Beruflich Dokumente
Kultur Dokumente
By
Khaqan Majeed
National University of Sciences and Technology (NUST)
i
Certificate
This is to certify that work in this dissertation/report has been carried out by Mr. Khaqan
Majeed and completed under my supervision, ORC-2 BYCO Oil and Petroleum Limited,
Karachi, Pakistan.
Supervisor: ______________
Engineer. Abdul Qader
Assistant Advisor
Advisory Department ORC-2
BYCO Oil and Petroleum Limited, Karachi.
Remarks:
ii
Acknowledgment
First of all we are bow before ALLAH, The Almighty to thank for his countless blessing
and bounties.
Secondly we are highly thankful to Engr. Abdul Qader our internship advisor, who
guided us, encouraged us and accepted nothing less than our best efforts.
We are also thankful to our Parents who kept our spirit high and didn’t let us down.
Special thanks to our Friends for their continuous support and technical assistance.
At last but never the least we are thankful to all members of operation department at
ORC-2 (BYCO) specially Eng. Hisham Hafeez Khan , Eng. Muhammad Noman and Mr.
Hafiz Junaid for their precious time and value able advices.
iii
Abstract
This report consists learning that we got during internship period at ORC-2 BYCO Oil
and Petroleum Limited Karachi. Safety is always first priority in any industry. We have
discussed safety target of BYCO, main hazard which can occur in refinery area and emergency
alarms for different alarming situation.
Second thing, upon which whole refinery is dependent, is utilities. To run plant it requires
water and power. Water treatment plant, power house, cooling tower, compressor, boiler and fire
line network is discussed in utilities.
Refinery Process is divided in black oil movements, white oil movements and oil
movements. Black oil movement is treatment of crude oil. Products of crude distillation unit are
further treated to meet end user requirements. White oil movement is treatment of Overhead
product Naphtha. Naphtha is treated in hydro treating unit to convert sulfur and nitrogen into
hydrogen sulfide and ammonia. Naphtha contains hydrocarbons C1 to C10 which are separated
in gas treatment unit where we get LPG, light naphtha and heavy naphtha. Light naphtha is
treated in isomerization unit to convert n-paraffin to iso-paraffin. Heavy Naphtha is treated in
plat former to crack into lighter hydrocarbons to make gasoline.
iv
Table of Contents
1- Environmental, Health and Safety (EHS)............................................................................................... 1
1.1- Targets .......................................................................................................................................... 1
1.1.1- LTI .......................................................................................................................................... 1
1.2- Safety Signs ................................................................................................................................... 1
1.2.1- Blue ........................................................................................................................................... 1
1.2.2- Green......................................................................................................................................... 1
1.2.3- Yellow ........................................................................................................................................ 1
1.2.4- Red ............................................................................................................................................ 1
1.3- Main Hazards ................................................................................................................................ 1
1.3.1- Fire ............................................................................................................................................ 1
1.3.2- Chemical.................................................................................................................................... 1
1.3.3- Confined Area ........................................................................................................................... 2
1.3.4- Electric....................................................................................................................................... 2
1.3.5- Noise Hazard ............................................................................................................................. 2
1.3.6- Radiation ................................................................................................................................... 2
1.3.7- Thermal ..................................................................................................................................... 2
1.3.8- Physical...................................................................................................................................... 2
1.4- Emergency Alarms ........................................................................................................................ 2
2- Utilities .............................................................................................................................................. 3
2.1- Water treatment: .......................................................................................................................... 3
2.1.1- Dissolved Air Flotation (DAF) ................................................................................................ 3
2.1.2- Multi Media Filter (MMF) ..................................................................................................... 4
2.1.3- Reverse Osmosis (RO) ........................................................................................................... 5
2.1.4- Electro De-Ionization............................................................................................................. 6
2.2- Boilers ........................................................................................................................................... 8
2.2.1- Flash Vessel ................................................................................................................................. 8
2.2.2- DEARATOR .................................................................................................................................. 8
2.2.3- Boiler ........................................................................................................................................... 9
2.3- Cooling Tower ............................................................................................................................. 12
v
List of Tables
Table 1 Boiling ranges of crude oil fraction ............................................................................................... 14
Table 2 Trays Distribution in Fractionator ................................................................................................. 18
Table 3 Contaminats value in Panex Feed .................................................................................................. 27
vii
List of Figures
Figure 1 DAF System ..................................................................................................................................... 4
Figure 2 Process Flow Diagram ofMMF ........................................................................................................ 5
Figure 3 Process Flow Diagram of Sea water RO .......................................................................................... 6
Figure 4 Process Flow Diagram of Brackish Water RO and CEDI .................................................................. 7
Figure 5 Diagram of DE aerator .................................................................................................................... 9
Figure 6 Process flow diagram of Boiler ..................................................................................................... 11
Figure 7 Diagram of DEsalter ...................................................................................................................... 15
Figure 8 Process flow diagram of DE salter................................................................................................. 16
Figure 9 Process Flow Diagram of CDU ....................................................................................................... 19
Figure 10 Process Flow Diagram of Plant-6 ................................................................................................ 22
Figure 11 Process flow diagram of M.E.A ................................................................................................... 24
Figure 12 Process flow diagram of Gas treatment Plant ............................................................................ 25
1
Safety always has been first priority in industry to make life and environment safe. For
BOPL safety now means tomorrow is safe. For everyone who work there safety training and
obey the safety rules are compulsory.
1.1- Targets
BOPL has safety targets to make environment safe.
LTI
1.1.1- LTI
BOPL keep zero last time injury. Every time when accident occurs, injury rate should be
zero.
1.2.1- Blue
Blue color is compulsory which should be obeyed whatever the circumstances are.
1.2.2- Green
This color guides about safety. Green tell what should do according to equipment or
place.
1.2.3- Yellow
Yellow color is warning color.
1.2.4- Red
Red color is about fire. Equipment with red color is about fire.
1.3.1- Fire
Fire may occur in refinery site due to hydrocarbon leakage. So safety measurement is
done to control fire if it occurs.
1.3.2- Chemical
As BOPL is dealing with crude oil to make pure products from it.
During the production there may be leakage of hydrocarbons. To control
chemical leakage different safety measurement are done.
2
1.3.4- Electric
Electric shock may occur as there are different wires.
1.3.6- Radiation
Radiation equipment are installed for different purposes. When they
are switched on, common labor is kept away from site. Only men in
appropriate radiation dress are allowed to enter radiation zone.
1.3.7- Thermal
Different equipment like furnace, stack, heat exchanger, boiler, steam
lines have thermal effect. So always keep a distance to avoid thermal affects.
1.3.8- Physical
Moving machinery like cranes, are working on site. Irrelevant person
should remain away from site because they can make physical damage.
Fire
Chemical Leakage
Radiation Exposure
Equipment Damage
2- Utilities
Utilities are section of industry that provides power, water and other things to run the
production unit. Commonly they include:
Water Treatment
Boiler
Compressor
Cooling Tower
Power House
Fire Water Network
Sea Water
Boring Wells
Sea water is pumped from sea to open channel. Two submersible pumps are used to
extract water from sea.
In boring well, water from 1oom depth is extracted. Currently 20 pumps are working.
Water from sea and boring wells is transported through open channel whose length is 1.5 km.
Water treated for use in boiler to form steam, for making steam water should be distilled.
To make distilled water different process are being used.
Poly electrolyte
DAF is simply open water tank which contain scrapper. Water from
chemical pretreatment is injected into water tank. A water recycle is made in
DAF, in which air is inserted. This air traps or adhere solid particles with it
and due to buoyancy, they are deposited on water surface. Poly electrolyte
helps to make flocks. These suspended particles are removed from surface by
scrapper. After DAF treatment water turbidity is equal 5 NTU. In DAF
system 5 pumps are being used, 3 for feed and 2 for back wash.
Open Channel
Water Intake Channel
Feed Pump
DAF
(2-Duty/1-
standby)
Pre chlorination
Coagulant
Pump
Pump
Backwash Underground
E-9
Pump water tank
DAF
Recirculation
Air Blower
Pump
Water from DAF, is send to MMF to remove further suspended particles. At inlet
turbidity of water is 5 NTU while after treatment it is less than 1 NTU.
5
Filter Feed
Pump
Automatic
Turbimax
Media Filters
Filter Feed
Pump
Underground
water tank
Figure 2 Process Flow Diagram of MMF
a- Seawater RO
Water after treatment in DAF and MMF, contains 40000 TDS. Before
entering pressure vessel, water flow through 5um cartridge filter as a
minimum pre-filtration step for protection of the membrane elements. To
6
Five micron
Cartridge Filter
Energy Recovery
Turbo
Inline Static
High Pressure
Mixer
Pump
Antiscalant
Feed Pump
SMBS
Pump
b- Brackish Water RO
After treating water in seawater RO, TDS come to 400mg/l which
categories it in brackish water. Permeate from seawater RO is treated in
brackish water RO system. This system contains 7 pressurized vessels. Water
at 144 psig is injected at outside of membrane element. Here after treatment
TDS is 20mg/l while recovery is about 90%.
RO Membrane
90% Recovery
Underground Product
Water Tank Caustic Soda
Post pH
Feed Pump RO Membrane Feed Pump
90% Recovery
Underground BWRO
Tank
Figure 4 Process Flow Diagram of Brackish Water RO and CEDI
8
2.2- Boilers
Boilers are pressure vessels designed to heat water or produce steam,
which can then be used to provide space heating and/or service liquid
heating. Boiler is categories in two types i.e. water tube boiler and fire tube
boiler. In ORC-2, water tube boiler is used to make high pressure steam.
Three boilers are installed with common DE aerator but separate economizer
and stack assembly. Here we are using it to make steam. Three type steams
are used.
HP
MP
LP
remove oxygen. It reacts with dissolved O2 and separate it water stream. Sodium
sulphite is non-scaling agent. Here both mechanisms are used for DE aeration.
Mechanical DE aeration occurs first than chemical DE aeration.
a- LP DE aerator
Feed water is sprayed by means of nozzle from top. LP steam is
injected at bottom through steam Spurger. Dissolved gases will be vaporized
and will vent from top. DE aerator is kept at height to create pressure head. In
LP DE aerator water is discharged at low pressure 19barg. Water from LP
DE aerator is used at BOPL plant area as process water in re-boiler etc.
b- HP DE aerator
HP DE aerator works same like LP DE aerator. Water discharge is at
50.3barg. Discharge of HP DE aerator is used as feed water of boiler.
2.2.3- Boiler
Water from HP DE aerator is used as feed water in boiler. At ORC-2, all
three boilers are water tube boiler. A water tube boiler is a type of boiler in
which water circulates in tubes heated externally by the fire. The circulated
water is heated by the hot gases and converted into steam at the vapor space
in the drum. These hot gases are produced by burning fuel inside the furnace.
The whole assembly of boiler and process is discussed below.
a- Economizer
Economizer is installed to recover heat from flue gases of boiler by
heating feed water. Flue gases from boiler have large amount of heat while
feed water is at ambient temperature. If feed water is injected at ambient
temperature in boiler it will increase fuel consumption to gain heat. So before
injecting feed water in boiler, it is indirectly contacted with flue gases. Water
will gain heat from flue gases. Flue gases go from 292 oC to 186 oC
temperature. Now it can be vented in atmosphere. In ORC-2, three boilers are
installed. Each boiler is connected to separate economizer and stack column.
10
b- Steam Drum
A steam drum is a standard feature of a water-tube boiler. It is a
reservoir of water/steam at the top end of the water tubes. The drum stores
the steam generated in the water tubes and acts as a phase-separator for the
steam/water mixture. The difference in densities between hot and cold water
helps in the accumulation of the "hotter"-water/and saturated-steam into the
steam-drum. Different type chemical dosing is also done for different
purposes.
c- Burner
Two burners are installed in boiler each with dual fuel system. In
dual fuel facility, they can be run either at furnace oil or fuel gas. Control
ratio of air to fuel is injected for complete combustion. Furnace oil is
atomized with help of steam. Steam makes furnace oil mist. This mist
formation completely burns otherwise showering of furnace oil by nozzles
will not help it to burn. As boilers are forced draught boilers air is forced to
combustion chamber by blower to maintain a positive pressure.
d- Down Comers and Riser Tubes
Water form steam drum comes by gravity via tubes called down
comers. Down comers passes through combustion chamber as it gain heat, its
vapors rise through tubes called riser. In down comers water from steam
drum goes down to mud drum. During pass of down comer from combustion
zone it get heat. Riser tubes connects mud drum to steam drum. Hot water
from mud drum goes through riser tubes to steam passing through
combustion chamber. The steam and water mixture enters the steam drum
through riser tubes; drum internals consisting of demister separate the water
droplets from the steam producing dry steam. Saturate water at bottom of
steam drum is again flows through down comers. By this cycle saturated
steam is generated in steam drum. Saturated steam discharges from top of
steam drum to make super heat steam.
e- Super Heater
Saturated steam from steam drum is further heated to convert rest
vapors to steam. It will create dry steam. This zone consist thin tubes of
steam and flue gases from combustion chamber. This zone is named
convection zone as heat is transferred from flue gases to steam tubes. Here
we get super heat steam which is ready for use in plant.
f- Water Drum/Mud Drum
The Mud drum is a unit which is located beneath the steam drum to
collect the solid materials which precipitate out of the boiler feed water due
11
to the high pressure and temperature conditions of the boiler. The process by
which suspended solids are collected in the boiler is referred to as cycling.
Cycling occurs because the boiler feed water is sent through the boiler drum a
number of times. This is done to produce the maximum amount of steam per
unit volume of feed water. On each run through the boiler drum, a portion of
the boiler feed water is vaporized. This results in an increase in the solids
concentration in the boiler drum. Eventually, the solids concentration hinders
the ability to maintain steam generation efficiency. At this time, a stream of
compressed air is used to blow the solids into the mud drum beneath the
boiler. The mud drum then stores these materials for later disposal. This
process of using compressed air to remove the collected suspended solids is
referred to as blow down.
Condensate BOPL
Condensate
LP Deaerator
BOPL Steam
Condensate Steam HP Deaerator
Flash Vessel
Feed to BOPL
Stack
Economizer
Demin
Water
Steam
Drum
HP
Steam Super
Heater
V-2
Mud
Drum
e- Absolute Humidity
Absolute humidity is a measure of the actual amount of water vapor
(moisture) in the air, regardless of the air's temperature. The higher the
amount of water vapor, the higher the absolute humidity.
f- Relative Humidity
Relative humidity can be expressed as the ratio of the partial pressure
of the water vapor in mixture to the saturated vapor pressure of the water at
given temperature.
14
Naphtha 0-320
Kerosene 320-510
3.1.1- Feed
The feed to the unit normally imported mostly from Qatar Marine
crude. Oil is shipped from oil ship to directly unit by single point mooring
buoy facility. BYCO is first company of Pakistan having single mooring
point (SPM) buoy facility. The unit is designed to handle 115 MBPD. The
feed is pumped to the unit from crude storage by pumps located near the
crude tanks.
3.1.2- De-salter
After preheating crude oil in heat exchanger, it is pumped to de-salter
unit. The crude oil contains salt of calcium and magnesium in the form of
dissolved salt in the tiny droplet of water which forms a water-in oil
emulsion. This water cannot be separated by gravity or through mechanical
means. It is separated through electrostatic water separation. This process is
called desalting. In the electrostatic de-salter, the salty water droplets are
caused to coalesce and migrate to the aqueous phase by gravity.
15
and the lighter fractions condense on the trays higher up in the column. At
different elevations in the column, with special trays called draw-off trays,
fractions can be drawn out on gravity through pipes, for further processing in
the refinery.
The main column is typically 50 m (164 ft) high and is equipped with
about 37 valve trays. The vapor goes up in tremendous amounts and at a high
flow rate, necessitating a large diameter column above the flash zone. At the
bottom of the stripping section, steam is injected into the column to strip the
atmospheric residue of any light hydrocarbon and to lower the partial
pressure of the hydrocarbon vapors in the flash zone. This has the effect of
lowering the boiling point of the hydrocarbons and causing more
hydrocarbons to boil and go up the column to be eventually condensed and
withdrawn as side streams. In the overhead condenser, the vapors are
condensed and part of the light naphtha is returned to the column as reflux.
Further reflux is provided by several pump around streams along the column.
In the distillation tower, heat required for separation is provided by the
enthalpy of the feed. For effective separation heat has to be removed from the
tower, in this case, by the overhead condenser and several pump around
streams along the tower length.
The side draw products (Kerosene, LGO and HGO) are stripped to
control their initial boiling point. The strippers contain several trays and the
stripping is done using steam at the bottom of the stripper or re-boiler type
side stream strippers. The end boiling point of the side stream is controlled by
the flow rate of the side stream product.
The overhead vapor is condensed at the top of the tower by heat
exchange with the cool crude coming into the unit and by air and cooling
water. The liquid product is called light straight run naphtha. Part of this
product is returned to the column as an external reflux. Down the column,
other products are withdrawn, such as heavy straight run naphtha, kerosene or
jet fuel, LGO and HGO. All of these products are withdrawn above the feed
tray. The atmospheric residue is withdrawn from the bottom of the column. It
is used as furnace oil currently. After installation of VDU, residue of CDU
will be treated to get asphalt and other products.
The main column is equipped with 37 valve trays. The trays
distribution between products as shown in
18
a- Re-boiler
Re-boiler is heat exchanger used to provide heat to the bottom of
distillation columns. It boils the partial bottom product of the distillation
column to generate vapors which are returned to the column to drive the
distillation separation. This stream is called bottom reflux.
b- Pump Around
A pump around circuit consist of withdrawing hot liquid from the
column, cooling it, and returning the cold liquid to the column. To achieve
this progressive cooling, pump around are used, one at the top of the column
(total pump around) and one at approximately middle of the column
(intermediate pump around). This pump around cooling accomplishes a
number of tasks. First, the cold liquid condenses more of the rising vapors
thus providing more reflux to compensate for the withdrawal of products
from the column.
Second, heat is removed from the column at higher temperatures. This
is in addition to the heat removal from the condenser which takes place at
relatively lower temperatures, thus the thermal efficiency of the column is
improved and the required furnace duty is reduced. Third, pump around
streams reduce the vapor flow rate throughout the column. Therefore, the
required column is smaller than what would otherwise be required if pump
around streams where not there. The drawback to using more pump around
streams is that they tend to reduce the fractionation because a more
fractionated liquid is mixed after cooling with a less fractionated liquid a few
trays above.
c- Reflux
In the overhead condenser, the vapors are condensed and part of the light naphtha is returned
to the column as reflux. Purpose of reflux is to increase purity and to maintain temperature
gradient by decreasing temperature in upper section.
3.1.5- Accumulator
At top of the column, vapors are routed to an overhead condenser,
typically cooled by water or air coolers. At the outlet of overhead condenser,
19
liquid (naphtha) and gases are separated in an accumulator at 40oC. Gases are
routed to a compressor for further recovery of LPG (C3/C4), while the liquids
(Naphtha) are pumped to a stabilizer column.
3.1.6- Strippers
The products are also drawn from different trays of the column. These
are called side draw-offs. The purpose of the side stripper is to remove some
light hydrocarbons by using steam injection. The lightest side draw-off from
the fractionating column is a fraction called kerosene, boiling in the range
150-280oC, which flows into a smaller column called side-stripper. Side
stripper contains three separate sections. They are kerosene, LGO and HGO
stripping section respectively. Stripper contains total 28 trays. Kerosene is
achieved at 354oF from first stripping section. It is run down. To make jet
fuel from kerosene then kerosene is further treated.
LGO at 510oF is stripped from second stripping section. This is used
as diesel oil. While from third stripping section, HGO at 663oF which is
currently mixed with furnace oil as plant-4 is under construction.
3.1.7- Chemical Dosing
In overhead product, total pump around and intermediate
pump around we are adding neutralizing amine and filming amine.
Neutralizing amine controls pH to avoid corrosion while filming amine
protects from fouling.
Accumulator
Naphtha
Fractionator 1C-1
Crude Oil
Kerosene
E-2 E-7
Stripper
E-3 E-6
LGO
E-5 DEsalter
Furnace
Steam
HGO
Furnace Oil
Figure 9 Process Flow Diagram of CDU
20
RSH + H2 RH + H2S
b- Denitgenation
Furnac
e
6C-3
6G-1 1P-234
1A
H2 H2
6C-5 6C-2
6C-1
To Plant 8
Figure 10 Process Flow Diagram of Plant-6
23
Rich M.E.A is sent plant-9 to remove H2 S from it and make lean M.E.A.
Hence plant-9 is under construction.
To Fuel Gas
8C-14
8C-2
8C-13 De-isoheaxanizer
Plant-6 Light Naphtha to
Naphtha Plant-16 (isom)
8C-1De-Ethanizer
Plant-7
Overhead
Platformer
8C-4
Butane
8C-6 8C-12
8C-23
8C-22
8C-7 M.E.A
absorber
8C-8B
8C-8A
8C-10
To Plant-9 Propane
Contaminants Value
Sulfur <0.5ppm
Nitrogen <0.5ppm
Water <0.1ppm
d- Scrubber
The gases are then passed through gas scrubber to remove hydrogen
chloride. Gases are injected from bottom while caustic soda is showered from
top column. Caustic soda absorbs HCl and leaves from bottom while propane
and butane from top are accumulated for further treatment.
4.3.3- Molex Unit
Molex unit is installed to separate n-paraffin and iso-paraffin which
are made in Panex unit. It contain rotary valve and adsorption chamber.
The molex feed from penex stabilizer bottom, is pumped to chloride
guard bed. Chloride guard bed remove chlorides from the molex feed.
Cartridge filter is installed to make more pure from contaminants.
a- Rotary Valve
The adsorbent is equally divided into eight beds contained in one
chamber. At one time there are two streams entering and two streams leaving
the chamber through the bed lines connected to the rotary valve.
b- Adsorbent Chamber
The streams entering the chamber are the feed and DE-sorbent.
Extract and raffinate exit the chamber. The pump around stream continually
circulates from the pump around pump to the top of the chamber, through the
chamber, and back to the pump. The pump around stream is used to control
the rate of flow through discrete sections of the chamber referred to as zones.
1- Adsorption Chamber (Zone 1)
The normal paraffin in the feed are adsorded by the adsorbent and the
iso-paraffin are rejected.
2- Purification Chamber (Zone 2)
The beds between the extract bed line and the feed bed line. Zone II
acts as a non-selective void flushing zone or purification zone.
3- Buffer (Zone 3)
The bed between the DE sorbent bed line and raffinate bed line. Zone
III acts as a buffer zone separating adsorption and desorption zones.
4- Desorption (Zone4)
The beds between the extract bed line and DE sorbent bed line. In
zone IV the normal paraffin in the adsorbent are desorbed and exchanged
with the DE sorbent. This is referred to as the desorption zone.
c- Extract Column
After passing through rotary valve the feed is then passed to the
extract column. The normal paraffin in the feed is adsorbed by the adsorbent
and the iso-paraffin are reject. The extract contains straight chain
hydrocarbons. The extract contains the n-paraffin and DE sorbent, leaves the
29
chamber between zone 2 and 3.it flows through the rotary valve, protective
strainers, extract mixing drum and then to the extract column.
d- Raffinate Column
The raffinate is the final product contains iso-pentanes and iso-
hexanes and collected as raffinate. The raffinate containing the higher octane
iso-paraffin and DE sorbent leaves the chamber between zones 1 and 4,
flowing through the rotary valve, and to the raffinate mixing drum. The
raffinate column sends the lighter DE sorbent components overhead and
drops the n-paraffin out the column bottom. The iso-paraffin are sent to
storage after being cooled in the raffinate bottoms.
30
5- Oil Movements
Oil movements are related to handling of crude oil before process and
final products after process. It deals lodging, preparation, monitoring and
transport of crude oil while it deals with achievement, supply and tank
control of final product.
There are 37 tanks are installed for final product while 6 tanks for
crude oil storage. Four type tanks are used for storage of oil which are
following: