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Internship Report

September 2015

BYCO Oil Refinery Hub Baluchistan

: Submitted By :

Muhammad Haider Ali Khan Graduate Chemical Engineer

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Table of Contents

ORC-1 ....................................................................................................................................................................... 2

Overview: ................................................................................................................................................................... 3

Pre Treatment Section: .............................................................................................................................................. 3

Naphtha Splitter: ........................................................................................................................................................ 5

HSD Treatment: .......................................................................................................................................................... 5

LSU Extraction: ........................................................................................................................................................... 6

Hydrotreater: ............................................................................................................................................................. 7

Reformer Unit: ........................................................................................................................................................... 8

Product Specs Summary: ........................................................................................................................................... 9

Process Economization: ........................................................................................................................................... 10

Control Parameters: ................................................................................................................................................. 11

ORC-2 ..................................................................................................................................................................... 12

Overview .................................................................................................................................................................. 13

Crude Distillation Unit .............................................................................................................................................. 13

Kero-hydrotreater .................................................................................................................................................... 14

LPG Separation Unit ................................................................................................................................................. 14

Naphtha Splitter ....................................................................................................................................................... 15

Platformer ................................................................................................................................................................ 15

Vacuum Distillation Unit .......................................................................................................................................... 16

Isom Unit .................................................................................................................................................................. 16

Comparison between ORC-1 and ORC-2 .................................................................................................................. 17

The HSEQ Department ......................................................................................................................................... 18

Overview .................................................................................................................................................................. 19

Safety ....................................................................................................................................................................... 19

Health ....................................................................................................................................................................... 20

Environment and Quality Management .................................................................................................................. 20

Oil Movement & Tank Farm .................................................................................................................................... 23

Overview .................................................................................................................................................................. 24

Tank Farm ................................................................................................................................................................ 24

ATG Apparatus ......................................................................................................................................................... 26

Glossary………………………………………………………………………………………………………………………………………………………………….28

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ORC-1 (CDU and Reformer)

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Overview:

Crude Distillation Unit (CDU) as the name suggests is a distillation process in which distillation of crude is done. Distillation is a physical separation process in which Crude oil is split into its different components on the basis of volatility.

The general products of the CDU are:

• Naphtha: Both Light and Heavy Naphtha streams. • Kerosene: A blend of different components which can be further separated into fuels of different

characteristics • Diesel Streams: Diesels blends which are later separated into High Speed Diesel, Low Speed Diesel etc. • Residues: Mainly considered as Furnace Fuel Oil.

The main part of the CDT are:

• Desalter • Pre flash Tank • Distillation Tower • Naphtha Splitter

Pre Treatment Section:

These section include the pretreatment steps leading to the distillation tower. The process flow for this section is shown below:

The section starts with crude charging. There are two flow trains for pretreatment, at a time one of them is in operation whereas the other is on standby. As in all refineries in the world, the first unit process is desalting. The desalter at BYCO are only used when the salt concentration excides 5 ppm but in the crude feed this concentration is usually below 1 ppm hence the desalters are not in operation (Can be activated in accordance to requirement). After desalting the crude is heated to 200 degrees through heat exchange. Then the crude is fed to the pre flash tower where the lighter fractions are removed. These fractions leave as gases from the tower top and collected in the reflux drum. Here they condense to form naphtha rich liquid which is split into two streams, one that goes back as reflux and the other that is the naphtha splitter feed. The lightest fractions of crude mainly impurities, methane and ethane leave reflux drum as gases which are flared out. The heavier crude components leave the pre flash tower as liquid and are preheated to 370 degrees through a furnace before being feed into the distillation tower.

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Distillation Tower:

After pretreatment section the crude enters the distillation tower at 700 degree centigrade. In the distillation tower, steam is used as a heating source and it brings about the necessary conditions for separating the crude into its components. The distillation tower system is shown below:

Distillation Tower Highlights:

• Number of Trays: 38 in total. • Type of Tray: Fixed Valve Plates. • Refinery Capacity: 35,000 barrels per day • Top Pump Around: Available between Plates 8 and 10 • Bottom Pump around: Available between Plates 28 to 33 • Feed Charge: At the 34th Plate • Feed Inlet Temperature: 370 degrees Centigrade. • Reboiler: No reboiler, temperature controlled by the means of direct contact with superheated steam at 460.C

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The crude entered at the 34th plates splits unto 4 major fractions i.e. Naphtha, High Speed Diesel, Kerosene and Furnace Fuel Oil. The Naphtha and gasoline which are the lightest fraction of the Crude are very volatile and leave as vapor from the top of the distillation column, after which they are collected into the reflux drum. The Reflux drum acts as a separator vessel. Three streams leave from the reflux drum, one is the light impure gases containing methane and ethane which are sent to the flare. The second is the tower reflux which splits into the third stream which is sent to the Naphtha Splitter. At the 22nd Plate HSD is removed for further treatment. Whereas at the 19th plate, Kerosene is removed which is further purified by a side strippers before it can be exported out of the unit. At the bottom of the tower we get the residue in the form of Furnace Fuel Oil.

Naphtha Splitter:

Naphtha is composed of a Lighter Fraction and a Heavier Fraction. Light Naphtha is very valuable as it is a primary component of Gasoline, a fuel for automobiles. Whereas Heavy Naphtha has to be reformed before it can be blend into Gasoline to improve its Research Octane Number or in basic terms its efficiency.

The Naphtha Splitter Unit is shown below:

The export streams form the Pre Flash tower of the pretreatment section and the tower reflux drum stream are combined. This combined stream is then heated to 115’C before being fed to the Splitter column. In the column due to difference in Volatility the Light Naphtha Stream separates from the Heavy Naphtha. The Light Naphtha is then cooled and stored in the reflux drum. On cooling the Light Naphtha condenses and the even lighter components flash out to the flare. The Light Naphtha is then sent to the LPG Plant. The heavy Naphtha is collected from the bottom and sent to the Reformer Section.

HSD Treatment:

The HSD removed from the 22nd plate of the Distillation Tower is then treated in the HSD Treatment section. Here the HSD is split into two streams each passing through a side stripper where unwanted impurities mostly kerosene composites are stripped out. These strippers are used to increase the flash point of diesel by stripping out lighter components. After stripping these streams are then rejoined and exported out of the CDU.

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LSU Extraction:

In this Unit, LPG is extracted from Light Naphtha coming from the Naphtha Splitter. LPG is a mixture of 60% Propane and 40% Butane but the LPG produced in BYCO is primarily Propane with traces of Butane.

The LSU (LPG Separation Unit) PFD is shown below:

The process is similar to stripping in which the Naphtha Feed is heated in a tray columns in which Ethane then Propane and finally Butane are removed in separate columns. After LPG removal from the Light Naphtha stream, it goes into MerOx Treater after which both Naphtha and LPG are stored in their respective storage tanks.

MerOx Treater:

MerOx is a term driven from Mer which stands for Mercaptans and Ox which stands for oxidation. This process is used to remove Mercaptans i.e. the sulphur containing hydrocarbons from the LPG and Naphtha streams. It can also be used to treat Kerosene. Sulphur presence in fuel is highly undesirable as it makes the fuels sour. Use of such fuels in combustion engines can lead to corrosion and production of Sulphur oxides which are primary and secondary pollutant. In MerOx treatment these sulphur compounds are converted to liquid disulphides which can be removed through separation techniques.

MerOx treatment is done by means of caustic showering. The reactions involved in the processes are as follows:

Step 1: 2RSH + 2 NaOH → 2NaSR + 2 H2O

Step 2: 4NaSR + O2 + 2H2O → 2RSSR + 4NaOH

Overall Reaction: 4 RSH + O2 → 2RSSR + 2H2O

After passing the reactor the liquid streams pass through separators which remove any oil-soluble substances, organometallic compounds (especially copper) and particulate matter.

The Merox treater flow for LPG and Naphtha are the same. The Flow is shown below:

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The Naphtha or LPG Stream are sent into the prewash tank. In the prewash tank there is a set level of caustic through which the products are bubbled out. The density difference causes the Naphtha and LPG to move towards the top and the caustic to settle down. After prewashing the Naphtha and LPG are sent through the extractor. Caustic is showered from the top and it helps in absorbing the sulphur as shown in the step one of the reaction. After extraction the Naphtha and LPG pass into the settler where due to difference in densities the caustic settles down and the sweetened Products are received on the other end.

The MerOx treater flow for Kerosene is different. This is because of very small difference in densities with caustic, hence it can’t be separated on basis of densities. The flow is shown below:

The kerosene stream after prewashing is fed to the Settler Reactor, in this vessel there is a fixed bed of Charcoal. The Kerosene is then reacted with caustic and a catalyst. After the reaction the product stream is removed from the bottom and fed to the salt filter. The salt filter has a bed of salt, this salt absorbs the water which forms as a result of the reaction. After passing the salt filter the kerosene enters the clay filter, in this filter all the solid particles are removed. The caustic removed is sent for regeneration. The sweetened kerosene is rundown as a product.

The regeneration is similar for both LPG and Kerosene MerOx. The reacted caustic is first oxidized to form Disulphides (As shown in the second reaction) and pure caustic is formed as a byproduct. This caustic is again used as a washing and reacting agent in the system. The Disulphides are insoluble in the caustic and are separated in a 3 phase separators where the impure gases flash out, the caustic is removed from the middle and the Disulphides are removed from the boot.

Hydrotreater:

Hydro treatment or hydro processing is a pretreatment step before the Heavy Naphtha can be reformed. During the hydro treatment process the following are removed from the Naphtha stream:

• Sulphur and its compounds • Nitrogen and its compounds • Metallic components removed • Olefins and aromatics saturated.

These removals are important because most of these compounds act as catalyst poison in the reformer as well as it reduces load on the reformer as most of the unsaturation is already removed.

The reactions that take place in the reactor are catalytic so Cobalt Molybdenum Catalyst is used and the reaction temperatures of 300 degrees centigrade are maintained through pre heating.

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The following reactions take place in the reactor:

1. Hydrodesulphurization: Removal of sulphur and its organic compounds. 2. Hydrodenitrogentaion: Removal of Nitrogen and its organic compounds by conversion into ammonia 3. Hydrodeoxyenation: Removal of organic oxygen compounds by conversion into water 4. Hydrodemetallization: Removal of organometals by conversion into metal sulfides. 5. Hydrocracking: Breakdown of large hydrocarbon chains into smaller chains 6. Hydro aromatization: Conversion of chains into cyclic and aromatic structures

After Hydro treatment the Heavy Naphtha is ready for reforming. The real PFD for this unit as follows:

The Naphtha from Storage or Distillation tower is preheated to the Hydrotreater reactor conditions after which the product is sent to the separator where the impure gases like Nitrogen oxides, Sulphur Oxides, Oxygen and water vapors are separated as Fuel gas. The hydrotreated product is then sent to the Desulfurizer where sulphur is extracted from the hydrotreated product. The bottom product of the desulfurizer is Hydrodesulphurized stream that can be used as reformer feed or stored as sweet naphtha.

The Reactor is composed of three layers. The top and bottom layer are resins in between which there is a fixed bed of the catalyst. The resins are used as sieves and strainers for solid impurities. The resins also ensure proper flow of naphtha through the catalyst, which is important to avoid channeling.

Reformer Unit:

The heart of the refinery is the reformer whereas the brain is the reformer reactors. The reformer section is is used to convert the heavy naphtha into a reformate stream of high octane number.

Heavy Naphtha is complex mixture of up to 300 hydrocarbons with carbon atoms ranging from 5-12 per molecule. These components can be categorized as Naphthenes, Paraffins, Olefins and Aromatics. The key of the reforming process is to change the structures of the paraffins, naphthenes and olefins to increase the aromatic composition of reformate. The more the aromatics i.e. benzene, xylenes, toluene etc. present in reformate the better the octane number. The higher the octane number of Gasoline it will enhance the efficiency of the engine and reduce the chances of knocking in the engine, which can be catastrophic in the long run.

The PFD for this section is as follows:

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In general in a reformer 86 different reactions take place. Which can be categorized into the following 6 basics types of reactions:

• Dehydrogenation: Naphthenes or cyclic compounds release Hydrogen to form aromatics. • Dehydrocyclisation: Paraffins release hydrogen to convert to Naphthenes and Aromatics. • Isomerization: Structures of Paraffins, Naphthenes and Aromatics altered without change in molecular weight. • Transalkylation: The transfer of an attached alkyl from one structure to another. • Hydrocracking: Breakdown of Larger Paraffins and Naphthenes into smaller Paraffins. • Hydroalkylation: Removal of Alkyl groups attached to Aromatics.

The reactions are catalyst driven. The catalyst used is basically a Rhenium/Aluminum by metallic catalyst. Overall conversions are shown below:

• cyclohexenes: 99% Conversion • Cyclopentanes: 87% Conversion • Paraffins: 39% Conversion

The best feature of the reformer is that hydrogen that is required is produced from the reaction as a byproduct. For each percent hydrogen required, 12.5% more is produced. This excess ratio enables the refinery to full fill its hydrogen requirement in reformer and Hydrotreater section.

Most of the reactions are endothermic in nature. The catalyst have a SOR (Start of Run) Temperature of 475’C to EOR (End of Run) Temperature of 510’C in the first two reactors, as most of the reactions here are endothermic. The reactions in the last reactor are exothermic thus the heating requirement there is very low.

Reformate before rundown is stabilized by stripping LPG components out and have the required product specs. After stabilizing the Gasoline Reformate is run down as a commercial grade product.

Product Specs Summary:

Every Refinery Product has to have some set Product Specs before it can be sold to the market. The important specs of the different refinery products are listed below:

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• Naphtha:

For Naphtha product the most important Product Spec is Ried Vapor Pressure (RVP). RVP is a common measure of the volatility of gasoline. It is defined as the absolute vapor pressure exerted by a liquid at 100 °F (37.8 °C) as determined by the test method ASTM-D-323.

The higher the RVP, it reflects more volatility. Volatility is a measure of the presence of lighter ends in a liquid mixture. Volatility is a big hazard during transportation as the Flash point of the vapor clouds is lower than that of the liquid mixture, thus it can explode in the vessels designed in accordance to the transportation specs of the liquid mixture.

To reduce the RVP of Naphtha and Gasoline it stabilized to strip out the LPG and lighter impurity gases. • HSD:

HSD is the most valuable product produced at BYCO. Hence it is refined to produce the purest blends. The following Specs are checked for HSD:

1. 90% D-86 Test: This ASTM graded taste is used to determine the Boiling Point ranges of the HSD mixture 2. Pour Point 3. Flash Point 4. Cloud Point 5. IBP 50%: To calculate the initial boiling point of the HSD Mixture. 6. Color 7. Water Content

• Furnace Fuel Oil:

Furnace Fuel Oil has the following Specs: 1. Flash Point 2. Viscosity 3. Pour Point

Process Economization:

One of the most crucial element of any refinery is process economization. The heating requirements of a refinery are very high and if these requirements are fulfilled by external means it will require a hefty fixed capital cost. On the other hand the energy produced as a result of the refining process are very high, that the can overcome the requirement deficit. Thus a process is economized by using the process energy produced.

In CDU section, the Products produced from the distillation tower are very hot, having unrequired energy. This energy is recovered by heat exchange to preheat crude oil before it enters the desalter section and the Preflash tower. The Pump arounds are also cooled with heat exchange with crude oil. In most of the overhead collection tanks in this section, very light gases and impure gases with high heating value are separated and used as a fuel in furnaces.

Similarly in the hydroreformer section, the bottom products of the desulphurizer and stabilizer are reboiled in the convection zone which has a very high energy reservoir. There is a process boiler installed which is used to make process steam, further utilizing energy and making steam for use in the process. The preheating exchangers and furnaces are heated by the overhead and bottom products.

Furnace Fuel Oil, a product of the distillation tower, which is heated by an oil heater to heat reboilers installed in the facility.

Such steps ensure process economization making the process eco-friendly and pocket friendly as well.

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Control Parameters:

In recent times process variable control has become essential to ensure product quality and process safety. Different types of controllers like level control valves, pressure control valves and flow control valves etc. are used in industries. Following Crucial Controllers are installed at ORC-1.

Preflash Section:

Location Type Control Parameter Operation Fail Safety Comments Crude Feed PCV Pressure Air to Close Open Feed is crucial for system

Naphtha Splitter Feed LCV Level Air to Open Closed Valve closes in case of Air Failure

Tower Reflux TCV Temperature Air to Close Open Reflux is active in any condition

Born Furnace Feed LCV Level Air to Open Close Feed cut off on air failure

Crude Tower Section:

Location Type Control Parameter Operation Fail Safety Comments

Bottom PA FCV Flow Air to Close Open Active irrespective of Air

Reflux TCV Temperature Air to Close Open Active irrespective of Air

Top PA TCV/FCV Temperature/Flow Air to Close Open Active irrespective of Air

Kero Stripper Feed LCV Level Air to Open Closed Closed on Air Failure

HSD Stripper Feed LCV Level Air to Open Closed Closed on Air Failure

Naphtha Splitter Section:

Location Type Control Parameter Operation Fail Safety Comments

Naphtha Feed PCV Pressure Air to Close Open Active irrespective of Air

Reflux TCV Temperature Air to Close Open Active irrespective of Air

Fuel Gas PCV Pressure Air to Close Open Active irrespective of Air

Hydroreformer Section:

Location Type Control Parameter

Operation Fail Safety Comments

Naphtha Feed FCV Pressure Air to Open Closed Active irrespective of Air

Fuel Gas Overhead PCV Temperature Air to Open Closed Active irrespective of Air

Desulphurizer Reflux TCV Temperature Air to Close Open Active irrespective of Air

Desulphurizer Feed LCV Level Air to Open Closed Closed on Air Failure

Desulphurizer Bottom FCV Flow Air to Open Closed Closed on Air Failure

Stabilizer Reflux TCV Temperature Air to Close Open Active irrespective of Air

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ORC-2 (Crude Distillation, Vacuum Tower and Isom Unit)

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Overview:

ORC-2 is also a refining process. It has a capacity of 35000 bpd. The following diagram is a PFD overview of ORC-2:

Crude Distillation Unit:

The CDU of ORC-2 is similar to ORC-1. It just varies in configuration. As shown below:

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Kero-hydrotreater:

One of the major differences in ORC-1 and 2 is that here Kero is hydrotreated to make further products. The flow of Kero-hydrotreater is as follows:

LPG Separation Unit:

The LPG Separation Unit is very similar to the one in ORC-1. The only addition is De-isohexanizer which is a stripping column that strips out molecules with carbon equal or less than 6. These molecules are then sent to Isom Unit for isomerization.

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Naphtha Splitter:

Platformer:

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Vacuum Distillation Unit:

Isom Unit:

Isom unit is basically an isomerization reactor system. In this system the normal paraffinic chains are converted to iso-paraffinic chains. There are following sub sections in the Isom Unit:

Pretreatment Section:

In the pretreatment section the ISOM feed enters after LPG separation. It is collected from the overhead drum of de-Iso-hexaniser in the LPG Separation Unit. The feed is first screened through strainers and filters to remove solid debris and impurities. After that it is preheated before being fed into the drier.

In the drier there are hydrophobic material that separate water or moisture from the liquid stream. It is very essential to remove the moisture as it is a strong acidic poison. There are two driers installed in a series.

After passing the drier the feed has been pretreated and is feed into a buffer vessel.

Reactor Section:

From the buffer vessel the liquid stream is again heated to the reaction temperature and fed to reactors attached in series. The catalyst used in the reactor is Platinum/Aluminum Complex with chloride covering.

In the reactor, reformation occurs and straight chained hydrocarbons are converted to branched hydrocarbons that can be blended with gasoline to enhance RON.

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After the reaction reformate is feed to the stabilizer. The function of stabilizer is to strip out the lighter ends from the stream. The lighter ends are usually LPG or impure gases used as Fuel. The bottom of the stabilizer is fed into the absorbent chamber.

Absorbent Chamber:

The absorbent chamber is a mixing chamber in this chamber there are following four streams:

Feed: The Reformate that is rich in Iso and Normal Paraffins. Absorbent: A material that absorbs normal Paraffins. Refinate: The product stream rich in Iso Paraffins. Extract: The product stream rich in Normal Paraffins.

The function of this chamber is to separate the Iso Paraffins which are our desired product from normal paraffins that is undesired secondary product.

Comparison between ORC-1 and ORC-2:

The principles behind the processes in ORC-1 and ORC-2 are same but there are following differences:

• Efficiency: ORC-2 is more efficient process due to multiple extra refining steps. • Capacity: ORC-1 has a max capacity of 12000 BPD whereas ORC-2 can be operated at 35000 BPD • Configuration: There are multiple extra steps of refining in ORC-2

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The HSEQ Department

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Overview:

HSEQ stands for Health, Safety and Environment. As technology develops, the industries become more complex and dangerous. To tackle any emergencies that might arise in any industry there is a need of means of ensuring safety and health. Thus the concept of a HS department which was responsible to maintain health and safety came into being. With time it was observed that industries contribute a lot to the pollution of the environment. Hence the authority to monitor the environment and ensure product quality, the alphabet E which stands for environment was integrated with HS to make the HSE department. The quality of the product has to be monitored to thus another department which ensures quality is integrated into the HSE, this makes the HSEQ department

BYCO has a fully functional HSE department that runs around the clock 365 days an year. The details of which are highlighted below.

The HSE department of BYCO can be broken down into:

• ERT (Emergency Response Team) • Medical Services • Process Safety • Construction Safety and Analysis • IMS (Integrated Management Safety)

Safety:

The processes taking place in a refinery are very sensitive and extremely hazardous. The HSE department takes step to ensure safety and incase of any emergency has the capability to respond to it.

Individual Safety:

In BYCO, the HSE department their safety moto is “Safety starts from you”. Every individual that enters the refinery is entrusted with the responsibility to ensure his safety and the safety of the equipment.

There is a strict code on clothing inside the refinery, no one can enter without wearing a helmet, safety shoes and an overall. Other than that for further safety PPEs (Personal Protective Equipment) like googles, sound mufflers, gloves, SCBA (Self Containing Breathing Apparatus) etc are readily available in case of need.

Other than that the HSE also arranges seminars and trainings to spread safety skills and habits in the individuals working in the refinery.

Equipment Safety:

As much as human safety is important, the safety of equipment is essential too. HSE department regularly inspects equipment to check if it is in proper working condition and establishes rules to operate or work with the equipment.

In case of maintenance of equipment there is a proper work permit system. These work permits are only provided after proper classification of the type of work, hazard analysis and insurance that the work will not affect the other equipment. There are four types of work permits at BYCO:

1. Hot Permit: Hot work is any process that can be a source of ignition when flammable material is present or can be a fire hazard regardless of the presence of flammable material in the workplace. For such work a hot work permit is required.

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2. Cold Permit: A cold work permit shall be obtained for all general work that does not involve activities related to hot work, i.e. the tolls and equipment used or the work itself do not generate any spark. And cold work refers to general maintenance work on the plant or equipment where the uses of any open flames, any source of ignition or any electrical equipment is not allowed.

3. Confined Space Certificate: A confined space is an enclosed area with limited space and accessibility. To work in such places proper measures and equipment is required. After the arrangements are made the HSE analyzes the work places and approves the certificate to allow the progression of the work.

4. Excavation Certificate: A refinery is a series of complex pipes and equipment which are at times even installed underground. Thus before any excavation work a proper certificate is required to ensure that due to the relevant work none of the underground installations are effected.

Emergency Response Team:

HSE has developed an Emergency Response team to tackle any emergency that might arise in the refinery. The ERT is properly trained in search and rescue as well as tackling emergencies like fire etc.

The ERT team has two ambulances and two fire trucks which are on the standby around the clock and have the ability to reach the site of any emergency within a minute and a half.

The usual emergency in any refinery is the threat of fire. The first line of defense against these is fire alarms and water sprinklers installed in potential places where a fire can occur. The ERT has two state of art fire trucks which have ability to tackle fire with the means of water, foam and DCP (Dry Chemical Powder). There are also fire extinguishers with DCP, CO2 and foam installed around the plant.

Emergency Information and Evacuation Plan:

The first step to tackle an emergency is its information. The HSE has a hotline established where any emergency can be informed at any time. Other than that MCPs (Manual Call Points) are installed at different points across the refinery, which when activated send an indication to the ERT informing them of the location of the emergency.

There are 6 assembly points in the plants, these points are established for cases of emergency in which the workers have to be evacuated and these serve as muster points. The ERT also analyzes and designs evacuation plans which are installed at all major facilities in the plant indicating the path to the nearest Assembly Point.

Health:

HSE has a functional clinic and hospital at the plant. This clinic is manned by doctors and nurses all around the year. All basic first aid services are present at the clinic. The clinic has all modern equipment like ECG, defibulators and x ray machines etc. It also has an operation theater where minor operations can take place. In case of severe emergencies the clinic has 2 operational ambulances on standby to take the victims to the nearest biggest hospitals.

The Health department also provide first aid trainings. It also holds seminars to impart healthy habits and information to safeguard against different diseases.

Environment and Quality Management:

Another essential component of HSE is Environment and Quality Management. It is a social responsibility of engineers and operators to protect the environment, this is monitored by the HSE department.

HSE department has a laboratory where the product and different refuse of the plant. The products are analyzed periodically to analyze quality of the product. Similarly the refuses and discharges are analyzed. If in case they excide the set limits, the HSE analyzes the process to find the root cause of the deviation and eliminate it.

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The main component of Quality Management is the IMS and ISO certification. IMS is integrated management systems this system composes of internal and external auditors of the HSEQ department that periodically analyze the plant to ensure quality, health, safety and environmental protection. The results of the IMS analysis results in approval of ISO certifications for the refinery. BYCO has the following certifications:

1. ISO 9001: This certification ensures Quality standards of the refinery. The certification credits the Quality Management System of the refinery for running in accordance to the set international standards.

2. ISO 1401: This certifications is given to companies with Environmental Management Systems set on the international standards.

3. OHAS 1801: This certification is given to companies maintaing occupational, health and safety standards

Lab:

The lab is the hearth of the quality and environment management department. The lab preforms test on the different products, feed and discharges of the process to look for anomalies. In case of detection of anomalies processes are analyzed to find the root cause and then steps taken to remove them.

The Lab has the following testing facilities:

• Gas Testing • Environment Testing • Waste Water Testing • Fuel Testing • Utility Water Testing • Crude Testing

Different equipment present in the lab include:

• Gas Chromatography: The chromatography used in analytical chemistry for separating and analyzing compounds that can be vaporized without decomposition.

• Gas Liquid Chromatography: An analysis technique for finding the constituents of a liquid mixture. • Viscosity Bath: Apparatus used to find viscosities of different crude components. • Flash Point: Analysis of flammability of fuels. • Oxidation Stability: An index of the rate of oxidation which dependent on the quality and type of base oil as well

as the additive package used. • Distillation: Test for crude components • Spectrophotometer: Used to detect and quantify Mercaptans (Sulphur containing hydrocarbons) in a sample. • Spectrode: Used for metal analysis of sample.

Similarly the following tests are conducted in water analysis:

pH Analysis Conductivity BoD/CoD Analysis Total Dissolved Solids (TDS) Analysis Hardness Analysis Analysis of impurities: like Zinc, Phosphate, Chlorides, Free Chlorine, Iron and Sulphides. Laglier Index: It simply indicates the driving force for scale formation and growth in terms of pH. Ryznar Stability: The Ryznar stability index is calculated to give an indication about the potential of scale and

indirectly the corrosion potential. Total Alkalinity Test

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The following table shows the different types of Crude tests on its components:

Test Name Units Naphtha Kerosene High Speed Diesel (HSD) Furnace Fuel Oil (FFO)

Specific Gravity N/A Y Y Y Y Flash Point .C Y Y Y

Viscosity Cst Y Y Distillation .C Y Y Y Doctor Test N/A Y Y

H2S Test ppm Y Y Mercaptans ppm Y Y

Cu Corro Test N/A Y Y Y RVP Psi Y

Color Say bolt N/A Y Y ASTM Standard Test Cloud Point .C Y Y Pour Point .C Y Y Y

Sulphur Wt% Y Y Y Y Water Content Vol% Y Y Y

Sediments Wt% Y Y Cetane Index N/A Y

Sodium/Potassium ppm Y Calcium ppm Y BS&W Vol%

Oxidation Stability N/A Y Y Existent Gum mg/ml Y Y

RON N/A CCR Wt%

Weathering .C Benzene Vol% Y Y

Vanadium ppm Y

Color Say bolt: Used for color analysis of crude components. Cu Corro: Corrosion analysis of oils which corrode copper components in automobile engines. CCR: Carnot son Carbon Ratio. Weathering: A test for LPG volatility. Doctor Test: Qualitative Test for Mercaptans. RVP: Reid Vapor Pressure measure of the volatility of gasoline. Vanadium Test: Metal Analysis test for Furnace Fuel Oil Sediment test: This test is used for sediment detection in Diesel of Furnace Oil. BS&W: Base Sediment and Water analysis of Crude Oil.

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Oil Movement & Tank Farm

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Overview:

Oil movement section is responsible for crude storage, transfer to required plants and shipment of finished products.

Oil movement deals with the following materials:

• Crude Oil

• Naphtha both forms Heavy and Light

• LPG Gas

• HSD

• MS: Motor Spirit

• Furnace Fuel Oil

Tank Farm:

Tank farm is storage area of crude. The following types of Tanks are available here:

External Floating Roof: Commonly used to store large quantities of petroleum products such as crude oil or condensate. It comprises an open- topped cylindrical steel shell equipped with a roof that floats on the surface of the stored liquid. The roof rises and falls with the liquid level in the tank. This assembly is designed to minimize vapor space and keep the stored fluid under pressure at all times. In principle, this eliminates breathing losses and greatly reduces the evaporative loss of the stored liquid. There is a rim seal system between the tank shell and roof to reduce rim evaporation.

The roof has support legs hanging down into the liquid. At low liquid levels the roof eventually lands and a vapor space forms between the liquid surface and the roof. The support legs are usually retractable to increase the working volume of the tank.

Due too little vapor space, and consequently a much smaller risk of rim space fire. External roof tanks are usually installed for environmental or economic reasons to limit product loss and reduce the emission of volatile organic compounds (VOC), an air pollutant.

The major disadvantage of this assembly is that rain water and snow can accumulate on the roof; eventually the roof may sink. This water can also seep into the tank and contaminate the stored fluid.

The assembly is shown below:

Internal Floating Roof: These tanks are nothing but cone roof tanks with a floating roof inside which travels up and down along with the liquid level. This floating roof traps the vapor from low flash-point fuels. Floating roofs are supported with legs or cables on which they rest. IFR tanks are used for liquids with low flash-points

The general assembly of an IFR is shown below:

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Fixed Roof: Fixed roof tanks are common in production facilities to store hydrocarbons with vapor pressures close to atmospheric pressure. In this use, they should be equipped with pressure-vacuum valves and purged with natural gas to eliminate air intake into the vapor space. Product evaporative losses can be high especially when crude is added to the tank and vapors are expelled through the pressure vent valve.

The General Assembly of this tanks is as follows:

LPG Bullets: The two main forms of LPG are commercial butane and commercial propane. LPG may be liquefied by moderately increasing the pressure or by reducing the temperature. Refrigerated storage is used by gas suppliers to store large volumes of LPG. The main form of LPG storage is in special tanks known as 'pressure tanks'. Commonly these pressure tanks are termed 'bulk tanks' or LPG Bullets. because LPG has a high coefficient of expansion in its liquid phase, the tanks are never completely filled with liquid (tanks are filled to approximately 85% of their water capacity), the remaining space being taken up with vapor (often referred to as the vapor space) to facilitate expansion without allowing the liquid to become 100% full (often known as hydraulically full). As LPG gas (vapor) is drawn from the tank, the vapor pressure in the tank falls and the liquid boils, producing more vapor and restoring the pressure.to maintain boiling, the liquid absorbs heat from itself, from the metal wall of the tank in contact with the liquid (known as the wetted surface area) and from the air surrounding the tank. The available gas 'off take', therefore, is dependent upon the surface area of the tank, the quantity of liquid within the tank and the temperature. The low temperature of the liquid (often indicating excess off take) may be indicated as 'sweating' (where the water vapor in air condenses on the wetted surface area of the tank) and if the off take is large enough 'frosting' (where the condensed water vapor freezes) on the walls of the tank.

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When the liquid temperature rises, for instance in summer, the vapor pressure increases, when the liquid temperature drops, the vapor pressure drops.

These Bullets look like this:

ATG Apparatus:

ATG is Automatic Tank Gauge System. This system is installed in all the Tanks available in the tank farm. With help of sensors the ATG monitoring systems can control:

Pressure Temperature Flowrate Pressure

In storage tanks, evaporation losses and storage conditions are very important. If the conditions are not monitored it can lead to heavy losses as most of the refinery products are extremely volatile. For this purpose ATGs are installed to monitor the conditions in real time.

The ATG apparatus is connected as follows:

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Glossary

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Crude Oil Refinery: is a group of industrial facilities that turns crude oil and other inputs into finished petroleum products.

Refinery’s Capacity: refers to the maximum amount of crude oil designed to flow into the distillation unit of a refinery, also known as the crude unit.

Reforming: Is a process in which using controlled heat and pressure conditions with or without the presence of catalyst the structures of hydrocarbons are altered to make higher octane products to blend with gasoline.

Distillation: A physical process to separate crude into its components.

MerOx: stands for Mercaptans Oxidation, it’s a catalytic chemical process of removing sulphur containing compounds from LPG, Naphtha and Kerosene before their further refinement.

Hydrotreater: Is a catalytic chemical process in which sulfur compounds, nitrogen compounds and unsaturated hydrocarbons are removed to enhance different properties of fuels.

LPG: LPG or liquefied Petroleum Gas is a liquefied mixture of propane and butane.

Naphtha: It’s a mixture of hydrocarbons with carbon atoms ranging from 5-12 per molecule with boiling points ranging from 90 to 200 degree centigrade.

Kerosene: A liquid mixture of hydrocarbons with carbon atoms ranging from 6-16 per molecule and boiling points of 150 to 275 degree centigrade.

Gasoline: Gasoline is a fuel extracted from crude with hydrocarbons containing carbon atoms ranging from 5 to 9 per molecule.

Diesel: Is a liquid mixture constituent of Crude oil, it has hydrocarbons with carbon atoms ranging between 200 to 300 degree centigrade.

Furnace Fuel Oil: This is the residue obtained by crude distillation, it’s a mixture of hydrocarbons with carbon atoms ranging from 9-70 carbons per molecule. It can be further refined to get valuable products.

Atmospheric Distillation: Crude Distillation done under atmospheric conditions.

Vacuum Distillation: Used for distillation of residues obtained from distillation of crude.

Desalter: It is the very first unit process in an oil refinery that removes salt from the crude oil.

Isom Unit: Isomerization is a process in petroleum refining that converts n-butane, n-pentane and n-hexane into their respective Iso-paraffins of substantially higher octane number.

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RVP: Reid Vapor Pressure is defined as the absolute vapor pressure exerted by a liquid at 100 °F (37.8 °C) as determined by the test method ASTM-D-323.

Stabilization: The removal of lighter ends like LPG from a refinery product.

RON: The RON is determined by running the fuel in a test engine with a variable compression ratio under controlled conditions, and comparing the results with those for mixtures of Iso-octane and n-heptane

IBP: Initial Boiling Point

FBP: Final Boiling Point

The End