INTERNSHIP REPORT

INDIAN OIL CORPORATION

LIMITED
MATHURA REFINERY

Pre Fire Fighting Plan

,

Submitted by :--
Submitted to :--
Chetan Lokhande,
Mr. Rajneesh Tewari Divyansh Singh,
DGM ( Fire and Safety ) Adwit Dwivedi ,
IOCL Mathura Refinery Nivedita Dhilwania,
Deeptanshu ,
Bhoumik Patle
 CERTIFICATE

It is certified that the project titled, “PRE-FIRE FIGHTING PLAN AT IOCL

MATHURA at IOCL Mathura” was completed by Chetan Lokhande, Divyansh
Singh, Adwit Dwivedi, Nivedita Dhilwania, Deeptanshu, and Bhoumik Patle
under my guidance during the period of 28 days starting from 15 June 2024 to
12 July 2024. The same is hereby approved.

Submitted to: --
Mr. Rajneesh Tewari
DGM (Fire and Safety)
IOCL Mathura Refinery

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 ACKNOWLEDGEMENT

We wish to record our deep reverence & gratitude to Mr. Rajneesh Tewari
DGM (Fire and Safety) for their help which have sustained our efforts at all
stages of this and for their constant guidance and support. We are extremely
thankful to all the staff of the IOCL, Mathura for providing guidance and
support during attachment.

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 INDEX
S.no Specifications Page No.

1. Foreword on Mathura Refinery 4-5

2. Introduction 6-6

3. Pre-Fire Fighting Plan -

4. AVU Scenarios 7-19

5 Fire Protection Facilities in Refinery 20-25

6. Road Specifications for Tank cooling Water and 26-28

Foam Pourer Inlet Water.

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 FOREWORD ON MATHURA
REFINERY
Mathura Refinery, was commissioned in 1982 with a capacity of 6.0 MMTPA
to meet the demand of petroleum products in north western region of the
country, which includes National Capital Region. Refinery is located along the
Delhi-Agra National Highway about 154 KM away from Delhi. The major
secondary processing units initially were Fluidised Catalytic Cracking Unit
(FCCU), Vis-breaker Unit (VBU) and Bitumen Blowing Unit (BBU). The original
technology for these units was sourced from erstwhile USSR, UOP etc. Soaker
drum technology of EIL was implemented in VBU in the year 1993.Refinery was
revamped to the capacity of 8.0 MMTPA in 1988.
For production of unleaded Gasoline, Continuous Catalytic Reforming Unit
(CCRU) was commissioned in 1998 with technology from IFP, France. A Diesel
Hydro Desulphurisation Unit (DHDS) was commissioned in 1999 for production
of HSD with low Sulphur content of 0.25% wt (max). Subsequently, Once
Through Hydrocracker Unit (OHCU) with a capacity 1.2 MMTPA was
commissioned in 2000. FCCU Revamp was undertaken in 2014 to increase the
processing capacity of the unit from 1.3 to 1.5 MMTPA.
Its close proximity to the magnificent wonder Taj Mahal adds to extra
responsibility towards a cleaner environment. For upgrading environmental
standards, old Sulphur Recovery Units (SRU) were replaced with new Sulphur
Recovery Units with 99.9 % recovery in the year 1999. Additional Sulphur
Recovery Unit (4th SRU) was implemented as a hot standby and was
commissioned by 2011. Refinery had also set up four nos. of continuous
Ambient Air Monitoring Stations far beyond the working area before
commissioning in 1982 as a mark of its concern towards the community and
archaeological sites. At Mathura Refinery, technology and ecology go hand in
hand with continuous endeavour for Product Quality up-gradation, Energy
Conservation and Environment Protection.

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Following units were added to meet the fuel specifications.
• Diesel Hydro-treating unit (DHDT) & MS Quality Up-gradation Unit
(MSQU) were installed with world class technology in 2005 for
production of Euro-III grade HSD & MS as per Auto Fuel Policy of Govt. of
India.
• Project for FCC Gasoline Desulphurization (FCCGDS) and Selective
Hydrogenation Unit (SHU) was commissioned in 2010 and supply of
Euro-IV grade MS and HSD started on continuous basis from February
2010.
• Mathura refinery was one of the 1st refineries in the country to produce
BS VI grade fuels, and has been supplying National Capital Territory, New
Delhi with BS VI fuels since 1st April, 2018

Major products: LPG, Motor Spirit (BS-VI), Superior Kerosene Oil, High Speed
Diesel (BS-VI), Naphtha, propylene for PP production, Bitumen, Sulphur.

Mode of Product Dispatch:

• Product pipeline: MDPL, MAGPL, MBPL
• Tank Wagon for MS, HSD, Naphtha, FO.
• Tanker trucks for LPG, MS, HSD and ATF

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 INTRODUCTION
Industrial training plays a vital role in the progress of future engineers. Not
only does it provide insights about the future 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. Mathura.
The experience gained during this short period was fascinating to say the least.
It was a tremendous feeling to observe the operation of different units and
processes. It was overwhelming for us to notice how such a big refinery is
being monitored and operated with proper coordination to achieve desired
results.
During our training we realized that to be a successful fire engineer one needs
to put his concepts into action. Thus, we hope that this training serves as a
stepping stone for us in future and help us carve a need for ourselves in this
field.
At last, we are truly grateful to our Mentor Mr. Rajneesh Tewari Sir,
DGM (Fire and Safety) IOCL Mathura Refinery and all Mathura Fire Department
Fraternity for guiding us in completing our project.

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 “PRE-FIRE FIGHTING PLAN”
AVU (Atmospheric Vacuum Distillation Unit)

Identification of possible emergency scenarios in AVU:

Scenario 1 Naphtha stabilizer reflux pump (11-P-11 A/S) seal failure
Scenario 2 Stabilizer reflux pump (16-P-8 A/B) seal failure
Scenario 3 AVU Pre Flash Tower Reflux Drum (011-V-2) failure
Scenario 4 AVU Crude Tower Reflux Drum (011-V-2) catastrophic
failure

SCENARIO 1 - Naphtha stabilizer reflux pump (11-P-11A/S)

seal failure

I. OPERATING/PROCESS PARAMETERS:
• Temperature: 32°C
• Pressure: 33 Kgf/cm²
• Feed flow: 9200 M3/hr.

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 II. CONSEQUENCE: An instantaneous release of inventory containing light
Naphtha resulting in pool fire, Jet flame, vapor cloud & flash fire.

Type of Incident Probability of occurrence

Pool Fire Possible
Jet Flame Possible
Flash Fire Possible
Vapor release Possible
Vapor cloud explosion Possible
BLEVE Not Possible
Toxic Release Not Possible
On-site consequences If Fire is uncontrolled then nearby plant
& downstream plant may affect
Off-site consequences N/A

III. FIRE PROTECTION FACILITIES AVAILABLE

• Double headed hydrant at ground level: 03 Nos.
• 04 headed hydrant at ground level: 01 Nos.
• MV water spray system available for pump area (operating valve on west
side towards Rd no. 9).
• Fire Extinguishers: 10 Kg & 50 Kg DCP
• MCP-590 available on North East side of pump area. (On pillar AVU/PR/1-
14)

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IV. APPROACH FOR FIRE TENDERS
In case of any emergency, Fire tender can approach from Road No. 8 or
can be approach from Road No.9. Approach of Fire tender will be as per
prevailing wind direction.
Windsock is available on Road No. 8 & on Road No. 9.

V. ACTION TO BE TAKEN IN EMERGENCY

• Fire tender turns out and reaches the site as the alarm received
on the repeater panel at Fire Control room. (Or message
received by any other mode of communication).
• In case of any emergency in old unit, one Foam Tender approach
to the site.
• MV Water spray for pumps area to be actuated.
• Rescue affected personnel & transfer to waiting ambulance.
• Water curtain to be applied on downstream side to prevent
exposure to nearby pumps.
• Foam is applied on spillage hydrocarbon to extinguish the Fire.
• Continue the cooling of pump with water spray until the process
isolated the system and all inventory gets diluted.
• Water spray is used to cool the nearby arca.
• Keep Fire control room informed of developments from time to
time.
• Review the situation with production & maintenance
department from time to time.

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VI. PLOT PLAN

SCENARIO 2 - Stabilizer reflux pump (16-P-8 A/B) seal failure

I. OPERATING/PROCESS PARAMETERS:
• Temperature: 31°C
• Pressure: 33 Kgf/cm²
• Feed flow: 33 M3/hr.
II. CONSEQUENCE: An instantaneous release of inventory containing
light Naphtha resulting in Jet flame, pool fire, vapor cloud & flash fire.

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 Type of Incident Probability of occurrence
Pool Fire Possible
Jet Flame Possible
Flash Fire Possible
Vapor release Possible
Vapor cloud explosion Possible
BLEVE Not Possible
Toxic Release Not Possible
On-site consequences If Fire is uncontrolled then nearby plant
& downstream plant may affected
Off-site consequences N/A

III. FIRE PROTECTION FACILITIES AVAILABLE

• Double headed hydrant at ground level: 03 Nos.
• 04 headed hydrant at ground level: 01 Nos.
• MV water spray system available for pump area (operating valve on south
east side towards intermediate road near column 16-C-4).
• Fire Extinguishers: 10 Kg & 50 Kg DCP
• MCP-573 & MCP-575 available on North side near C/R and MCP-596 ON
East side of 16-C-4.

IV. APPROACH FOR FIRE TENDERS

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 In case of any emergency, Fire tender can approach from Road No. 14.
Approach of Fire tender will be as per prevailing wind direction.
Windsock is available on Road No. 8 & on Road No. 14
(14° 3 crossing)

V. ACTION TO BE TAKEN IN EMERGENCY

• Fire tender turns out and reaches the site as the alarm received
on the repeater panel at Fire Control room. (Or message
received by any other mode of communication).
• In case of any emergency in old unit, one Foam Tender approach
to the site.
• MV Water spray for pumps area to be actuated.
• Rescue affected personnel & transfer to waiting ambulance.
• Water curtain to be applied on downstream side to prevent
exposure to nearby pumps.
• Foam is applied on spillage hydrocarbon to extinguish the Fire.

• Continue the cooling of pump with water spray until the process
isolated the system and all inventory gets diluted.
• Water spray is used to cool the nearby arca.
• Keep Fire control room informed of developments from time to
time.
• Review the situation with production & maintenance
department from time to time.

VI. PLOT PLAN

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SCENARIO 3 – AVU Pre Flash Tower Reflux Drum (011-V-2)
Failure

I. OPERATING/PROCESS PARAMETERS:
• Temperature: 100°C
• Pressure: 2 Kgf/cm²
• Feed flow: 140 M3/hr.
II. CONSEQUENCE: An instantaneous release of inventory containing light
Naphtha and LPG resulting in pool fire, Jet flame, vapor cloud & flash fire.

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 Type of Incident Probability of occurrence
Pool Fire Possible
Jet Flame Possible
Flash Fire Possible
Vapor release Possible
Vapor cloud explosion Possible
BLEVE Not Possible
Toxic Release Not Possible
On-site consequences If Fire is uncontrolled then nearby plant &
downstream plant may affect
Off-site consequences N/A

III. FIRE PROTECTION FACILITIES AVAILABLE

• Double headed hydrant at ground level: 03 Nos.
• 04 headed hydrant at ground level: 01 Nos.
• Fire Extinguishers: 10 Kg & 50 Kg DCP
• MCP-590 available on North East side of pump area. (On pillar AVU/PR/1-
14)

IV. APPROACH FOR FIRE TENDERS

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 In case of any emergency, Fire tender can approach from Road No. 8 or
can be approach from Road No.9. Approach of Fire tender will be as per
prevailing wind direction.
Windsock is available on Road No. 8 & on Road No. 9.

V. ACTION TO BE TAKEN IN EMERGENCY

• Fire tender turns out and reaches the site as the alarm received on the
repeater panel at Fire Control room. (Or message received by any other
mode of communication).
• In case of any emergency in old unit, one Foam Tender approach to the
site.
• MV Water spray for pumps area to be actuated.
• Rescue affected personnel & transfer to waiting ambulance.
• Water curtain to be applied on downstream side to prevent exposure to
nearby pumps.
• Foam is applied on spillage hydrocarbon to extinguish the Fire.
• Continue the cooling of pump with water spray until the process isolated
the system and all inventory gets diluted.
• Water spray is used to cool the nearby arca.
• Keep Fire control room informed of developments from time to time.
• Review the situation with production & maintenance department
from time to time.

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 PLOT PLAN

SCENARIO 4 – AVU Crude Tower Reflux Drum (011-V-1)

Failure

I. OPERATING/PROCESS PARAMETERS:
• Temperature: 100°C
• Pressure: 1 Kgf/cm²
• Feed flow: 100 M3/hr.

II. CONSEQUENCE: An instantaneous release of inventory containing light

Naphtha resulting in pool fire, Jet flame, vapor cloud & flash fire.

Type of Incident Probability of occurrence

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 Pool Fire Possible
Jet Flame Possible
Flash Fire Possible
Vapor release Possible
Vapor cloud explosion Possible
BLEVE Not Possible
Toxic Release Not Possible
On-site consequences If Fire is uncontrolled then nearby plant &
downstream plant may affected
Off-site consequences N/A

III. FIRE PROTECTION FACILITIES AVAILABLE

• Double headed hydrant at ground level: 03 Nos.
• 04 headed hydrant at ground level: 01 Nos.
• Fire Extinguishers: 10 Kg & 50 Kg DCP
• MCP-590 available on North East side of pump area. (On pillar AVU/PR/1-
14)

IV. APPROACH FOR FIRE TENDERS

In case of any emergency, Fire tender can approach from Road No. 8 or
can be approach from Road No.9. Approach of Fire tender will be as per
prevailing wind direction.
Windsock is available on Road No. 8 & on Road No. 9.
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V. ACTION TO BE TAKEN IN EMERGENCY
• Fire tender turns out and reaches the site as the alarm received on the
repeater panel at Fire Control room. (Or message received by any other
mode of communication).
• In case of any emergency in old unit, one Foam Tender approach to the
site.
• MV Water spray for pumps area to be actuated.
• Rescue affected personnel & transfer to waiting ambulance.
• Water curtain to be applied on downstream side to prevent exposure to
nearby pumps.
• Foam is applied on spillage hydrocarbon to extinguish the Fire.
• Continue the cooling of pump with water spray until the process isolated
the system and all inventory gets diluted.
• Water spray is used to cool the nearby arca.
• Keep Fire control room informed of developments from time to time.
• Review the situation with production & maintenance department
from time to time.

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 PLOT PLAN

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 FIRE PROTECTION FACILITIES
AVAILABLE IN REFINERY
Fire protection is crucial in refineries due to several reasons:

I. Highly flammable materials: Refineries deal with large quantities of

highly flammable substances such as crude oil, gasoline, diesel, and
various chemicals. These substances can easily ignite and lead to
devastating fires if proper precautions are not in place.

II. Complex processes: Refineries consist of intricate processes

involving high temperatures, pressures, and volatile materials. The
potential for leaks, equipment failure, or human error increases
the risk of fires. Fire protection systems help detect and suppress
fires at their early stages, minimizing the damage and preventing
their escalation.

III. Catastrophic consequences: Refinery fires can have severe

consequences for both human life and the environment. They can
result in injuries or fatalities to refinery workers and nearby
communities. Moreover, the release of toxic gases, smoke, and
pollutants from a refinery fire can pose a significant threat to air
and water quality, wildlife, and ecosystems.

IV. Business continuity: Refineries are critical infrastructures that play a

crucial role in the energy supply chain. A fire can disrupt operations,
leading to significant downtime, production losses, and financial
impacts. Effective fire protection measures help safeguard the
continuity of operations and prevent disruptions to the energy
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 supply.

V. Regulatory compliance: Refineries are subject to stringent safety

regulations and standards enforced by governmental agencies.
These regulations require the implementation of adequate fire
protection systems and emergency response plans to ensure the
safety of workers, communities, and the environment. Compliance
with these regulations is essential to avoid penalties and legal
consequences.

Given these factors, investing in comprehensive fire protection

systems, including fire detection, suppression, and prevention
measures, is essential to mitigate the risks associated with fires in
refineries. These systems help ensure the safety of personnel,
protect assets, and prevent or minimize the impact of potential
fires on the environment and surrounding communities.

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FIRE FIGHTING INSTALLATIONS

1. Hydrant-A hydrant is a vital firefighting device designed to provide

quick access to a water supply. It consists of an outlet connected to a
network of underground or aboveground pipes, allowing firefighters
to attach hoses and efficiently extinguish fires. Hydrants are
strategically placed throughout urban areas and industrial sites.
They serve as reliable water sources, often connected to municipal
water supplies or dedicated water storage tanks. Firefighters can
easily connect their hoses to the hydrant's outlet, utilizing the water
pressure to combat fires effectively. Hydrants undergo regular
maintenance and inspections to ensure their proper functioning
during emergencies.

2.Monitor- A fire monitor, also known as a water monitor , is a

specialized device used in firefighting to deliver large volumes of
water or fire fighting agents to suppress fires. It is typically
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mounted on a fixed base or a vehicle and consists of a nozzle, a
water or foam inlet, and controls for adjusting the flow and direction
of the water sh·eam. Fire monitors are designed to deliver high flow

rates and long-range coverage, allowing firefighters to effectively

control and cxtingu.ish fires from a safe distance. They arc
commonly used in industrial facilities, airports, and large-scale fire
protection systems.

3.HVLRM- HVLRM stands for High Volume Long Range Monitor,

which is a specialized firefighting device used to deliver large
volumes of water or firefighting agents over long distances. It is
designed to provide enhanced firefighting capabilities in situations
where conventional fire suppression methods may be inadequate.
H VLRMs are typically mounted on firefighting vehicles or fixed
installations and consist of a powerful water or foam nozzle
capable of delivering a high flow rate and projecting the stream
over significant distances. These monitors are used in industrial
settings, airports, and other scenarios where the fire may be
remote, large-scale, or difficult to access. HVLRMs play a crucial

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role in combating fires effectively and protecting life and proper.

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4.Fire extinguisher - A fire extinguisher is a portable device designed to
extinguish small fires. It contains a pressurized extinguishing agent, typically
a chemical or foam, that can be discharged onto a fire to suppress or
extinguish it. Fire extinguishers are essential safety tools commonly found in
homes, businesses, and public spaces. They are categorized based on the
type of fire they are designed to combat, such as Class A (ordinary
combustibles), Class B (flammable liquids), Class C (electrical fires), and Class
K (kitchen fires). When operated by pulling the safety pin and squeezing the
handle, the extinguishing agent is expelled through a nozzle, allowing
individuals to take immediate action in containing or putting out fires before
they spread. Regular inspection and maintenance are important to ensure
fire extinguishers are in proper working condition.

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 Road Specifications
Fire water inlet line and foam pourer inlet line road specifications are crucial
for firefighters for several reasons:

1. Quick Access: Detailed specifications help firefighters quickly locate and

access water and foam resources during emergencies, saving valuable time.

2. Operational Efficiency: Knowing the exact location and specifications

ensures that firefighters can efficiently connect hoses and other equipment,
optimizing their response efforts.

3. Safety: Clear specifications reduce the risk of errors or mishaps, which can
be dangerous in high-pressure fire situations.

4. Coordination: Accurate information aids in coordinating efforts among

multiple fire units, ensuring a unified and effective response.

5. Pre-Planning: Firefighters can use these specifications for pre-incident

planning, conducting drills, and ensuring familiarity with the infrastructure of
the area.

6. Compliance: Following road specifications ensures adherence to safety

regulations and standards, which is essential for legal and insurance purposes.

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