufacture that specific grade of lube oil.

Now the manufactured lube oil is sent to three departments for

packaging namely small can filling, barrel filling and tank lorry

filling. In small can filling the lube oil is filled in small packages

with quantities varying from 1 to 20 litters. In barrel filing the oil

is packaged into a much larger quantity namely 210 litters. A

barrel is a large container which can contain 210 litters of oil. For

large scale dispatch tank lorry filling is used. A tank lorry with

large capacity is filled with the lube oil and dispatched to the

desired location.

In the whole process, the quality control department keeps an

eye on the quality of the oil which is dispatched. Even before the

manufacture of the lubricating oil, the quality control lab keeps a

tab on various important parameters of the oil.

The maintenance of all the machines in the plant is overseen by

the maintenance department. The maintenance department is

also responsible for overlooking the electrical system of the plant.

The finance department is responsible for allocating funds to

various vendors and repair works to be undertaken in the plant.

There is also a security department which monitors the security

in the plant. The fire security also comes under it and all the

proper equipment are kept in place.

13

Base Oil & Base Oil Storage Tanks The base oil, also known as raw oil used for manufacturing lubricating oil. The

main sources of base oil are Haldia Refinery, HPC, CRL and the rest are mainly

imported. The main types of base oil used in the plant are TOBH / TOBL /

HVI SP / LN / IN/ 500 SN HN/BN/BP/BITUMEN/PIB/PAO etc.

Mineral oil term is used to encompass lubricating base oil derived from crude oil.

The American Petroleum Institute (API) designates several types of lubricant

base oil:

Group I – Saturates <90% and/or sulphur >0.03%, and Society of

Automotive Engineers (SAE) viscosity index (VI) of 80 to 120

Manufactured by solvent extraction, solvent or catalytic dewaxing, and

hydro-finishing processes. Common Group I base oil are 150SN (solvent

neutral), 500SN, and 150BS (bright stock)

Group II – Saturates over 90% and sulphur under 0.03%, and SAE

viscosity index of 80 to 120

Manufactured by hydrocracking and solvent or catalytic dewaxing

processes. Group II base oil has superior anti-oxidation properties since

virtually all hydrocarbon molecules are saturated. It has water-white colour.

Group III – Saturates > 90%, sulphur <0.03%, and SAE viscosity

index over 120

Manufactured by special processes such as isohydromerization. Can be

manufactured from base oil or slag wax from dewaxing process.

Group IV – Polyalphaolefin (PAO)

Group V – All others not included above such as naphthenic, PAG,

esters.

In North America, Groups III, IV and V are now described as synthetic

lubricants, with group III frequently described as synthesised

hydrocarbons, or SHCs. In Europe, only Groups IV and V may be classed

as synthetics.

The lubricant industry commonly extends this group terminology to

include:

Group I+ with a Viscosity Index of 103–108

Group II+ with a Viscosity Index of 113–119

14

Group III+ with a Viscosity Index of at least 140

Can also be classified into three categories depending on the prevailing

compositions:

Paraffinic

Naphthenic

Aromatic

Lubricants for internal combustion engines contain additives to reduce

oxidation and improve lubrication. The main constituent of such lubricant

product is called the base oil, base stock. While it is advantageous to have a

high-grade base oil in a lubricant, proper selection of the lubricant additives

is equally as important. Thus some poorly selected formulation of PAO

lubricant may not last as long as more expensive formulation of Group III+

lubricant.

Currently there are 26 number of storage tanks in the plant which stores nearly

12000 KL of base oil as a whole. Storage tanks are large containers that hold

liquids or gases, in this case base oil. They work under very little or no pressure

which distinguishes them from pressure containers. These tanks are rounded in

shape, i.e. they are cylindrical in nature with either conical bottom or

hemispherical bottom. Every storage tank is equipped with heating facility.

Certain storage tanks are meant for a specific type of oil only. Oil cannot be

loaded in it, until the tank is washed three times.

The details of every storage tank with its capacity are given in the following:

STORAGE TANK CAPACITY (Litres)

1) S -1 1053488

2) S-2 1052859

3) S-3 590968

4) S-4 596715

5) S-5 1054022

6) S-6 1052685

7) S-7 264720

8) S-8 264950

9) S-9 265272

10) S-10 260263

11) S-11 262746

15

12) S-12 593059

13) S-15 1058264

14) S-16 1533231

15) S-17 1057465

16) S-18 1054337

17) S-19 1555729

18) S-20 2114736

19) S-21 2141021

20) S-22 2173390

21) S-23 250997

22) S-24 250990

23) S-25 3384459

24) S-26 3385108

25) S-27 3189609

26) S-28 3217977

16

Additives & Additives Storage Tanks

Additives are the other chemical ingredients of the Lubricant used with

proper proportions to produce desired effect. A large number of additives are used to impart performance characteristics to the

lubricants. The main families of additives are:

• Antioxidants

• Detergents

• Anti-wear

• Metal deactivators

• Corrosion inhibitors, Rust inhibitors

• Friction modifiers

• Extreme Pressure

• Anti-foaming agents

• Viscosity index improvers

• Demulsifying/Emulsifying

• Stickiness improver, provide adhesive property towards tool

surface (in metalworking)

• Complexing agent (in case of greases)

Note that many of the basic chemical compounds used as detergents (example:

calcium sulfonate) serve the purpose of the first seven items in the list as well.

Usually it is not economically or technically feasible to use a single do-it-all

additive compound. Oils for hypoid gear lubrication will contain high content of

EP additives. Grease lubricants may contain large amount of solid particle friction

modifiers, such as graphite, molybdenum sulphide.

Barrels filled with additives

17

Additives Storage Tanks

Additive oil storage tanks are also pretty much similar to base oil storage tanks.

There are 4 number of additive storage tanks in the plant. This is because the

quantity of additive required to make lubricants are very small. So as per their

requirement, their availability is also small. Some additives are also brought in

barrels (which is discussed later on). The following are the list of the additive

tanks and their capacity.

STORAGE TANK CAPACITY (In Litters)

1) A-5 251660

2) A-6 251345

3) A-7 251412

4) A-8 254680

Nearly all the additive storage tanks which are there in plant are of cylindrical type

with heating facility. Different types of additive which are kept in it are VI

improver, TBN, PIB (polyisobutylene) etc. All the tanks are located near new

filling centre.

18

Transfer Systems

The base oil and additives are stored in their respective tanks.

Then both type of oil are further transferred from storage tanks

to blending kettles. To make a certain grade of lubricating oil we

need base oil and additive in correct proportion as directed by

the Quality Control (QC) laboratory. Then both the oils are

mixed inside a blending kettle using various processes. The oil is

transferred with the help of pumps located in the blending

section. The pumps are controlled semi-automatically under the

keen observation of the persons sitting in the control room. Their

work in the section is to control the pumps through computer

system, better known as PLC.

Step 1: At first the base oil is brought from one storage tank to another

with the help of pumps. These pumps are controlled by motors. The

motors are also controlled semi-automatically. The manual part of the

process includes the attachment and detachment of pipes connecting

the pumps to various kettles. The automatic part includes the starting

of the motor. The process is that a desired quantity of base oil is to be

transferred from one tank to another. So the computer shows exactly

how much quantity of base oil should be transferred. The quantity is

fixed by the managers.

Step 2: After manually connecting the pipe to the desired output pipe

of the tank, the motor is started by the person sitting in the control

room. The weight of the base oil is shown by the unit Kg. During the

transfer process when a certain amount of oil is left to be transferred,

the system alerts the person in the control room. For example, when

600kg of oil is left to be transferred then the first siren is buzzed. The

second siren is buzzed when around 300Kg is left to be transferred.

Then the motor automatically stops after the second siren.

19

Step 3: The oil which remains stuck in the pipeline is transferred with

the help of air. Another valve is manually opened in the pipeline from

which the compressed air is supposed to pass. This air pushes the

remaining oil in the pipeline into the desired tank. A certain tolerance

is allowed regarding the quantity which is transferred. Not only base oil

but additives are also transferred using this technique.

If the additive to be transferred is very viscous, then more force

would be required to transfer it. If the force required exceeds the

force provided by the pumps, then the oil could get stuck in the

mechanism or it would take a great effort for the pump to transfer

it which means more wear and tear of the motor and the pump as

well as the pipelines. To solve this problem the additive is mixed

with a little amount of base oil to make it less viscous and easy to

flow. This does not affect the product as the mixing here is

compensated at the time of manufacturing the lubricant.

At the time when more than one type of base oil is to be

transferred, the process is extended a bit further. After the

transfer of one type of base oil is done another type of base oil is

transferred into the same tank. Since different base oils are of

different densities, therefore both the base oils floats above the

other in the tank.

Pipes through which the oil is transferred from storage tanks to blending kettles.

20

The Pumps connected at suction through storage tank and delivery to blending kettles

21

Lube Blending & Blending Kettles

The physical mixing process of blending components of a

lubricant to create a final product is called Lube Blending.

Lube oil blending and additive mixing is a fully automatic batching

process performed within four parallel lines each consisting of one

blender and one weigh hopper. Keeping the weight ratios of the lube

oil components is ensured by their precise weighing and is program-

controlled by remote opening-closing of dedicated flap valves.

Fig: Process Flow Diagram

PROCESS FLOW

DIAGRAM

BASE OIL TANKS

BULK ADDITIVES

DIRECTLY CHARGED

INTO BLENDING

KETTLE

BARREL ADDITIVES

CHARGED INTO

SUMPS

STIRRER

SUMP

STREAM COILS

FOR HEATING

AIR SPIDER

FOR AIR

PURGING

H

E

A

T

I

N

G

A

N

D

A

I

R

P

U

R

G

I

N

G

PUMP

BULK LOADING SMALL CAN FILLING BARREL FILLING

TANK LORRY FILLING

AND DISPATCH

DIRECT DISPATCH STACKING AND

STORING FOR FUTURE

DISPATCH

STACKING AND

STORING FOR FUTURE

DISPATCH

DIRECT DISPATCH

22

The blending process is the most important process in the entire plant. This

process is divided into three parts-

Mixing

Heating

Air Purging

The conical container called blending kettle is used to blend the lube. The base oil

from the tanks are put into the kettle to be blended. The bulk additives are directly

charged into the sump from where it is taken to the kettle.

The kettle is lined by heating coils along the inner walls to heat its contents during

the process of blending. The mixing is mainly done in three ways-using the stirrer,

using a pump and using air.

Step 1: A stream of air is used for air purging

Step 2: the motorized stirrer is used to mechanically stir the mixture to make it

homogeneous

Step 3: Finally a pump is present outside at the bottom of the kettle to set up a

cycle where the lube is continuously brought out of the kettle through the discharge

point at the bottom and is pumped back into the kettle. Thus, setting up a cycle to

blend the lubricant. The temperature of the mixture is measured and maintained

using a temperature gauge.

The Paharpur plant is incorporated with manual blending process. But in most

of the modern lube blending plants, modern blending techniques is used. Some

of the key parts of the modern blending techniques are-

Blending Systems

Automatic Batch Blending

In-Line Blending

Simultaneous Metered Blending

Process Automation Systems

WinBlend System Seven

Compact Blend System

e-BLEND Controller

Transfer Systems

Drum Decanting

Piggable Systems

23

Blending Kettles

A blending kettle is a small conical container or tank where the

mixing of different grades of liquids is done in correct proportion to

obtain a desired product. In this plant, base oil and additive are

mixed inside the blending kettle in a predetermined proportion to

obtain different types of lubricating oils. Unlike a storage tank, a

blending kettle not only stores the product but is also the place of

various processes which are required to make the finished product.

In Paharpur plant, there are 23 blending kettles. Some of them have

been converted into blending kettles from storage tanks.

Kettle No. Capacity (in KL) Facilities

BT 1/2/8/9 33 Heat,Stir,Air Blow & Circulation

BT 3/4/7 15 Heat,Stir,Air Blow & Circulation

BT 10/11/17 12 Heat,Stir,Air Blow & Circulation

BT 18 25 Heat,Stir,Air Blow & Circulation

BT 5/6 60 Heat,Stir,Air Blow & Circulation

FP 3 50 Heat,Stir,Air Blow & Circulation

BT 12/13/14/15/16 65 Heat,Stir,Air Blow & Circulation

FP 1 130 Heat,Stir,Air Blow & Circulation

S 10/13/14 240 Heat,Stir,Air Blow & Circulation

24

Inside Blending Kettle

After the transfer of base oil and additive in the blending kettle there

are various processes involved in making the lubricating oil. First the oil

is checked for any moisture content. This is done in the quality control

laboratory. Moisture content of the oil is checked with the help of

crackle test.If the oil is found to have high moisture content, then it is

heated with the help of steam. Inside the blending kettles there are

tubes which coil around the inner surface of the kettle. Through these

tubes, hot steam is passed. This hot steam increases the temperature of

the oil and releases the moisture content. Thus the oil becomes free

from water content. In the whole process the steam never directly

comes in contact with the oil. Ever directly comes in contact with the

oil.

After de moisturizing the oil, it is mixed. Remember the base oil and

the additives are of different densities. So it needs to be mixed with one

another. The mixing of the oil is done in three ways:-

Air Spangler

Agitator.

Circulation.

The type of mixing which is to be chosen depends basically on:-

Dehydration

Viscosity

Temperature

Duration

AIR SPANGLER

In this process air is circulated inside the kettle for mixing the oils. Every tank is connected to a

pipe compressed air flows. When two base oils are to be mixed, then the valves of one such

pipe are opened to allow the compressed air to pass through the oil. Air is introduced in the

kettle through a line. The air is circulated inside the kettle as long as the oil doesn’t get mixed

completely. While the process is on it is not advisable for anyone to stay near the kettle as it

may throw off some amount of oil outside. Due to this drawback this process is seldom used

for mixing purpose. Also the efficiency of this process is very low. Therefore apart from this

method, two other methods are used.

25

AGITATOR

Inside the blending kettle there is a mechanical stirrer fitted in its centre. It consists of blades

analogues to the ceiling fan at our home. Now when the oil is required to be mixed this stirrer

is turned on. It rotates just like the ceiling fan inside the kettle. The motion of the stirrer creates

a whirlpool inside the kettle which helps the oil to get mixed. The stirrer is kept on rotating up

to a certain time after which it is stopped. The stirrer is rotated both clockwise and anti-

clockwise after a time delay.

CIRCULATION

This method is most widely used one. Here the unmixed oil is circulated in a circulating line.

After the transfer of base oil and additive in the kettle, the circulating line is opened by the

persons sitting in the control room through computer. As soon as the circulating line is opened,

the oil is released from downwards, moves up through the line and then re-enters the kettle

from upward. Thus the oil keeps on circulating through the pipe as long as it is not mixed. This

is the most efficient way of mixing the oils. For the implementation of this method, it requires a

separate line for circulation.

Fig: Blending Kettle-Line Diagram

26

BOILER

A boiler is a large container where steam is produced due to combustion

and various other mechanisms. It is a closed vessel in which water or other

fluid is heated. The fluid does not necessarily boil as the name suggest.

The heated fluid exits the boiler for use in various processes or in heating

applications. The pressure vessel of a boiler is usually made of steel or

wrought iron. The source of heat for a boiler is combustion of any of

several fuels such as wood, coal, oil or natural gas.

In fire tube boiler, the water partially fills a boiler barrel with a small volume left

above to accommodate the steam. This type of boiler is used in nearly all steam

locomotives. The heat source is inside a furnace that has to be kept permanently

surrounded by water in order to maintain the temperature of heating surface just

below boiling point. The furnace can be situated at one end of a fire tube which

lengthens the path of the hot gases, thus augmenting the heating surface which

can be further increased by making the gases reverse direction through a second

parallel tube. These types of boilers usually have a low rate of steam production,

but high steam storage capacity. Fire tube boilers mostly burn solid fuels, but are

readily adaptable to those of liquid and gaseous types.

In Paharpur plant the steam generating capacity of each boiler is 5 ton per hour.

Below is a rough cross section sketch of a boiler.

27

The process in the boiler is initiated by a force draft. The air is entered in the

combustion chamber through force draft. The heat is generated in the

combustion chamber inside. This is called 1st pass. The heated air is passed

through the air tubes, which are fitted inside. These tubes pass through the water

inside the boiler. The heated air is passed in the tube. Due to this, these tubes

gets heated up which heats up the water in turn. The water gets heated up without

directly coming in contact with water. This heated water produces steam, which is

passed through the steam outlet. This steam is then dried, with the help of air

dryer. The end product is then fed to various pneumatic equipment in the plant

which includes barrel filling machines, small can filling machines and other

equipment. The air which is produced after the combustion and which is used to

heat up the water, is then passed to a chimney which is then outlet to the

atmosphere. This is how steam is produced in the plant.

5 tonne Boiler

28

Air Dryer

A compressed air dryer is a device for removing water vapour from

compressed air. Compressed air dryers are commonly found in a wide

range of industrial and commercial facilities. The process of air

compression concentrates atmospheric contaminants, including water

vapour. This raises the dew point of the compressed air relative to free

atmospheric air and leads to condensation within pipes as the

compressed air cools downstream of the compressor.

a) Air Dryer b) Control Panel of Air Dryer

Excessive water in compressed air, in either the liquid or vapour phase,

can cause a variety of operational problems for users of compressed

air. These include freezing of outdoor air lines, corrosion in piping and

29

equipment, malfunctioning of pneumatic process control instruments,

fouling of processes and products and more.

There are various types of compressed air dryers. Their performance

characteristics are typically defined by the dew point. So, essentially

water vapour is removed from compressed air to prevent condensation

from occurring and to prevent moisture from interfering in sensitive

industrial processes.

30

Lube Despatching Section

The Lube Despatching Section is associated with FILLING of different

grades of Lubricants in mainly three ways-

Barrel Filling

Manual Filling

Bulk Filling

Small Can Filling

Barrel Filling:

Machine Used: In the whole plant there are two automatic and one semi-

automatic filling machine. The machines as a whole is called in-line weight filler.

One automatic barrel filling machine is located besides the blending tank and

another behind the maintenance department. Both the filling machine works on

same principal though they have been manufactured by different companies.

Control: Each barrel filling machine is controlled by two PLC. One PLC is

responsible for filling the barrel and another PLC is responsible for carrying the

barrel up to the end point. Both PLC’s apparatus are joined to get a complete

system out of it.

Explanation of the system under the first PLC:-

The lid tight barrel is first entered into the system with the help of in fed roller

conveyor. Then the barrel comes into the entrance of a chamber. Inside the

chamber, there are 9 positions where a barrel stops. The chamber contains eight

31

doors (so that any manual work can be done if any discrepancies occur in the

system).

1) At the first position the barrel is checked for any abnormalities in the entrance

only.

2) After checking the barrel is moved to the second position. Here the barrel is

synchronized in a certain position where filling could start. This happens as the

barrel comes to the position and is then slightly lifted up. Then it is rotated so as

to synchronize it in a perfect position, i.e. to find the mouth of the barrel.

3)At this position the seal of the barrel is opened and is carried to the 8th position

where it gets put on again.

4) Here the barrel comes to an empty position so as to wait for its turn to get filled

up.

5) The barrel is filled with the required graded oil. The amount of oil to be filled

is determined by weight that is entered in the control system. This weight is

determined by the people sitting in the control based on the oil’s density.

6) Same process occurs here as in 5th. Actually two barrels are filled at a time, so

filling is dedicatedly done at 5th and 6th positions simultaneously.

7) Then the barrel waits for its turn to get sealed.

8) Here the cap which was opened previously is carried up to this position and

fitted in the barrel appropriately.

9) At this position heat sealing is done using the Indian oil logo.

10) This position provides a final check for the barrel. After this position the

barrel comes out of the chamber and is carried to the end point of this part of

apparatus. In case a snag occurs inside the chamber, the problem is being shown

in the display control panel. Then the problem is addressed manually by opening

the concerned door which is provided in the chamber.

Explanation of the system under the second PLC:-

The filled barrel enters this system through roller conveyor. There is a sensor

fitted at the entrance which acknowledges their entry. Then the barrel comes to a

point where its movement is halted. At this point four barrels are collected. From

another side wooden pallets are dispatched. These pallets are kept in a place

inside the apparatus. The apparatus can hold maximum 7 pallets at a time. These

pallets are moved in the manner of FIFO (First In First Out). The lowermost

pallet is moved forward so that the filled barrels can be put on it. Then a metallic

plate is used to move the filled barrels on the pallets. Each pallet can have

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maximum four barrels. Then these barrels are moved towards the desired truck

using fork lift (3-ton capacity).

Pallet side control panel:-

The control panel consists of one stop button, one restart button, an auto manual

rotating switch, two rotating switch to control the forks of the system (forks refers

to the rods that lifts the pallets inside the system). No one is allowed to go inside

the apparatus. In case someone enters the premises of the apparatus, the sensor

in place senses the movement and immediately the apparatus will be switched off

automatically. The switching off is indicated by the green glow of restart button

being off. The panel is restarted by pushing the restart button.

The whole system is controlled by sensors. On an average if all goes well, i.e. if

there are sufficient barrels and oil supply and no snag occurs in the machine, then

the system can generate up to 75 barrels/hour.

Manual Filling:

Machine Used: semi-automatic filling machine

named Avery.

Process: One person controls the whole system

out here. The weight of the oil to be filled is set

beforehand in the machine. Here opening and

closing of cap and sealing are done manually.

The capacity of this machine depends totally on the speed of manpower. Ideally

it is 45-50 barrels per hour. The semi-automatic system has been installed before

the automatic one. Its contribution to barrel dispatch might not match with the

automatic filling machines, but it acts as a booster for completion of barrel filling.

On a hectic day where demands of barrel filling are to be met urgently, this

machine helps a lot. The only drawback of this kind of filling machine is the use

of manpower and much lower rate of filling the barrels than the automatic ones.

The rate of production in this case completely depends on the speed of the

person operating the filling machine.

Bulk Filling:

In Bulk loading section there are 3 bays for loading 3 tank Lorries at a time.

33

Small Can Filling:

Small cans of quantities 1 litre to 20 litres is filled up here. Machines play a big

role in this section. Here manpower is used for mostly watch purpose. Small cans

of quantities 1, 5, 6, 7.5, 10, 12, 20 litres are manufactured. Out of this only 7.5

litre packaging is done manually. Apart from that, the process of all other

packaging is same. Let us see how packaging in small can filling is done.

Machine Used:

Semi-automatic 3-5 lt Filling Machine

Rotary filler 20 cans per minute

Induction Sealing Machine

Inkjet Printer

Cap Sealing Machine

Carton Sealing Machine

Automatic 3-5 lt Filling Machine

Rotary Filler 20 cans per minute

Automatic screw can mapping machine

Inkjet Printer

Induction Sealing Machine

Carton Sealing Machine

1 lt. Filling Machine:

80 caps per minute

Cap sealing machine

Inkjet printer

Induction sealing machine

Carton sealing machine

34

Process:

1) Firstly the required quantity of vessel is

brought, say of 5 litres.

2) Then the company stickering is done on the

box.

3) Then filling of lube oil is done in the can.

Actually the can is filled with 4.3 litres of oil.

The remaining weight accounts for the can

density. Also if a 5 litre can is filled with 5 litre of

oil then overflow might take place.

4) The can is then sealed with a cap. The caps which are used for sealing the cans are kept in a

separate section. From there the caps are brought to seal the cans.

5) After that, batch number, manufacturing date and price of the can are marked by air marker.

6) Then heat filling is done. There is a seal inside the cap. In this process the cap is heated and

the seal inside the cap if fitted in the bottle. This type of sealing can only be done by applying

heat to the cap.

7) The ready can then proceeds to a weight measuring instrument. Here the weight of the can

is measured. Now a certain tolerance is accepted in the weight. This means the weight of the

container can increase or decrease up to a certain limit. If it increases or decreases beyond that

limit then the container is punched out by a puncher.

8) After the container if checked, it is cartooned along with other containers and then

dispatched to the required location.

(All the above work is done electro pneumatically by the machines. Therefore compressed air

plays a big role in the functioning of the machines. However filling for the 7.5 litre is done semi

automatically. Here the process of filling oil in the container is done by pressing a push button.

The amount of oil which is to be filled is predetermined considering the container density and

overflow rate. The container is sealed manually by a person stationed at the end of the system.

Here also the container is marked by an air marker which shows its product number,

manufacturing date and MRP.)

35

AGRO SPRAY SECTION

This type of oil is used as a pesticide in certain agricultural purposes. This oil

cannot be used in all types of plantation. Its use is only restricted to tea gardens

and mango tree plantation. This may be regarded as one type of grade of lube oil.

It has a dedicated manufacturing facility in the small can section itself. This type

of oil is not manufactured round the year. It is only manufactured as per demand

of the customer. Small can filling section takes the amount of oil required from

storage tank. Then they transfer it to the buffer tank. This buffer tank is located

inside the small can filling. From the buffer tank oil is taken through pump and

filling is done. The amount of filling which is to be done is pre-set electronically.

SERVO Orchard Spray Oil:

This Oil is blended from high quality base stock especially for protection of

apple trees from San Jose scale. The oil is sprayed in the form of oil-in-water

emulsion on apple orchards during the months of December / January when the

ambient temperature is around 3 to 40C. The emulsion dissolves the waxy

protective shield of the insect and the oil film envelops it thereby killing the

insect by cutting off its air supply. It can be used for protection of eucalyptus,

cinchona etc. The oil does not have any toxic influence and is approved by Fruit

Research Station, Shalimar.

SERVO Rubber Spray Oil:

This Oil is a low viscosity product developed for use in rubber plantations. This

oil has an excellent solvency power with copper oxychloride for spray on rubber

plantations to combat the severe attack of fungus PHYTOPHTHORA which

leads to abnormal leaf fall affecting the vitality of the trees and resulting in loss of

latex yield. The mixture of oil and copper oxychloride is applied either by mini

micron sprayers or aerial spraying. The spreading characteristics of the oil enable

the copper particles to readily and uniformly distribute on the leaf surfaces and

leaf stalks and at the same time not permitting copper to be easily washed out. It

is approved by Rubber Research Institute of India, Kottayam.

36

ELECTRA PLANT

In Paharpur plant, transformer oil is manufactured separately in Electra Plant.

The transformer oil must not contain any moisture otherwise it causes dangerous

hazards to the transformer where it will be used. So the entire process is done

ensuring no water is present in the lubricant.

At first the mixture of additives and base oil are mixed in the

blending kettle by agitator, air purging and circulation, heat coils

under very high voltage.

Then the lubricant is taken to service tank to store the oil. From

there the oil is taken to Processing Unit which is skid mounted.

Here various type of filters under specified pressure refine the oil

and make it ready for final despatch.

In the barrel filling process, before filling the oil barrels are washed

with liquid nitrogen to make sure there is no moisture.

Electra Plant Setup

37

Effluent Treatment Plant (ETP)

As per pollution control board, no hazardous waste should not emit or

go out from a plant above some specified limit. In case of Lube

Blending Plant, the main hazardous waste is mixture of oil and water.

So there are 2 Effluent Treatment Plants (100/150KL) in the plant.

FIG: Effluent Treatment Plant

Many oils can be recovered from open water surfaces by

skimming devices. Considered a dependable and cheap way to

remove oil, grease and other hydrocarbons from water, oil

skimmers can sometimes achieve the desired level of water

purity. At other times, skimming is also a cost-efficient method to

remove most of the oil before using membrane filters and

chemical processes. Skimmers will prevent filters from blinding

prematurely and keep chemical costs down because there is less

oil to process.

Typically, the oil layer is skimmed off and subsequently re-

processed or disposed of, and the bottom sediment layer is

removed by a chain and flight scraper (or similar device) and a

sludge pump. The water layer is sent to further treatment

consisting usually of an electro-flotation module for additional

removal of any residual oil and then to some type of biological

38

treatment unit for removal of undesirable dissolved chemical

compounds.

Parallel plate separators are similar to API separators but they

include tilted parallel plate assemblies (also known as parallel

packs). The parallel plates provide more surface for suspended

oil droplets to coalesce into larger globules. Such separators still

depend upon the specific gravity between the suspended oil and

the water. However, the parallel plates enhance the degree of oil-

water separation. The result is that a parallel plate separator

requires significantly less space than a conventional API separator

to achieve the same degree of separation.

Here in Paharpur plant, the oily water separator is working under

three columns and a skimmer to get the useful oil from the waste

water. These columns are-

Primary Column : Coarse separating stage

Multimedia Filter : Suspended solid, dust particle separation

(Made of granular filtering material)

Coalescer Column : Micronics size oil particle separation

(Made of oleophilic material)

Primary Column Multimedia Filter Coalescer Column

Effluent treatment plant has the following components:

1. Air Compressor

2. Skimmer

3. Sump

4. Pump

5. Multimedia Filter

6. Butterfly Valves

7. Electro-Pneumatic Valves

The captured oil is taken to SLOP TANK for treatment and the rest

water is drained out to the environment.

39

Quality Control Laboratory The QC laboratory plays an important role in the plant. Here the oil is tested at

every stage before being used as a lubricant. The quality of base oil and additive is

tested here by various standard methods. The amount of base oil and additive

which is to be used to make a certain lubricant is also determined here. Then

required instructions are given to the control room to make that lubricant with

correct proportion of base oil and additive. The quality of base oil which is

received from the barge is scrutinized for moisture content with various tests such

as crackle test. Even the end product, i.e. the lubricant which is made is tested

before dispatching to its destination, is checked for quality and weight issues.

The lubricant oil contains approximately 90% of base oil and rest 10% additives

which are added to it. There are different types of base oil and they are presented

in terms of their viscosity. Indian oil produces the base oil of certain standard, i.e.

of certain fixed viscosities. If the customer desires the lubricant to be of certain

viscosity that isn’t standard viscosity, then different types of base oil are blended

to get the desired result. In QC lab three types of lubricant are made and tested:-

Automotive

Industrial

Specialty

The base oil and additive are mixed by heating and air circulation. The end result

is then tested for different properties like appearance, colour, flash point, pour

point, kinetic viscosity, viscosity index, foaming test, stability, Ca%, Zn%, Ph%,

base oil viscosity, emulsion test, rust test, TAN(total acid number), TBN(total

base number).

40

The different tests that are performed in QC lab are-

CRACKLE TEST:

The crackle test is a simple test to identify the presence of free and emulsified

water suspended in the oil, provided a few simple rules are followed.

a) Raise the hot plate temperature to 320°F (160°C). Always use the same

temperature.

b) Violently agitate oil sample to achieve homogenous suspension of water in

oil.

Using a clean dropper, place a drop of oil on the hot plate.

Observations:

a) If no crackling or vapor bubbles are produced after a few seconds, no free

or emulsified water is present.

b) If very small bubbles (0.5 mm) are produced but disappear quickly,

approximately 0.05 to 0.10 percent water is present.

c) If bubbles approximately 2 mm are produced, gather to the center of the

oil spot, enlarge to about 4 mm, then disappear, approximately 0.1 to 0.2

percent water is present.

d) For moisture levels above 0.2 percent, bubbles may start out about 2 to 3

mm then grow to 4 mm, with the process repeating once or twice. For even

higher moisture levels, violent bubbling and audible crackling may result.

e) Be wary of the presence of dissolved gases, fuel, refrigerants and volatile

solvents, which can cause false positives.

Limitations:

Although generally applicable, the crackle test does have some limitations:

a) The method is non-quantitative.

b) Hot plate temperatures above 320°F (160°C) induce rapid scintillation that

may be undetectable.

c) The method does not measure the presence of chemically dissolved water.

Safety:

Exercise extreme caution when performing the crackle test on oils that might

contain hazardous gases or low boiling point volatiles (such as ammonia

compressor oils), which might produce fumes and vapors that present inhalation

and/or serious skin or eye injury upon contact. When evaluating these oils, the

41

hot plate should remain under a vent hood that allows the analyst to conduct the

test without coming into contact with fumes or vapors.

a) Wear protective eyewear and long sleeves.

b) Perform test in a well-ventilated area.

POUR POINT TEST:

Procedure: The specimen is cooled inside a cooling bath to allow the formation

of paraffin wax crystals. At about 9 °C above the expected pour point, and for

every subsequent 3 °C, the test jar is removed and tilted to check for surface

movement. When the specimen does not flow when tilted, the jar is held

horizontally for 5 sec. If it does not flow, 3 °C is added to the corresponding

temperature and the result is the pour point temperature.

It is also useful to note that failure to flow at the pour point may also be due to

the effect of viscosity or the previous thermal history of the specimen. Therefore,

the pour point may give a misleading view of the handling properties of the oil.

Additional fluidity tests may also be undertaken. An approximate range of pour

point can be observed from the specimen's upper and lower pour point.

FLASH POINT TEST:

There are two basic types of flash point measurement - open cup and closed cup.

In open cup devices the sample is contained in an open cup which is heated, and

at intervals a flame is brought over the surface. The measured flash point will

actually vary with the height of the flame above the liquid surface, and at sufficient

height the measured flash point temperature will coincide with the fire point. The

best known example is the Cleveland open cup (COC).

There are two types of closed cup testers: non-equilibrium, such as Pensky-

Martens where the vapours above the liquid are not in temperature equilibrium

with the liquid, and equilibrium, such as Small Scale (commonly known as Seta

flash) where the vapours are deemed to be in temperature equilibrium with the

liquid. In both these types the cups are sealed with a lid through which the

ignition source can be introduced. Closed cup testers normally give lower values

for the flash point than open cup (typically 5–10 °C lower, or 9–18 °F lower) and

42

are a better approximation to the temperature at which the vapour pressure

reaches the lower flammable limit.

The flash point is an empirical measurement rather than a fundamental physical

parameter. The measured value will vary with equipment and test protocol

variations, including temperature ramp rate (in automated testers), time allowed

for the sample to equilibrate, sample volume and whether the sample is stirred.

TAN (Total acid number):

The total acid number (TAN) is a measurement of acidity that is determined by

the amount of potassium hydroxide in milligrams that is needed to neutralize the

acids in one gram of oil. It is an important quality measurement of crude oil. The

TAN value indicates to the crude oil refinery the potential of corrosion problems.

It is usually the naphthenic acids in the crude oil that causes corrosion problems.

This type of corrosion is referred to as naphthenic acid corrosion (NAC).

TAN value can be deduced by various methods, including

•Potentiometric titration: The sample is normally dissolved in toluene and

propanol with a little water and titrated with alcoholic potassium hydroxide (if

sample is acidic). A glass electrode and reference electrode is immersed in the

sample and connected to a voltmeter/potentiometer. The meter reading (in

millivolts) is plotted against the volume of titrant. The end point is taken at the

distinct inflection of the resulting titration curve corresponding to the basic buffer

solution.

•Colour indicating titration: An appropriate pH colour indicator e.g.

phenolphthalein, is used. Titrant is added to the sample by means of a burette.

The volume of titrant used to cause a permanent colour change in the sample is

recorded and used to calculate the TAN value.

Apart of these test many more tests are performed like the foaming test, rust test,

TBN etc. Thus QC laboratory is a vital part of paharpur plant as it helps in

maintaining the standard of the lubricants produced in the plan

43

Industrial Safety in Lube Blending Plant

An industrial safety is a countermeasure crucial in any hazardous plants

such as oil and gas plants. They are used to protect human, plant, and

environment in case the process goes beyond the control margins. As

the name suggests, these systems are not intended for controlling the

process itself but rather protection.

Industrial Safety can be provided through four ways-

Personal Protective Equipment (PPE)

Fire Safety

Security System

Safety from other hazards

Personal Protective Equipment:

Personal protective equipment (PPE) refers to protective clothing, helmets,

goggles, or other garments or equipment designed to protect the wearer's body

from injury. The hazards addressed by protective equipment include physical,

electrical, heat, chemicals, biohazards, and airborne particulate matter.

Protective equipment may be worn for job-related occupational safety and

health purposes, as well as for sports and other recreational activities. "Protective

clothing" is applied to traditional categories of clothing, and "protective gear"

applies to items such as pads, guards, shields, or masks, and others.

44

Head Protection:

Helmets are generally used for head protection. Different types of helmets are

used for different purposes. The helmets should have some standard properties

for industrial purpose. These are-

1) Temperature resistant

2) Strong & Durable

3) Rachet fit

4) Air Ventilation

5) Lightweight

6) Recyclable

Most of the helmets are made of HDPE, FRP, and ABS.

Examples of some helmets used in different industrial purposes-

Thermo-guard 9000 series, Vista 8000 Series, Ultra Vent 7000 Series, Helmet

Attachable Ear Muff etc.

45

Hand Protection:

Different types of gloves are used for hand protection in different industrial

purposes. Gloves are available to protect against:

Chemicals, contamination and infection (e.g. disposable latex/vinyl/nitrile

gloves)

Electricity, when voltage is too high

Extremes of temperature (e.g. oven gloves, welder's gloves)

Mechanical hazards (e.g. rigger gloves, chainmail gloves)

Mechanic gloves prime concern is to protect hands against mechanical type

of applications, where harsh elements of mechanical work is directly

detecting your hands required to be secured against the highest or lowest

levels of risks depending upon the working environment which is normally

measured in terms of different rating standards specifying the class of

gloves.

Hand safety concerns mechanical types of applications where the

involvement of highest and lowest level of risks

Lacerations and other wounds from sharp objects

46

Foot Protection:

Different types of cover shoes are available for foot protection. The

shoes should have these properties-

Different types of shoes are –

Ankle shoes

PVC shoes

Rock Master Gumboot

Edge Red Ex

Colin

47

Fall Protection:

There are different equipment for fall protection. Namely-

Anchor, body harness, connecting lines etc.

Anchor Body harness Connecting Lines

48

Fire Safety:

In common language, fire is burning of matter. In technical terms, fire is a chemical reaction

where matter reacts with oxygen under certain conditions to release heat and light energy. The

fire process can be considered as

Three conditions are essential component of any fire:

Fuel

Oxygen

Heat

Classification of fire:

Tank Fire

LPG Storage Vessel and Horton Spheres

TT Cargo Fires

Rail Tank Wagons

Electrical Machinery Fires

Pumps and Compressor Fires

Trench or Pit Fires

Sewer Fires

Spill Fires above Ground

Laboratory Fire

49

Fire Prevention:

The different processes for preventing fire are as follows-

Different Fire Extinguishers:

50

Security Systems:

Security system in the plant provides safety from any unwanted out-comers, any

terrorist attack, or any worker issues etc.

Security System is controlled by

Security Guards ( DGR )

Closed Circuit Cameras (CCTV)

Safety from other hazards: There are different types of hazards which should be prevented by

some safety measures.

In any case of lorry accidents or other transport problems,

authorisation faces different problems. These problems should be

prevented by proper training of the employees or by some other

means.

Sometimes oils are overflown from barrels, these problems (oil-

spillage) should be prevented to minimum level.

Suggestions on Safety Improvement

51

Though the basic safety procedure is well maintained in Paharpur plant, there are

some points to be highlighted to improve safety standard more firmly—

Though helmets are provided to each and every employees working in-field,

it is seen that some of them are not wearing it properly. This could bring

upon accidents. Therefore, the authority can take more strict action on this

issue.

The shoes that maximum employees are wearing are not safe according to

their line of work. Proper cover shoes should be provided by the authority

to ensure personal safety of each employee.

It is found that the blending kettles are not covered properly. This could be

dangerous for any employee. The blending kettles should be covered by

hard metallic cover or net.

The safety indicators (do’s and don’ts) should be in right place in the plant.

In case of very high noise generating regions, employees should wear ear

muffs.

Security system should be properly maintained and well skilled security

guards should be recruited to fight any emergency situation.

There are some very congested places in the plant (the blending kettle

platform, blending D etc.). There should be some modifications needed to

avoid any accidents in these regions.

Safety campaign must be carried out in a more regular basis so that the

employees can be cautious enough to fight any situation.

The firefighting equipment should be placed and in the right places.

52

Conclusion

I have gained knowledge by this training in various aspects as an

engineer, as I had first-hand experience in Indian Oil Corporation

limited. Training here, enhanced my cognition, as the employee has

explained, with commitment, all the doubts and question that arise in my

mind. This chance thrown at me, was a boon as I had only seen that real

about all the equipment seen in the industry, which now, I am able to

distinguish well enough. This was not possible with books knowledge. I

heartily thanks all employees of IOCL to have help me all throughout

my training.

I would like to express my gratitude to all those who gave me the

chance to complete this training. I want to thank the department of

training and development of IOCL, Eastern Region for giving me

permission to commence this training. It is really great opportunity for

me by which I had learned here many more of lube blending. I am

deeply indebted to Lube Blending Plant, Paharpur (Kolkata) for giving

such opportunity to students by which they complete their vocational

training which is the part of the course.