NAME|Internship Report
Internship Organization:
Internship Role/Position:
Internship Duration:
Internship Supervisor:
1. Internship Overview
I successfully completed my Vocational Training at Bharat Petroleum Corporation
Limited (BPCL), Bina Refinery, where I was allotted the Hydrogen Generation Unit
(HGU). During the training period, I gained hands-on exposure to the production of
hydrogen through the Steam Methane Reforming (SMR) process. I observed how
hydrogen, an essential utility in refining operations, is generated and efficiently circulated to
other process units within the refinery.
In addition to the technical aspects, I also became familiar with crucial plant safety
protocols and equipment, including fire extinguishers, Manual Call Points (MCPs),
emergency call points, safety showers, and designated assembly areas. This experience
not only enhanced my understanding of refinery operations and utilities but also
emphasized the importance of operational safety and emergency preparedness in an
industrial setup.
2. Objectives
The primary objectives of my vocational training at BPCL Bina Refinery were as follows:
● To analyze and improve the efficiency of a Shell and Tube Heat Exchanger
This involved understanding its operational parameters, identifying possible inefficiencies,
and exploring ways to enhance heat transfer performance within the Hydrogen Generation
Unit (HGU).
● To study various feed inlets and product outlets
Gaining insights into the flow distribution, inlet and outlet streams, and how they influence
the overall unit performance and downstream processes.
● To understand the plant’s safety systems and equipment
Learning about the role and functioning of safety equipment such as fire extinguishers,
Manual Call Points (MCPs), emergency call systems, safety showers, and assembly
points to ensure safe plant operation and emergency preparedness.
3. Roles and Responsibilities
1) Studying the Process Description Manual and P&ID (Piping and Instrumentation
Diagrams)
● I thoroughly analyzed the process flow and instrumentation layouts to gain a clear
understanding of the unit’s operation, control systems, and interconnections between
various equipment.
2) Assisting in Hydrogen Sampling and Purity Analysis
I supported the technical team in collecting hydrogen samples at various stages of the
production process. These samples were tested to ensure that the purity met the required
standards before being supplied to other process units in the refinery.
4. Key Learnings and Contributions
1) Hydrogen Production Process
I learned how hydrogen with over 99% purity is produced using naphtha and mixed
pentane as feedstocks through the Steam Methane Reforming (SMR) process.
2) Working of Major Equipment
I gained a practical understanding of the working principles and functions of critical process
equipment such as reformers, reactors, boilers, and shell-and-tube heat exchangers,
and how they integrate to ensure continuous and efficient operation.
3) Catalysts Used in Hydrogen Production
I studied the types and roles of industrial catalysts used in different reforming and
purification steps. This includes catalysts like Sulfided Cobalt-Molybdenum (Co-Mo),
commonly used in desulfurization and hydroprocessing reactions essential for hydrogen
purity and efficiency.
5. Skills Gained
1)Interpretation of P&IDs (Piping and Instrumentation Diagrams)
I learned to accurately read and understand P&IDs, which enhanced my ability to trace
process flows, identify key instrumentation, and comprehend the layout and
interconnection of equipment within the plant.
2) Participation in Safety Drills and Emergency Protocols
I actively took part in safety drills and familiarized myself with on-site emergency
procedures, including the use of Manual Call Points (MCPs), fire extinguishers, safety
showers, and the location and significance of assembly points during plant emergencies.
3) Basic Process Monitoring and Sample Handling
I assisted in hydrogen sampling and purity checks, gaining hands-on experience in process
monitoring and understanding quality control standards for hydrogen as a utility in refinery
operations.
6. Challenges Faced
1) Understanding Complex Industrial Processes in a Short Duration
Adapting to the highly technical and large-scale operations of the Hydrogen Generation Unit
(HGU) within a limited training period was initially challenging. It required continuous
effort to grasp the working principles of interconnected units and equipment.
2) Interpreting Detailed P&IDs and Technical Manuals
● The complexity and depth of Piping and Instrumentation Diagrams (P&IDs) and
process manuals demanded focused learning and repeated consultations with
mentors to correctly interpret process flows, symbols, and instrumentation.
3) Exposure to a High-Safety Industrial Environment
● Operating in a refinery environment with strict safety protocols required heightened
alertness and discipline. Participating in safety drills and understanding emergency
procedures in real time was both a responsibility and a learning curve.
4) Sampling and Handling High-Purity Hydrogen
Assisting in the sampling of hydrogen, a highly flammable gas, involved adhering to rigorous
safety measures and precise handling, which demanded both caution and attention to detail.
7. Conclusion & Takeaways
My vocational training at BPCL Bina Refinery was a highly enriching experience that
offered me practical exposure to industrial operations within the Hydrogen Generation
Unit (HGU). I developed a solid understanding of hydrogen production using steam
methane reforming with feedstocks like naphtha and mixed pentane. The training allowed
me to study technical documents such as P&IDs and process manuals in depth, observe the
functioning of major equipment like reformers, boilers, heat exchangers, and participate
in critical safety drills and emergency response procedures. I also assisted in sampling
hydrogen to monitor its purity, gaining insight into quality control processes and plant
safety systems.
Key Learning: One of the most impactful takeaways was understanding how process
efficiency and safety go hand-in-hand in large-scale industrial operations, especially when
dealing with high-purity and high-risk substances like hydrogen.
NAME | Project Report
Project Title:
Project Duration:
Supervisors:
1. Problem Statement
In large-scale industrial operations such as those at BPCL Bina Refinery, heat exchangers
play a critical role in optimizing energy use and maintaining process efficiency. During my
vocational training, I was assigned the task of studying a Shell and Tube Heat Exchanger
used in the Hydrogen Generation Unit. The primary challenge was to analyze its
performance parameters, identify factors contributing to efficiency losses, and explore
methods to improve its thermal efficiency through better heat transfer, reduced fouling, or
operational adjustments. The goal was to enhance overall unit performance by ensuring the
heat exchanger operates closer to its design potential.
2. Objectives
1) To study the design and working principles of a Shell and Tube Heat Exchanger
used in the Hydrogen Generation Unit (HGU) at BPCL Bina Refinery.
2) To analyze operational parameters such as inlet and outlet temperatures, pressure
drops, and flow rates to assess the current efficiency of the heat exchanger.
3) To identify potential causes of efficiency loss, such as fouling, scaling, flow imbalance,
or thermal resistance.
4) To suggest and evaluate methods for improving the heat exchanger’s efficiency,
including operational optimizations or maintenance strategies.
5) To understand the relationship between heat exchanger performance and the
overall efficiency of the hydrogen production process.
3. Methodology / Approach
To evaluate the performance of the Shell and Tube Heat Exchanger, a systematic approach
was followed. The first step involved a thorough study of the equipment’s design,
configuration, and operating conditions. Real-time process data such as inlet and outlet
temperatures, pressure, and flow rates were obtained from the Distributed Control
System (DCS) panel.
Using this data, the Log Mean Temperature Difference (LMTD) method was applied to
calculate the actual heat transfer rate and assess the thermal efficiency of the heat
exchanger. The obtained values were then compared with the theoretical design
performance to identify deviations and possible inefficiencies.
Additionally, factors such as fouling, scaling, and flow distribution were considered in the
analysis to suggest possible improvements in operational practices or maintenance
schedules.
4. Key Results & Achievements
After analyzing the Shell and Tube Heat Exchanger using process data obtained from the
DCS panel and applying the LMTD method, the following results were obtained:
● The outlet temperature of the hot fluid (TH₂) was calculated to be 63.49°C, based on
energy balance.
● The actual heat duty (Qactual) was determined as 522,240 kcal/hr on both the tube
side (cold fluid) and shell side (hot fluid), indicating balanced energy transfer across the
exchanger.
● The design heat duty (Qdesign) was 1,153,000 kcal/hr.
Based on these values, the efficiency of the heat exchanger was found to be:
● Efficiency on Tube Side = (522,240 / 1,153,000) × 100 = 45.29%
● Efficiency on Shell Side = (522,240 / 1,153,000) × 100 = 45.29%
This analysis highlighted that the heat exchanger was operating at less than 50% of its
design efficiency, indicating significant scope for improvement.
Improvement Measures Suggested:
Cleaning and Descaling: Build-up of fouling or scaling on the heat transfer surfaces could
be reducing efficiency. Regular maintenance and cleaning schedules were suggested.
Flow Optimization: Balancing the flow rates of hot and cold fluids to approach the optimal
heat transfer condition.
Monitoring Temperature Differential: Improving control over inlet and outlet
temperatures to maximize the LMTD.
Inspection of Baffles and Tubes: Mechanical wear or blockages may impact flow and
surface area utilization.
Result: Through this analytical approach and proposed improvements, steps were
identified to potentially increase the exchanger’s thermal efficiency significantly,
bringing it closer to its design performance.
5. Skills Utilized & Learned
1) Heat Exchanger Performance Evaluation
Gained hands-on experience in calculating the thermal efficiency of a Shell and Tube Heat
Exchanger using real-time process data and the Log Mean Temperature Difference
(LMTD) method.
2) Data Interpretation from DCS (Distributed Control System)
Learned how to read and extract critical operational parameters such as temperature, flow
rate, and pressure from the DCS panel for analytical purposes.
3) Application of Energy Balance Principles
Developed the ability to apply mass and energy balance equations to real industrial
systems for determining outlet conditions and process performance.
4) Analytical Problem-Solving
Improved my problem-solving skills by identifying causes of efficiency loss and suggesting
practical solutions to optimize heat exchanger performance.
5) Understanding of Heat Transfer Equipment
Enhanced my understanding of the working of reformers, boilers, pumps, and heat
exchangers, as well as the role of catalysts in hydrogen production.
6)Technical Reporting and Documentation
Learned how to compile technical data, calculations, and observations into a structured
report format suitable for academic and industry standards.
6. Conclusion & Future Scope
My vocational training at BPCL Bina Refinery, particularly in the Hydrogen Generation
Unit (HGU), provided me with a valuable opportunity to bridge theoretical knowledge with
real-world industrial practices. Through hands-on exposure, I developed a deep
understanding of hydrogen production via steam methane reforming, the role of catalysts,
and the importance of safety protocols in refinery operations.
A major component of my training involved evaluating the performance of a Shell and Tube
Heat Exchanger. By applying the LMTD method and using live data from the DCS panel, I
successfully calculated the exchanger’s thermal efficiency and identified key factors affecting
its performance. Although the current efficiency was found to be around 45.29%, several
recommendations were made to improve it through maintenance, operational adjustments,
and performance monitoring.
Overall, this experience enhanced my technical, analytical, and safety awareness skills, and
reinforced the importance of efficiency optimization in process industries.
