Training Report

CHAPTER 1:

PROCESS DESCRIPTION

The ADU (Atmospheric Distillation Unit) separates most of the lighter end products such as gas, gasoline,

naphtha, kerosene, and gas oil from the crude oil. The bottoms of the ADU is then sent to the VDU

(Vacuum Distillation Unit).

Crude oil is preheated by the bottoms feed exchanger, further preheated and partially vaporized in the feed

furnace and then passed into the atmospheric tower where it is separated into off gas, gasoline, naphtha,

kerosene, gas oil and bottoms.

Atmospheric and Vacuum unit (AVU) of Mathura Refinery is designed to process 100% Bombay High

Crude and 100% Arab Mix crude (consisting of Light and Heavy crude in 50:50 proportion by weight) in

blocked out operation @ 11.0 MMTPA.

AVU consists of following sections:

Crude Desalting section

Atmospheric Distillation section

Stabilizer section

Vacuum Distillation section

STREAM DAYS : 345 days per year

TYPES OF CRUDE:

Low Sulphur Indian : Bombay high.

Nigerian : Girasol, Escravos, Farcados, Bonny light

High Sulphur Imported : Arab Mix, Kuwait ,Dubai, Ratawi,

Basra etc

1

STEPS OF OPERATION IN AVU PROCESS

CDU

CRUDE RECEIVING

CRUDE PREHEATING (FIRST STAGE)

DESALTING OF CRUDE

CRUDE PREHEATING (SECOND STAGE)

PREFRACTIONATOR DISTILLATION

CRUDE PREHEATING (THIRD STAGE)

RAISING TEMPERATURE WITH FIRED HEATERS

ATOMOSPHERIC DISTILLATION

NAPHTHA STABILISATION

PRODUCT ROUTING AFTER HEAT RECOVERY

VDU

FEED TEMPERATURE INCREASE WITH FIRED HEATER

VACUUM DISTILLATION

PRODUCT ROUTING AFTER HEAT RECOVERY

FEED SUPPLY

Crude oil is stored in eight storage tanks (eight tanks each having a nominal capacity of 50,000 m3

whereas remaining other 2 tanks are of 65,000 m3 nominal capacity). Booster pumps located in the

off-sites are used to deliver crude to the unit feed pumps. Filters are installed on the suction manifold

of crude pumps to trap foreign matter. For processing slop, pumps are located in the off-site area,

which regulate the quantity of slop into the crude header after filters. Provision to inject proportionated

quantity of demulsifier into the unit crude pumps suction header with the help of dosing pump is

available.

2

SYSEM DESCRIPTION:

Crude Oil is heated up to 136 -141 ºC in the first train of heat exchangers operating in two parallel

sections up to the desalter which is connected in series. Desalting temperature as required can be

maintained manually by operating the bypass valve of heat exchangers.

A two-stage desalter has been designed for 99% salt removal. It is designed to use stripped sour water

for desalting which is being taken from the stripped sour water unit. Provision to use DM water/

services water is also provided. The electric field in the desalter breaks the emulsion and the outlet

brine from the 1st stage desalter is sent to ETP on level control.

The crude after leaving the desalter is preheated to 250 to 265 ºC. The preheated crude is further

heated and partially vaporized in Atmospheric Furnace (four furnaces with four pass each). Heater is a

box type vertical furnace with up-firing burners. 7 nos. in each section are provided on the floor with

FG and FO firing facilities. Each crude furnace has fourteen burners.

FURNACE OPERATION:

1.CDU Fired Heater

2.VDU Fired Heater

Like any conventional process heater, these heaters are also having two distinct heating section: (I) a

radiant section, which houses the burners and forms the combustion chamber or fire box: and (ii) a

convection section which receives heat from the hot flue gases leaving the radiant section and is

therefore placed above the radiant section.

1. CDU Fired Heater:

The convection section has 8 rows of tubes with 8 nos. tubes in each. The two rows of shock tubes, i.e.

the two rows just above the radiant section are plain tubes without studs. The rest six rows are of

extended surface type having cylindrical studs. All the convection bank tubes are of 152 mmx8mm

dimension and 5Cr 1/2 Mo material of construction. Of these 64 tubes in the convection section, 4 no’s

3

studded tubes are for the service of superheating MP steam for strippers; and the rest 60 nos. tubes are

for crude oil service. Crude oil to be heated enters the convection section in four passes. From outlets

of the convection bank, it passes through crossovers provided inside the furnace into bottom coils of

the radiant section. Steam flow is of single pass to superheating coils. Provision exists to vent out MP

steam ex- super heating coils of furnaces to atmosphere through silencers.

In the radiant box, 84 nos. tubes are arranged horizontally along the height of the two sidewalls. The

tubes are of 152x8mm dimension and 5 Cr 1/2 Mo material of construction. There are 21 tubes in each

pass and the pass flows are up the radiant section to the heater outlet from top of radiant box to join the

900mm dia. Transfer line going to crude fractionator. Heater tubes rest on wall-supported hangers and

are arranged in such a fashion as to facilitate free expansion. The floor of furnace is elevated above

grade and the hot air duct (supplying combustion air to burners) runs across the length of the furnace

below the furnace floor. The skin temperature of tubes is limited to 550 0C.

2. VDU Fire Heater:

Like any conventional process heater, these heaters are also having two distinct heating section: (I) a

radiant section, which houses the burners and forms the combustion chamber or fire box: and (ii) a

convection section which receives heat from the hot flue gases leaving the radiant section and is

therefore placed above the radiant section. The Max box temp should be maintained less than 801 0 C.

The convection section has 13 rows of tubes with 8 nos. tubes in each. The top three rows are for the

service of superheating LP steam for vacuum column and the rest 10 rows are for RCO service. The

three rows of shock tubes, i.e. the three rows just above the radiant section are plain tubes without

studs. The next seven rows are of extended surface type having cylindrical studs. Provision exists to

vent out MP steam ex- super heating coils of furnaces to atmosphere through silencers.

There are 5 rows of tubes in arch zone and 9 rows of tubes in radiation zone for each pass for heating

the RCO. The tubes material of construction is 9Cr 1Mo.

4

The floor of furnace is elevated above grade and the hot air duct (supplying combustion air to burners)

runs across the length of the furnace below the furnace floor. The skin temperature of tubes is limited

to 542 0C.

The furnaces are of balanced draft type with forced draft (FD) fans to supply combustion air and

induced draft (ID) fan to take suction of the flue gases through air-preheating system and discharge the

same to stack.

CRUDE D ISTILLATION UNIT :

The column is provided with 56 trays of which 8 are baffle trays in the stripping section. Heated and

partly vaporized crude feed coming from fired heater enters the flash zone of the column at tray no. 46

at 355 ºC/365 ºC. Hydrocarbon vapours flash in this zone and get liberated. Non-flashed liquid

moves down which is largely bottom product, called RCO.

MP steam having some degree of superheat is introduced in the column below tray no. 46 at

approximately 3.5 kg/cm2 (g) and 290 ºC for stripping of RCO. Steam stripping helps to remove

lighter constituents from the bottom product (RCO). Hydrocarbon vapours liberated by flashing moves

up along with the steam in the column for further mass transfer at trays in the upper section.

Reduced crude oil product is collected at the bottom of the column and the overhead vapours are

totally condensed in Overhead air Condenser and train condenser. This condensed overhead product is

separated as hydrocarbon and water in the reflux drum. Water is drawn out under inter-phase level

control and sent to sour water drums.

STABILIZER:

Unstabilized Naphtha containing Fuel Gas, LPG and Naphtha is sent to stabilizer under cascaded flow

control. LPG is pumped to MEROX for treatment.Fuel Gas generated during BH/AM operation is

routed to Fuel Gas Amine treatment Unit to remove H2S before being routed to the plant Fuel Gas

Distribution Header.

5

VACUUM DISTALATION UNIT:

Hot RCO from the atmospheric column bottom at 355 ºC is mixed with slop recycle from Vacuum

Column, heated and partially vaporized in 8-pass vacuum furnace and introduced to the flash zone of

the vacuum column. The flash zone pressure is maintained at 115-120 mm of Hg. Steam (MP) is

injected into individual passes and regulated manually. Three injection points have been provided on

each pass. This is to maintain required velocities in the heater, which is Fuel Gas, Fuel Oil or

combination fuel fired. Each cell is provided with 10 burners fired vertically upshot from furnace

floor along the centerline of the cell.

The vaporized portions entering the flash zone of the column along with stripped light ends from the

bottoms rise up in the vacuum column and is fractionated into four side stream products in 5 packed

sections. The hydrocarbon vapours are condensed in the Vac Slop, HVGO, LDO and LVGO sections

by circulating refluxes to yield the side draw products. Vacuum is maintained by a two-stage ejector

system with surface condensers. The condensed portion from the condensers are routed to the hot well

from where the non-condensable are sent to the vacuum furnace low-pressure burners or vented to the

atmosphere. Oil carried over along with the steam condensate is pumped to the vacuum diesel

rundown line by overhead oil pumps.

6

CHAPTER 2:

DEMAND SUPPLY DATA, MANUFACTURERES IN INDIA

DEMAND AND SUPPLY DATA

The turnover of Indian Oil Corporation for the year ended 31.03.2007 was Rs. 114,864 Crore as

compared to Rs. 117,371 Crore in the previous year. The reduction in turnover is mainly on

account of reduced sale of crude and product to other Oil Marketing Companies. Further, the

inland sales volume reduced by 0.63 million metric tones, from 47.80 million metric tones in

2006-07 to 47.17 million metric tones during 2007-08, registering a decline of 1.32%. The

reduction in sales is mainly due to lower off-take of HSD, SKO and Naptha consequent to slow

down of economy.

EXPORT EARNING

During the year, Indian Oil Corporation earned Rs. 2,078 Crore through experts as against Rs.

2,206 Crore in 2006-07. The exports include exports of lubricants to Nepal, Sri Lanka,

Indonesia, Bangladesh, Bahrain and Mauritius, and sale of ATF to international airlines.

PIPELINES

Indian Oil Corporation owns and operates the largest network of crude and product pipelines in

the country with a total length of 6,523 km and overall capacity 43.45 MMT. The pipeline

network transported 40.36 MMT of crude and petroleum products during 2007-08 against the

previous year’s throughput of 39.44 MMT.

MARKETING

During the year, Indian Oil’s Marketing Division performed well in all key areas despite

increased competition and unpredictable market conditions. New initiatives in the form of

products and services were taken to achieve ‘Customer Delight’.

7

SALES

During 2007-08, IndianOil Corporation sold 47.17 MMT of petroleum products as compared to

47.80 MMT in the previous year. The actual demand for petroleum products in the country

during the year was much below the projections. This had an adverse impact on Indian Oil

Corporation’s sales. Despite the sluggish demand and severe competitions, IOCL increased its

market share in products like MS(Retail) and HSD (Retail). Indian Oil Corporation

commissioned 350 Retail Outlets and 19 SKO / LDO Dealerships during the year, raising their

total number to 7,870 and 3,455 respectively. This includes 80 jubilee Retail Outlets.

CUSTOMER SERVICE

In Indian Oil Corporation’s pursuit to provide better services, IVSR based complaint tracking

and redressal system for customers was launched in 33 Indane Area Offices. Further, in order to

provide value added services to monitoring public, Indian Oil Corporation, in association with

State Bank of India, launched the SBI-Indian Oil Co-branded pre-paid card called “Smart Gold”

for customers to avail of products and services at IndianOil retail outlets. Indian Oil Corporation

introduced 35 ATMs at retail outlets during the year in various parts of the country, thereby

bringing the total number of ATM’s installed to 57. The IndianOil-Citibank co-branded credit

card has reached a membership of 1.48 lakh as on 31.03.2008.Indian Oil Corporation, in

association with Chennai based Sundaram Finance ltd., also launched “Power Plus Fleet Card”

for transport fleet operators.

INDANE COOKING GAS

During the year, Indian Oil Corporation enrolled 26 lakh Indane customers, and the cumulative

Indane consumer population reached 322 lakh. The number of Indane distributorships

commissioned during the year was 457 raising the total number of distributors to 3,881. During

the year, seven new Indane Bottling Plants were commissioned, thus raising the total number of

Indane Bottling Plants to 78 and the total bottling capacity to 32.21 metric tones per annum.

8

AVIATION

Indian Oil Corporation continued to be market leader in Aviation Fuel supply business with a

market share of 67.9%. The entire Aviation Fuel requirements of Indian Navy and Indian Army,

and over 87% requirement of Indian Air Force was met by IOCL. The major requirements of

other market segments like Indian Airlines were catered to by Indian Oil Corporation. IOCL

commissioned a state-of-the-art Hydrant Refuelling System at Netaji Subhas Chandra Bose

Airport in Kolkata during the year for use of Industry. As part of customer service initiatives

Indian Oil Corporation has developed a user-friendly IndianOil Aviation web page on Internet,

providing information on ruling prices, service network, aviation highlights, and information on

products available location-wise.Indian Oil Corporation organized the 11th International

Aviation Conference at Hyderabad, which was attended by representative of major international

airlines, IATA, aviation equipment manufactures and Government.

LUBRICANTS

Indian Oil Corporation produced 3.96 lakh metric tones of lubes and 0.13 lakh tonne of grease

during the year. In spite of depressed market conditions, Indian Oil Corporation improved its

market share in finished lubricants. 36 R bazaar-on-wheels were added to penetrate the bazaar

trade. 24 R stockists (auto) and 11 R stockists (industrial) were commissioned during the year to

give a thrust to lubricant sales. During the year, R lubricants were launched in Bangladesh and

Sri Lanka.

SPECIALITIES

Indian Oil Corporation introduced four new products, viz., Needle Coke (Guwahati Refinery),

Microcrystalline Wax (Haldia Refinery), and Polymer Grade Hexane and Butene-2 (Gujarat

Refinery) in the market as import substitutes.

SHIPPING

149 product import tankers, 11 product tankers and 444 crude import tankers were handled

during the year.

9

QUALITY ASSURANCE

IOCL consistently accorded top priority on Quality Assurance for its products and services.

IndianOil continues to be the market leader for testing petroleums products by providing the

largest network of testing facilities. More than 2 lakh samples were tested in its 37 laboratories

located across the country. During the year, a mobile laboratory was added at Patna, taking the

number of mobile laboratories to 23. Laboratory Information Management System was

successfully commissioned in a few IndianOil laboratories with the Laboratory Documentation

and Management System software developed by the Quality Control Department of Marketing

Division.

INTERNATIONAL TRADE

Indian Oil Corporation arranged import of crude oil, petroleum products and lubricants for

meeting the country’s requirements through a carefully selected diversified mix of supply

sources and also exported petroleum products during 2007-08 as detailed hereunder:

Quantity(MMT) Value (Rs. Crore)

Imports

Crude Oil - 47.98 38,910.15

Petroleum Products, including for

Nepal Oil Corporation 2.28 2,506.80

Lube Base Oils / Lubricants / Additives 0.02 51.30

Exports

Petroleum Products 0.21 203.41

Lubricants 1,382 MT 4.28

Principal Subsidiaries:

10

Indo Mobil Ltd. (50%); Avi-Oil Ltd. (25%); Indian Oiltanking Ltd. (25%); Petronet India Ltd.

(16%); Petronet VK Ltd. (26%); Petronet CTM Ltd. (26%); Petronet CIPL Ltd. (12.5%);

IndianOil Petronas Ltd. (50%); IndianOil Panipat Power Consortium Ltd. (26%); IndianOil TCG

Petrochem Ltd. (50%); Librizol India Pvt. Ltd. (50%).

Principal Competitors: Bharat Petroleum Corporation Ltd.; Hindustan Petroleum Corporation

Ltd.; Royal Dutch/Shell Group of Companies.

Refinery Division

IndianOil controls 10 of India’s 20 refineries. The group refining capacity is 60.2 million metric

tonnes per annum (MMTPA) or 1.2 million barrels per day -the largest share among refining

companies in India. It accounts for 33.8% share of national refining capacity.

IndianOil refineries have an ambitious growth plan with an outlay of about Rs. 55,000 crore for

capacity augmentation, de-bottlenecking, bottom upgradation and quality upgradation. Major

projects under implementation include a 15 MMTPA grassroots refinery at Paradip, Orissa,

Naphtha Cracker and Polymer Complex at Panipat, Panipat Refinery expansion from 12

MMTPA to 15 MMTPA, among others.

PRODUCTS OF AVU

11

The unit is to produce the following products designated by T.B.P. cuts also:-

1 LPG To be sent to 'Merox' Treating Unit

2 C5-120 0C Cut

C5-118 0C Cut

Naphtha Component (CRU Feed) .

3 120-135 0C Cut (BH)

118-142 0C Cut (AM)

Heavy Naphtha for routing along with other

diesel components to HSD storage.

4 135-255 0C Cut(BH)

142-255 0C Cut(AM)

To be used as Superior Kerosene

To be used as 'ATF' after "Merox"

treatment.

5 255-296 0C Cut (BH)

To be used as Superior Kerosene

6 255-300 0C Cut (AM) HSD component

7 296 0C--325 0C Cut

300 0C--330 0C Cut

HSD component (Light Gas Oil)

8 325 -380ºC Cut

330 -386ºC Cut

HSD component (Heavy Gas Oil)

9 Light Vacuum. Gas Oil

(< 380 0C cut)

Component for HSD or LDO.

10 380 – 425 0C Cut LDO Component.

(Alternatively Blend for FCC feed)

11 425 –530 0C Cut

(Heavy Vacuum. GasOil)

Feed stock for FCC/OHCU unit.

12 Vacuum. Slop Blended with RCO/SR for VBU feed stock

12

13 Atmospheric Residue (RCO) Feed for VDU During Nigerian run to be

used as a component for IFO.

14 Vacuum Residue(SR) To be used as feed for Bitumen Unit

during Imp Crude run, or as a feed

component for Visbreaker unit.

During BH Crude run to be used

as a Component for IFO, RFO or HPS

along with Vac Slop..

15 Hydrocarbon Gas To be used as Refinery Fuel Gas

OTHER MANUFACTURERS

Bharat Petroleum and Hindustan Petroleum.Both are state-controlled, like Indian Oil

Corporation. There are two private competitors, Reliance Petroleum and Essar Oil.

13

CHAPTER 3:

PUMPS AND VALVE TYPES

All pumps used in AVU were centrifugal types.

PUMPS

S.NO EQUIPMENT SERVICECAPACITY

M3/hr

SUC.PR

Kg/cm2

DIS. PR

Kg/cm2

NPSH

REQ.

M

1. 10P-1A Crude charge Pump 545.0 3.6 21.9 6.0

2. 10P-1B Crude charge Pump 545.0 3.6 21.9 6.0

3. 10P-1C Crude charge Pump 545 3.6 21.9 8.6

4. 10P-1S Crude charge Pump 545.0 3.6 21.9 6.0

5. 10P-2 Desalter water pumps 55.0 1.0 22.5 4.0

6. 10P-2S Desalter water pump 55.0 1.0 22.5 4.0

7. 10P-2A Desalter water pump 55.0 1.0 22.5 4.0

8. 10P-4 Caustic sol. Circulation Pump 25.0 1.0 8.5 4.0

9. 10P-4S Caustic sol. Circulation Pump 25.0 1.0 8.5 4.0

10. 10P-5 Caustic dosing pump 0.60 1.0 17.0 7.0

11. 10P-5 S Caustic dosing pump 0.60 1.0 17.0 7.0

12. 10P-6A Brine Pump. 25.0 9.6 16.5 -

S.NO EQUIPMENT SERVICE CAPACITY SUC.PR DIS. PR NPSH

14

M3/hr Kg/cm2 Kg/cm2

REQ.

M

13. 10P-6B Brine Pump. 25.0 9.6 16.5 -

14. 10P-7A Brine Pump. 25.0 9.6 16.5 -

15. 10P-7B Brine Pump. 25.0 9.6 16.5 -

16. 11P-102A Post Desalter Pump 604 10.4 23.9 12.0

17. 11P-102B Post Desalter Pump 604 10.4 23.9 12.0

18. 11P-102C Post Desalter Pump 604 10.4 23.9 12.0

19. 11P-102S Post Desalter Pump 604 10.4 23.9 12.0

20. 11P-2 Stabiliser feed pump 300.0 2.4 17.6 4.0

21. 11P-2S Stabiliser feed pump 300.0 2.4 17.6 4.0

22. 11P-3 Main Column Reflux

Pump/Over Head Product

550.0 4.1 11.3 6.0

23. 11P-3S Main Column Reflux

Pump/Over Head Product

550.0 4.1 11.3 6.0

24. 11P-4A ATF CR pump 415.0 4.5 12.6 6.0

25. 11P-4B ATF CR pump 415.0 4.5 12.6 6.0


M3/hr

SUC.PR

Kg/cm2

DIS. PR

Kg/cm2

NPSH

REQ.

M

26. 11P-4S ATF CR pump 415.0 4.5 12.6 6.0

27. 11P-5 ATF Product pump 380.0 4.0 11.3 5.0

15

28. 11P-5S ATF Product pump 380.0 4.0 11.3 5.0

29. 11P-7 HK draw off pump 265.0 3.1 10.7 4.0

30. 11P-7S HK draw off pump 265.0 3.1 10.7 4.0

31. 11P-8 LGO draw off pump. Alternate

Services are (i) HGO draw off

(ii) Flushing oil

214 3.8 11.6 3.4

32. 11P-8S LGO draw off pump. Alternate

Services are (i) HGO draw off

(ii) Flushing oil

214 3.8 11.6 3.4

33. 11P-9 HGO draw off pump 170.0 3.3 11.6 3.4

34. 11P-11 Stabiliser reflux pump 140.0 11.33 17.2 6.0

35. 11P-11S Stabiliser reflux pump 140.0 11.33 17.2 6.0

36. 11P-15A Heavy Naphtha draw off pump 171.0 3.4 8.9 2.2

37. 11P-15B Heavy Naphtha draw off pump 171.0 3.4 8.9 2.2

38. 11P-16A HK CR pump 568.0 5.2 10.9 3.3

39. 11P-16B HK CR pump 568.0 5.2 10.9 3.3

40. 11P-16C HK CR pump 568.0 5.2 10.9 3.3

41. 11P16 Pump out from CBD drums

11V-11/11V-12

80.0 1.0 4.9 5.0

42. 11P-17 Corrosion inhibitor dosing pump 0.45 1.1 11.0 7.0

43. 11P-17S Corrosion inhibitor dosing pump 0.45 1.1 11.0 7.0

44. 11P-18 Ammonia sol. dosing pump 0.20 10.0 17.0 7.0

16

45. 11P-18S Ammonia sol. dosing pump 0.20 10.0 17.0 7.0

46. 11P-22S Pump out from CBD drums

11V-11/11V-12

50.0 1.0 17.0 -

47. 11P-23A Pump out from Desalters 100.0 1.1 7.6 1.5

48. 11P-26 Gas condensate pump out from

011V-9 drum

8.0 1.75 7.15 1.8

49. 11P103A Prefractionator reflux pump. 183 3.2 8.9 2.4

50. 11P103S Prefractionator reflux pump. 183 3.2 8.9 2.4

51. 11P104A LGO CR Pump 670 5.0 13.2 6.0

52. 11P104B LGO CR Pump 670 5.0 13.2 6.0

53. 11P104S LGO CR Pump 670 5.0 13.2 6.0

54. 11P-105A Tempered water pump 230 3.2 7.0 8.0

55. 11P-105B Tempered water pump 230 3.2 7.0 8.0

56. 11P-105S Tempered water pump 230 3.2 7.0 8.0

57. 11P-106A Ammonia dosing pump for

11C101

- - - -

58. 11P-106S Ammonia dosing pump for

11C101

- - - -

59. 11P-107A Corr. inhibitor dosing pump for

11C101

- - - -

60. 11P-107S Corr. inhibitor dosing pump for

11C101

- - - -

61. 11P-108A Prefractionator Bottom Pump 509 4.4 26.6 7.0

17

62. 11P-108B Prefractionator Bottom Pump 509 4.4 26.6 7.0

63. 11P-108C Prefractionator Bottom Pump 509 4.4 26.6 7.0

64. 11P-108S Prefractionator Bottom Pump 509 4.4 26.6 7.0

65. 11P109A LPG Product pump. 49 10.8 19.0 5.0

66. 11P109S LPG Product pump. 49 10.8 19.0 5.0

67. 11P110A Caustic Recirculation Pump for

11V6.

63.0 6.5 11.5 8.0

68. 11P110S Caustic Recirculation Pump for

11V6.

63.0 6.5 11.5 8.0

69 12P-1A Atm. Residue pump 420.0 3.4 14.7 3.3

70. 12P-1B Atm. Residue pump 420.0 3.4 14.7 3.3

71. 12P-1S Atm. Residue pump 420.0 3.4 14.7 3.3

72. 12P-2A Light vacuum gas oil pump 220.0 2.6 10.6 2.5

73. 12P-2S Light vacuum gas oil pump 220.0 2.6 10.6 2.5

74. 12P-2C Light Vacuum gas oil pump 220.0 2.6 10.6 2.5

75. 12P-2B Light vacuum gas oil pump 220.0 2.6 10.6 2.5

76. 12P-3A HVGO pump (425-530ºC Cut) 400.0 2.4 24.6 -

77. 12P-3B HVGO (425-530ºC Cut) 400.0 2.4 24.6 -


M3/hr

SUC.PR

Kg/cm2

DIS. PR

Kg/cm2

NPSH

REQ.

M

78. 12P-3C HVGO (425-530ºC Cut) 400.0 2.4 24.6 -

18

79. 12P-4 Vacuum. Slop pump 40.0 1.4 16.5 3.5

80. 12P-4S Vacuum. Slop pump 40.0 1.4 16.5 3.5

81. 12P-5 Vacuum. Residue pump 200.0 1.0 20.0 5.0

82. 12P-5S Vacuum. Residue pump 200.0 1.0 20.0 5.0

83. 12P-5A Vacuum. Residue pump 200.0 1.0 20.0 5.0

84. 12P-5B Vacuum. Residue pump 200.0 1.0 20.0 5.0

85. 12P-6 Condensate pump out from

012V-1

35.0 1.0 3.8 4.0

86. 12P-6S Condensate pump out from

012V-1

35.0 1.0 3.8 4.0

87. 12P-7 LDO pump 12.0 2.5 7.2 3.0

88. 12P-7S LDO pump 12.0 2.5 7.2 3.0

89. 12P-8 Over head oil pump 4.0 1.0 3.8 -

AVU VALVES

S.NO TAG.NO. DESCTRIPTION UNIT ALARMS TRIP EFFECTS

1

11FFRC150

1 CRUDE TO CDU FURN. M3/HR750/720 640

11F-1/2/3/4 FO/FG SDV CLOSE

19

2 11BPAL59 11F-1 FG PR LOW KG/CM2 0.8/0.5 0.3 11F-1 FG SDV SHALL CLOSE



5 11BPAL62 11F-4 FO PR LOW KG/CM2 0.8/0.5 0.3 11F-4 FO SDV SHALL CLOSE





10 11BPAL75 11F-1 PG PR LOW KG/CM2 0.8/0.5 0.2 11F-1 PG SDV SHALL CLOSE




14 11PHH704 11F-1 ARCH PR HIGH MMWC 2.0/3.0 5 RESPECTIVE FURNACE

15 11PHH746 11F-2 ARCH PR HIGH MMWC 2.0/3.0 5 STACK DAMPER OPENS

16 11PHH748 11F-3 ARCH PR HIGH MMWC 2.0/3.0 5 HOT AIR DAMPER CLOSES

17 11PHH804 11F-4 ARCH PR HIGH MMWC 2.0/3.0 5 FO/FG SDV SHALL CLOSE

18 11PLL741 11K-1 DISCH PR LOW MMWC 225/210 200 RESPECTIVE FD FAN

19 11PLL742 11K-2 DISCH PR LOW MMWC 225/210 200 DISCH DAMPER CLOSES AND

20 11PLL743 11K-3 DISCH PR LOW MMWC 225/210 200 IGV OF RUNNING FAN

21 MOTOR OF ANY FD FAN GETS - - - OPENS FULL

20

TRIP

22

11PHH

703

11F-1/2/3/4 COMMON DUCT

PR HIGH MMWC

0/2.0 5

1.MSD OPENS FULL.IF MSD

DOES NOT OPEN WITH IN 30

SECS THEN ALL FO/FG SDVs

CLOSE,11F1/2/3/4 STK

DAMPERS OPEN,FD/ID TRIPS.

23

11PLL7

10 ALL FD FANS FAIL MMWC140/100 60

11F-1/2/3/4 FO/FG SDVsCLOSE

24

11TI73

6 11K-4 I/L TEMP HIGH 0C

210/220 250ID FAN TRIPS,MSD OPENS

FULL,11F-1/2/3/4 STACK

DAMPERS OPEN

25 HS EMERGENCY SWITCH -

- -

EMERGENCY SWITCH AT

DCS/FIELD IF ACTUATED -

MSD OPENS ,FO/FG/PG SDV

OF 11F1/F2/F3/F4

CLOSES ,STACK DAMPER

OPENS,ID/FD TRIPS

26

12FLL2

309 12F101 PASS-1 FLOW M3/HR40/35 20

IF ANY PASS LO-LO FLOW

27

12FLL2

310 12F101 PASS-2 FLOW M3/HR40/35 20

SECURITY ACTUATES THAN

28

12FLL2

311 12F101 PASS-3 FLOW M3/HR40/35 20

12F101 FO/FG SDVs CLOSE

29

12FLL2

312 12F101 PASS-4 FLOW M3/HR40/35 20

FD/ID FANS TRIP

30 12FLL2 12F101 PASS-5 FLOW M3/HR 40/35 20

21

313

31

12FLL2

314 12F101 PASS-6 FLOW M3/HR40/35 20

32

12FLL2

315 12F101 PASS-7 FLOW M3/HR40/35 20

33

12FLL2

316 12F101 PASS-8 FLOW M3/HR40/35 20

34

12PLL2

302 12F101 FG PR LOW(for PG) KG/CM21.0/.6 0.3

12F101 PG SDV CLOSES35

12PLL2

307 12F101 IFO PR LOW(for PG) KG/CM25.5/5.0 2.2

36

PSL230

3 12F101 FG PR LOW KG/CM21.0/.6 0.3

12F101 FG SDV CLOSES

37

PSL230

6 12F101 FO PR LOW KG/CM25.5/5.0 2.2

12F101 FO SDV CLOSES

38

DPSL2

301A (Atm.Steam-FO) DP KG/CM21.0/0.8 0.45

39

12PAH

H6104 12F101 ARCH PR HIGH MMWC

0.0/1.0 5

IF ANY TWO VALUES OF

12PAHH6104A/B/C CONFIRM

HIGH PR,THEN FO/FG SDV

CLOSES, HV6101 GET OPEN.

40

SSL610

1 12FD01A LOW SPEED RPM400\350 300

IF ANY ONE OF S.NO.42 TO 46

41 SSL610 12FD01B LOW SPEED RPM 400\350 300 ACTUATES- FO/FG TO 12F101

22

2

42

FSL610

3 12FD01A LOW AIR FLOW Nm3/hr

30000\250

0023734

SDVs CLOSE,HV6101 OPENS,

43

FSL610

4 12FD01B LOW AIR FLOW Nm3/hr

30000\250

0023734

AND ID/FD FANS TRIP

44

FSLL61

05 12F101 LOW AIR FLOW Nm3/hr

30000\250

0023734

DURING TURNDOWN OR

WITHOUT APH ,ONLY ONE

FD FAN RUNS.IF IT

TRIPS,OTHER FD FAN

STARTS. IN THIS FO/FG

SHALL ATTAIN FOR TIME

PERIOD 30 SEC

45 SSL6103 12ID-02 LOW SPEED RPM

400/350 250

12F101 STACK DAMPER

OPENS, IF IT FAILS TO OPEN

WITHIN 20 SEC THAN FO/FG

SDVs CLOSE,ID/FD FANS

TRIP.

46 HS6112 EMERGENCY SWITCH -

- -

EMERGENCY SWITCH AT

DCS/FIELD IF ACTUATED -

MSD OPENS ,FO/FG/PG SDV

OF 12F101CLOSES ,STACK

DAMPER OPENS,ID/FD TRIPS

47 SOV77 11C-2 LOW LEVEL (SWITCH 20/15 - SDV ON SRN R/D CLOSES

48 SOV500 11V-9 HIGH LEVEL (SWITCH 25/30 - SDV ON LP GAS TO 11F1/2/3/4

CLOSES

49 12F101 TRIPPING - - - SDV ON OFF GAS TO 12F101

23

12C1 TOP PRESSURE mmHGa 80/90 125 CLOSES

CHAPTER 4:

MOTORS DATA

S.NO EQUIPMMENT SERVICE KWAmps

(FLC)

1. 10PM-1A Crude charge Pump-Motor 440 45

24

2. 10PM-1B Crude charge Pump-Motor 440 45

3. 10PM-1C Crude charge Pump-Motor 520 53

4. 10PM-1S Crude charge Pump-Motor 440 45

5. 10PM-2 Desalter water pump-Motor 110 187

6. 10PM-2S Desalter water pump-Motor 110 187

7. 10PM-2A Desalter water pump-Motor - -

8. 10PM-4 Caustic Circulation Pump-Motor 15 27

9. 10PM-4S Caustic Circulation Pump-Motor 15 27

10. 10PM-5 Caustic dosing pump-Motor 2.2 5

11. 10PM-5 S Caustic dosing pump-Motor 2.2 5

12. 10PM-6A Brine Pump-Motor. 15 22

13. 10PM-6B Brine Pump-Motor. 15 22

14. 10PM-7A Brine Pump-Motor. 15 22

15. 10PM-7B Brine Pump-Motor. 15 22

16. 11PM-102A Post Desalter Pump-Motor 485 50

17. 11PM-102B Post Desalter Pump-Motor 485 50

18. 11PM-102C Post Desalter Pump-Motor 485 50

19. 11PM-102S Post Desalter Pump-Motor 485 50

20. 11PM-2 Stabiliser feed pump-Motor 200 20

21. 11PM-2S Stabiliser feed pump-Motor 200 20

25

22. 11PM-3 11C1 Reflux Pump-Motor 160 262

23. 11PM-3S 11C1 Reflux Pump-Motor 160 262

24. 11PM-4A ATF CR pump-Motor 132 224

25. 11PM-4B ATF CR pump-Motor 132 224

26. 11PM-4S ATF CR pump-Motor 132 224

27. 11PM-5 ATF draw off pump-Motor 160 262

28. 11PM-5S ATF draw off pump-Motor 160 262

29. 11PM-7 HK draw off pump-Motor 90 156

30. 11PM-7S HK draw off pump-Motor 90 156

31. 11PM-8 LGO draw off pump-Motor. 75 132

32. 11PM-8S LGO draw off pump-Motor. 75 132

33. 11PM-9 HGO pump-Motor 75 132

34. 11PM-11 Stabiliser reflux pump-Motor 45 78

35. 11PM-11S Stabiliser reflux pump-Motor 45 78

36. 11PM-15A Heavy Naphtha pump-Motor 55 91

37. 11PM-15B Heavy Naphtha pump-Motor 55 98

38. 11PM-16A HK CR pump-Motor 150 266

39. 11PM-16B HK CR pump-Motor 150 266

40. 11PM-16C HK CR pump-Motor 150 266

41. 11PM16 CBD Pump-Motor 11 20

42. 11PM-17CORROSION INHIBITOR DOSING

0.8 1.7

26

PUMP

43. 11PM-17SCORROSION INHIBITOR DOSING

PUMP-MOTOR

0.8 1.7

44. 11PM-18 Ammonia sol. dosing pump-Motor 0.6 1.4

45. 11PM-18S Ammonia sol. dosing pump-Motor 0.4 1.1

46. 11PM-22S CBD Pump-Motor 7.5 13.5

47. 11PM-23A Desalter Pump-Motor 45 82

48. 11PM-26 11V9condensate pump-Motor 19 32

49. 11PM103A Prefractionator reflux pump-Motor. 75 125

50. 11PM103S Prefractionator reflux pump-Motor. 75 125

51. 11PM104A LGO CR Pump-Motor 440 49.5

52. 11PM104B LGO CR Pump-Motor 440 49.5

53. 11PM104S LGO CR Pump-Motor 440 49.5

54. 11PM-105A Tempered water pump-Motor 55 93

55. 11PM-105B Tempered water pump-Motor 55 93

56. 11PM-105S Tempered water pump-Motor 55 93

57. 11PM-106A Ammonia dosing pump-Motor 3.7 8

58. 11PM-106S Ammonia dosing pump-Motor 3.7 8

59. 11PM-107A

Corr. inhibitor dosing pump-Motor

1.1 11

60. 11PM-107S Corr. inhibitor dosing pump-Motor 1.1 11

27

61. 11PM-108A Prefractionator Bottom Pump-Motor 570 60

62. 11PM-108B Prefractionator Bottom Pump-Motor 725 74

63. 11PM-108C Prefractionator Bottom Pump-Motor 570 60

64. 11PM-108S Prefractionator Bottom Pump-Motor 570 60

65. 11PM109A LPG Product pump-Motor. 37 63

66. 11PM109S LPG Product pump-Motor. 37 63

67. 11PM110A Caustic Recirculation Pump-Motor - -

68. 11PM110S Caustic Recirculation Pump-Motor - -

69 12PM-1A Atm. Residue pump-Motor 280 31

70. 12PM-1B Atm. Residue pump-Motor 280 31

71. 12PM-1S Atm. Residue pump-Motor 280 31

72. 12PM-2A LVGO pump-Motor 132 224

73. 12PM-2S LVGO pump-Motor 132 217

74. 12PM-2C LVGO pump-Motor 110 178

75. 12PM-2B LVGO pump-Motor 132 224

76. 12PM-3A HVGO pump-Motor 475 60

77. 12PM-3B HVGO pump-Motor 475 60

78. 12PM-3C HVGO pump-Motor 475 60

79. 12PM-4 Vacuum. Slop pump-Motor 90 145

80. 12PM-4S Vacuum. Slop pump-Motor 90 145

28

81. 12PM-5 Vacuum. Residue pump-Motor 160 262

82. 12PM-5S Vacuum. Residue pump-Motor 160 262

83. 12PM-5A Vacuum. Residue pump-Motor 160 255

84. 12PM-5B Vacuum. Residue pump-Motor 160 262

85. 12PM-6 12V1 Condensate pump-Motor 5.5 10.3

86. 12PM-6S 12V1 Condensate pump-Motor 5.5 10.3

87. 12PM-7 LDO pump-Motor 90 149

88. 12PM-7S LDO pump-Motor 90 149

89. 12PM-8 12V1 Oil pump-Motor 11 21

90. 12PM-8S 12V1 Oil pump-Motor 11 21

91. 12PM-9 HVGO Pump back-Motor 60 101

92. 12PM-9S HVGO Pump back-Motor 60 101

93. 10AC-12 Desalter brine A/C-Motor 40 72

94.11ACM-107(A-X)

Atm. Column OH A/C-Motor 15 28

95. 11ACM-6A ATF cut A/C –Motor 40 72

96. 11ACM-8A HGO cut A/C –Motor 40 72

97. 11ACM-8B LGO cut A/C-Motor 40 72

98. 11ACM-10A HVGO cut A/C-Motor 40 72

99. 11ACM-10B HVGO cut A/C-Motor 40 72

100. 11ACM-11 LVGO CR A/C-Motor 40 72

101 11ACM-14 HGO A/C –Motor 40 72

29

102. 11ACM-101(A-T) Prefractionator O/H A/C-Motor 40 53

103. 11ACM-108(A-H) Tempered Water A/C-Motor. 22 40

104. 12ACM- 1 A/B LDO A/C-Motor 40 72

105. 12ACM-2 A/B LVGO A/C-Motor 22 38

106. 12ACM-3 A/B HVGO A/C-Motor 11 20

107. 11KM-1/2/3 FD fan-Motors 230 26.5

110. 11KM-4 ID fan-Motor 410 46.5

111. 12FD01A/B FD fan-Motors 90 155

112. 12ID02 ID fan-Motor 132 226

30

CHAPTER 5:

LINE SIZING

S.NO PSV NO. EQUIPMENT DISCHARG

E TO

SET PR

(Kg/cm2)

INLET Dia.

(inches)

OUTLET

Dia(inches)

1 10PSV01 10V1A/B/C/D 11C101 14.5 6 8

2 10PSV02 10V1A/B/C/D 11C101 14.5 8 10

3 10PSV03 10V1A/B/C/D 11C101 14.5 8 10

4

10PSV05 10E1 Tube

Outlet

CBD 31.2 1 1.5

5

10PSV07 10E3 Tube

Outlet

CBD 31.2 1 1.5

6

10PSV08 10E26A Shell

Outlet

CBD 31.2 1 1.5

7

10PSV09 10E6 Tube

Outlet

CBD 31.2 1 1.5

8

10PSV10A 10E2 Tube

Outlet

CBD 31.2 1 1.5

9

10PSV11 10E9 Tube

Outlet

CBD 31.2 1 1.5

10

10PSV12 10E10 Tube

Outlet

CBD 32.9 1 1.5

11 10PSV1013 10E7 Tube CBD 31.2 1 1.5

31

Outlet

12

10PSV39 11E17 Shell

Outlet

CBD 31.2 1 1.5

13

10PSV2401 10E4 Tube

Outlet

OWS 28 0.75 1

14

10PSV2402 11E39A/B Tube

Outlet

OWS 28 0.75 1

15

10PSV2403 10E16 Tube

Outlet

OWS 28 0.75 1

16

10PSV2404 10E1B Tube

Outlet

OWS 28 0.75 1

17 10PSV15 10E15 OWS 36 0.75 1

18

10PSV60 10E10A/B Tube

Outlet

CBD 31.2 1 1.5

19

11PSV48 10E26B Shell

Outlet

CBD 31.2 1 1.5

20

11PSV29 11E7 Tube

Outlet

CBD

32.9 1 1.5

21

11PSV2002 11E08 Shell

Outlet

CBD 32.9 1 1.5

22

11PSV2003 11E102A/B

Tube Outlet

CBD

32.9 1 1.5

32

23

11PSV2004 11E40 Tube

Outlet

CBD

32.9 1 1.5

24

11PSV32 11E10 Tube

Outlet

CBD

32.9 1 1.5

25

11PSV31 11E9 Tube

Outlet

CBD

32.9 1 1.5

27

11PSV2001 11E103 Tube

Outlet

CBD

32.9 1 1.5

28

11PSV40 11E18 Tube

Outlet

CBD

32.9 1 1.5

29

11PSV49 11E112 Tube

Outlet

CBD

32.9 1 1.5

30

11PSV50 11E28 Tube

Outlet

CBD

34.3 1 1.5

31

11PSV34 11E12 Tube

Outlet

CBD

34.3 1 1.5

32

11PSV35 11E13 Tube

Outlet

CBD

34.3 1 1.5

33

11PSV33 11E11 Tube

Outlet

CBD

34.3 1 1.5

34

11PSV36 11E14 Tube

Outlet

CBD

34.3 1 1.5

35

11PSV37 11E15 Tube

Outlet

CBD

34.3 1 1.5

33

36

11PSV47 11E25 Tube

Outlet

CBD

34.3 1 1.5

37

11PSV58 11E38A Tube

Outlet

CBD

34.3 1 1.5

38

11PSV59 11E38B Tube

Outlet

CBD

34.3 1 1.5

39

11PSV57 11E37 Tube

Outlet

CBD

34.3 1 1.5

40

11PSV56 11E36 Tube

Outlet

CBD

34.3 1 1.5

41

11PSV2601 11E108A/B/C/D

Tube Outlet

OWS

7 0.75 1

42 11PSV2501 11C101 Flare 5 8 10

43 11PSV2502 11C101 Flare 5 8 10

44 11PSV2503 11C101 Flare 5 8 10

45 11PSV2504 11C101 Flare 5 8 10

46 11PSV2505 11C101 Flare 5 8 10

47

11PSV2101 11E104 Tube

Outlet

CBD

34.3 1 1.5

48

11PSV2102 11E105 Tube

Outlet

CBD

34.3 1 1.5

49

11PSV4504 11E107 Tube

Outlet Atmosphere 7 0.75 1

50 11PSV4503 11E109 Tube Atmosphere 11 0.75 1

34

Outlet

51

11PSV4502 12E110A/B

Tube Outlet Atmosphere 11 0.75 1

53

PSV6401 11V-NEW1 Top

head Atmosphere 3.5 2 3

54

PSV6402 11V-NEW1 Top

head Atmosphere 3.5 2 3

55 11PSV5A 11V1 Flare 5 6 8

56 11PSV5B 11V1 Flare 5 6 8

57 11PSV6A 11V2 Flare 5 6 8

58 11PSV6B 11V2 Flare 5 6 8

59 11PSV9A 11V9 Flare 8 2 3

60 11PSV9B 11V9 Flare 8 2 3

61 11PSV41 11E19A ABD 19.5 1 1.5

62 11PSV42 11E19B ABD 19.5 1 1.5

63 11PSV55 11E35 ABD 15.5 1 1.5

64 11PSV7A 11V3 Flare 13.5 3 4

65 11PSV7B 11V3 Flare 13.5 3 4

66 11PSV20A 11E34A/B ABD 22 2 3

67 11PSV20B 11E34C/D ABD 22 2 3

68 11PSV43 11E20A Atmosphere 19.5 1 1.5

69 11PSV44 11E20B Atmosphere 19.5 1 1.5

35

70 11PSV46 11E24 Atmosphere 19.5 1 1.5

71 11PSV45 11E23 Atmosphere 19.5 1 1.5

72 PSV1301 11V10 Flare 5 4 6

73 PSV1302 11V10 Flare 5 4 6

74 11PSV10A 11V10 Flare 7 3 4

75 11PSV10B 11V10 Flare 7 3 4

76 12PSV1 12E1A Atmosphere 6 2 3

77 12PSV2 12E1B Atmosphere 6 2 3

78 12PSV3 12E1C Atmosphere 6 2 3

79 12PSV4 12E1D Atmosphere 6 2 3

80 12PSV5 12E1E Atmosphere 6 2 3

81 12PSV6 12E2 Atmosphere 10 2 3

82 12PSV7 12E3 Atmosphere 9 2 3

83 10PSV13 10E13A Atmosphere 25 2 3

84 10PSV14 10E13B Atmosphere 25 2 3

86 11PSV2B 11C1 Flare 4 8 10

87 11PSV2C 11C1 Flare 4 8 10

88 11PSV2D 11C1 Flare 4 8 10

89 11PSV2E 11C1 Flare 4 8 10

90 11PSV2F 11C1 Flare 4 8 10

36

91 11PSV2G 11C1 Flare 4 8 10

92 11PSV2H 11C1 Flare 4 8 10

93

11/1PSV10

1 11E1A Atmosphere - - -

94 11PSV3A 11C2 Flare 13.5 8 16

95 11PSV3B 11C2 Flare 13.5 8 16

96 11TSV101 11E41 Atmosphere - - -

97 11PSV8A 11V6 ABD 13.5 3 4

98 11PSV8S 11V6 ABD 13.5 3 4

99 11PSV5002 11P107A

To pump

suction 12 - -

100 11PSV5001 11P107S

To pump

suction 12 - -

101 11PSV21A

MP Steam to

unit Atmosphere 15 8 12

102 11PSV21B

MP Steam to

unit Atmosphere 15 8 12

103 11PSV27 CWR ex 11E2A Atmosphere 10 2 3

104 11PSV28 CWR ex 11E2B Atmosphere 10 2 3

105 11PSV53

CWR ex

11E34A/B Atmosphere 10 2 3

106 11PSV54 CWR ex Atmosphere 10 2 3

37

11E34C/D

107 10PSV17A Caustic ex 10P5

Suction of

Pump 16 1 1.5

108 10PSV17B

Caustic ex

10P5S

Suction of

Pump 16 1 1.5

109 10PSV19

Caustic to Pump

Suction CBD 14 1 1.5

38

CHAPTER 6:

INSTRUMENTATION

S.NO

. TAG NO. SERVICE UNIT RANGE LO

LOL

O HI

HIH

I

1 11PRC11

11V-10 FUEL

GAS PR KG/CM2 0 - 6.0 2.4 2.2 3.5 3.6

2 11FIC301

FUEL GAS TO

11V-10 NM3/HR 0 - 16000 3000 2800

1200

0

1250

0

3 11FR65

FO SUPPLY TO

UNIT M3/HR 0 - 75 20 15 70 75

4 11FR66

FO RETURN EX

UNIT M3/HR 0 - 66 20 15 50 60

5 11FR64B

FUEL GAS TO

FURNACES NM3/HR 0 - 12000 5000 2000

1100

0

1200

0

6 11FI63

PILOT GAS TO

FURNACES NM3/HR 0 - 630 200 150 500 600

7 AT29-03

FUEL GAS EX

11V-10 oC 0 - 600 20 15 80 100

8 11PRC16

MP STEAM TO

UNIT KG/CM3 0 - 16 9.5 9.0 12.5 12.8

9 11FR67

MP STEAM TO

UNIT T/HR 0 - 100 20 15 50 55

10 11PAL303 MP STEAM TO KG/CM2 0 - 16 10 9.0 12.5 13

39

UNIT

11 AT29-06

STEAM TO

UNIT oC 0 - 600 210 200 275 300

12 12AT32-24

FO SUPPLY

TEMP oC 0 -600 130 120 190 200

13 AT32-25

FO RETURN

TEMP oC 0 600 130 120 190 200

14 12FR93 CW TO UNIT M3/HR 0 - 8820 3900 3500 7000 7500

15 12PAL57

CW TO UNIT

PR KG/CM2 0 - 6 2.5 2.2 5.0 5.5

16 10HCD01

HC DETECTOR

CHEM. AREA % LEL 0 - 100 0 0 5 10

17 10AMGD01

NH3

DETECTOR

CHEM. AREA PPM 0 - 100 0 0 10 20

18 11PH01

11V1 WATER

pH VALUE - 0-14 5 4 7 8

19 12PH01

12V1 WATER

pH VALUE - 0-14 5 4 7 8

CRUDE PRE-HEAT TRAIN-1

40

S.NO TAG NO SERVICE UNIT RANGE LO

LOL

O HI

HIH

I

1 10PI03 CRUDE TO UNIT KG/CM2 0 - 10 3.0 2.5 5.5 6.0

2 10FFRC1030 CRUDE TO UNIT M3/HR 0 - 2200 750 720 1350 1400

3 10PC1001 DESALTER PR KG/CM2 0 - 25 9.0 8.0 12.8 13

4 10FC1901 CRUDE TO 11E-17 M3/HR 0 - 750 280 250 475 500

5 10FC1902

CRUDE TO 11E-

26A M3/HR 0 - 750 280 250 475 500

6 10FI01057 CRUDE TO 10E-3 M3/HR 0 - 600 280 250 475 500

7 10HIC1901 CRUDE TO 10E-3 % 0 - 100 40 30 75 90

8 10TC1901

CRUDE EX 11E-

26A oC 0 - 150 60 50 120 130

9 10TI1902 CRUDE EX 10E-6 oC 0 - 150 40 35 125 135

10 10TI1903 CRUDE EX 10E-9 oC 0 - 150 70 65 130 140

11 10TI1904 CRUDE EX 10E-7 oC 0 - 200 110 100 170 180

12 10TI1905 CRUDE EX 11E-17 oC 0 - 150 60 50 120 130

13 10TI1906

CRUDE EX 11E-

16B oC 0 - 150 65 55 130 140

14 10TI1907 CRUDE EX 10E-1A oC 0 - 150 100 90 130 140

15 10TI1908 CRUDE EX 10E101 oC 0 - 200 110 100 160 175

41

16 10TI1909 CRUDE EX 10E-2 oC 0 - 200 110 100 160 175

17 10TI1910

CRUDE EX 11E-

26B oC 0 - 200 110 100 160 175

18 10TI1911 RCO EX 11E-26B oC 0 - 400 150 140 250 280

19 10TI1912 LVGO EX 10E-3 oC 0 - 150 100 90 130 140

20 10TI1913 HK EX 10E-6 oC 0 - 150 40 30 140 150

21 10TI1914

CRUDE EX 10P-

1A/B/C/S oC 0 - 100 25 22 50 60

22 10TI1915 HK TO 10E-6 oC 0 - 350 210 200 235 250

23 10TI1916 RCO EX 11E-26A oC 0 - 300 120 110 210 220

24 10TI1917 ATF TO 11E-17 oC 0 - 300 110 100 180 190

25 10TI1918 LVGO EX 10E-2 oC 0 - 200 120 110 180 190

26 10TI1919 ATF EX 11E-17 oC 0 - 150 45 40 130 140

27 10TI1920 ATF CR EX 10E-101 oC 0 - 200 120 110 150 155

28 10TI1921 HVGO EX 10E-9 oC 0 - 200 120 110 160 170

29 10TI1922 LVGO TO 10E-2 oC 0 - 250 155 150 195 200

30 10TI1923 HVGO EX 10E-7 oC 0 - 200 135 125 175 185

31 10TI1924 LGO EX 10E-1A oC 0 - 200 120 110 180 190

32 10FICN1 SLOP TO UNIT M3/HR 0 - 43.3 0 0 40 43

DESALTERS ASSEMBLY

42


LOL

O HI

HIH

I

1 10LIC401

10V-1A

INTERFACE

LEVEL % 0 - 100 20 15 45 50

2 10LI401A

10V-1A

INTERFACE

LEVEL % 0 - 100 20 15 45 50

3 10LIC402

10V-1B

INTERFACE

LEVEL % 0 - 100 20 15 35 40

4 10LI402A

10V-1B

INTERFACE

LEVEL % 0 - 100 20 15 35 40

5 10LIC403

10V-1C

INTERFACE

LEVEL % 0 - 100 20 15 40 50

6 10LI403A

10V-1C

INTERFACE

LEVEL % 0 - 100 20 15 45 50

7 10LIC404

10V-1D

INTERFACE

LEVEL % 0 - 100 20 15 35 40

8 10LI404A 10V-1D

INTERFACE

% 0 - 100 20 15 35 40

43

LEVEL

9 10LIC01 10V-5 LEVEL % 0 - 100 60 55 95 100

10 10FIC601

WATER TO

10V-1D M3/HR 0 - 72.3 10 8 30 32

11 10FIC602

WATER TO

10V-1B M3/HR 0 - 72.3 10 8 30 32

12 10FI603

WATER TO

10V-1A M3/HR 0 - 72.3 10 8 32 30

13 10FI604

WATER TO

10V-1C M3/HR 0 - 75 10 8 35 40

14 10FI106

CRUDE TO

10V-1A M3/HR 0 - 1500 400 350 600 700

15 10FI107

CRUDE TO

10V-1C M3/HR 0 - 1500 350 300 900 1000

16 10FI108

10V-1C

DESLUDGING

FLOW M3/HR 0 - 50 0 0 10 15

17 10FI109

10V-1D

DESLUDGING

FLOW M3/HR 0 - 50 0 0 10 15

18 10T501

CRUDE TO

10V-1A oC 0 - 220 100 90 155 160

19 10T502

CRUDE TO

10V-1B oC 0 - 220 100 90 155 160

44

20 10TI503

CRUDE TO

10V-1C oC 0 - 600 100 90 155 160

21 10T504

CRUDE TO

10V-1D oC 0 - 600 100 90 155 160

22 10T36-18

BRINE EX

10AC-12 oC 0 - 600 30 20 80 90

23 10AI-01

10V-1A TR-1

CURRENT oC 0 - 100 10 0 40 50

24 10AI-02

10V-1A TR-2

CURRENT oC 0 - 150 10 0 40 50

25 10AI-03

10V-1A TR-3

CURRENT oC 0 - 150 10 0 40 50

26 10AI-04

10V-1B TR-1

CURRENT oC 0 - 150 10 0 40 50

27 10AI-05

10V-1B TR-2

CURRENT oC 0 - 150 10 0 40 50

28 10AI-06

10V-1B TR-3

CURRENT oC 0 - 150 10 0 40 50

29 10AI-07

10V-1C TR-1

CURRENT oC 0 - 150 10 0 40 50

30 10AI-08

10V-1C TR-2

CURRENT oC 0 - 150 10 0 40 50

31 10AI-09

10V-1C TR-3

CURRENT oC 0 - 150 10 0 40 50

45

32 10AI-10

10V-1D TR-1

CURRENT oC 0 - 150 10 0 40 50

33 10AI-11

10V-1D TR-2

CURRENT oC 0 - 150 10 0 40 50

30 10AI-12

10V-1D TR-3

CURRENT oC 0 - 100 10 0 40 50

31 10PDI401

10V1A MIXING

VALVE DP Kg/cm2 0 – 1.2 0.6 0.5 1.1 1.2

32 10PDI402

10V1B MIXING

VALVE DP Kg/cm2 0 – 1.2 0.6 0.5 1.1 1.2

33 10PDI403

10V1C MIXING

VALVE DP Kg/cm2 0 – 1.2 0.6 0.5 1.1 1.2

34 10PDI404

10V1D MIXING

VALVE DP Kg/cm2 0 – 1.2 0.6 0.5 1.1 1.2

CRUDE PREHEAT TRAIN-2

46


LOL

O HI

HIH

I

1 11FI2001

CRUDE TO

11E-102 M3/HR 0 - 775 280 250 475 500

2 11HIC14

CRUDE TO

11E-102 % 0 - 100 20 15 70 80

3 11FI011128

CRUDE TO

11E-16A M3/HR 0 - 664 280 250 475 500

4 11HC1001

CRUDE TO

11E-16A % 0 - 100 20 15 70 80

5 11FI011129

CRUDE TO

11E-8 M3/HR 0 - 664 280 250 475 500

6 11HC1002

CRUDE TO

11E-8 % 0 - 100 20 15 70 80

7 11TI2001

HK CR EX 11E-

16A oC 0 - 300 120 110 180 190

8 11TI2002

CRUDE EX

11E-16A oC 0 - 300 120 110 190 200

9 11TI2003

HVGO EX 11E-

18 oC 0 - 300 200 190 250 260

10 11TI2004

HVGO EX 11E-

103 oC 0 - 300 225 210 260 275

11 11TI2005 CRUDE EX oC 0 - 300 150 140 240 250

47

11E-18

12 11TI2006

CRUDE EX

11E-103 oC 0 - 300 170 160 260 270

13 11TI2007

LGO CR EX

10E-10 oC 0 - 350 200 190 270 280

14 11TI2008

CRUDE EX

10E-10 oC 0 - 300 180 170 280 290

15 11TI2009 LGO EX 11E-7 oC 0 - 300 150 140 260 275

16 11TI2010

CRUDE EX

11E-40 oC 0 - 300 175 165 280 290

17 11TI2011 SR EX 11E-8 oC 0 - 350 160 150 250 260

18 11TI2012

CRUDE EX

11E-8 oC 0 - 250 120 110 190 200

19 11TI2013

HK CR EX 11E-

10 oC 0 - 300 150 140 240 250

20 11TI2014

CRUDE EX

11E-10 oC 0 - 300 130 120 200 210

21 11TI2015 SR EX 11E-9 oC 0 - 350 200 190 280 290

22 11TI2016

CRUDE EX

11E-9 oC 0 - 300 180 170 250 260

23 11TI2017 LGO EX 11E-40 oC 0 - 350 150 140 240 250

24 11TI2018

ATF CR EX

11E-102 oC 0 - 250 110 100 250 260

48

25 11TI2019

CRUDE EX

11E-102 oC 0 - 300 120 110 160 175

26 11TI2020

HGO EX 11E-

112 oC 0 - 300 110 100 250 260

27 11TI2021

CRUDE EX

11E-112 oC 0 - 300 130 120 180 190

28 11TI2022

CRUDE EX

11E-7 oC 0 - 300 140 130 200 210

29 11TI2023 LGO TO 11E-40 oC 0 - 400 260 250 290 300

30 11TI2024

ATF CR TO

11E-102 oC 0 - 300 150 140 200 210

31 11TI2025

CRUDE EX 11P-

102ABCS oC 0 - 200 110 100 150 160

49

CDU APH

S.NO TAG NO SERVICE UNIT RANGE LO LOLO HI HIHI

1 11TI705 FLUE GAS TO APH oC 0-600 300 250 425 450

2 11TI718 FLUE GAS TO APH oC 0-600 300 250 425 450

3 11PR707 FLUE GAS TO APH MMWC 0-100 -85 -90 0 0

4 11PI738 FLUE GAS EX APH MMWC -200-0 -120 -150 -50 -20

5 11TI727 FLUE GAS EX APH oC 0-600 160 150 210 215

6 11TI741 FLUE GAS EX APH oC 0-600 160 150 210 220

7 11TI736 11K4 SUCTION TEMPERATURE oC 0-1000 160 150 205 210

8 11TI737 FLUE GAS TO STACK oC 0-550 170 160 390 410

9 11ANSO2 CDU FURNACE SO2 PPM 0-500 20 10 200 250

10 11MSD01 MAIN STACK DAMPER % 0-100 20 10 80 90

11 11PIC702 FURNACE COMMON DRAFT MMWC -20 TO +20 -15 -20 0 +1

12 11HIC701 11K1 MANUAL LOADER % 0-100 30 25 70 75




16 11PI711 11K1 DISCHARGE PRESSURE MMWC 0-600 230 220 380 400



19 11PLL741 COLD AIR EX 11K1 MMWC 0-600 230 220 400 410



22 11TIC728 HOT AIR EX 11SH1 oC 0-150 40 30 100 110

50



25 11TI738 HOT AIR EX 11SH1 oC 0-600 40 30 100 110

26 11TI739 HOT AIR EX 11SH2 oC 0-600 40 30 100 110

27 11TI740 HOT AIR EX 11SH3 oC 0-600 40 30 100 110

28 11TI717 COMBUSTION AIR TO APH oC 0-600 35 30 80 90

29 11PLL710 APH I/L AIR PRESSURE MMWC 0-600 140 110 360 400

30 11PR709 APH I/L AIR PRESSURE MMWC 0-600 150 120 350 400

31 11TI731 COMBUSTION AIR EX APH oC 0-600 200 175 310 325

32 11TI735 COMBUSTION AIR TO FURNACE oC 0-600 200 175 300 325

33 11TI719 FLUE GAS EX APH1 oC 0-600 170 160 225 240




37 11TI723 HOT AIR EX APH1 oC 0-600 160 150 300 320




51

12C-1 (VACCUM DISTILLATION COLUMN)


LOL

O HI

HIH

I

1 12LC2202 12C-1 BOTTOM LEVEL % 0 - 100 50 40 85 90

2 12LI2201 12C-1 BOTTOM LEVEL % 0 - 100 40 35 90 95

3 12LRC11 12C-1 BOTTOM LEVEL % 0 - 100 40 35 95 100

4 12LIHL28 12C-1 BOTTOM LEVEL % 0 - 100 0 0 40 50

5 12FRC74 SR TO TANK M^3/Hr 0 - 239 30 25 225 230

6 12FRC75 SR TO TANK M^3/Hr 0 - 22500

7 12FRC51 SR TO BITUMEN M^3/Hr 0 - 200 0 0 195 200

8 12FI2701 SR TO BITUMEN M^3/Hr 0 - 300 0 0 250 275

9 12FRC52 SR TO VBU M^3/Hr 0 - 100 0 0 60 75

10 12FRC39 SR QUENCH TO 12C1 M^3/Hr 0 - 140 20 15 135 140

11 12FRC38

SR PUMPS MINIMUM

FLOW M^3/Hr 0 - 40 0 0 40 40

12 12FRC40 S.STEAM TO 12C-1 KG/HR 0- 12000 2500 2000 5000 6000

13 12FRC14B S.STEAM TO 12C-1 KG/HR 0 - 2900 1500 1200 2500 2900

14 12TRC12 12C-1 BOTTOM TEMP oC 0 - 600 320 300 380 385

52

15 12PR47 12C-1 BOTTOM PR MMHG 0 - 200 70 60 110 120

16 BT31-03 SR R/D TEMP oC 0 - 600 90 75 180 200

17 BT31-04 SR TO VBU TEMP oC 0 - 600 160 150 220 230

18 12TIN4 12C-1 FLASH ZONE TEMP oC 0 - 500 380 370 412 414

19 12PIN4 12C-1 FLASH ZONE PR MMHG 0 - 200 75 70 110 120

20 12TIN312 VAC SLOP DRAW TEMP oC 0 - 500 370 360 400 425

21 12LIC103 12V-10 LEVEL % 0 - 100 40 30 80 90

22 12FRC102 VAC SLOP P/B TO 12C-1 M3/HR 0 - 51 10 5 40 45

23 12FRC50 VAC SLOP R/D FLOW M3/HR 0 - 50 10 5 50 50

24 12PIN6 12C-1 PR MMHG 0 - 200 80 75 110 120

25 BT34-28 12C-1 TEMPERATURE oC 0 - 600 250 240 290 300

26 BT34-19 HVGO DRAW TEMP. oC 0 - 600 295 290 325 330

27 12TIN68 HVGO DRAW TEMP. oC 0 - 600 295 290 325 330

28 12LIC102 HVGO TRAY LEVEL % 0 -100 45 40 70 75

29 12FRC101 HVGO P/B FLOW M3/HR 0 -166 40 35 80 100

30 12PI2201 HVGO P/B TO 12C-1 PR Kg/ CM2 -1 TO +3 0.1 0.08 0.8 1.0

31 12FRC37 HVGO REFLUX TO 12C-1 M3/HR 0 - 400 120 100 300 320

32 BT34-23 HVGO REFLUX TEMP. oC 0 - 600 100 90 170 175

33 12FRC49 HVGO R/D FLOW M3/HR 0 - 326 100 90 310 325

34 12FIC100 HOT FEED TO FCC M3/HR 0 - 146 0 0 80 100

53

35 BT34-22 HVGO EX 11AC 10 A oC 0 - 600 100 90 190 200

36 BT34-24 HVGO EX 11AC 10 B oC 0 - 600 100 90 190 200

37 BT31-02 HVGO R/D TEMP. oC 0 - 600 85 80 160 170

38 12TI211 LDO DRAW TEMP oC 0 - 500 240 230 280 290

39 12LIC101 LDO TRAY LEVEL % 0 - 100 25 20 75 80

40 12FIN2 LDO P/B M3/HR 0 - 235 50 40 210 220

41 12FRC150 LDO R/D FLOW M3/HR 0 – 40 5 0 30 35

42 BT34-33 LDO EX.12AC1A/B oC 0 - 500 75 70 150 160

42 BT34-18 LVGO DRAW TEMP. oC 0 - 600 160 150 200 205

43 12LIC-13 LVGO TRAY LEVEL % 0 - 100 50 45 80 85

44 12FIC-13 LVGO P/B FLOW M3/HR 0 - 127 40 25 125 127

45 12FRC-63 LVGO REFLUX FLOW M3/HR 0 - 382 120 100 360 380

46 12FRC-36 LVGO R/D FLOW M3/HR 0 - 92 0 0 90 92

47 BT34-25 LVGO EX 11AC11 oC 0 - 600 70 60 140 150

48 BT31-01 LVGO TO 12 E-2 oC 0 - 600 70 60 140 150

49 BT34-27 LVGO R/D TEMP. oC 0 - 600 25 20 90 100

50 BT-N-46 LVGO REFLUX TEMP oC 0 - 600 50 45 80 85

51 BT-N-51 12E3 CWR TEMP oC 0 - 600 25 20 70 80

52 12FRC-48 LVGO R/D FLOW ( OLD ) M3/HR 0 - 40 0 0 40 40

53 12TRC-10 12C-1 TOP TEMP. oC 0 - 200 50 45 80 90

54

54 BT34-02 12C-1 TOP TEMP. oC 0 - 200 50 45 80 90

55 12PRC-01 12C-1 TOP PR. MMHG 0 - 200 45 40 80 90

56 12PR-47A 12C-1 TOP PR. MMHG 0 - 200 45 40 100 110

57 12PI-2203 12C-1 TOP PR. MMHG

-0.92TO

0.92

-

0.875 -0.88 0.175 0.19

58 12PRC-66 MP STEAM TO EJECTOR Kg/ CM2 0 - 16 8 7.5 11.0 11.5

59 BT34-32 12-V-2 TEMP oC 0 - 600 25 20 45 50

60 12PT-03 EJECTOR OFF GAS PR. Kg/ CM2 0 -0.3 0.025 0.01 0.12 0.15

61 12LIC-12 12V-1 INTERFACE LEVEL % 0 - 100 35 25 70 80

62 12LIC-29 12-V-1 OIL LEVEL % 0 - 100 30 25 75 85

63 12LIC-29A 12-V-1 OIL LEVEL % 0 - 100 30 25 75 85

64 12FI-155 12V-1 OIL TO MGO M3/HR 0 - 7.0 0.8 0.5 6.8 7

65 12LIC-14 12V-5 INTERFACE LEVEL % 0 - 100 30 20 70 80

66 12HIC-201 HGO TO 12C-1 % 0 - 100 0 0 65 80

67 12PIC02 12V6 PRESSURE Kg/cm2 0 - 0.3 0 0 0.1 0.15

68 12HIC-2901 NITROGEN TO 12C-1 % 0 - 100 0 0 50 60

69 BT34-12 COND. EX 12E-1A Oc 0 - 600 20 15 45 50

70 BT34-13 COND. EX 12E-1B Oc 0 - 600 20 15 45 50

71 BT34-14 COND. EX 12E-1C oC 0 - 600 20 15 45 50

72 BT34-15 COND. EX 12E-1D Oc 0 - 600 20 15 45 50

73 BT34-16 COND. EX 12E-1E Oc 0 - 600 20 15 45 50

55

74 BT34-17 GAS EX 12V-2 oC 0 - 600 20 15 45 50

75 12TI1A

12J1A CONDENSATE

TEMP. ºC 0 - 1000 0 0 110 120

76 12TI2A

12J2A CONDENSATE

TEMP. ºC 0 – 1000 0 0 110 120

77 12TI1B

12J1B CONDENSATE

TEMP. ºC 0 - 1000 0 0 110 120

78 12TI2B

12J2B CONDENSATE

TEMP. ºC 0 – 1000 0 0 110 120

79 12TI1C

12J1C CONDENSATE

TEMP. ºC 0 – 1000 0 0 110 120

80 12TI2C

12J2B CONDENSATE

TEMP. ºC 0 – 1000 0 0 110 120

81 12TI1D

12J1D CONDENSATE

TEMP. ºC 0 – 1000 0 0 110 120

82 12TI2D

12J2B CONDENSATE

TEMP. ºC 0 - 1000 0 0 110 120

83 BT-N-47 LVGO EX 11AC-11 ºC 0 - 600 70 60 140 150

84 BT-N-48 LVGO TO 12E-3 ºC 0 - 600 70 60 140 150

85 12FRC53 SR TO RCO M3/HR 0 – 50 10 5 40 45

56

CHAPTER 7 :

SAFETY MEASURES ADOPTED

7.1) INTRODUCTION

It is essential to recognize the various possible hazards in The operationof the plant so that the

remedial measures can be planned. Following are some of the common safety hazards

encountered in the FCC Unit.

7.2) HAZARDS OF PETROLEUM PRODUCTS

All petroleum products give out vapors in amount depending upon the type of product. On

expansion LPG forms a thick cloud of vapors. These vapors in a confined space, will tend to

make the atmosphere leaner in oxygen content thus making it difficult to sustain normal

breathing (asphyxiation).

The hydrocarbon vapours also produce some adverse physiological effects. Fire and explosion

hazards are associated with these vapours under favourable conditions.

The hydrocarbon vapours heavier than air collect at low points near ground level. These vapours

have anesthetic effects. If air with hydrocarbon concentration of 0.1% is inhaled for about 5

minutes, the person feels giddy. If the concentration increases to 0.5% and person inhales such

air for about four minutes, the exhibits symptoms similar to alcoholism. The maximum

concentration of hydrocarbon (except H2S) should not exceed 0.1% to avoid intoxication of

personnel.

7.2.1) Explosion – Fire

When the proportion of hydrocarbons in the hydrocarbon air mixture falls within the explosive

limits, an explosion or fire could occur in presence of ignition, such as spark or an open fire. A

hydrocarbon air mixture can more on the ground over a considerable distance and catch fire with

in contact with a spark or an open fire. An explosion occurs when the air hydrocarbon mixture is

57

enclosed in a vessel and a fire takes place when the above conditions exist in the open. Explosion

produces a considerable volume of gas, which creates high pressure causing damage. Explosion

could initiate another explosion or fire at a distance of ten to a hundred meters because of its

physical nature. Explosion is generally followed by a fire.

Explosive limits of Hydrocarbons

Product Lower Explosive Limit

(LEL, % Vol./Vol of air)

Upper Explosive Limit

(LEL, %Vol /Vol of air)

hydrogen 4.1 74.2

methane 5.3 14.0

ethane 3.2 12.5

ethylene 2.75 28.6

Propane 2.37 9.5

7.3) SOURCE OF HEAT AND OPEN FIRE

Any fire source near the area having presence of Hydrocarbonsconstitutes a danger by its open

flame igniting the hydrocarbon vapours of evaporating and heating the hydrocarbons to the

ignition point. Example of each hazards are match sticks, cigarettes, blow-pipe, smithy shop

various furnaces etc.

58

Auto Ignition

For combustion, three conditions are necessary. These are combustible material, sufficient

quantity of oxygen and a source of heat. In free air, there is no risk of ignition if the hydrocarbon

vapor temperature is less than the ignition temperature. However, if the temperature of

hydrocarbon vapor is equal to its ignition temperature, the vapor can catch fire on mixing with

oxygen from the atmosphere, even without the help of a flame or a spark. This is known as

Auto-ignition are generally more as the molecular weight of the hydrocarbons increases. The

auto ignition temperature of some of important hydrocarbons are given below:

Product Auto Ignition Temperature ( ºC )

Hydrogen 589

Ethane 516

Ethylene 450

Propane 466

Butane 430

Pentane 309

Hexane 247

Sparks

Ignition of Hydrocarbon vapours and air mixture can be produced by a spark, which may cause

an explosion of fire. The possible sources of sparks are:

1) Rubbing of ferrous metals between themselves or with other hazard material like concrete.

2) Rubbing of iron shoe sole with ground or metallic parts.

3) Filling of iron tools

4) Stroke of a steel hammer on a hard body like metal or concrete.

59

5) Sparks from lose electrical wheel.

Lightning

Lightning can fall on metallic objects such as chimneys, tower, tanks and tall building. These

can damage the structures or lead to ignition of hydrocarbon air mixture, if present. The

vent/safety relief valve discharge at high points to the atmosphere are especially vulnerable to

lightning.

Static Electrical charges

Static electrical charges can be produced by rubbing different bodies between themselves and

these can accumulate and produce sparks strong enough to initiate a fire or an explosion. Such

charges can be produced by rubbing of petroleum products on the internal surfaces of pipes,

tanks and various equipment. The handling of dry substances as coke, sulfur, etc. in metal chute,

binds or even though relatively dry air can also result in the generation of static electricity. Static

charges can also be produced by other operation such as a driving belt, cleaning with silk or

charges can also be produced by other operation such as a driving belt, cleaning with silk or

nylon cloth and fine mesh screens and filters, etc. A proper system of grounding is essential for

such operation.

7.4 GENERAL SAFETY GUIDELINES

All employees and persons responsible for operation in the FCC process should be experience in

petroleum refinery operating techniques and should be familiar with applicable safety practices.

All necessary precautions should be taken to avoid accidents. The following general safety rules

are applicable to FCC unit operations. These must be known and strictly observed by all

personnel. Clean oil and grease off, the skin carefully. If allowed to stay, it serves as an agent

for maintaining dust, dirt and harmful bacteria on the skin. Wash the hands and skin with soap

and water.

60

1.) Smoking should be permitted only at approved smoking locations.

2) If an employee’s clothing becomes contaminated with acids, caustics, alcohols, aromatic

hydrocarbons or any other chemical solution, he must remove clothes immediately and

shower.

3) Defective tools should not be used.

4) When using chiesels, cold cuts, sticking wrenches, hammers or punches, examine the striking

surfaces frequently for burrs and other foreign matter. Non sparking tools should be used.

5) Use proper tools for the work involved, i.e. do not use a file for a bar, a hand wrench for a

hammer etc.

6) Over-stressing tools or equipment has frequently caused serious injuries. Take precaution to

prevent injuries to yourself or others.

7) Safety belts or lifelines shall be used when working 2 meter’s or more above ground, where

it is not practical to make other provisions to prevent falling.

8) Falls are the second largest cause of accidental deaths. Do not take the following chances:

Failure to look where you are going.

Standing on boxes, chairs and make shifts instead of ladders or platforms.

Neglecting to use handrails and running on stairs.

Failing to face ladder when carrying objects on the same.

9) Tools and materials should not be dropped from heights. They must be carried down.

10) Standing or walking under materials suspended by ropes, chains or cables should not be

permitted. Stay in the clear until material is well secured.

Electrical Equipment

1) Don’t temper with electrical apparatus. This is the work of qualified electrician.

2) Don’t remove light bulbs to plug-in power equipment.

3) Use only approved electrical fittings, the cover of electrical fitting in hazardous areas

should be secured properly to avoid entry of explosive gases.

4) All electrical equipment must be properly grounded.

5) An electrical extension wire must not be used if it is in bad condition, laid through water

or in such manner as to allow motorized equipment to travel over it.

6) Employees should regard all electrical wires as live and dangerous.

61

7) Never close a switch or breaker that has been opened unless authorized to do so by your

supervisor.

8) All electrical breaker must be de-energized and locked before process equipment can be

worked upon.

9) All live fuse, lighting and power cabinets must be kept closed.

10) If an electrical power unit motivates moving machinery and it is necessary to make repairs

to it, then refer to and follow the electrical lock out procedure laid down by the plant

management.

SAFETY RULES FOR PARTICULAR OPERATIONS

The following safety instructions are for the operations carried out frequently in the FCC unit.

These must, in addition to the general safety rules, be understood and observed strictly by all

personnel.

Sample and purge connections

Sample and purge connections on liquefied products have two valves. Always open the upstream

valve fully and adjust the flow by the downstream valve. This is done so that upstream valve is

always operable in case of frosting. Draining of LPG or Gasolene vessels should not be done

unattended. Operator should be present as long as draining/venting is going on.

Isolation of safety valves

Many safety valves are provided with the isolation valves at upstream and downstream of the

safety valve. This is to facilitate the repair of safety valve. It is important to ensure that these

isolation valves are kept in open condition. When a safety valve is to be taken out of line, bring

the spare safety valve in line or shut down the equipment if the spare safety valve is not

provided.

62

High point vents and relief valve discharges

The hydrocarbon discharges from the high point vents and relief valve discharges to atmosphere

pose hazard due to lightning. Such discharges are normally provided with steam purge

connections. It is essential to keep small purge of steam in these lines, especially in monsoons

when there is likelihood of lightning.

SAFETY PRECAUTIONS FOR PREPARATION OF EQUIPMENT FOR

MAINTENANCE

Process equipment: Column, Vessel etc.

Before opening any equipment, it should be purged to render the internal atmosphere non-

explosive and breathable. Operations to be carried out are:

Isolation with valves and blinds.

Draining and depressurization.

Replacement of vapours or gas by steam, water or inert gas.

Washing of columns and vessels with water. Suitable service water connections have

been provided at various points in the unit.

Ventilation of equipment.

Opening of top manhole.

Testing of inside atmosphere with explosive meter

Complete opening if inside atmosphere is satisfactory.

Note: Open a vent on the upper part of the vessel to allow gases to escape during filling and to

allow air inside the vessel during draining.

63

Precautions Before handing over equipment

Following items should be checked by a responsible operating supervisor before an equipment is

handed over for maintenance after it has been purged.

1) Ascertain that the equipment is isolated by proper valves and blinds.

2) Ascertain that there is no pressure of hydrocarbons in the lines, vessel and equipment.

3) Check that steam injection lines and any inert line connection are disconnected or

isolated from the equipment.

4) Put tags on the various blinds so as to avoid mistakes. Maintain a register for blinds.

5) Keep the surrounding area cleaned up.

6) Get explosive meter test done in vessel, lines, equipment and surrounding area.

If welding or hot work is to be done, also:

1.) Keep fire-fighting devices ready for use nearby.

2.) Close the neighbouring surface drains with wet gunny bags.

3.) Keep water flowing in the neighbouring area to cool down any spark bits, etc.

After the above operations have been made, a safety permit should be issued for carrying out the

work. A responsible operating supervisor should be personally present at the place of hot work

till the first torch is lighted. Hot work should be immediately suspended of instructed

bythesupervisor. .

When people have to enter a vessel for inspection or other work, one person should stand outside

near the manhole of the vessel for any help needed by the persons working inside.

64

CHAPTER 8:

ENVIRONMENTAL ISSUES

The potential environmental impacts associated with the refinery are expected to vary depending

upon the construction alternative selected for the refinery and the selected effluent discharge

alternative. A brief discussion of the types of environmental impacts analyzed in the DEIS is

summarized below.

Groundwater, Soils and Spills

Ground water occurs beneath the refinery site. Groundwater is in the underlying material called

“till” which was deposited by glaciers in an approximately 100- foot thick layer. Ground water

generally moves slowly in till layers due to low permeability. Depth to water in the till aquifer

typically ranges from 5-15 feet. Ground water in the till appears to flow toward the southwest at

about 0.4 to 2.4 ft/year. Ground water also occurs in the Ft. Union Formation, which underlies

the till and the Fox Hills Formation which underlies the Ft. Union Formation.

It is anticipated that there would be spills and leaks at the proposed refinery facility. Almost all

refineries and other petrochemical facilities such as gas stations eventually have spills and leaks.

The majority of spills and leaks would be completely contained within the facility and would not

impact the environment. However, over time, it is expected that there would be some

contamination of soils and groundwater immediately underneath the refinery site due to leaks

andspills. The contamination would remain generally within the refinery site unless a major spill

occurred or a series of spills and leaks occurred over time.

Areas within the refinery storing synthetic crude or refinery products would be required to be

lined and have secondary containment (e.g., berms) to hold the entire contents of storage tanks.

Areas with a high potential for spills such as the loading area for trucks and railcars would also

be paved and curbed.

65

Transportation

The refinery will increase traffic on local roads and on the rail line. With the shipment of

refinery products, there would be an increased probability of petroleum products spills along the

pipeline corridor, transportation corridors and the rail line.

Air Quality

Air emissions from the refinery would be minor. Potential air emissions have been modeled;

demonstrating that the proposed facility would not cause any exceedances of the National

Ambient Air Quality Standards (NAAQS) or Prevention of Significant Deterioration (PSD)

increments. At this time, EPA has determined that no Clean Air Act permits will be required for

the facility because the total quantity of air pollutants emitted throughout the year by the refinery

are less than the regulatory thresholds for any air permits.

Human Health

With proper operation of the refinery, potential impacts to human health are anticipated to be

negligible to the general public. Pollutants or materials which would be of concern to public

health would be contained within the refinery, treated to nontoxic levels or disposed of at

approved hazardous waste facilities.

Environmental Justice, Socioeconomics

Environmental Justice concerns that are raised in the DEIS include many of the issues addressed

above, such as air pollution emissions the discharge of pollutants into surface waters and ground

water and hazardous waste generation. The DEIS also addresses socioeconomic effects of

constructing and operating a new refinery.

Economic benefits associated with the refinery may increase the quality of life for members of

the MHA Nation. However, negative effects to the quality of life may be experienced by the

communities surrounding the facility due to increases in highway traffic, noise, and light

pollution during construction and operation.

66

CHAPTER 9:

PROBLEMS IDENTIFIED AND SOLUTIONS

1.In Desalter chloride is the source of hydrogen chloride evolved during distillation, thus its

presence is one of the indices of corrosion potential of the crude. Magnesium chloride is the

most prolific producer of HCl with calcium and sodium in descending order. Apart from

chlorides, carbonates and sulfates may be present in significant quantities. Sulfates especially

may be troublesome for sulfate scale formation.

These water-soluble impurities are brought along with the residual water-content into the crude

oil. Much of the sediment also may be associated with this dispersion of water. Water drops

ordinarily are so small that gravity would require a prohibitively long time to draw all of the

drops to the bottom of a storage tank, even if the tank were free from convection currents.

Moreover, this water dispersion, or in other words, the emulsion received at the refinery has been

'aged' over an extended period by stabilisers. These stabilisers are molecules or groups of

molecules asphalts, etc. in the oil that are least similar to the bulk oil (i.e. least similar to the

most prevalent oil molecular species), and therefore subject to less intermolecular force. Being

less attracted to the internal body of the oil, the exceptional material will be rejected to the

interface of the oil-water drops. Such material may include asphalts, asphaltenes, resins

sediments etc. Such rejected surface-active materials comprise a physical bar that prevents water

drops getting close enough to bring about coalescence. Before the drops can coalesce, therefore

the stabiliser film must be reduced in thickness and tenacity, and ruptured. An effective means

for aiding this is heat. Heat increases the solvency of the bulk oil for the stabiliser, reduces the

viscosity of the oil and decreases the viscosity and cohesion of the film. These effects though

decrease the viscosity and cohesion of the film, these effects though very much beneficial are

normally not adequate to permit coalescence.

2. Furthermore another important consideration is that the chances of collision among drops in

this sparse population of drops are relatively few. The limitation of distance between drops is

dealt with by dispersing about 5 percent of fresh water to the oil. Thus the water has been

67

increased about 25 times and the distance between drops surfaces reduced by 10 Even so, the

added water is not likely to combine with a satisfactory portion of the brine particles and

coalesce effectively without additional means.

PROBLEMS IDENTIFIED AND CORRECTION DURING REVAMPS

(1). SCHEME FOR REDUCTION IN MOISTURE CONTENT OF MGO STREAM:

In order to meet the BS-III Specification Diesel both the LS & the HS diesel was routed

to DHDS/DHDT for reduction in total Sulphur and improvement in Cetane number. Only 10 %

of straight run find its destination as final product. Temperature is not expected to be an issue

after blending of hydro-treated and straight run diesel. The moisture content of MGO stream

from AVU, however needs to be brought down to meet the final BS-III specification which is <

200 ppm. This will also reduce the hydrocarbon loss during draining/preparation of the

DHDS/DHDT feed tanks.

In order to bring down the moisture in LGO stream of AVU a two pronged approach was

exercised in 2005 shutdown.

Reduction in LGO R/D temperature:

The quantity of LGO drawn from the column is much higher than the design value and

the LGO R/D temperature observed in peak summer is 60 Deg C. In order to bring down its

rundown temperature after considering various options it has been observed that cleaning 10-E-

1A Heat exchanger & converting 11-E-26A into dual service (i.e. LGO & RCO) will be most

efficient and the same has been executed in 2005 shutdown. Apart from the above,11-AC-14

which was previously HGO Air-cooler has been retrofitted for LGO service. The above two

modifications is expected to bring down the LGO rundown temperature to 40-45°C.

68

Procurement of new coalescer for MGO (HSD ex AVU) stream.

A coalescer of 150 m3/Hr capacity was procured from M/S Ravi Techno and placed south

side of ATF cooler 11-E-1A. Provisions were made to route the MGO through the coalescer. The

moisture ridden(< 200 ppm). MGO stream can be routed either to MGO pool or to

DHDS/DHDT feed pool. The introduction of the coalescer and exchanger in the MGO circuit

will increase the Pressure drop in the LGO circuit which will be offset by

Reduction in LGO R/D flow by shifting the load from LGO to HK & HGO.

Splitting the total MGO between DHDT/DHDS & MGO R/D line.

(2). PROVISION FOR ROUTING VAC. SLOP AND SR IN RCO R/D CIRCUIT:

The CDU of Mathura Refinery was revamped from 8MMTPA to 11MMTPA in June 2004.

The Process Design Basis was finalized in May 1999. Due to wide gap in the finalisation of

Process Design Basis and the final execution of the project following variations has been

observed:

Decrease in desalter temperature by around 20°C

Decrease in pre-fractionator feed temperature by around 19°C

Reduced pre-heat for CDU furnaces by around 47°C

Reduction of COT in CDU furnaces by around 41°C

More than 90% less heat duty in Train-1 and Train-3

More than 75% less heat duty in RCO- tempered water circuit

More than 50% more heat duty in SR-tempered water circuit

Various reasons attributed to above were:

No RCO spill over after Sep. 2003 leading to low heat duty in certain exchangers.

Processing 14% more RCO than design in Vacuum column thus overloading certain

exchangers.

69

Partial coking of 11F3 and 11F4

In order to remove some of the above bottlenecks the following has been executed in 2005

shutdown:

Provision to route Vacuum Slop and S.R. in RCO line leading 11-E-38 B .

A control valve has been provided in RCO circuit leading to 11-E-38B.

Net load on the Tempered Water system came down by 3.5 Mkcal/Hr. The total increase in Heat

duty recovered in the Pre-Heat train comes out to be 7 Mkcal/Hr considering processing of 1200

M3/Hr of HS crude & 50 % HS crude processing throughout the year.

This has led to

Improved performance of Desalter due to increase in Desalter temperature

Improved performance of Pre-Fractionator as its feed temperature increases

Greater flexibility and safety in the Tempered Water System.

Monetary benefit of Rs.3.51 Cr./Yr

(3). Routing of Stabilized Naphtha from DHDT to AVU:

The Naphtha from DHDT is having high end point and low octane, thus limiting its

blending in the MS pool. In order to utilize this naphtha effectively, it is proposed to process this

stream in AVU. The existing Wild Naphtha line from DHDS has been used to route stabilized

naphtha from DHDT to AVU.

Provisions has been made in 2005 shutdown for routing the Stabilized Naphtha

to 11-V-2 by means of a hook-up in condensate drain line from 11V10.

with the top reflux of 11-C-1 at the D/S of reflux control valve 11-FRC-14.

The total quantity of the Naphtha is expected to be maximum of 9-10 m3/hr @ 45 °C which

shall not pose any problem for the control of top temperature.

70

REFERENCES

1. AVU MANUAL AT IOCL MATHURA OLD UNIT.

2. WEBSITE : WWW.IOCL.COM

71

Training Report

Documents

crude furnace

preheated crude

crude header

types of crude

heavy crude

crude fractionator

radiant section

crude oil service