SUMMER SECOND BATCH 2014

NAME: - MUHAMMAD AHSAN KHANYEAR: - 3RD BATCH: - 2012DEPARTMENT: - CHEMICAL ENGINEERING

DEDICATION

We dedicate our efforts to our loving parents, friends, colleagues,

all teachers who have not only been a source of motivation to us but

also extended their help whenever needed. Without their help and

motivation it would have not possible for us to do all this.

2 | P a g e

ACKNOWLEDGEMENTIn the name of Allah, the Most Gracious, the Most Merciful

All praises be to Allah, Lord of the Worlds, the Beneficent and the Merciful. Owner of the

Day of Judgment, Thee (alone) we worship; Thee alone we ask for help. Show us the

straight path, the path of those whom Thou hast favored; Not (the path) of those who earn

Thin anger nor of those who astray.

(Al-Quran)

Thanks are due to ALLAH Almighty whose kind grace enabled us to accomplish this

report. We also pay our gratitude to loving parents, kind teachers especially our Sir Qazi

3 | P a g e

Bilal, Sir Sarang and Sir Rashid and others who have not only been a source of motivation

to us but also extended their help whenever needed. Without their help and motivation it

would have not possible for us to do all this.

May almighty bless all these patrons and put on the right path!

(Aameen)

TABLE OF CONTENTSPage

Company Profile...............................................................................................................4 Organization Structure..................................................................................................... 5 Vision & Values………………………………………………………………………....6 EHS Department.............................................................................................................. 7 Laboratory........................................................................................................................11 Operations Department.....................................................................................................15

Process……………..............................................................................................15 Fraction Distillation Unit.....................................................................................16 Reforming Unit....................................................................................................17 Merox Unit...........................................................................................................17 LPG Separation Unit……………………………………………………………18 De-Sulfurizer.......................................................................................................18 Distributed Control System (DCS)......................................................................19 Boiler....................................................................................................................20 Water Tube Boiler................................................................................................20 Heat Exchanger…………………………………………………………………22 Shell and Tube Heat Exchangers………………………………………………..22 Cooling Tower………………………………………………………………….22

4 | P a g e

Furnaces………………………………………………………………………...23 Splitter column………………………………………………………………….24 Reverse Osmosis Plant………………………………………………………….24

Inspection ……………………………………………………………............................26 Mechanical ……………………………………………………………………………..27 Instrumentation................................................................................................................37 Oil Movement ………………………………………………………………………….40 Logistics………………………………………………………………………………...41 References…………………………………………………………………………........42

COMPANY PROFILEByco is Pakistan’s emerging energy companies engaged in the businesses of oil refining, petroleum marketing, chemicals manufacturing and petroleum logistics. Headquartered in Karachi, we are serving our mission to fulfill the energy demand within and beyond borders.

Byco owns the following companies:

Byco Petroleum Pakistan Limited (BPPL) Byco Oil Pakistan Limited (BOPL) Byco Terminals Pakistan Limited (BTPL)

Byco Petroleum Pakistan Limited was incorporated in Pakistan as a public limited company on January 09, 1995 and was granted the certificate of commencement of business on March 13, 1995. The shares of the company are listed on the Karachi, Lahore and Islamabad Stock Exchanges. The Company is engaged in the business of refining crude oil into various saleable components including Liquefied Petroleum Gas, Light Naphtha, Heavy Naphtha, High Octane Blending Component, Motor Gasoline, Kerosene, Jet Fuels, High Speed Diesel and Furnace Oil.

The Oil Refinery is located at District Hub, Lasbela, Balochistan . The company has the capacity to produce 30,000 bpd from February 2008 after debottlenecking of the whole plant which has been now increased upto 40,000 bpd by doing some modifications in plant. The

5 | P a g e

company is now growing aggressively with more than 219 retail outlets throughout the country. Oil Refinery Complex- II is under construction and after its completion, BPPL will able to produce 150,000 bdp. The company takes pride in having the largest capacity crude oil storage tanks in the country. Its capacity is 0.35 MN barrels.

BPPL continues to work on its unique way by introducing Pakistan’s first SPM Project. SPM stands for Single Point Mooring. The Single Point Mooring (SPM) facility being set up for the first time in Pakistan will revolutionize the handling of petroleum and oil products in the Country. The facility is being setup to allow the handling of imported crude oil and other petroleum products through the SPM. The SPM can currently handle vessels of 100,000 deadweight tonnage and has the expansion capacity to add two more pipelines which shall enhance facility's throughput.

This high number is possible because the company keeps updating its procedures and is currently a mixture of old and latest technology. Owing to great localization that has been done in the past few years the company has become independent and does not require external helps to solve their problems.

ORGANIZATION STRUCTURE

6 | P a g e

Vision & Values7 | P a g e

Our vision is to be a leading energy company through delivering the core business, achieve sustainable productivity and profitability to deliver a superior shareholder return.

Byco values are the guiding principles that define how it conducts its business and what it stands for as a company. This includes:

Getting high standards of care for environment, health and safety. Investment in human capital, offer competitive employment terms and provide safe and

congenial working environment and an equal opportunity for all our employees. Entail human resource development and promotes openness, professionalism, teamwork

and trust. Enhancing value addition, implementing conservation measures and growth up-gradation

through addition of newer generation technologies. Credibility, goodwill and reputation earned through ethical practices, honesty, integrity

and respect for people. Safeguarding of shareholders' interest and providing them with a consume rate return on

equity is an integral part of our business ethics.

These values are the basis of our commitment to operate as a sustainable energy company.

ENVIRONMENT HEALTH AND SAFETY DEPARTMENT

EHS (Environment Health & Safety) department is one of the most essential department of Byco Petroleum Pakistan. At Byco Petroleum Pakistan Limited the EHS department works

8 | P a g e

under an IMS (Integrated Management System). The main target is to develop the company on professional basis and to meet the international standards as set by the international organizations and to be a responsible corporate entity with respect to Environment, Health and Safety.

The standards that are being followed at the Byco Petroleum Pakistan Limited are:

EMS (Environmental Management System) ISO 14,001 QMS (Quality Management System) ISO 9001 OHSAS (Occupational Health Safety Assessment Series) ISO 18,001

As far as Environmental Department is concerned, Pak-EPA (Pakistan Environmental Protection Agency) keeps a check and balance on the environmental regulations.The company ensures for the protection, conservation, rehabilitation and improvement of environment, for the prevention and control of pollution, and promotion of sustainable development.NEQS (National Environmental Quality Standards) drafted by the Pak-EPA are also to be followed.

MAJOR SOURCES OF POLLUTION:-

No biodegradable waste: It consist of two types:

(i) Hazardous waste (medical waste or contaminated soil)(ii) Municipal waste (kitchen or domestic waste)

Emission of toxic gases: It contains:

(i) SOX(ii) NOX(iii) CO₂

SAFETY:-

Safety is the state of being "safe", the condition of being protected against physical, social, spiritual, financial, political, emotional, occupational, psychological, educational or

9 | P a g e

other types or consequences of failure, damage, error, accidents, harm or any other event which could be considered non-desirable. This can take the form of being protected from the event or from exposure to something that causes health or economical losses. It can include protection of people or of possessions. Safety is divided into 3 parts:

Fire Safety Process Safety Construction Safety

FIRE SAFETY:-

Fire safety refers to precautions that are taken to prevent or reduce the likelihood of a fire that may result in death, injury, or property damage. The biggest danger which an oil refinery can face is fire. As BPPL is an oil refinery which deals with the fuel which in any condition can burn steadily and can destroy the plant area even the workers working there. Threats to fire safety are referred to as fire hazards.

Fire is the combination of three factors:

Fire can be produced by the presence of all the three mediums present in the fire triangle. Vitality of these agents is such that if we eliminate any one of them, Fire initiation becomes impossible.

Fuel Oxygen Heat

PROCESS SAFETY:-

10 | P a g e

Process safety focuses on preventing fires, explosions and accidental chemical releases in chemical process facilities or other facilities dealing with hazardous materials. A process safety incident is the "Unexpected release of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals. . Incidents continue to occur in various industries that use highly hazardous chemicals which exhibit toxic, reactive, flammable, or even explosive properties, or may exhibit a combination of these properties. BPPL minimizes the hazards that are caused during process by LEL testing and keep check and balance on it.

CONSTRUCTION SAFETY:-

Hazards on the sites includes fall from height, vehicle crash, electrocution and being struck by falling objects. . Some of the main health hazards on site are asbestos, solvents, noise, and manual handling activities. The laws that BPPL follows concerning construction safety are that of OSHA(Occupational Safety and Health Administration).

SAFETY EQUIPMENTS:

This includes equipments which help in alerting from emergency situations: Fire Alarms Smoke Detectors PCV (Pressure Control Valves) TCV (Temperature Controlling Valves) LCV (level Control Valves) Safety Valves

11 | P a g e

WORK PERMITS (PTW);

These permits are classified by the work that is required to be done:

Cold Work Permit: Activates involve working in plant areas Hot Work Permit: This includes the work in which sparks are produced. Confined Space Entry Certificate: e.g. Work inside Confined Spaces. Excavation Work Permit: Including civil work.

PPEs (Personal Protective Equipments):

Safety features are followed by every worker at the BPPL. All the workers wear PPE’s for their safety. This includes:

Gloves , Air Filters , Goggles at sensitive areas Safety Cover Body Safety at height. Hard Helmets Safety Shoes

Personal Protective Equipments

12 | P a g e

LABORATORYA laboratory (lab) is a facility that provides controlled conditions in which scientific research, experiments, and measurement may be performed. Laboratory plays an important role in BPPL for testing the different standards of fuels that are being produced in Byco oil refinery. These fuels are produced by passing the crude oil from different processes. Products include are Liquid fuels, Gaseous fuels and Lubricants.

Fuels that are being produced from crude oil are:

Gasoline High Speed Diesel Jet Fuel Furnace Oil Naphtha Liquefied Petroleum Gas (LPG) Kerosene

LAB SAFETY:

In many labs, though, hazards are present. Therefore in laboratories where dangerous conditions might exist, safety precautions are important. Rules exist to minimize the individual's risk, and safety equipment is used to protect the lab user from injury or to assist in responding to an emergency. The Occupational Safety and Health Administration (OSHA) in the United States, recognizing the unique characteristics of the laboratory workplace, has tailored a standard for occupational exposure to hazardous chemicals in laboratories. This standard is often referred to as the "Laboratory Standards". In BYCO inspections are conducted on a regular basis to assess hazards due to chemical handling and storage, electrical equipment, biohazards, hazardous waste management, housekeeping and emergency preparedness, radiation safety, ventilation as well as respiratory testing and indoor air quality.

Terminologies Related to Fuel Check:13 | P a g e

Pour Point: The pour point of a liquid is the lowest temperature at which it becomes semi solid and loses its flow characteristics. ASTM D-5949, Standard Test Method for Pour Point of Petroleum Products.

Flash Point: The flash point of a volatile material is the lowest temperature at which it can vaporize to form an ignitable mixture in air. Measuring a flash point requires an ignition source. At the flash point, the vapor may cease to burn when the source of ignition is removed. ASTM D-93, Standard Test Method for Flash Point of Petroleum Products.

Cloud Point: The cloud point of a fluid is the temperature at which dissolved solids are no longer completely soluble, precipitating as a second phase giving the fluid a cloudy appearance. ASTM D-5773, Standard Test Method for Cloud Point of Petroleum Products.

14 | P a g e

Apparatus for Testing Fuels:

Viscosity Bath: Viscosity bath tester is oil testing machine which tells the viscosity of oil at different temperatures. There are two types of viscosity bath in testing lab. One bath is calibrated on -20 °C and the other at 50 °C. Fuel furnace oil is examined in the bath. The whole equipment consists of two portions. The upper is called bath tub and the lower is called setting bath. The setting bath consists of a compressor and a condenser while bath tub consists of freezing reagent such as alcohol. We cannot use water as a reagent because at -20*C, it will freeze. There are two tubes in bath tub in which oil is immersed. This tube is called viscometer tube. Each tube has its own factor. The oil is sucked in the tube up to a certain level and it is then allowed to fall, meanwhile the time is noted of the fall, up to a level. This time in seconds is multiplied with the factor of that particular tube which gives the viscosity of the oil.

Potentiometric Titrator: Potentiometric titrator determines the acidity and neutralization value of oil. 5gms of oil is mixed with 20ml of alcohol in a beaker. The beaker is stirred with magnetic stirrer meanwhile 0.1molar solution of KOH is added in a beaker gradually. The electrode automatically turns off the instrument when the neutral point is achieved and titration is completed. The acidity of solution must be less than 0.03mg. It means oil must be very slightly acidic.

15 | P a g e

Biochemical Oxygen Demand (BOD): Biochemical oxygen demand or B.O.D. is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time period. The term also refers to a chemical procedure for determining this amount. This is not a precise quantitative test, although it is widely used as an indication of the organic quality of water. The BOD value is most commonly expressed in milligrams of oxygen consumed per litre of sample during 5 days of incubation at 20 °C and is often used as a robust surrogate of the degree of organic pollution of water. The sample is kept at 20 °C in the dark to prevent photosynthesis (and thereby the addition of oxygen) for five days, and the dissolved oxygen is measured again. The difference between the final DO and initial DO is the BOD.

OPERATIONS DEPARTMENTOperation may be defined as jobs or tasks consisting of one or more elements or subtasks, performed typically in one location.

An operations department typically attends to those administrative, logistical, and other duties necessary for an organization's day-to-day functioning. Depending on the nature of the organization, an operations department, sometimes called a back office, may be responsible for a diverse range of responsibilities. Operations departments exist in businesses and other organizations in every segment of the economy, including — but not limited to — such diverse

16 | P a g e

segments as the financial services industry, including banks and brokerages, as well as academia, manufacturing, non-profit organizations, and the military.

In BYCO PETROLEUM PAKISTAN, the basic purpose of operation department is to control and regulate the refining process of crude currently in ORC-1. Operation department carries out the overall operations that are being carried out in the refinery for various unit and sections for the proper working of plant in order to meet the desired demands.

Process:

Raw or unprocessed crude oil is not generally useful in industrial applications, although "light, sweet" (low viscosity, low sulfur) crude oil has been used directly as a burner fuel for steam vessel propulsion. The lighter elements, however, form explosive vapors in the fuel tanks and are therefore hazardous, especially in warships. Instead, the hundreds of different hydrocarbon molecules in crude oil are separated in a refinery into components which can be used as fuels, lubricants, and as feedstock in petrochemical processes that manufacture such products as plastics, detergents, solvents, and fibers such as nylon and polyesters.

Oil can be used in a variety of ways because it contains hydrocarbons of varying molecular masses, forms and lengths such as paraffins, aromatics, naphthenic (or cycloalkanes), alkenes, and alkynes. While the molecules in crude oil include different atoms such as sulfur and nitrogen, the hydrocarbons are the most common form of molecules, which are molecules of varying lengths and complexity made of hydrogen and carbon atoms, and a small number of oxygen atoms. The differences in the structure of these molecules account for their varying physical and chemical properties, and it is this variety that makes crude oil useful in a broad range of applications.

Crude oil is separated into fractions by fractional distillation. The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom. The heavy bottom fractions are often cracked into lighter, more useful products. All of the fractions are processed further in other refining units.

The first unit operation in a refinery is the continuous distillation of the petroleum crude oil being refined. The overhead liquid distillate is called naphtha and will become a major component of the refinery's gasoline (petrol) product after it is further processed through a catalytic hydrodesulfurizer to remove sulfur-containing hydrocarbons and a catalytic reformer to reform its hydrocarbon molecules into more complex molecules with a higher octane rating value. The naphtha is a mixture of very many different hydrocarbon compounds. It has an initial boiling point of about 35 °C and a final boiling point of about 200 °C, and it contains paraffin, naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from those containing 4 carbon atoms to those containing about 10.

There are basically four units in ORC-1 namely:

17 | P a g e

CRUDE DISTILLATION UNIT REFORMING UNIT MEROX UNIT DESULPHURIZER

Fractional Distillation Unit:

Fractional distillation is useful for separating a mixture of substances with narrow differences in boiling points, and is the most important step in the refining process. Fractional distillation is carried out in crude distillation unit.

Because hydro carbons have different boiling temperatures, they can be separated easily by a process called fractional distillation. The steps of fractional distillation are as follows:

1) You heat the mixture of two or more substances (liquids) with different boiling points to a high temperature. Heating is usually done with high pressure steam to temperatures of about 1112 degrees Fahrenheit / 600 degrees Celsius.

2) The mixture boils, forming vapor (gases); most substances go into the vapor phase.

3) The vapor enters the bottom of a long column (fractional distillation column) that is filled with trays or plates. The trays have many holes or bubble caps (like a loosened cap on a soda bottle) in them to allow the vapor to pass through. They increase the contact time between the vapor and the liquids in the column and help to collect liquids that form at various heights in the column. There is a temperature difference across the column (hot at the bottom, cool at the top).

4) The vapor rises in the column.5) As the vapor rises through the trays in the column, it cools.6) When a substance in the vapor reaches a height where the temperature of the column

is equal to that substance’s boiling point, it will condense to form a liquid. (The substance with the lowest boiling point will condense at the highest point in the column; substances with higher boiling points will condense lower in the column.).

7) The trays collect the various liquid fractions which are extracted out relevantly.

REFROMING UNIT:-

18 | P a g e

Catalytic reforming is a chemical process used to convert petroleum refinery naphthas, typically having low octane ratings, into high-octane liquid products called reformates which are components of high-octane gasoline (also known as high-octane petrol). Basically, the process re-arranges or re-structures the hydrocarbon molecules in the naphtha feedstocks as well as breaking some of the molecules into smaller molecules. The overall effect is that the product reformate contains hydrocarbons with more complex molecular shapes having higher octane values than the hydrocarbons in the naphtha feedstock. In so doing, the process separates hydrogen atoms from the hydrocarbon molecules and produces very significant amounts of byproduct hydrogen gas for use in a number of the other processes involved in a modern petroleum refinery. Other byproducts are small amounts of methane, ethane, propane, and butanes.

MEROX Unit:

Merox is an acronym for mercaptan oxidation. It is a proprietary catalytic chemical process used in oil refineries and natural gas processing plants to remove mercaptans from LPG, propane, butanes, light naphtha, kerosene and jet fuel by converting them to liquid hydrocarbon disulfides.

The Merox process requires an alkaline environment which, in some of the process versions, is provided by an aqueous solution of sodium hydroxide (NaOH), a strong base, commonly referred to as caustic. In other versions of the process, the alkalinity is provided by ammonia, which is a weak base. Processes within oil refineries or natural gas processing plants that remove mercaptans and/or hydrogen sulfide (H2S) are commonly referred to as sweetening processes because they results in products which no longer have the sour, foul odors of mercaptans and hydrogen sulfide. The liquid hydrocarbon disulfides may remain in the sweetened products, they may be used as part of the refinery or natural gas processing plant fuel, or they may be processed further.

LPG Sepa ra tion Unit (LSU):

The condensed Light naphtha comprising of carbon 1-7 are sent into LSU unit. Here they are processed in a series of loops using dpropanizer and debutanizerand feed back to the exchanger. Using this loop the products butane and propane are separated and then mixed according to the requirement (60% propane and40% butane or 70% propane and 30% butane) to make LPG. Now after cooling and condensation the product is sent to storage tanks.

De-Sulfurizer:19 | P a g e

Hydro desulfurization (HDS) is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of removing the sulfur is to reduce the sulfur dioxide (SO2) emissions that result from using those fuels in automotive vehicles, aircraft, railroad locomotives, ships, gas or oil burning power plants, residential and industrial furnaces, and other forms of fuel combustion.

Another important reason for removing sulfur from the naphtha streams within a petroleum refinery is that sulfur, even in extremely low concentrations, poisons the noble metal catalysts (platinum and rhenium) in the catalytic reforming units that are subsequently used to upgrade the octane rating of the naphtha streams.

The industrial hydro desulfurization processes include facilities for the capture and removal of the resulting hydrogen sulfide (H2S) gas. This unit is also known as HYDROTREATER.

Hydrogenation is a class of chemical reactions in which the net result is the addition of hydrogen (H).Hydrogenolysis is a type of hydrogenation and results in the cleavage of the C-X chemical bond, where C is a carbon atom and X is a sulfur (S), nitrogen (N) or oxygen (O) atom. The net result of a hydrogenolysis reaction is the formation of C-H and H-X chemical bonds. Thus, hydrodesulfurization is a hydrogenolysis reaction. Using ethanethiol (C2H5SH), a sulfur compound present in some petroleum product.

Ruthenium disulfide appears to be the single most active catalyst, but binary combinations of cobalt and molybdenum are also highly active.

Distributed Control System (DCS)A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring.

Distributed control systems (DCSs) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement

20 | P a g e

production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use setpoint control to control the flow of material through the plant. The most common example is a setpoint control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired setpoint. Large oil refineries have many thousands of I/O points and employ very large DCSs.

In BYCO, highly advanced DCS system is installed which regulates and controls the process and operation accurately and economically. The operator in the control room defines the set point for the desired process based on the current conditions.

Some of the on field equipments used by BYCO plant are given by:

Remote Display Unit (RDU):

The Remote Display Unit (RDU 40) is a robust display unit for outdoor use in hazardous areas. If the number of temperature elements per tank is 6 or less, the RDU 40 is the most cost effective solution for field display. In this case the temperature elements can be connected directly to the Tank Radar Gauge (RTG) without using a Data Acquisition Unit (DAU). Each screen view can display 7 text lines with 16 characters.

It displays calculated data such as level, average temperature, volume, signal strength etc. Data can be displayed in lists or as single values, with a choice for the operator to have a user defined view.

Data can be displayed in lists or as single values, with a choice for the operator to have a user defined view. Up to two units can be connected to the same Tank Radar Rex gauge.

BOILERA boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications. A boiler or steam generator is a device used to create steam by applying heat energy to water. Although the definitions are somewhat flexible, it can be said that older steam generators were commonly termed boilers and worked at low to medium pressure. A boiler is used wherever a source of steam is required.The form and size depends on the application, mobile steam engines such as steam locomotives, portable engines and steam-powered road vehicles typically use a smaller boiler that forms an

21 | P a g e

integral part of the vehicle. Stationary steam engines, industrial installations and power stations will usually have a larger boiler connected to the point of use by piping.

There are two types of boiler:

Fire Tube Boiler Water Tuber Boiler

At BPPL, there are only Water Tube Boiler that are installed in plant.

Water Tube Boiler:

A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the walls of the furnace to generate steam.

The heated water then rises into the steam drum. Here, saturated steam is drawn off the top of the drum. In some services, the steam will reenter the furnace through a superheater to become superheated. Superheated steam is defined as steam that is heated above the boiling point at a given pressure. Superheated steam is a dry gas and therefore used to drive turbines, since water droplets can severely damage turbine blades.

Cool water at the bottom of the steam drum returns to the feedwater drum via large-bore 'downcomer tubes', where it pre-heats the feedwater supply. (In 'large utility boilers', the feedwater is supplied to the steam drum and the downcomers supply water to the bottom of the waterwalls). To increase economy of the boiler, exhaust gases are also used to pre-heat the air blown into the furnace and warm the feedwater supply. Such water tube boilers in thermal power station are also called steam generating units. Different type of phenomenon is observed in water tube boiler, out of which some are discussed below:

Starvation: This term is used to represent the water shortage in water tube boiler. Shortage of water will result in melting of tube because of high temperature in tube without water.

Carry Over: This term is used to indicate the excess of water in boiler.

22 | P a g e

Scavenging: This term is used to show the deposition of silica on the wall of tubes. It is a very serious type of damage. The only way to overcome this problem is to replace the tubes.

De-Errator:

It is the part of Water Treatment Plant. Its function is to remove the dissolve corrosive gases from water.

Applications: Water tube boilers are now commonly used because of their efficiency, capacity and other different factors. Some of its applications are as under:

1) Stationary2) Marine3) Railway4) Hybrids5) Road

HEA T EX CHA NG ERA heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall to prevent mixing or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.

S h e ll a nd Tube H ea t E x c h a ng e rs:

23 | P a g e

In Byco the heat exchangers are mainly shell and tube type. Shell and tube heat exchangers consist of a series of tubes. One set of these tubes contains the fluid that must be either heated or cooled. The second fluid runs over the tubes that are being heated or cooled so that it can either provide the heat or absorb the heat required. A set of tubes is called the tube bundle.

C OO LING T O W E R A cooling tower is a heat rejection device which extracts waste heat to the atmosphere through the cooling of a water stream to a lower temperature. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the working fluid to near the dry-bulb air temperature.

Induced draft :-

A mechanical draft tower with a fan at the discharge (at the top) which pulls air up through the tower. The fan induces hot moist air out the discharge. This produces low entering and high exiting air velocities, reducing the possibility of recirculation in which discharged air flows back into the air intake. This fan/fin arrangement is also known as draw-through.

FURNACESA furnace is a device used for heating. An industrial furnace or direct fired heater, is an equipment used to provide heat for a process or can serve as reactor which provides heats of reaction.The heaters are usually designed for specific process operations and most of

24 | P a g e

cylindrical vertical or box type design. We have seen both types of furnaces In Byco. Furnaces here are mainly for crude unit.

Born Fu rn ace :

It is a dual fueled cylindrical furnace with 10 burners each for furnace oil and gas fuel. The three main portions of furnace are

radiation zone convection zone stack

Radiant section The radiant section is where the tubes receive almost all its heat by radiation from the flame.

Convection section The convection section is located above the radiant section where it is cooler to recover additional heat. Heat transfer takes place by convection here, and the tubes are finned to increase heat transfer.

Stack The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers. It collects the flue gas and brings it up high into the atmosphere where it will not endanger personnel.

SPLITTER COLUMN

25 | P a g e

A splitter is usually a simple distillation column that makes a top and bottom product, whereby the feed has been "split" into two streams.

(1- Light Product)(2- Heavy Product)

Light naphtha from the splitter tower overheads is first cooled and then condensed in an air fin fan cooler into the overhead reflux drum. From this overhead drum LSR is provided as reflux to the splitter tower or routed to the light naphtha stabilizer tower located in the Gas plant for stabilization and recovery of light ends LPG. Un-condensed vapors are recirculated to the Crude unit overheads section for recovery.

The splitter tower bottoms are Heavy Naphtha and forms the feed to the Naphtha Hydrotreater section and subsequently the Catalytic Reformer feedstock. This stream is routed as a hot feed to the Naphtha Hydrotreater.

REVERSE OSMOSIS PLANTA Reverse Osmosis Plant is a manufacturing plant where the process of reverse osmosis takes place.

Reverse osmosis (RO) is a water purification technology that uses a semi permeable membrane. This membrane technology is not properly a filtration method. In reverse osmosis, an applied pressure is used to overcome osmotic pressure. Reverse osmosis can remove many types of molecules and ions from solutions, and is used in both industrial processes and the production of potable water. The result is that the solute is retained on the pressurized side of the membrane and the pure solvent is allowed to pass to the other side. To be "selective", this membrane should not allow large molecules or ions through the pores (holes), but should allow smaller components of the solution (such as the solvent) to pass freely.

26 | P a g e

REVERSE OSMOSIS SYSTEM

27 | P a g e

Raw Water Tank

Sand/ Activated Carbon Filter

Castridge Filter

RO MEMBRANE Product Tank

INSPECTIONThe codes and standard followed by Byco are ASME, API, and ASTM.There are two areas of inspection

1. Stationary area The mechanical integrity is ensured here.

2. Rotatory areaIn this area, vibrational motion is monitored.

MECHANICAL INTEGRITY:The mechanical structure is observed and checked. The damages due to welding, temperature increment is very dangerous for the refinery. Following things are monitored

1. Flame pattern2. Refractory material3. Tube’s hanger expansion and carbonization 4. Transfer line temperature 5. Corrosion 6. Welding damages

VIBRARTION CHECK:The displacement is observed in this test, the radial and axial vibration is checked in mm/s

INSPECTION SCHEDULE:There are plans and schedules of the inspection department. The furnace is observed weekly, locating pins are affected by thermal expansion. The heat exchanger is examined properly.

INSPECTION TOOLS:The following tools are used for inspection purpose.

1. ALCOMETER:It is use to check thickness of paint in micrometer. The tanks of LPG unit are critical so thickness of paint is sustained and properly check through AlcoMeter.

2. TEMPERATURE METER:Ultraviolet light is used to check the temperature of the insulation.

3. SONA GAUGE:The thickness of the material is checked, the material is greased first to get right and true reading. In Byco, the thickness of flange is checked using sona gauge.

28 | P a g e

MECHANICAL

Mechanical department facilitates the maintenance department by assisting them in maintaining the stationary and rotary components of the plant. Stationary components include Pipes, Tanks, Cooling towers, Heat exchangers etc. Rotary components include Pumps, Turbines, Compressors, and Fan etc. These components are maintained by department with the help of different machines. These machines are:

CENTRIFUGAL COMPRESSOR:-

A type of dynamic compressor that compresses air and expels it with a centrifugal force from a rotating wheel with radial vanes. Centrifugal compressors are often used for fans and cooling units.

ROTARY COMPRESSOR:-

A compressor that derives its pressurizing ability from two interlocking threaded cylinders. The male-female thread interaction traps and compresses air.

29 | P a g e

RECIPROCATING COMPRESSOR:-

A Reciprocating Compressor or piston compressor is a positive-displacement compressor that uses pistons driven by a crankshaft to deliver gases at high pressure.

CENTRIFUGAL PUMP:-

Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an engine or electric motor. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser or volute chamber (casing),

from where it exits.

Common uses include water, sewage, petroleum and petrochemical pumping. The reverse function of the centrifugal pump is a water turbine converting potential energy of water pressure into mechanical rotational energy.

30 | P a g e

ROTARY PUMP:-

Rotary pumps are capable of pumping more fluid than reciprocating pumps of the same weight. A number of types are included in this classification, among which are the gear pump, the screw pump, and the moving vane pump. Unlike the centrifugal pump, the rotary pump is a positive-displacement pump. This means that for each revolution of the pump, a fixed volume of fluid is moved regardless of the resistance against which the pump is pushing it.

RECIPROCATING PUMP:-

A reciprocating pump is a positive plunger pump. It is often used where relatively small quantity of liquid is to be handled and where delivery pressure is quite large.

31 | P a g e

LATHE MACHINE:

A Lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation.Lathes are used in woodturning, metalworking, metal spinning, and glass-working. Lathes can be used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped metalworking lathes can also be used to produce most solids of revolution, plane surfaces and screw threads or helices.The material can be held in place by either one or two centers, at least one of which can be moved horizontally to accommodate varyingmaterial lengths. Other work-holding methods include clamping the work about the axis of rotation using a chuck or collet, or to a faceplate, using clamps.

Parts of Lathe Machine:Lathe Machine is made up of many parts. Their names are listed below:

1) Head Stock2) Tail Stock3) Chuck4) Bed5) Tool Post6) Clutch7) Cross Slide8) Hand Wheel9) Carriage10) Feed Selector

32 | P a g e

DRILLING MACHINE:

A drill is a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill bit or driver bit, used for drilling holes in various materials or fastening various materials together with the use of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated while pressed against the target material. The tip, and sometimes edges, of the cutting tool does the work of cutting into the target material. This may be slicing off thin shavings (twist drills or auger bits), grinding off small particles (oil drilling), crushing and removing pieces of the workpiece (SDS masonry drill), countersinking, counterboring, or other operations.

Drills are commonly used in woodworking, metalworking, construction and do-it-yourself projects. Specially designed drills are also used in medicine, space missions and other applications. Drills are available with a wide variety of performance characteristics, such as power and capacity.

TOOL ROOM:

Tool Room is the room where all the tool are placed that are used in maintenance of different valves, pumps and units that are part of the plant. Tool room contains the following tool:

Spanner Vernier caliper Micro Meter Allen key Files Pipe cutter Socket wrench set Chain block

33 | P a g e

SPANNER

A Spanner (also called a wrench) is a tool used to provide grip and mechanical advantage in applying torque to turn objects—usually rotary fasteners, such as nuts and bolt or keep them from turning.

The most common shapes are called open-ended spanner and ring spanner.

Open-ended spanner:-

A one-piece wrench with a U-shaped opening that grips two opposite faces of the bolt or nut.

This wrench is often double-ended, with a different-sized opening at each end. The ends are generally oriented at an angle of around 15 degrees to the longitudinal axis of the handle. This allows a greater range of movement in enclosed spaces by flipping the wrench over.

Ring spanner:-

A one-piece wrench with an enclosed opening that grips the faces of the bolt or nut. The recess is generally a six-point or twelve-point opening for use with nuts or bolt heads with a hexagonal shape. The twelve-point fits onto the fastening at twice as many angles, an advantage where swing is limited. Eight-point wrenches are also made for square-shaped nuts and bolt heads. Ring spanners are often double-ended and usually with offset handles to improve access to the nut or bolt.

34 | P a g e

SCREW SPANNER:

The obvious advantage of an adjustable spanner is that it will cope with a whole range of nut sizes, within the capacity of the jaws. The most common version has its jaws set at an angle of 15 degrees to the shaft, but other angles are available, including a 90 degree version. When in use, it is important to adjust the jaws so that the spanner is a good fit on the nut. Use the spanner so the main strain is taken by the solid section of the head rather than the adjustable part

VERNIER CALIPER:

A vernier scale is a device that lets the user measure more precisely than could be done by reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the measurement lies in between two of the marks on the main scale.

MICRO METER:-

A micrometer sometimes known as a micrometer screw gauge is a device incorporating a calibrated screw widely used for precise measurement of components.

35 | P a g e

ALLEN KEY:

An L-shaped tool consisting of a rod having a hexagonal cross section, used to turn a screw (Allen screw) with a hexagonal recess in the head. A different size of key is required for each size of screw.

FILES:

A file is a metalworking, woodworking and plastic working tool used to cut fine amounts of material from a work piece. It most commonly refers to the hand tool style, which takes the form of a steel bar with a case hardened surface and a series of sharp, parallel teeth. Most files have a narrow, pointed tang at one end to which a handle can be fitted Files have forward-facing cutting teeth, and cut most effectively when pushed over the work piece.

36 | P a g e

PIPECUTTER:

A pipe cutter is a type of tool used by plumbers to cut pipe. Besides producing a clean cut, the tool is often a faster, cleaner, and more convenient way of cutting pipe than using a hacksaw, although this depends on the metal of the pipe. There are two types of pipe cutters. Plastic tubing cutters, which really look much like a pair of pruning shears, may be used for thinner pipes and tubes, such as sprinkler pipe. For use on thicker pipes, there is a pipe cutter with a sharp wheel and adjustable jaw grips.

37 | P a g e

Socket wrench set:

A socket wrench is a wrench with interchangeable heads called sockets that attach to a fitting on the wrench, allowing it to turn different sized bolts and other fasteners. The most common form is a hand tool popularly called a ratchet consisting of a handle with a ratcheting mechanism built in, so it can be turned using a back-and-forth motion in cramped spaces. A socket has a cup-shaped fitting with a recess that grips the head of a bolt. The socket snaps onto a  male fitting on the handle. The wrench usually comes in a socket set with many sockets to fit the heads of different-sized bolts and other fasteners. The advantage of a socket wrench is that, instead of a separate wrench for each of the many different bolt heads used in modern machinery, only a separate socket is needed, saving space.

Chain Block:-

A Chain block is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps. It may be manually operated, fiber or wire rope as its lifting medium. The load is attached to the hoist by means of a lifting hook.

38 | P a g e

INSTRUMENTATION

Instrumentation is the branch of engineering that deals with measurement and control. From this definition, it is obvious that we need to monitor that power plants parameters and setting points to have faster reaction within milliseconds. Systems used to monitor the power plants link the field instruments to the control room or main display through Monitoring Systems like DCS (Distributive Control System ), PLC (Programmable Logic Control).

Modern instrumentation not only provides control of a power plant but it can also provide information that permits the optimization of the plant in terms of fuel consumption, efficiency and maximum income or profit. 

This can be done by information provided to the operators and supervisors or it can be done with computer programs linked to the control system.

IMPORTANCE OF INSTRUMENTATION: Measurement is an integral way of interaction among humanity and physical world. It provides us a dependable and reproducible path of quantifying the world in which we

live.

39 | P a g e

PROCESS VARIABLES:

The basic variables need to be measured in a process plant are:

Temperature

Pressure

Level

Flow rate

The following four devices are used to show PV (process value):

Pressure indicator Temperature indicator Level indicator Flow indicator

The following four transmitters are used to transmit data to the control room:

Pressure transmitter Temperature transmitter Level transmitter Flow transmitter

SENSORS USED AT A REFINERY:

For the mentioned process variables the sensors are used accordingly at BPPL. Some of them are listed below.

PRESSURE SENSORS:

A pressure sensor measures pressure, typically of gases or liquids. A pressure sensor usually acts as a transducer; it generates a signal as a function of the pressure imposed.  Pressure sensors can also be used to indirectly measure other variables such as fluid/gas flow, speed, water level, and altitude. Pressure sensors can alternatively be called pressure transducers, pressure transmitters etc.

40 | P a g e

TEMPERATURE SENSORS:

Big differences exist between different temperature sensor or temperature measurement device types. Using one perspective, they can be simply classified into two groups, contact and non-contact. Both contact and non-contact sensors require some assumptions and inferences in use to measure temperature. Many, many well-known uses of these sensors are very straightforward and few, if any, assumptions are required.

CONTROL VALVES:

Control valves are valves used to control conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors that monitor changes in such conditions.

The opening or closing of control valves is usually done automatically by electrical, hydraulic or pneumatic actuators. Positioners are used to control the opening or closing of the actuator based on electric or pneumatic signals. BPPL has the following control valves:

Pressure Control Valves (PCV) Temperature Control Valves (TCV) Flow Control Valves (FCV) Level Control Valves (LCV) Pressure Safety Valves (PSV)

41 | P a g e

OIL MOVEMENT AND LOGISTICS

Oil movement department consists of transferring the crude from decanting to storage tanks then to process area and then to the shipment region from where it is supplied.

In Byco, there are three section of Oil Movement,1. Decanting2. Shipment3. Tanks

Crude is supplied from decanting region to storage tanks where it is stored. Then sample crude is sent to the laboratory for BS & W (Bottom sediments and water) test. After successful result, crude flows into the pre flash tower through a chain of pipes and pumps. From Pre flash it is sent to the crude distillation unit for further treatment. After completion of distillation process crude is sent to the crude separator to separate water from crude. Separated water is then drowned into the sea and the crude is stored in storage tanks in its different forms.

According to engineering point of view, the main task of oil movement department is,1. Planning:

When Crude comes to the decanting area, the tanks are designated in which the crude is stored.

2. Monitoring3. Material balancing:

42 | P a g e

The crude required is properly measure before and after receiving from third party.

OPERATION OF OIL MOVEMENT:The operation of oil movement department is mainly focuses on,

1. Inter Tank Transferring2. Plant Feed3. Transport4. Rundown

STORAGE TANKS:Storage tanks available at BYCO are used for storing crude before and after the processing. Storage tanks of 70 to 85 diameters are available at BPPL. Storage tanks consist of steel pipes that are provided for the filling or discharge of crude. There are 37 tanks, 6 for crude while remaining for product storage.

There are three types of tanks at BPPL:

1. Internal floating roof2. External floating roof3. Fixed roof

LPG BULLETS:LPG bullets are cylindrical and horizontal containers used for storing Liquefied petroleum gas. Similar types of LPG bullets are stored at BPPL for storing huge amounts of liquefied petroleum gas.

PUMPS:There are booster pumps and feed pumps are installed at BPPL. All pumps are centrifugal type. Booster pumps are used for pumping crude from the tanks to the process area where as feed pumps are used for pumping the crude with in the process area.

LOGISTICS : Function of logistics department at BYCO Petroleum is to bring the Crude at refinery than transfer it to storage tanks then oil movement department sent it to process area, after processing again logistics department is responsible for the selling of crude.

There are four locations available for logistics department:

1. Crude import 2. Decanting3. Shipment4. Export Naphtha through terminal on kemari

43 | P a g e

Crude is brought through sea ships to a Jetty then it is transferred to tanks where it is stored for a day or a two allowing the impurities to settle down. Then crude is brought through Lorries to decanting region then it is forced into tanks. There are four tanks having capacity of 50000 barrel each. Two new tanks have been completed having capacity of 3.5 lac barrel each. After that crude is processed, after processing crude is stored in tanks, then it is sent to shipment. The finished product is sent to the BYCO outlets or sold to PSO, Total or other suppliers. The finished product of BYCO consists of LPG, Petrol, Naphtha, Diesel, Furnace oil and Jet Fuel.

References:-

http://www.ehs.berkeley.edu/ http://www.intertek.com/petroleum/fuel-testing/ http://www.britannica.com/EBchecked/topic/166098/distillation http://www.britannica.com/EBchecked/topic/215525/fractional-distillation http://en.wikipedia.org/wiki/Hydrodesulfurization http://en.wikipedia.org/wiki/Merox http://en.wikipedia.org/wiki/Petroleum_refining_processes http://en.wikipedia.org/wiki/Catalytic_reforming https://www.google.com.pk/?gws_rd=ssl#q=boiler http://en.wikipedia.org/wiki/Pump http://en.wikipedia.org/wiki/Furnace http://www.ventechequipment.com/NapthaSplitterUnit.htm http://en.wikipedia.org/wiki/Reverse_osmosis_plant

44 | P a g e