Beruflich Dokumente
Kultur Dokumente
VERIFICATION STATEMENT
I hereby verify that this report was written by IYLIA SYAHIRA BINTI MOHAMAD
KHIR (I/C No.:921027-10-6320; Matric ID: 14794) and all information regarding this
company and projects involved are NOT confidential.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
ACKNOWLEDGEMENT
With the Name of Allah the Most Gracious, the Most Merciful
First and foremost, I would like to praise and thanks Allah S.W.T for His blessings and
the strength He granted me, I am able to complete my last phase of industrial training for
fourteen (14) weeks. I would like to give gratitude to my Host Company, PETRONAS
Penapisan (Terengganu) Sdn Bhd (PPTSB) for giving me an opportunity in being part of
the big organization and thus, able to experience working environment and gain valuable
knowledge in this company.
Not to forget, my parents, Mohamad Khir Isa and Saufiah Muhammad Ali who
are very supportive. Their encouragement and motivation has been one of the keys that
strengthen me in enduring this long period of industrial project.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
TABLE OF CONTENTS
ABSTRACT 1
CHAPTER 1: INTRODUCTION 2
1.1 Objectives 2
1.2 Scope of Study 3
1.3 Problem Statement 5
1.4 Relevancy of Project 7
2.1 Feasibility of the Project within the Scope and Time Frame 8
2.2 Critical Analysis Literature 9
2.2.1 Introduction to Desalter 9
2.2.2 Process Description of Desalting Crude Oil 11
2.2.3 Hard Water 19
2.2.4 Carbonate Scaling 19
2.3 Citation and Cross Referencing 23
CHAPTER 3: METHODOLOGY 25
4.1 Findings 33
4.2 Data Gathering/Data Analysis 35
4.2.1 Desalter Efficiency 35
4.2.1 Carbonate Scaling 42
5.1 Impact 43
5.2 Relevancy to the Objectives 44
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STUDENT INDUSTRIAL PROJECT REPORT 14794
REFERENCES 52
APPENDICES 53
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LIST OF FIGURES
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LIST OF TABLES
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STUDENT INDUSTRIAL PROJECT REPORT 14794
ABSTRACT
This project involves the trouble shooting of non-routine problem of the unit Desalter in
Crude Distillation Unit. The title of this project is Carbonate Scaling Affects the
Efficiency of Desalter.
The usage of hard water in Desalter System has led to precipitation of carbonate
scale in pipeline. Thick scale was formed in pipeline and some area is found to be totally
clogged. Effluent water pipeline of Desalter has to be replaced in order to stabilize the
efficiency of Desalter.
The rectification work done is found to be able to solve the Desalter’s efficiency
issue. Few recommendations which focused on the solution to main contributor to this
issue (usage of hard water) are shared too, inclusive of recommendations on removing
the scale formed.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
CHAPTER 1: INTRODUCTION
1.1 OBJECTIVE
These four objectives are crucial for the Crude Distillation Unit, Refinery
Production Department of PETRONAS Penapisan Terengganu Sdn Bhd (PPTSB).
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STUDENT INDUSTRIAL PROJECT REPORT 14794
This project is about trouble shooting non-routine problem of the process unit in KR-1
plant (refinery plant). The process unit is the Desalter, Unit C-115, located in the area of
Crude Distillation Unit (CDU). The unit is labelled in blue dotted line box in Figure 1,
showing its position in CDU.
The trouble shooting problem involved is replacing the effluent water pipeline
that was found to be clogged. During the pipeline replacement, the Desalter is shut down
and the crude feed is bypassing the Desalter. As Desalter is one of the important
equipment in the early stage of distillation, troubles hooting have to be done to cater the
problem.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
The type of Desalter is the single stage desalting unit and it is the only Desalter in KR-1
plant of PPTSB. It uses the application of electrical coalescence. Figure 2 shows basic
components and cross section of a typical Desalter that applies the application.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Desalter is one of the important equipment in crude oil refinery plant. It removes
inorganic salt, water and sediment from the petroleum crude oil feedstock before it is
refined. These are necessary to hinder problems downstream of the Desalter.
Water is injected to the crude in order for the salt in crude to dissolve in water,
making it easier to be removed. However the type of water used for the Desalter system
in CDU is a hard water. When hard water is left untreated, the composition in water
deposits go on building-up, reducing energy and system efficiency. The formation of
scale will cause damage to pipework and equipment especially to systems that involve
high temperature. If the hard scale problem is severe, the damage to equipment may be
irreversible, resulting in the need for new appliances, or even whole system replacement.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Student Industrial Project (SIP) requires a study or project to be done within the
last phase of internship period.
Below are the list of subjects learned by the author that are related to this project:
Subjects Relation
Chemical properties
Organic Chemistry
Chemical reaction involved
Process of desalting
Principle of Chemical Engineering
Equipment operation
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STUDENT INDUSTRIAL PROJECT REPORT 14794
2.1 Feasibility of the Project within the Scope and Time Frame
The involvement in this project requires the author to understand and be familiar with the
operation of Desalter. Before the project starts, the author did some reading on the
Desalter’s operation manual including other reading materials. Site visit was done too for
familiarization with units involved in the desalting system. A flow diagram was drawn
for personal reference with verification from the KR-1 production engineer. All these
were done during the 2 weeks gap of Student Industrial Training (SIT) and Student
Industrial Project (SIP) periods.
Plant and Facilities Risk Assessment, Standing Job Orders, Standard Operation
Procedure for Desalter Shutdown and Start Up and other necessary documents for trouble
shooting were prepared by KR-1 Production Engineers and Production Supervisors which
then verified by Operation Manager during the second week of SIP period. Project
execution, stabilization of equipment together with project analysis were done in a month.
The month of July is focused on the documentation of the project report. By the end of
July, the author presented her study in carbonate scale and its effects on Desalter pipeline
to the Production Engineers of CDU. In the middle of August, the project is presented to
the UTP and Host Company supervisors.
Within the allocated time (14 weeks), the author managed to involve fully in the
project inclusive of the completion of the project’s report.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Of these salts, the most heat-stable salt is NaCl. As for MgCl2 and CaCl2, they are
least heat-stable and moderately heat stable respectively. At crude tower flash zone,
MgCl2 will hydrolyze at temperature of 650 ºF and at 770 ºF for CaCl2. The HCl liberated
from hydrolysis of salt in the flash zone has great affinity of water. HCl remains a
noncorrosive vapour as long as no water is present. However, the droplets of water that
condense from the tower overhead will dissolve all the HCl they contact.
As for NaCl, Sodium (Na) ions has found to be the most harmful metal for
catalysts. Presence of Sodium within the catalyst active sites causes catalyst activity to
decrease. This decrease in activity implies that used catalyst must be replaced more often
to maintain a standard activity level.
To prevent the corrosion issue from happening, every crude distillation unit in oil
refinery plant requires the process of desalting. A crude Desalter should remove 90% of
the salt content in the crude.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
The main purpose for the high temperature is lower the oil viscosity in order to
increase the water droplets settling rate in the Desalter. High temperature promote
coalescence of water droplets by enhancing the drainage of oil-surfactant layer
surrounding the droplets. Larger water droplets thus formed and settle more rapidly in the
lower viscosity oil.
This reasoning relates with the second function of a Desalter is to carry out the
dehydration of crude oil in order to bring down the water content to below than 0.1%. It
is necessary to do so as the existence of water relate with the change in phase of HCl from
vapour to liquid at flash zone, which need to be avoided. The dehydration process
involves washing of the crude, dilution of saline water in the crude and removal of the
water.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Salt content of crude oil that is greater than 10 lb/1000 bbl (expressed as NaCl) requires
a single stage desalting to minimize salt deposition on heat transfer surfaces and acids
formed by decomposition of the chloride salts which are the major factors of fouling and
corrosion. If the crude oil salt content is more than 20 lb/1000 bbl, two-stage desalting is
used. There are also cases where residua are catalytically processed, these crudes used
three-stage desalting. In KR-1 plant, a single stage desalting system is used. Figure 4
shows the common structure of a single stage desalting unit.
The salt in the crude is in the form of dissolved or suspended salt crystals in water
emulsified with the crude oil. In simple words, the principle of Desalter is to wash these
salt from the crude oil with water. Problems occur in obtaining efficient and economical
water/oil mixing, water-wetting of suspended solids, and separation of the wash water
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STUDENT INDUSTRIAL PROJECT REPORT 14794
from the oil. The pH, gravity, and viscosity of the crude oil, as well as the volume of wash
water used per volume of crude, affect the separation ease and efficiency.
Desalting is carried out by mixing the crude oil with water from 3 to 10 vol % at
temperatures from 200 to 300 ºF (90 to 150 ºC). Both the ratio of the water to oil and the
temperature of operation are functions of the density of the oil. Typical operating
conditions are:
Since KR-1 plant processes Tapis crude (sweet crude of API 50), the volume of water
wash used is 5% of crude feed, with temperature of 130 ºC.
When the crude oil enters the Desalter, it will flow into a spcially deigned Petreco
distributor. The functions of this component of Desalter is to meter the flow of crude oil
so that it will flow uniformly throughout the length of the vessel.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
The salts present in crude oil are dissolved in the wash water where eventually the
oil and water phases are separated in the settling vessel. Chemicals known as demulsifier
are being added to assist in breaking the emulsion. This increases the efficiency of water
separation for the crude.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
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The brine produced normally covers one third to half of the Desalter. A layer of
emulsion too developed in between layers of oil and water. However, the thinner the
emulsion layer, the more efficient the Desalter operates.
The brine solution or also known as the effluent water is being continuously
removed. At this point, a heat exchanger takes part in the operation. Heat exchangers
provide the transfer of heat energy between fluids that are at different temperatures. The
cold side will absorb the heat from the hot side, increasing its temperature as it leaves the
exchanger. At the same time, the hot side will release its heat to the cold side, reducing
its temperature by the end of the flow. This helps in cost saving in terms of usage of fuel
gas for heating and workload of other instrument namely furnace, boiler and cooler.
The effluent water flows into the tube side (hot side) of Heat Exchanger E-
124A/B, with Treated Water from Utility flows in the shell side (cold side). Process of
heat exchange takes place whereby heat from the effluent water is absorbed by the treated
water. This reduces the effluent water’s temperature from 120 to 60 ºC before it flows
into the Waste Water Treatment.
Other than salt, other harmful contaminants that are removed in Desalter are the
clay, silt, rust and other debris. It is critical that these undesirable residues are extracted
from the crude oil as they can promote heat exchanger fouling, plugging and erosion on
downstream equipment and residual product contamination. The suspended solids are
usually very fine sand, clay, and soil particles; iron oxide and iron sulfide particles from
pipelines, tanks, or tankers; and other contaminants picked up in transit or production.
The tertiary yet important function of the Desalter system is the removal of suspended
solids from the crude oil. Total suspended solids removal should be 60% or better with
80% removal of particles greater than 0.8 micron in size. They are being removed during
mud wash.
Over time, these separated solids or sludge will accumulate in the bottom of the
Desalter vessel. Hence, the Desalter must be periodically washed to remove this
accumulation. This cleaning operation is handled by the ‘mud washing’ system installed
in the bottom of the vessel to occasionally remove the solids. Mud washing consists of
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STUDENT INDUSTRIAL PROJECT REPORT 14794
agitating the sludge with water so that they are washed out. These solids are then routed
to the wastewater system.
In CDU plant, the operation of mud wash takes place once per day. The sludge
need to be remove daily to avoid the accumulation becomes thicker and hard to be
remove. The source of water comes for the mud wash operation comes from the Utility
Unit, the same source of water used in the shell side of Exchanger E-124A/B. During the
mud wash operation, the flow of water to the tube side of E-124A/B is diverted to the
mud wash pipeline (Figure 9). It then flows out of the Desalter into the same pipeline for
effluent removal, and being channeled to the wastewater system.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
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The crude oil densities are close to the density of water and temperature above
280 ºF (138 ºC) are needed. It is sometimes necessary to adjust the pH of the brine to
obtain pH values of 7 or less in the water. If the pH of the brine exceeds 7, emulsions can
be formed because of the presence of sodium naphthenate and sodium sulfide. For most
crude oils it is desirable to keep the pH below 8.0. Better dehydration too is obtained in
electrical Desalters when they are operated in the pH range of 6 to 8 with the best
dehydration obtained at a pH near 6. The pH value is controlled by using another water
source or by the addition of acid to the inlet or recycled water.
Calcium (Ca) and Magnesium (Mg) ions are the common minerals in water. These ions
get into water when it comes in contact with limestone and other rocks that contain
calcium compounds. This can happen, for instance, when rainwater flows over these
rocks on its way to a reservoir.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Full equation:
Ca (HCO3)2 (aq) → CO2 (g) + H2O (l) + CaCO3 (s) (5)
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STUDENT INDUSTRIAL PROJECT REPORT 14794
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Deposition of salts, wax and corrosion have been reported for heat exchanger’s upstream
of the Desalter, while chemical reaction fouling and corrosion fouling are dominant
downstream of the Desalter (Crittenden et al., 1992).
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STUDENT INDUSTRIAL PROJECT REPORT 14794
They also stated that fouling, which is often described as the deposition of
unwanted material on a heat transfer surface, diminishes the heat transfer and increases
the pressure drop of the system. Due to fouling, operation and maintenance costs are
increasing significantly. By decreasing the fouling and economic effects can be reduced.
There are several ways of fighting scales. There are preemptive methods like
chemical inhibitors that hinder the scale growth. These methods are limited in their use,
because inhibitors works best for specific scale types and crystal structure. A more
versatile methods for scale fighting are removal after deposition. Chemical removal is a
cheap method for scale removal, but it is effectiveness depends on the porosity and the
type of scale. Mechanical removal is another method for removing scales after scale
deposition, and usually involves scraping, drilling or inducing vibrations to pipes and
equipment. (Nergaard, M., et al., Trondheim, November 2010).
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STUDENT INDUSTRIAL PROJECT REPORT 14794
CHAPTER 3: METHODOLOGY
The project consists of three stages which are study on Desalter system and
carbonate scaling, project execution and equipment stabilization.
The first step in conducting the project is to gather all important information related to
Desalter system and carbonate scaling. As a trainee, the author is required to understand
the concept of Desalter and the issue that it involves in so that it would be easier to relate
with the technicality and practicality of the problem.
The major factors that affect how efficiently the system can remove salt form crude oils
are:
o As wash water injection rate increase from the minimum system rates to
the maximum system rates, the amount of salt remaining in the treated oil
generated will decrease
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Mixing Intensity
o Mixing intensity refers to the degree of oil and water mixing that is
achieved in a mixing valve due to the pressure drop across that valve. The
greater the pressure drop, the greater the mixing intensity. Condition of
undermixing or overmixing should be avoided. Under mixing (insufficient
pressure drop) results in insufficient desalting process and low water
carryover (less water is carried into the treated oil, but not much salt is
removed).
o The interface in Desalter, the transition region where water and oil meet,
must be maintained at a level below the electrodes, but not so low that oil-
in-water carryover increases. If water-level rises to the electrode zone, the
electrodes will be shorted out.
Process Temperature
Process Pressure
o The back pressure valve for the system will normally be set to maintain a
pressure at the vessel which is at least 20 psi above the vapour pressure of
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STUDENT INDUSTRIAL PROJECT REPORT 14794
the oil and water mixture in the Desalter. If system back pressure decreases
for any reason, ‘gassing’ may occur in the vessel. Symptoms of excessive
gassing are arcing at the electrode zone, variations in voltmeter readings,
excessive water in the treated oil, and poor slat removal. The normal
operating values for system back pressure should present gassing. The
pressure of the Desalter is maintained between 20 to 25 bar by regulating
downstream of crude pump.
ii. The water carried over into the treated oil must be kept to a minimum
iii. The oil carried over into the effluent water must be kept to a minimum
Carbonate Scale
Scale occurrence, formation and prevention have been investigated. In a natural gas
reservoir, water with dissolved ions will always be present.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
The author followed the execution of the project, starting from the draining process up to
the start-up of the Desalter.
Throughout the execution, the author followed the Production Supervisor and
Field Operator to witness and experienced the work.
After the rectification work, the Desalter need to be monitored closely to make sure its
operation goes back to normal. The author monitored the flow rate of crude and effluent
water through PI software. Not only that, sample analysis is obtained from Lab Unit (data
extracted from LIMS software) and those from NALCO Company.
The author also followed the Production Engineer to site in order to observe and
monitor the condition Desalter directly, not just monitor from the data received.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Key milestones of the project indicates the focus events throughout the project execution as shown below.
15 August 2014
14 August 2014
Report
Submission
7 July 2014
2nd SV
24 May – 1 Jun 2014 Consultation:
1st SV
Consultation: Report Submission
for Reviewing by
Project Update project's HC SV
15 May 2014 Execution: progress to UTP SV
Shutdown and
Title Start Up of
Confirmation Desalter
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STUDENT INDUSTRIAL PROJECT REPORT 14794
The Gantt chart inclusive of all activities during project execution with particular timeline according to week as shown below.
WEEK
ACTIVITY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Project Identification
Confirmation of Project Title
Identifying Objectives and Scope of Study
Literature Review Preparation
Collecting Reading Materials
Drafting of Literature Review
Project Execution
Shutdown of Desalter
Rectification Work by Maintenance Department
Start Up of Desalter
Stabilization of Desalter
Project Analysis Execution
Collecting Data
Analysing Data
Report Preparation
Report Writing
Submitting Report for HC SV Review
Report Completion
Correcting Report
Submitting Report for HC SV Approval
Submitting Report to UTP SV
Project Presentation
Aidilfitri Celebration (Holiday)
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STUDENT INDUSTRIAL PROJECT REPORT 14794
In conducting the project, several tools have been utilized. The tools are being classified
into two groups which are software and document tools. The lists of the tools are as
follows.
The software tools usage is mainly for calculation and report completion purposes. The
software tools are:
Software Function
Microsoft Excel
To extract data from Plant Information (PI)
Process Book
LV LIMS
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Documents Function
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4.1 Findings
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Trycock
Date
#5 #4 #3 #2 #1 Effluent Water
2-Apr CRUDE CRUDE CRUDE + EMULSION CRUDE + EMULSION CRUDE + EMULSION NA
7-Apr CRUDE CRUDE CRUDE + EMULSION CRUDE + EMULSION CRUDE + EMULSION NA
13-Apr CRUDE CRUDE CRUDE + EMULSION CRUDE + EMULSION CRUDE + EMULSION NA
Before Shutdown
22-Apr CRUDE CRUDE CRUDE + EMULSION CRUDE + EMULSION CRUDE + EMULSION CLEAR WATER
OILY
5-May CRUDE OILY WATER OILY WATER OILY WATER CLEAR WATER
WATER
OILY
6-May CRUDE OILY WATER OILY WATER OILY WATER CLEAR WATER
WATER
8-May CRUDE CRUDE CRUDE CRUDE CRUDE CLEAR WATER
12-May CRUDE CRUDE CRUDE CRUDE CRUDE + EMULSION CLEAR WATER
15-May CRUDE CRUDE CRUDE CRUDE CRUDE + EMULSION CLEAR WATER
19-May CRUDE CRUDE CRUDE CRUDE + EMULSION EMULSION + OILY WATER CLEAR WATER
5-Jun CRUDE CRUDE CRUDE + OILY WATER OILY WATER OILY WATER CLEAR WATER
10-Jun CRUDE CRUDE CRUDE CRUDE + OILY WATER OILY WATER CLEAR WATER
23-Jun CRUDE CRUDE CRUDE CRUDE + OILY WATER OILY WATER CLEAR WATER
After Start-Up
26-Jun CRUDE CRUDE CRUDE CRUDE + OILY WATER OILY WATER CLEAR WATER
6-Jul CRUDE CRUDE CRUDE + OILY WATER CRUDE + OILY WATER OILY WATER CLEAR WATER
9-Jul CRUDE CRUDE CRUDE CRUDE CRUDE + EMULSION HAZZY WATER
10-Jul CRUDE CRUDE CRUDE CRUDE CRUDE + EMULSION HAZZY WATER
13-Jul CRUDE CRUDE CRUDE CRUDE + OILY WATER OILY WATER CLEAR WATER
17-Jul CRUDE CRUDE CRUDE CRUDE OILY WATER CLEAR WATER
21-Jul CRUDE CRUDE CRUDE CRUDE + OILY WATER OILY WATER CLEAR WATER
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STUDENT INDUSTRIAL PROJECT REPORT 14794
22-Apr 12.1 4.6 0.2 0.2 26.6 83.3 62.1 63.2 -213.2
30-Apr 18.2 6.7 0.2 0.05 27.9 54.6 63.3 75 -95.7
5-May 15.6 6 0.2 0.05 28 49 61.3 75 -75
6-May 17.3 6.7 0.3 0.1 9.8 10.5 61.4 66.7 -7.1
8-May 12.7 5.4 0.25 0.1 24.5 20.3 57.4 64.5 17.1
12-May 15.8 5.8 0.2 0.15 21 39.9 63.2 76 -90
15-May 12.5 4.2 0.3 0.15 16.1 14 66.7 79.9 13
19-May 16.5 5.5 0.2 0.2 29.4 18.9 66.5 75 35.7
Average 15.24 6.00 0.23 0.11 22.65 30.67 60.55 69.88 -28.59
5-Jun 15.4 4.8 0.2 0.1 26.6 14.7 68.9 89.9 44.7
10-Jun 14.6 4.2 0.25 0.1 19.6 18 71.4 91.3 8.2
23-Jun 10.6 3.5 0.2 0.2 35 27 66.7 85.7 22.9
After Start-Up
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STUDENT INDUSTRIAL PROJECT REPORT 14794
From Table 8, the average amount of water in the crude itself is at 0.23%.
0.23
0.23% × Volumetric flow rate of Crude = × 325 m3 /hr
100
= 0.7475 m3 /hr
= 𝟎. 𝟕𝟓 𝐦𝟑 /𝐡𝐫
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STUDENT INDUSTRIAL PROJECT REPORT 14794
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STUDENT INDUSTRIAL PROJECT REPORT 14794
*The calculation of mass balance in Figure 23 is the same as the one in Figure 22.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Graph below shows the efficiency of Desalter, composed of Desalting Efficiency, Dehydration Efficiency and Solid Removal
Efficiency based on data in Table 8.
DESALTER EFFICIENCY
Desalting Efficiency, % Dehydration Efficiency, % Solid Removal Efficiency, %
150
100
50
PERCENTAGE
-50
-100
-150
-200
-250
DATE
From the result, the sample of scale analysed by NALCO is dried (heated) at
temperature of 105 ºC, elements discovered are mainly Calcium Oxide (CaO) at 51% and
Copper Oxide (CuO) at 5%.
The majority composition of Calcium Oxide from X-Ray Fluorescence (XRF) test on the
sample from the pipeline shows the existence of CaCO3. This is because, when Calcium
Carbonate is heated, it produces Calcium Oxide.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Based on the result and discussion presented, it can be concluded that the rectification
work done on the effluent water pipeline able to increase the efficiency of desalter.
5.1 Impact
Production and This project has benefits the production and unit in terms of:
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STUDENT INDUSTRIAL PROJECT REPORT 14794
There are four objectives that have been set during the early stage of the study:
The first objective is achieved. The author took this advantage to learn new things.
Equipment manual was read and also met with the panel controller and production
engineer to understand more on the operation of Desalter.
The second objective is being done to find a suitable solution that can be
recommended to the operation engineers.
The final objective is accomplished too whereby the shutdown procedure was
successfully done in order to bypass the crude from the Desalter. A strategic planning and
proper risk analysis that were applied throughout the project have managed to control any
implication.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Softener should be used as treatment for hard water. The Sodium ions (Na+) in
softener will replace Ca and Mg ions, reducing the probability of CaCO3 formation.
Other source of water recommended for Desalter wash water is the stripped sour
water. The generation of sour water comes from steam that is used as a stripping medium
in distillation. The steam is condensed as an aqueous phase and is removed as sour water.
Since this steam condenses in the presence of hydrocarbons, which contain hydrocarbons,
which contain Hydrogen Sulphide (H2S) and Ammonia (NH3), these compounds are
absorbed into the water at levels that typically require treatment. The typical treatment
for sour water is to send it to a stripper for removal of H2S and NH3. At least < 1 ppm
H2S and < 30 ppm NH3 can be achieved in the stripped sour water. The practice of using
stripped sour water requires new piping to route all sour water generated to the sour water
stripper. A high cost is needed to start it, but it can replace other unnecessary expenses
for the same rectification work in the future.
Demineralized water too can be used as wash water which will result in a very
high efficiency of operation, but the cost of producing demineralized water is too
expensive and not economical for Desalter that operates all the time.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
- Witnessed boroscope and Magnetic Flux Leakage Inspection at fin cooler E-21104
Follow operators performing their task on switching Preheat Train Exchanger of Diesel-
Crude line from Shell and Tube Heat Exchanger (E-142 A/B) to Plate Heat Exchanger
(E-142 C)
- The heat exchanger need to be switched over a period of time if the efficiency
of current heat exchanger has started to drop
The author joined the session of transfer knowledge on the Visual Basic for Excel
Application delivered by Amirul Ariff Sazali, trainee from UTP, to the engineers of
Aromatics Production Department (APD). The author applied the knowledge by
upgrading the template of CDU Preheat Train Exchangers monitoring performance.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Team Work
Integrated meeting
among Production
Engineer, Maintenance
Planner and Technical
Service Department Individual
Leadership
Calculation and
Standing order
analysis on
documentation for
Desalter's
local man guidelines
efficiency
Trouble Shooting
Non-Routine
Desalter Problem
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STUDENT INDUSTRIAL PROJECT REPORT 14794
PPTSB emphasized team work in order to ensure smooth operation and production.
PPTSB has developed the business team concept in order to ensure a rapid operation in
the company. Before the development of business team concept, the work force in PPTSB
is divided into two; Operation and Maintenance.
The author learned that the implementation of Business Team concept has created
an effective communication between operation and maintenance staffs.
There are three business team developed in PPTSB name Business Team One
(BT-1), Business Team Two (BT-2) and Business Team Three (BT-3). BT-1 is
responsible for the operation and maintenance in KR-1 and KR-2A while BT-2 is
responsible for KR-2B. Meanwhile BT3 manage the oil movement and shipping (OMS)
of the products in PPTSB.
BT-1: Refinery
Area: KR-1, and KR-2A plants
BT-2: Aromatics
Area: KR-2B plant
BT-3: OMS
Area: OMS
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STUDENT INDUSTRIAL PROJECT REPORT 14794
6.3.2 Ethics
Adapting to the working environment in PPTSB, the author has been familiar with the
working ethics such as MANTRA, No Gift Policies and time management.
i) MANTRA
In line with the Code of Business Ethics (COBE), Part II: Duties of Good Faith, Fidelity,
Diligence and Integrity, PPTSB has implemented the PETRONAS initiative “No Gift
Policy” programmes among the worker. This policy was established to avoid any conflict
of interest among the staff and the vendor supplier. Each party involved will not receive
any gift from the other party as prove of the commitment. This commitment is important
to avoid any affect towards the decision making process.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
Time Management is very important in any work environment. Same goes to PP(T)SB
where here, for non-shift staffs, flexi hours‘ were introduced. The staffs will work based
on the amount of hours which is normally 8 hours with 1 hour rest at 1 a.m. By applying
this system, the staff of PP(T)SB are able to manage their time more efficiently.
6.3.3 Management
i) Meeting
Every Sunday and Monday, BT-1 will held a meeting involving all production engineers,
maintenance planner and production supervisor to update on any work and issue. While
on Wednesday, the BT will held a discipline meeting which involved representative from
other support units, namely, Health, Safety and Environment (HSE), Technical Support
Department (TSD), Instrument, Rotary, and Electrical.
On the last Thursday of every month, the department meeting will be held, chaired
by Senior Manager of Refinery Production Department (RPD) to review the department’s
performance for that particular month.
By participating in these meetings, the author learned that they are necessary for
managing the unit operation as it is the medium for discussion and to update or notify
other related parties.
ii) Documentation
Being part of a big oil refinery plant, all sorts of work require proper documentation.
Other than for auditing purposes, the documentation is necessary for safety, health and
environment commitments. Crude oil refinery plant based work exposing workers to
danger at all times. Guidelines, standard procedure and safety analysis must be reviewed
by the operation side before the particular work can be done. All these paperwork are
then being documented for future reference.
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Problems/Challenges Solutions
Desalter need to be bypassed for few A period of time was allocated for the
days to give way for the pipeline Maintenance Department to do the
replacement rectification work
Tight schedule of the Operational Make used the opportunity the time after
Production Unit and also Production the Business Team meeting for a short and
Engineer which makes the integrated precise discussion.
meeting between these two parties
difficult to arrange.
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STUDENT INDUSTRIAL PROJECT REPORT 14794
REFERENCES
http://www.lenntech.com/applications/process/boiler/scaling.htm
http://www.merusonline.com/merusring
http://www.top5best.net/best-water-softeners/
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STUDENT INDUSTRIAL PROJECT REPORT 14794
APPENDICES
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