Scanned by CamScanner

A view of Tatipaka mini-refinery (showing distillation column and furnace)

A view of Tatipaka refinery from Google Earth (satellite image)

 ACKNOWLEDGMENT
Most humbly and respectfully, I would like to acknowledge the
efforts of all those people who are working at ONGC, Rajahmundry
Asset, who guided me throughout my project work.

I am greatly indebted to SHRI. Y.N Rao, DGM (Production), ONGC

Base Complex, Rajahmundry, Andhra Pradesh.

My guide for this training, for his valuable guidance, involvement and
support at every stage of the training.
I would like to thank all Shift in charges, who supervised me
throughout my stay in the plant which lead to the success of my
PROJECT WORK.

Further, I am very much thankful to all the employees at Tatipaka

Shift operating team for helping us to understand the various process
of Tatipaka Complex and getting me the information for preparing
this project.

-SHAHNAWAZ SHAMIM
 PREFACE
Oil and Natural Gas Corporation Limited (ONGC) is an
Indian multinational oil and gas company earlier headquartered
in Dehradun, Uttarakhand, India. As a Corporation, it's registered office is now
at Dindayal Urja Bhavan, Vasant Kunj, New Delhi 110070 India. It is a Public
Sector Undertaking (PSU) of the Government of India, under the
administrative control of the Ministry of Petroleum and Natural Gas. It is
India's largest oil and gas exploration and production company. It produces
around 77% of India's crude oil (equivalent to around 30% of the country's
total demand) and around 62% of its natural gas.

Its market capitalisation was INR 57.2 trillion (US$728 billion) in 31st March
2013 making it India's first largest publicly traded company. In a government
survey for fiscal year 2016-17, it was ranked as the largest profit-making PSU
in India. It is ranked 1st among the Top 250 Global Energy Companies
by Platts.

ONGC's operations include conventional exploration and production, refining

and progressive development of alternate energy sources like coal-bed
methane and shale gas. The company's domestic operations are structured
around 11 assets (predominantly oil and gas producing properties), 7 basins
(exploratory properties), 2 plants (at Hazira and Uran) and services (for
necessary inputs and support such as drilling, geo-physical, logging and well
services).

As on 31 March 2017, the company has 33,600 employees, out of which 2,208
are women (6.57%) and 245 are employees with disabilities (0.73%).
 CONTENTS
1) INTRODUCTION

 ONGC

 Tatipaka Refinery and Gas collecting station

2) INTRODUCTION TO CRUDE OIL AND ITS PROCESSING

 The composition and characteristics of crude oil

 Other basic definitions and correlations

 Basic processes

3) OUTLINE OF TATIPAKA COMPLEX

 Operation description

 Material Balance

 Production Rate

 Raw Material Type and Quality

 Process Flow Diagram

 Quality Parameters

 Gas Collecting Station(GCS)

 Gas Compression Plant(GCP)

 Mini-Refinery

 Effluent Treatment Plant(ETP)

 Quality Control Lab

4) Quality Parameters

5) Quality policy

6) Glossary
ONGC
Oil and natural Gas corporation Limited (ONGC) is the one of the
leading public-sector enterprises in the country with substantial
contribution to the energy sector and industrial and economic
growth in general. Born as the modest corporate house in 1956 as
a commission ONGC has grown today into a full-fledged integrated
upstream petroleum company with in-house service capabilities
and infrastructure in the entire range of oil and gas exploration
and production activities. It has been given the status of
“MAHARATNA” for the excellence achieved over the years and is
on the path of the further growth.

Mission Statement:

● Dedicated to excellence by leveraging competitive

advantages in R&D and technology with involved people.
● Imbibe high standards of business ethics and organizational
values.
● Abiding commitment to Health, Safety and Environment to
enrich quality of community life.

History:
● During Pre-Independence period the Assam Oil Company
and Attack Oil Company were the only oil companies in
India.
● After independence the national Government realized the
importance of oil and gas for rapid industrial development.
● Assam oil Company was producing oil at Digboi (discovered
in 1889)
● Oil India Ltd is a 50% joint venture between Government of
India and Burma Oil Company.
● In west Bengal, the Indo-Stanvac Petroleum project is a joint
venture between Government of India and Standard vacuum
oil company of USA.
● In 1955 Oil and natural gas directorate was set up which was
later converted to oil and Natural gas commission in August
1956.
● Oil and Natural gas commission was later changed to oil and
Natural Gas Corporation in 1994.
● In 1958, ONGC found an oil-well in Cambay now Khambhat
which was the first well owned by Government of India.
● ONGC went offshore in early 70’s and discovered a giant oil
field of Bombay High now knows as Mumbai High.

Marketing
Well fluid comprising of oil/condensate, water and gas is carried
from well head to installation via flow lines. The multiphase fluid is
diverted either to test header (for testing purpose) or to
production header for further processing (gas-liquid separation)
maintained at a specific pressure based on well head pressure.

The liquid from the separator is further stabilized by reduction of

separator pressure I the subsequent stage. The gas liberated from
low pressure separators are utilized for internal use like
Generators
set, Gas-engines in pumps etc. Stabilized liquid from LP separator
is further settled into storage tanks for draining out the water
quality as per guidelines of CPCB (Central pollution control Board)
is injected into effluent disposal well. Purified condensate/oil is
partly transported to Tatipaka Refinery for meeting the feed
requirement of the refinery and remaining oil is transported to
unloading station S-Yanam for further transportation M/S HPCL,
Visakhapatnam via ocean tankers. The gas from HP separator is
filtered into cartridge filters to scrub out any entrained liquid from
the gas. The dry gas is fed to GAIL trunk line after measurement in
custody transfers meters for distribution to different consumers. In
addition to above, adequate safety and firefighting system is
maintained in the installations.
 INRODUCTION TO TATIPAKA
REFINERY
 Type: Oil Refinery
 State: Andhra Pradesh
 Installed Capacity: 1,300 barrels per day
 Products: Diesel, Naphtha and Kerosene
 Owner: Oil & Natural Gas Corporation Limited (ONGC)
 Shareholders:
 Activity since: 2001

 Coordinates: 16.500354,81.895930
 Address: Nagaram Village, Razole Taluka, East Godavari District,
Andhra Pradesh
 Phone: +91 (883) 242 4348 (Visakhapatnam Corporate Office)
 Web: http://www.ongcindia.com
 Wikipedia: http://en.wikipedia.org/wiki/Tatipaka_Refinery
 Wikipedia: http://en.wikipedia.org/wiki/Oil_and_Natural_Gas_Corpor
ation

The O.N.G.C. Krishna-Godavari (K.G.) Project operates around the

Krishna-Godavari Basin in the inland as well as in the offshore area.

The corporation felt need for a refinery in the state for the following
reasons:

1) It would help save substantial transportation cost of crude oil, which

was earlier being sent to VIZAG refinery.
2) To minimize safety hazards otherwise involved in long distance
transportation.
3) To ensure uninterrupted availability of the Petro-chemical products.
4) To help decongest roads in the region by minimizing vehicular
movement.
The corporation’s plan to set up a refinery bore fruit on September
3,2001 by the inauguration of MINI-REFINERY at Tatipaka,
Nagaram Village in East Godavari district of Andhra Pradesh.

The Mini-Refinery is the first of its kind in Asia, a RELOCATABLE SKID

MOUNTED UNIT and is set up in a very compact area of 52500 square
meters and houses the sophisticated Distributed Control System
(D.C.S.) for the process dynamics control.

DISTRIBUTED CONTROL SYSTEM (D.C.S)

A distributed control system (DCS) is a computerized control

system for a process or plant usually with a large number of control
loops, in which autonomous controllers are distributed throughout
the system, but there is central operator supervisory control. This
contrasts with non-distributed control systems that use centralized
controllers; either discrete controllers located at a central control
room or within a central computer. The DCS concept increases
reliability and reduces installation costs by localizing control functions
near the process plant, with remote monitoring and supervision.

A typical diagram of DCS

INTRODUCTION TO CRUDE OIL AND ITS PROCESSING
The wheel, without doubt, was man’s greatest invention. However, until the late
18th century and early 19th century the motivation and use of the wheel was
limited either by muscle power, man or animal, or by energy naturally occurring
from water flow and wind. The invention of the steam engine provided, for the
first time, a motive power independent of muscle or the natural elements. This
ignited the industrial revolution of the 19th century, with its feverish hunt for
fossil fuels to generate the steam. It also initiated the development of the mass
production of steel and other commodities. Late in the 19th century came the
invention of the internal combustion engine with its requirement for energy
derived from crude oil. This, one can say, sparked the second industrial
revolution, with the establishment of the industrial scene of today and its
continuing development. The petroleum products from the crude oil used
initially for the energy required by the internal combustion engine, have
mushroomed to become the basis and source of some of our chemical, and
pharmaceutical products.

The composition and characteristics of crude oil

Crude oil is a mixture of hundreds of hydrocarbon compounds ranging in size

from the smallest, methane, with only one carbon atom, to large compounds
containing 300 and more carbon atoms. A major portion of these compounds
are paraffin’s or isomers of paraffins. Most hydrocarbon compounds present in
crude oil have been isolated however, but under delicate laboratory conditions.
In refining processes, the products are identified by groups of these
hydrocarbons boiling between selective temperature ranges. Thus, for example
a naphtha product would be labelled as a 90◦C to 140◦C cut.
There are present also as impurities, small quantities of sulphur, nitrogen and
metals. By far the most important and the most common of these impurities is
sulphur. This is present in the form of hydrogen sulphide and organic
compounds of sulphur. These organic compounds are present through the whole
boiling range of the hydrocarbons in the crude. They are similar in structure to
the hydrocarbon families themselves, but with the addition of one or more
sulphur atoms.
The most common metal impurities found in crude oils are nickel, vanadium,
and sodium. These are not very volatile and are found in the residuum or fuel oil
products of the crude oil. These are not removed as metals from the crude and
normally they are only a nuisance if they affect further processing of the oil or if
they are a deterrent to the saleability of the fuel product.
Nitrogen, the remaining impurity is usually found as dissolved gas in the crude
or as amines or other nitrogen compounds in the heavier fractions. It is a
problem only with certain processes in naphtha product range (such as catalytic
reforming). It is removed with the sulphur compounds in this range by
hydrotreating the feed to these processes.
Although all crude oils contain the composition described above, rarely are
there two crude oils with the same characteristics. This is so because every
crude oil from whatever geographical source contains different quantities of the
various compounds that make up its composition.

Different types of crude oil:

There are four types of crude oil:
Class A: Light, Volatile Oils: These oils are highly fluid and highly toxic to
humans and include jet fuel and gasoline.

Class B: Non-Sticky Oils: These oils are waxy and less toxic to humans and
include diesel fuel and light crude oil.

Class C: Heavy, Sticky Oils: These oils are brown or black and sticky or tarry
and include most crude oils. Their toxicity is low, but if spilled, their impacts on
waterfowl and wildlife can be severe.

Class D: Non-Fluid Oils: These oils are non-toxic and include heavy crude
oils. They are difficult to clean up, and if spilled, their impacts on waterfowl
and wildlife can be severe.

MAJOR PRODUCTS PRODUCED IN TATIPAKA REFINERY:

Crude oil is divided into four major products along with two
additional two products:

Major products
 CRUDE OIL @ 3300C
 SKO: Superior Kerosene oil
 HSD: High Speed Diesel
 LSHS: Low Sulphur Heavy Stock (reduced crude oil)
New products in addition:
 HF HSD (b/w SKO & HSD)
 MTO (b/w NAPHTHA& SKO)
 HF HSD: High Flash High Speed Diesel
 MTO: Mineral Turpentine oil

HF HSD Production:
● Normal HSD produced up to 2005
● Huge demand foreseen for HFHSD due to increased activity in KG offshore
● Already normal HSD demand met for RJY and CAUVERY onshore rigs and
production installations
● Feasibility of HFHSD studied
● Operational obstacles removed modifications carried out (additional product
order installed)
● Operating parameters analysed and modified, succeed in the production of
HFHSD.

MTO Production:
● Change in market dynamics after supply of reliance gas motivated to diversify
product line
● MTO produced on experimental basis in July 2010
● Marketing tie-up and installation of facilities completed.
● Commercial production started in April 2011
● Received CMD innovation group award for the refinery team
in 2011

Applications of MTO
● Adhesive industries
● Paint and resin industries
● Thinner industries
● Agro-chemical, households, insecticides and fungicides
industries.
● Paint catalysts, driers, coating industries
● Textiles, cloth, paper, printing processing industries
● Degreasing and cleaning purpose in machineries, machine
spares manufacturing industries
DIESEL
Definition of Diesel
Diesel fuel in general is any liquid fuel used in diesel engines. The most
common is a specific fractional distillate of petroleum fuel oil.

Composition of Diesel Fuels:

It is a general property of hydrocarbons that the auto-ignition temperature is
higher for more volatile hydrocarbons. Therefore, the less volatile middle
distillate fractions of crude oil boiling in the range of 150-400 C are suitable as
diesel fuels. The hydrocarbons in the diesel fuels include paraffins, naphthene’s,
olefins and aromatics. Carbon number of these fuels ranges from 12-18. Diesel
fuels can contain both saturated and straight or unbranched chain unsaturated
hydrocarbons, but the latter are not present in large enough amounts to make
fuel oxidation a problem. The aromatics that are present generally are oxidant
resistant.
Petroleum-derived diesel is composed of about 75% saturated hydrocarbons
(primarily paraffin including n, iso, and cycloparaffins), and 25% aromatic
hydrocarbons (including naphthalene’s and alkyl benzenes). The average
chemical formula for common diesel fuel is C12H23, ranging approximately
from
C10H20 to C15H2.

Basic definitions and correlations

1) The true boiling point curve
This is a plot of the boiling points of almost pure components, contained in the
crude oil or fractions of the crude oil. In earlier times this curve was produced in
the laboratory using complex batch distillation apparatus of a hundred or more
equilibrium stages and a very high reflux ratio. Nowadays this curve is
produced by mass spectrometry techniques much quicker and more accurately
than by batch distillation.

2) The ASTM distillation curve

This type of distillation curve is used however on a routine basis for plant
and product quality control. This test is carried out on crude oil fractions
 using a simple apparatus designed to boil the test liquid and to condense the
vapours as they are produced. Vapor temperatures are noted as the
distillation proceeds and are plotted against the distillate recovered. Because
only one equilibrium stage is used, and no reflux is returned, the separation
of components is poor. Thus, the initial boiling point (IBP) for ASTM is
higher than the corresponding TBP point and the final boiling point (FBP) of
the ASTM is lower than that for the TBP curve.

3) API gravity

This is an expression of the density of an oil. Unless stated otherwise the API
gravity refers to density at 60◦F (15.6◦C). Its relationship with specific gravity is
given by the expression
API◦ = 141.5/sp.gr. − 131.5

4) Flash points

The flash point of an oil is the temperature at which the vapor above the oil will
momentarily flash or explode. This temperature is determined by laboratory
testing using an apparatus consisting of a closed cup containing the oil, heating
and stirring equipment, and a special adjustable flame. The type of apparatus
used for middle distillate and fuel oils is called the Pesky Marten (PM), while
the apparatus used in the case of Kerosene and lighter distillates is called the
Abel.
Given by the expression
Flash point ◦F = 0.77 (ASTM 5% ◦F − 150◦F)

5) Octane numbers
Octane numbers are a measure of a gasoline’s resistance to knock or detonation
in a cylinder of a gasoline engine. The higher this resistance is the higher will be
the efficiency of the fuel to produce work. A relationship exists between the
antiknock characteristic of the gasoline (octane number) and the compression
ratio of the engine in which it is to be used. The higher the octane rating of the
fuel then the higher the compression ratio of engine in which it can be used.
An octane number is that percentage of isooctane in a blend of isooctane
and normal heptane that exactly matches the knock behaviour of the gasoline.
Two octane numbers are usually determined. The first is the research octane
number (ON res or RON) and the second is the motor octane number (ON mm
or MON). The same basic equipment is used to determine both octane numbers,
but the engine speed for the motor method is much higher than that used to
determine the research number. The actual octane number obtained in a
commercial vehicle would be somewhere between these two. The significance
of these two octane numbers is to evaluate the sensitivity of the gasoline to the
severity of operating conditions in the engine. The research octane number is
usually higher than the motor number, the difference
between them is termed the ‘sensitivity of the gasoline.’

6) Viscosity
The viscosity of an oil is a measure of its resistance to internal flow and is an
indication of its lubricating qualities. In the oil industry it is usual to quote
viscosities either in centistokes (which is the unit for kinematic viscosity),
seconds Say bolt universal, seconds Say bolt furol, or seconds Redwood.
Viscosities is usually determined at temperatures of 100◦F, 130◦F, or 210◦F. In
the case of fuel oils temperatures of 122◦F and 210◦F are used.

7) Cloud and pour points

Cloud and Pour Points are tests that indicate the relative coagulation of wax in
the oil. They do not measure the actual wax content of the oil. In these tests, the
oil is reduced in temperature under strict control using an ice bath initially and
then a frozen brine bath, and finally a bath of dry ice (solid CO2). The
temperature at which the oil becomes hazy or cloudy is taken as its cloud point.
The temperature at which the oil ceases to flow altogether is its pour point.

8) Sulfur content
This is usually quoted as % wt. for the total sulphur in the oil.

BASIC PROCESSES
Oil and gas wells produce a mixture of hydrocarbon gas, condensate or oil;
water with dissolved minerals, usually including a large amount of salt; other
gases, including nitrogen, carbon dioxide (CO2), and possibly hydrogen
sulphide (H2S); and solids, including sand from the reservoir, dirt, scale, and
corrosion products from the tubing. The purpose of oil and gas processing is to
separate, remove, or transform these various components to make the
hydrocarbons ready for sale.

For the hydrocarbons (gas or liquid) to be sold, they must be:

 separated from the water and solids

 measured
 sold
 transported by pipeline, truck, rail, or ocean tanker to the user

Hydrocarbon preparation
The goal is to produce oil that meets the purchaser’s specifications that define
the maximum allowable amounts of the following:

 water
 salt
 other impurities

Similarly, the gas must be processed to meet purchaser’s water vapor and
hydrocarbon dewpoint specifications to limit condensation during
transportation.

The produced water must meet the following requirements:

 regulatory requirements for disposal in the ocean if the wells are offshore
 reservoir requirements for injection into an underground reservoir to
avoid plugging the reservoir
 technical requirements for other uses, such as feed to steam boilers in
thermal-flood operations, or in special cases, for irrigation

Field facilities
The equipment between the wells and the pipeline, or other transportation
system, is called an oilfield facility. An oilfield facility is different from a
refinery or chemical plant in several ways. The process is simpler in a facility,
consisting not of chemical reactions to make new molecules, but of:

 phase separation
 temperature changes
 pressure changes
In a refinery, the feed-stream flow rate and composition are defined before the
equipment is designed. For a facility, the composition is usually estimated based
on drill stem tests of exploration wells or from existing wells in similar fields.
The design flow rates are estimated from well logs and reservoir simulations.
Even if the estimates are good, the following change over the life of the field as
wells mature and new wells are drilled:

 composition
 flow rates (gas, oil, and water)
 pressures
 temperatures

Facilities have a design rate that is a best-guess maximum flow based on:

 the number of wells

 production profiles
 total oil or gas that can be produced from the reservoir

Function of a facility

Main process
The main function of an oil facility is to:

 separate the oil, gas, water, and solids

 treat the oil to meet sales specifications (e.g., BS&W, salt content, vapor
pressure)
 measure and sample the oil to determine its value
 deliver it to the transportation system (i.e., the pipeline, truck, ship, or
railroad car)

The gas must be treated for sales or disposal. In the past, disposal sometimes
meant flaring or venting, but now gas that can’t be transported is usually
compressed for reinjection into the reservoir. Gas treating may involve only
separation from the liquids, or it may include additional processes such as:

 compression
 dehydration
 removing H2S and CO2
 gas processing to condense heavier components that can be transported as
a liquid

Secondary process
In addition to processing the oil and gas for sale, the produced water and solids
must be treated for disposal. For produced water, treating usually includes
removal of dispersed and dissolved hydrocarbons and, in addition to separation
or oil skimming, may include:

 filtration
 deionization

or

 pumping

If treating of solids is required, it may include water washing and agitating the
solids to remove the oil and then separating the water from them.

Auxiliary systems
In addition to the process systems, auxiliary process heating and cooling may be
required. Process heat is usually needed for oil treating and superheating fuel
gas for use in gas turbine generators or compressors. Process cooling is usually
required for gas compression.

While, if necessary, facilities can be run without electric power, power

generation and electrical systems will usually be included for a facility that is
large or complex or for living quarters that are provided for personnel.

All facilities require safety systems, including:

 safety instrumentation and shutdown system

 fire and gas detection
 fire-fighting equipment
 a means of evacuation, such as life rafts and escape capsules for offshore
 other equipment, depending on the location and complexity of the facility
and whether it is manned
 The processes common to most energy refineries
1) The atmospheric crude distillation unit

In refining the crude oil, it is first broken up into those raw stocks that are the
basis of the finished products. This breakup of the crude is achieved by
separating the oil into a series of boiling point fractions which meet the
distillation requirements and some of the properties of the finished products.
This is accomplished in the crude distillation units. Normally there are two units
that accomplish this splitting up function: an atmospheric unit and a vacuum
unit.

2) The crude vacuum distillation unit

Further breakup of the crude is often required to meet the refinery’s product
slate. This is usually required to produce low cost feed to cracking units or to
produce the basic stocks for lubricating oil production. To achieve this the
residue from the atmospheric unit is distilled under sub atmospheric conditions
in the crude vacuum distillation unit.
This unit operates like the atmospheric unit in so much as the feed is heated by
heat exchange with hot products and then in a fired heater before entering the
distillation tower. In this case, however, the tower operates under reduced
pressure (vacuum) conditions.

3) The catalytic reformer unit

The purpose of the catalytic reformer plant is to upgrade low octane naphtha to
the high-octane material suitable for blending into motor gasoline fuel. It
achieves this by reforming some of the hydrocarbons in the feed to
hydrocarbons of high octane value. Notably among those reactions is the
conversion of cycloparaffin content of the feed to aromatics. This reaction also
gives up hydrogen molecules which are subsequently used in the refinery’s
hydrotreating processes.

4) The hydrotreating units (de-sulfurization)

Most streams from the crude distillation units contain sulfur and other
impurities such as nitrogen, and metals in some form or other. By far the most
common of these impurities is sulfur, and this is also the least tolerable of these
impurities. Its presence certainly lowers the quality of the finished products and
in the processing of the crude oil its presence invariably affects the performance
of the refining processes. Hydrotreating the raw distillate streams removes a
significant amount of the sulfur impurity by reacting the sulfur molecule with
hydrogen to form hydrogen sulfide (H2S) this is then removed as a gas.

5) The fluid catalytic cracking unit

This cracking process is among the oldest in the oil industry. Although
developed in the mid-1920s it first came into prominence during the Second
World War as a source of high octane fuel for aircraft. In the early fifties its
prominence as the major source of octane was somewhat overshadowed by the
development of the catalytic reforming process with its production of hydrogen
as well as high octane material. The prominence of the fluid catalytic cracking
unit (FCCU) was re-established in the 1960s by two developments in the
process. These were:
The use of highly active and selective catalysts (Zeolites)
The establishment of riser cracking techniques
Products from this process are:
_ Unsaturated and saturated LPG
_ Light cracked naphtha

_ Heavy cracked naphtha

_ Cycle oil (mid distillate)

_ slurry

6) Thermal cracking units

Thermal cracking processes are the true work horses of the oil refining industry.
The processes are relatively cheap when compared with the fluid cracker and
the hydrocracker but go a long way to achieving the heavy oil cracking
objective of converting low quality material into more valuable oil products.
The process family of Thermal Crackers has three members, which are:
_ Thermal crackers
_ Visbreakers
_ Cokers.

7) Gas treating processes

Gas treating is always required to remove theH2S impurity generated by

hydrotreating or cracking from the refinery fuel gas or hydrogen recycle
streams. The removal ofH2S for these purposes is accomplished by absorbing
the hydrogen sulfide into an amine or similar solution that readily absorbs H2S.
Stripping the rich absorbent solution removes the H2S from the system to be
further reacted with air to produce elemental sulfur. This latter reaction takes
place in specially designed sulfur plant.

8) The light end units

The full range naphtha distillate as the overhead product from the atmospheric
crude unit is further split into the basic components of the refinery’s volatile and
light oil products. This is accomplished in the light end plant which usually
contains four separate distillation units. These are:
_ The de-butanizer
_ The de-propanizer
_ The de-ethanizer
_ The naphtha splitter.
 OUTLINE OF TATIPAKA REFINERY
The Tatipaka complex comprises the following facilities
■ Gas collecting station
■ Low pressure gas processing and compression
plant (GCP)
■ Mini refinery
■ Effluent Treatment Plant (ETP)
■ Air compression facility
■ Power Generation facility

OPERATION DESCRIPTION
 Presently crude oil produced in nearby fields are processed independently
and transported to refinery by road tankers.
 The gas (natural gas) produced from the nearby 19 fields are received at
Tatipaka Gas Collecting Station (G.C.S.) located adjacent to the refinery.
 The gas received is processed for dehydration and condensate removal in
three (3) stages.
 The gas from the fields enter the G.C.S. through an inlet connected to
stage-1 High Pressure separator operating at a pressure of 75kg/cm 2. The
gas from the stage-1 separator passes through a Glycol Dehydration unit
before dispatch to consumers.
 The condensate from stage-1 enters the stage-2 separator operating at
16kg/cm2 pressure followed by stage-3 low-pressure separator operating
at 6kg/cm2 pressure before entering storage.

MATERIAL BALANCE
The unit normal capacity will have 1500barrels per day (bpd) with feed
corresponding to CASE-1 and CASE-2. The maximum capacity will have
2000bpd. The minimum capacity will have 1000bpd.
CASE-I: CRUDE-30% CONDENSATE-70%
CASE-2: CRUDE-70% CONDENSATE-30%

PLANT DESIGN CAPACITY:

CASE – 1: 252.7 tonnes per day (TPD)
CASE – 2: 258.3 tonnes per day (TPD)
PRODUCTION RATE (TPD)
PRODUCTS CASE-1 CASE-2
OBTAINED FROM (IN TPD) (IN TPD)
REFINERY
NAPHTHA 97.248 80.712
KEROSENE 74.208 74.496
DIESEL 46.128 37.776
RCO (L.S.H.S.) 32.352 63.576
TOTAL 249.94 256.56
LOSS 2.76 1.74

Raw Material Type and Quality

The raw material is PARAFINNIC-BASE TYPE CRUDE categorized as LIGHT
CRUDE OIL.
PROCESS FLOW DIAGRAM
Quality Parameters

PARAMETER Case-I Case-2

• Viscosity at 40ºC 1.78cst 2.544cst

• Temperature 46.5ºC 42.58ºC
• Sulphur 0.02% by weight 0.021% by
weight
• Salts 4ptb 3.75ptb
• Reid vapor pressure 5.2psi ------
• Pour point -6ºC 21ºC
• Metals-Vanadium <1ppm 0.01ppm
• Metals-Iron <0.5ppm 6.83ppm
• Metals- Nickel <1ppm 0.39ppm
• Density at 15ºC 0.795g/cc 0.812g/cc
• Carbon residue 0.45% by weight 0.38% by weight

GAS COLLECTING STATION

● Largest onshore installation in RJY asset w.r.t capacity of
gas handling.
● After producing 10 billion SCM gas, Tatipaka-GCS has become
the first on shore installation to achieve this milestone in
ONGC.

• Tatipaka gas collecting station is designed to handle 2.5 MMCMD of

natural gas collected from different onshore wells.

• Natural gas will be brought to GCS through sub surface pipe lines
processing consists of mechanical separation of gas, condensate & water.

Tatipaka GCS is a major installation in KG project with good infrastructural

facilities. The GCS collects and processes the gas that is produced from
different wells under Tatipaka complex. This is the largest on-shore installation
of K-G project where all associated also exist.
Process description:
Gas from about (at present 19) wells are directed to the production header. This
gas not only comprises of produced gas but also crude/condensate and water.
So, for the separation the gas is sent to a production separator with a liquid
boot.

PRODUCTION SEPARATOR
The well fluid is received in a 3-phase low pressure production separator,
operates at a pressure 6.0 kg/cm2. Three phase separations are achieved inside
the separator due to change in momentum of the well fluid and providing the
required time for the liquid phase. The gas stream from the top of separator is
routed to the filter separators for the filtration and knocks out of entrained liquid
particles. The produced gas from the LP production separator is routed to the LP
gas compressor at Tatipaka site.

The hydrocarbon liquid is separated in the production separator is routed to the

existing condensate storage via two phase liquid separators. The separated water
after passing through the basket filter is collected in the produced water
collection tank. Test separator has been provided at the site for testing
performance of the individual wells at low pressures i.e. 6.0 kg/cm2. The gas
separated from the test separator is metered and is connected to the separated
gas from the production separator prior to filter separators. The hydrocarbon
liquid stream from test separator is routed to two phase liquid separator and
produced water stream to produced water collection vessel.

Well fluid from the wells will flow to the production separator 10-V-101A/B
operating at about 110-120 kg/cm2 for separation of gas and liquid. The
hydrocarbon condensate is sent for condensate stabilisation.
A TYPICAL DIAGRAM OF THE GAS COLLECTING STATION(GCS)

 Gas Conditioning:

The gas is available from the separator at about 110-120 kg/cm2. The pressure
of this gas which is saturated with water is required to be reduced to
64.5kg/cm2 for feeding to the pipeline for supplying the gas to far off
consumers at 45kg/cm2. Glycol is injected in the gas to avoid hydrate formation
on pressure reduction. The gas along with glycol flows to the sales gas separator
(10-v-103) where glycol water mixture is separated from the gas. The gas from
the sales gas separator shall be heated to 100c in the fuel gas fired water bath
heater to avoid soil freeze-up around the gas pipeline. Coalesce separator 10-x-
105 is provided
to remove any carry-over of glycol to reduce the glycol losses.
 Condensate Stabilisation:
The condensate separated in the production separator is stabilised by heating
and flashing in two staged (HP&LP). The flashed gas is flared; however,
provision is kept compressing this gas for feeding to the sales gas separator in
future. The
condensate from the HP condensate drum is heated to 800c in water Bath heater
and flashed in LP condensate drum operating at 2.5kg/cm2. The gas from this
LP drum is used as fuel gas. The condensate flows to the condensate storage
tanks.

 Fuel Gas System:

Fuel gas is required for the sales gas heater, condensate heater and flare pilot
burner. Fuel gas is also used as purge gas for the flare header. The gas separated
in the LP condensate flash drum is estimated to be just sufficient for meeting the
fuel gas requirement. A provision is also kept using the HP condensate drum
gas as make-up fuel gas. A fuel gas K.O.D 10-v-106 is provided to separate the
liquid if any from the fuel gas.

 Flare System:

A flare system is provided to dispose off hydrocarbon wasted during normal

operation if any and the gas discharged through control and safety control
valves during upset conditions in the plant. A flare header is provided to collect
such discharges for routing them to flare stack. A flare gas Knock Out Drum is
provided near the flare stack to separate the liquid discharged to the flare header
and liquid formed in the header due to condensation.

 Instrument Air System:

Two non-lubricated air compressors (10-k-120A/B) (one operating +one

standby) are provided for meeting the station air requirement. One operating
and one standby instrument air dryers are provided to reduce the dew point of
compressed air to -15oc for use as instrument air. One air receiver (10-v-121) is
provided having backup capability of 30min.
TESTING FACILITIES

•A test separator is provided for tes ting the production fro m a well.
• The test header s hall be linked to the separator and the quantities of gas and
liquid separated will be measured.
•The gas after f low measurement will join the gas line from pro ductio n
separator.
•The water sha ll be drained.
•The hydrocarbon condensate is routed to the productio n separator.
•A provis ion is kept o perating the tes t separator at press ure lower than
production separator.
•Under this operatio n, the gas s hall be routed to sales gas separator and
condensate to H.P flash drum.
This provision should be used with care as hydrate is expected to form gas &
condensate control valves.

WELL MANIFOLD
• Well fluid will be received at the station.
• A well manifold is provided to receive feed from 20 wells and provision is
kept for 10 future wells.
• Well manifold has 2 headers, one production header and the other test
header.
• Maximum operating pressure is about 110-120 Kg/cm2

A well manifold is provided to receive feed from twenty wells and provision is
kept for ten future wells. well manifold has two headers, one production header
and the other test header.
OPERATION PRESSURE AND TEMPERATURE
OF GCS II

EQUIPMENTS PRESSURE TEMP

• PRODUCTION SEPERATORS 65 Kg/cm2 20ºC

• WELL FLOW LINE MANIFOLD 65 Kg/cm2 20ºC
• TEST SEPARATOR 65 Kg/cm2 20ºC
• SALES GAS SEPARATOR 60 Kg/cm2 15ºC
• COALER SEPARATOR 60 Kg/cm2 20ºC
• HP CONDENSATE VESSEL 18 Kg/cm2 20ºC
• LP CONDENSATE VESSEL 3 Kg/cm2 20ºC
• STORAGE TANKS Ambient pressure ambient
• GLYCOL REBOILER Ambient pressure 110ºC
• GLYCOL FLASH VESSEL 7 Kg/cm2 15ºC
• GAS BATH HEATER 60 Kg/cm2 0ºC
OIL BATH HEATER 18 Kg/cm2 10ºC

HYDROCARBONS PRESSURE CONDITION TEMP. CONDITION

• C1 (METHANE) 170 Kg/cm2 -170ºC

• C2 (ETHANE) 100 Kg/cm2 -120ºC

• C3 (PROPANE) 13 Kg/cm2 room temp

• C4 (BUTANE) 9 Kg/cm2 room temp

• C5 – C10 (PETROL) 1 Kg/cm2 room temp

• C10 – C12 (NAPHTHA) 1 Kg/cm2 room temp

• C16 – C32 (HSD) 1 Kg/cm2 room temp

 FEED STOCK CHARACTERISTICS
COMPONENTS WELL FLUID COMPOSITION
• C1 91.27%
• C2 2.28%
• C3 0.88%
• iC4 0.15%
• nC4 0.21%
• CO2 2.38%
• N2 1.52%
• C5+ 1.31%
 Gas Compression
Plant (GCP)
ONGC intends to process and compress LP gas at TATIPAKA refinery. The wells
located in this region were producing gas at high pressure 55‐65 kg/cm2, but over
the period of time due to ageing of reservoirs, the well pressure is depleting and
the same cannot cater to the GAIL gas distribution network. So it is required to
process the LP gas and compress it for feeding to the GAIL gas network.

Process Diagram of GCP

Process overview:
Liquid free low pressure gas after the filter separator is routed to the gas
compressor suction KOD operating at a pressure 5 kg/cm2. Gas flow from the
overhead of the suction KOD is metered before entering the compressor skid.
Liquid collected in the suction KOD flow to the intermediate blow down(IBD)
vessel. Intermediate blow down vessel is designed to receive various hydrocarbon
liquid streams from the suction KOD, discharge KOD, compressor package, trunk
line KOD and the fuel gas conditioning system. The gas stream from the blow
down vessel is routed to the flare. There are three compressor units, each of 4
LSCMD capacities. Gas form suction KOD is routed to the 1st stage suction
separator where any small amount of liquid left over in the gas stream is knocked
off. Gas from the suction separator flows into the 1st stage at 5kg/cm2 and
discharge pressure is 22-26 kg/cm2. As the discharge temperature of 1st stage gas
is 140 C, it is cooled in air cooled heat exchanger up to 58 C before entering the
2nd stage suction separator. Gas from overhead of the 2nd stage suction separator
is routed to the second stage of the compressor where it is compressed to 60-62
kg/cm2 and with a discharge temperature of 138 C. An air cooled after cooler,
cools the gas at the outlet of the second stage to a temperature of 58 C.
Compressed gas leaves the compressor skid and is routed to the discharge KOD.
Liquid from discharge KOD flows to the intermediate blow down vessel. The gas
from the discharge KOD goes to the GAIL terminal.

Process Description:
Liquid free LP gas after the Filter separator is routed to the gas compressor
suction KOD V‐107 operating at a pressure 5 kg/cm2. LP gas from the other three
sites that is Ponnamanda, Adavipalem and Mori is also routed to the compressor
suction KOD V‐107 via the Trunk KOD V‐109. Gas flow from the overhead of the
suction KOD is metered by FI 1202 before entering the compressor skid. Suction
KOD pressure controller PIC 1201 is a split range controller and controls the
pressure by operating PCV 1201A or PCV 1201B. PCV 1201A opens to control the
pressure around the set point of the controller PIC 1201. In case, the pressure
rises, PCV 1201B opens in proportion to relieve the excess pressure to the flare
header. Liquid collected in the suction KOD flows out under level control LIC 1204
to the intermediate blow down vessel V‐106.
Intermediate Blow Down Vessel:
Intermediate blow down vessel is designed to receive various hydrocarbon liquid
streams from the suction KOD, discharge KOD, compressor package, trunk line
KOD and the fuel gas conditioning system. The gas stream from the blow down
vessel is routed to the flare under pressure control PIC 1204. The interface level
controller ILIC 1203, controls and regulates the flow of HC liquid to the Liquid
separator while the water phase collected in the blow down vessel flows out into
the produced water vessel under level control LIC 1202.
Compressor Package:
There are three compressor units of 4 LSCMD capacity
The compressor package 10‐KA‐101A/B/C comprises of:
● First stage suction separator 10‐V‐1301
● First stage suction volume bottle 10‐V‐1302
● First stage discharge volume bottle 10‐V‐1303
● First stage intercooler 10‐E‐1301
● Second stage suction separator 10‐V‐1304
● Second stage suction volume bottle 10‐V‐1305
● Second stage discharge volume bottle 10‐V‐1306
● After cooler 10‐E‐1302
● After cooler separator 10‐V‐1307

Gas from suction KOD is routed to the 1st stage suction separator V‐1301 where
any small amount of liquid left over in the gas stream is knocked off. When level
inside V‐1301 reaches the high value configured for LI 1302 then the solenoid
operated valve SDV 1302 opens to drain the liquid to the intermediate blow down
vessel. Temperature and pressure of 1st stage separator is indicated by TI 1301
and PI 1302 which for normal operating condition are 40 °C and 5 kg/cm2g. Gas
from V‐1301 flows into the 1st stage of the compressor via the suction bottle
V‐1302.The suction pressure of the 1st stage is 5 kg/cm2g and discharge pressure
is 22.23 kg/cm2g. As the discharge temperature of 1st stage gas is 144 °C, it is
cooled in air cooled heat exchanger E‐1301 up to 58 °C before entering the 2nd
stage suction separator V‐1304. V‐1304 operates at a normal pressure of 21.8
kg/cm2g. The liquid collected in the vessel is drained by SDV 1303 which is a
solenoid operated valve, opening on high liquid level LI 1303 in the vessel. Gas
from overhead of the separator is routed to the second stage of the compressor
wherein it is compressed to 61.83 kg/cm2g and with a discharge temperature of
138 °C. An air cooled after cooler cools the gas at the outlet of the second stage
to a temperature of 58°C. Compressor is safeguarded against overpressure in
both the stages. PSV 1302A/B on 1st stage discharge has a set pressure of 27.42
kg/cm2g and PSV 1304A/B on 2nd stage discharge has a set pressure of 68.05
kg/cm2g. Design pressure and temperature for the 1st stage is 32 kg/cm2g and
177 °C and for the 2nd stage it is 80 kg/cm2g and 177 °C. Compressed gas leaves
the compressor skid and is routed to the discharge KOD V‐108. Gas flows out
under pressure control PIC 1202 via the demister pad located at the top of the
KOD. FI /FT 1203, meters the temperature and pressure compensated gas flow
rate to the battery limit.
Safeguard against high pressure is ensured by PSV 1204A/B and PSV 1205A/B with
set pressure of 80 kg/cm2g. Liquid from discharge KOD flows out under level
control to the intermediate blow down vessel. Compressor lubricating oil is used
for lubrication of the main bearing, crank pin bearing. After lubrication, oil is
collected in a sump of 216litre capacity. Inside the sump the lube oil is collected
from various bearing and hence at a higher temperature and lower viscosity. A
crankshaft driven, internally mounted main oil pump circulates the warm lube oil
to the shell side of the lube oil cooler E‐1306. Cooling achieved in the lube oil is
from 74 °C to 58 °C. Cooling water is used as the cooling medium on the tube side
of the cooler. TCV 1301 on the shell side outlet of E‐1306 monitors the
temperature of lube oil and if found low, the lube oil inlet flow bypasses the
exchanger E‐1306. The cooled lube oil provides lubrication to the bearings after
passing through duplex filters to remove any dust/dirt. The condition of the
duplex filters is checked for any clogging by monitoring the differential pressure
DPI 1301 across the filters. A hand operated priming pump is provided to allow
pre‐lubrication of bearings and build up a slight pressure in the lubricating system
prior to start up. A motor operated auxiliary pump can also be used in place of the
hand operated pump. An oil pressure regulation valve controls the oil pressure to
the frame lubrication system. Any excess capacity is bypassed to the main oil
pump suction. Normal oil pressure should be in the range of 378‐413 k Pa.
Viscosity of lubrication oil should be 115‐150 SSU at the normal operating sump
temperature to ensure adequate lubrication.
Tatipaka Mini-Refinery
INTRODUCTION
The refinery processes a normal quantity of 1500bpd of crude and
condensate with a maximum processing capacity of 2000bpd.
On average crude oils are made of the following elements or compounds.
CARBON 84%
HYDROGEN 14%
SULPHUR 1-3%
NITROGEN LESS THAN 1%
OXYGEN LESS THAN 1%
METALS LESS THAN 1%
SALTS LESS THAN 1%

These hydrocarbons are named as below depending on their structure. Methane

(C1), Ethane (C2), Propane (C3), Butane (C4) Naphtha(C5-C12), Kerosene
(C12-C16), High Speed Diesel (C16-C32), Low Sulphur Heavy Stock (C-32 &
above). The raw material crude oil is refined into various types of products such
as Naphtha, SKO, HSD and LSHS. Crude oil characteristics vary from light
(which is straw coloured liquid) to heavy (tar black solid). Crude oil is
also called sweet (<0.1ppm sulphur) and sour (>0.1ppm sulphur) crude oil
depending upon the amount of sulphur it
contains. At tatipaka crude oil is received in tankers from the wells at Kesanapal
li, Lingala, Nagayalanka, Raghavapuram, Nandigama, Vadaparru, Kanukollu,
Matsyapuri and many other wells in KG base.

PROCESS DESCRPITION

1. STORAGE OF CRUDE OIL:

Two tanks each of 500 m3 capacity are used for storage of crude which is
received every day from nearby fields constituting feed for refinery. One of
these tanks receives crude oil from tanker intermittently and condensate from
GCS on continuous basis. The other tank supplies feed to the refinery through
centrifugal pumps.
2. CRUDE & CONDENSATE STORAGE:
• Two tanks of 1500m3 capacity exist at the Gas Collecting Station.
These tanks are used as Crude/Condensate feed storage tanks for the
refinery.
• 320m3 of Crude/Condensate is received every day from nearby fields
into these tanks constituting feed for refinery. One of these tanks
receives Crude oil from tanker intermittently and condensate from GCS
on continuous basis. The other tank supplies feed to the refinery
through centrifugal pumps.
• They are mixed in the desired ratio and fed to the preheater by pump.

3. CRUDE CHARGING & PRE-HEATING:

 A mixture of crude and condensate with a composition range of 30% to 70%

is fed in a distillation column by adding de-emulsifier, at a temperature of
330
0 C, after passing through two stages of preheating exchangers, a de-salter
vessel and furnace.

 In first stage of preheating the crude feed is made to exchange heat

with Kerosene, Diesel &LSHS (cold LSHS) product streams in respective
heat exchangers

 After the first stage of preheating the crude enters the de-salter vessel which
is positioned between the two sets of exchangers.

 The salt content of the feed is separated in the de-salter vessel with the help
of mixing water with the feed and then breaking the emulsion with
temperature, high voltage and de-emulsifier.

 In second stage of preheating the crude feed is allowed to exchange heat

with kerosene circulating reflux, LSHS (hot LSHS) and diesel circulating
reflux streams and then enters in to furnace.
 Crude/Condensate mixture, which initially enters at 35ºC into this pre-
heating system, leaves the system at 2100ºC

4. CRUDE FURNANCE:
At a temperature of 170-1900C, feed enters the gas-fired furnace where crude
gets partially vaporised gaining a temperature of 3300C.
The CRUDE Furnace is also a HEAT TRANSFER ZONE wherein
CONVECTION HEAT TRANSFER further heats the pre-heated crude in the
CONVECTION ZONE firstly, followed by RADIATION HEAT
TRANSFER in the RADIATION ZONE finally.

The desalted crude from the desalter unit is further heated up to a

temperature of 220 oC by successive heat exchangers where in kerosene
circulating reflux at 185 oC, Diesel circulating reflux at 254 oC and RCO product
at 333oC respectively is used as heating medium. The heated crude is fed into
the furnace. By this operation, the Crude gets partially vaporized, gaining a
temperature of 340oC.

The furnace is fired with fuel gas (NATURAL GAS) controlled by the Coil Outlet
Temperature Controller (C.O.T.) that is cascaded with a pressure controller on
the fuel gas line.
Along with Crude/Condensate mixture feed, de-mineralized (D.M.) water from
the boilers in the form of saturated steam is also superheated in the furnace
for routing it to the crude column and the strippers.
5. ATMOSPHERIC DISTILLATION COLOUMN:

The atmospheric Crude column is the unit wherein, by HEAT TRANSFER and
MASS TRANSFER (DISTILLATION) operations, fractionates present in the
crude oil are extracted.

 The crude column operates at atmospheric pressure and fractionates crude fe

ed into Naphtha, Kerosene, Diesel & LSHS products.

 The column contains 49 trays (48 valve trays and 01 sieve tray).

 Different fractions get liquefied at different trays at the

temperatures just below their boiling point.
 Heavy naphtha is drawn from tray-11, kerosene is drawn from tray-22,
diesel is drawn fromtray-35 and LSHS from bottom of the distillation
column.

 Partially vaporized steam forms the furnace enters the column on the tray
number-44 from the top. The region between the 43rd and 44th trays is the
FLASHING ZONE. The significance of Flashing Zone is that it is the zone
(of length 2.5m) wherein the partially vaporized (85%vapor-15% liquid)
Crude feed (entering the column at pressure of 2.5kg/cm2) by difference in
pressure of column (0.8kg/cm2) separates out into vapor and liquid
components.

 The liquid component drops down (as L.S.H.S.) 6 trays onto tray #49.
 The vaporized component moves upwards to tray #1.

 Coming to the tray design, the trays used in this column are

VALVE TRAYS (known as TRIPOD TRAYS)

The upper extended surface of the tray is known as the WEIR. The lower
extension is the DOWN COMER. The inter–tray distances are approximately
0.70m (except of the flashing zone trays). The trays are so designed that the
level of Weir of one tray lies higher than that of the preceding tray’s down
comer, to restrict the super-heated steam flow through the gap between the
weir-down comer of the tray and the column wall, by creating liquid seal which,
otherwise, would hamper the vapor-liquid contact time in the preceding tray
thereby reducing the intended heat and mass transfer efficiency and subsequent
distillation.
 Coming back to the distillation part, after the necessary reflux requirements
are met, the distillation process starts. At the respective trays (where reflux
enters), by the virtue of contact between the vapor and the respective reflux,
there occurs Heat Transfer and Mass Transfer. The reflux being at lower
temperatures than the respective vapor, condensation of the vapor occurs.
The condensed liquid level starts rising on the respective tray and thereby
flooding occurs and the liquids pour on to the trays below.

 There are nozzles provided for drawing out the respective products. These
nozzles are connected to flow and pressure control valves.
• As such, after achieving the requisite liquid quantity (level), the nozzle
connected to respective Stripper is activated and thereby liquid draw occurs
(Heavy Naphtha at tray#11, Kerosene at tray#22 along with circulating
reflux draw out & Diesel at tray#35 along with circulating reflux draw out).

Atmospheric crude column Temperature range (ºC)

Section
• Tower overhead 108 – 111
• Heavy naphtha draws 126 – 129
• Kerosene draw 178 – 181
• Diesel draw 265 – 271
• Bottoms 325 – 344

5. Process at other various Individual sections:

a. Overhead section
b. Heavy naphtha section
c. Kerosene section
d. Diesel section
e. Low sulphur heavy stock section
f. Strippers
g. Circulating refluxes
h. Naphtha stabilizers
i. De-salter
j. Valve trays and sieve trays
k. Heat exchangers

a. Overhead section:

 The overhead vapour from the crude column at 1140C is withdrawn under
pressure control and is condensed and cooled in overhead condenser to
550C.
 The condenser utilizes cooling water as the cooling
medium and this condensed overhead product separates out as hydrocarbons
and water in the overhead accumulator.

 Water is withdrawn from the boot under level control and sent to the
effluent treatment plant for treatment.

 Crude column overhead pumps to the naphtha stabilizer pump part of the un-
stabilized naphtha from the accumulator under level cascade flow control
and the rest is sent back to the crude column as reflux.

 Crude column top temperature & reflux controller sets reflux demand.

 A split range pressure control maintains the column overhead pressure by co

ntrolling fuelgas make-up and vapour to flare.

b. Heavy naphtha section:

 Heavy naphtha is withdrawn as side product from tray-11 of the

crude column at a temperature of 1440C under level control sent to side-
stripper bottom.

 Light ends in the heavy naphtha steam are stripped in heavy naphtha side-
stripper using superheated steam.

 Stripped vapours sent back to tray-9 of the crude column and the
bottom product, heavy naphtha is pumped by gear pumps and cooled in
the heavy naphtha cooler using cooling water.

 Part of this stream is blended with final diesel product

(to maintain Cetane number of diesel oil) and the rest is mixed stabilized
naphtha in the naphtha storage tanks.

c. Kerosene section:

 Kerosene as Superior Kerosene Oil (SKO) is withdrawn as a side product

form chimney tray, which receives liquid from tray-22 of the crude
column at a temperature of 1860C under level control sent to side-
stripper bottom.

 Light ends in the kerosene stream are sent back to tray-19 of the
crude column and the hot bottom product of kerosene stripper is pumped
 by gear pumps, under flow control to the crude pre-heating section to
exchange heat with crude in crude/kerosene exchanger.

 The kerosene product gets cooled to 600C in the preheat train and further
cooled in kerosene product cooler to 400C using cooling water.

 The cooled product is stored is stored in kerosene storage tanks.

d. Diesel section:

 Diesel as High-Speed Diesel (HSD) is withdrawn as a side product from

tray-35 of the crude column at a temperature of 2900C under level
control of side-stripper bottom.

 Light ends in the diesel stream are stripped in the diesel side-stripper
using superheated steam.

 Stripped vapours are sent back to the tray-32 of the crude column and
the hot bottom of the diesel stripper is pumped by diesel product gear
pumps under flow control to the crude pre-heating train to exchange heat
with the crude in the crude/diesel exchanger.

 The diesel product gets cooled to 530C in the preheating section and
further cooled in diesel product cooler to 400C using cooling water and
the cooled product is stored in diesel storage tanks.

e. Low Sulphur Heavy Stock section(LSHS):

 Stripped LSHS at a temperature of 3300C is withdrawn from the bottom

of the crude column under level control cascaded with flow control.

 It is pumped by LSHS centrifugal pumps to the pre-heating of crude.

 This hot LSHS exchanges heat with crude in crude/LSHS (hot) exchanger
in first stage of heating and crude/LSHS (cold) exchanger and in turn
gets cooled to a temperature of 1100C in this pre-heating section in
second stage of heating.

 There after LSHS is sent to the storage tanks provided with steam heating
coils to avoid LSHS congealing.
f. Strippers:

 Stripper is also a process vessel (packed column) where heat transfer

operations and mass transfer (stripping) operations occur.

 Respective liquid streams drawn out from the nozzle are made to fall
through liquid inlet in the region above the stripper column and from the
bottom, steam is sent.

 In the stripping column the liquid and steam contact occur and then heat
transfer occurs between them.

 The steam being at lower temperature than that of the drawn

liquid, by direct contact in counter-current flow, decrease of liquid
temperature occurs.

 Mass transfer (stripping) occurs between the steam

and drawn liquid (from column), heavy liquid is drawn out through the
stripper bottom and the lighter vapour is sent back to the column as
reflux.

 The importance of refluxing of vapours is to maintain column

temperature, pressure balancing and to enhance product quality and
quantity.

 There are three (3) strippers, namely:

1. Heavy naphtha stripper, liquid drawn from tray -11 and its vapour
refluxing sent back totray-9.

2. Kerosene stripper, liquid drawn from tray-22 and its vapour refluxing
sent back to tray-19.

3. Diesel stripper, liquid drawn from tray-35 and its vapour refluxing sent
back to tray-32.

The design stripping steam flow rates are as follows:

SECTIONS Stream Flow Rates (kg/hr)

Main tower 64-68
Heavy Naphtha Stripper 45
Kerosene stripper 68
Diesel stripper 34-54

g. Circulating refluxes:

 In order to maximize the heat recovery and balance the tower loading,
heat is removed by way of circulating refluxes from kerosene and diesel
sections.

 Kerosene CR is withdrawn from kerosene product withdraw tray - 22

of the crude column at a temperature of 175-1850C.

 It is pumped by kerosene CR pumps, 20-P-102 A/B to the crude preheat

section where it exchanges heat with the crude in the crude/ kerosene CR
exchanger 20-E-104 A/B.

 Diesel CR is withdrawn from diesel product withdraw tray - 35 of

the crude column at temperature of 280- 2900C.

 Then it is pumped by diesel CR pumps, 20-P-103 A/B to the

crude preheating section where it exchanges heat with the crude in the
crude/diesel CR exchanger 20-E-105 A/B.

 The diesel CR is routed back to tray - 32 of the crude column after

exchanging heat in naphtha stabilizer re-boiler 20-E-112.

 The diesel and kerosene CR draw rate is controlled by a flow controller.

h. Naphtha stabilizers:

 The un-stabilized naphtha from the overhead naphtha accumulator of the

crude column is stabilized by removal of light ends in the naphtha
stabilizer column 20-C-105.

 The light ends are recovered as fuel gas and stabilized naphtha at 140C is
obtained from the bottom of the column under level control.

 The necessary heat required for light naphtha in re-boiler

is provided by diesel circulating reflux under temperature control of the
naphtha stabilizer bottom, through thermo-syphon re-boiler 20-E-112.

 Naphtha is further cooled in 20-E-113

using cooling water and sent to storage tanks 20-T-104 A/B.
  The stabilizer is provided with a stub in exchanger 20-E-111 to condense
the overhead vapour.

 Water is used as the cooling medium and water flow is

controlled by stabilizer top temperature control.

 The fuel gas from the top of the stabilizer is sent to fuel gas system.

 Stabilizer pressure is controlled by a pressure control

provided in the fuel gas line.

i. De-salter:

 The crude feed enters the De-salter vessel after the first stage of heating.

 In this process the salts are removed from the crude feed.

 The chemicals are added to the injection water and then added to crude
feed.

 The undesired salts are dissolved in the water and form an emulsion.

 The electric field is used to break the oil-water emulsion.

 By means of voltage (10KV-25KV) and temperature the fluid is separated

into two phases.

 Then the desalted crude is further sent to the second stage of heating.
1. Valve trays:
They have perforations which are covered by caps. These caps make the vapour
to move laterally through them.

Features of valve trays

 Provides best turndown and efficiency.

 Valves positioned parallel to the liquid flow allow the

liquid to flow unopposed across the tray.

 Lateral vapour release assures uniform contact in all active areas.

2. Sieve trays:
They are simple metal plates with holes in them. There is no lateral movement
of vapour.
Features:

 Most economical for low turndown

 Low pressure drop

 Each tray has two extensions namely the down-comer

(lower extension) and the weir (upper extension).

 Continuous condensation, vaporisation occurs at the trays which help

separating the required fractions more effectively.

3. Heat exchanger:

 Heat exchanger is a device built for efficient heat transfer from one
medium to the other.
 In Tatipaka refinery, shell and tube heat exchangers are used.
 A shell and tube heat exchanger have shell with a bundle of tubes inside
it.
 The crude feed flows in the tubes and the other fluid flows in the shell.
The shell is provided with baffles which maximise their heat efficiency.
PROCESS DIAGRAM OF MINI REFINERY
 The various flow streams and their flow rates are
as follows:

• Normal flow streams Flow rates (m3/hr)

• Crude feed 13.2
• Desalter wash water 0.8
• Crude column reflux 10.03
• Heavy naphtha product 1.6
• Kerosene product 3.9
• Kerosene CR 12.75
• Diesel product 2.3
• Diesel CR 18.5
• RCO product 3.0
• Stabilizer light naphtha 3.75

EQUIPMENT LIST OF MINI-REFINERY

PUMPS
Equipment Identification Quantity Type MOC Description
required

Crude feed pump 2 Centrifugal CS&CI Capacity:15.9m3/hr

;Head:221m

Kerosene CR pump 2 Centrifugal CS & CI Capacity :19.2

(12%Cr) m3/hr;Head:29.9 m

Diesel CR Pump 2 Centrifugal CS Capacity :30.0

&12%Cr m3/hr;Head:42.7 m

HN prod. pump 2 Centrifugal CS &CI Capacity:2.55m3/hr:Head:

13.1m
Kerosene product pump 2 Centrifugal CS & CI Capacity: 5.59m3/hr;
Head: 32.0m

Diesel product pump 2 Centrifugal CS&12% Capacity: 3.55m3/hr;

Cr Head: 45.1m

RCO Product pump 2 Centrifugal CS&12% Capacity: 5.78m3/hr;

Cr Head: 122.3m

Crude Col. O/H Reflux 2 Centrifugal CS %CI Capacity: 17.3m3/hr;

pump Head: 117.1m

Desalter water pump 2 Reciprocating SS Capacity: 800 LPH; Disc:

304&316 23.3kg/cm2-A

Corrosion inhibitor 2 Metering SS 304 Capacity: 10 LPH; Disc:

Injection pump &316 5.85kg/cm2-A

Demulsifier Injection 2 Metering SS 304& Capacity: 2 LPH; Disc:

Pump 316 23.7kg/cm2-A

Naphtha Loading Pump 2 Centrifugal CS &CI Capacity: 60 m3/hr; Head:

40.0m

Kerosene Loading Pump 2 Centrifugal CS& CI Capacity: 60 m3/hr; Head:

42.0 m

Diesel Loading Pump 2 Centrifugal CS &CI Capacity: 60m3/hr; Head:

45.0m

RCO Loading Pump 2 Centrifugal CS &CI Capacity: 60 m3/hr; Head:

58.0 m

Flushing Oil Pump 2 Gear CS, CI Capacity: 12 LPH; Disc:

&Steel 5.76 kg/cm2-A

CBD Pump 1 Centrifugal CS Capacity: 2 m3/hr; Head:

Vertical &12%Cr 20.0 m

OWS Pump 1 Centrifugal semi CS&CI Capacity 7m3/hr; Head:

submersible 25 m

Ammonia Injection Pump 2 Metering SS 304 Capacity 2 m3/hr; Disc:

&316 9.5 kg/cm2-A

TOTAL 36 -------- ------ -------

 COLUMNS
Equipment Quantity Type MOC Description Diameter Height
Identification Required
Crude Distillation 1 Tray Shell-CS, 49Trays; 1.067 m 34.31 m
Column Colum Internals- Vapor
n SS 410S Distributors
about tray
8,19,32,44;
Liquid
distributors
19,32;bottom
&interm seal
pan etc.
HN Side Stripper 1 Strctrd Shell-CS, 1 strctrd 305 mm 7.33m
packin Internals- packing;
g SS 410 steam
distributor;
bed support;
Liquid
distributors
etc.
Kerosene Side 1 Strctrd Shell-CS, 1 strctrd 305 mm 9.275m
Stripper packng Internals- packing;
SS 410 steam
distributor;
bed support;
Liquid
distributors
etc.
Diesel Side Stripper 1 Strctrd Shell-CS, 1 strctrd 305 mm 6.11 m
packng Internals- packing;
SS 410 steam
distributor;
bed support;
Liquid
distributorset
c.
LN Stabilizer 1 Strctrd Shell-CS, 2 strctrd Top: 20.974m
packng Internals- packing; 305mm;
SS 410 bed support; bottom:
feed inlet 460mm
distributor ;
liquid
distributor
etc.
TOTAL 5 ----- ------- ------------ ------- --
 HEAT EXCHANGERS
EQUIPMENT QUANTITY TYPE MOC DESCRIPTION
IDENTIFICATION REQUIRED
Crude kerosene 1 Hairpin CS Multi tube hairpin
exchanger (MOC for tube and
shell)
Crude cold RCO 1 Hairpin CS Multi tube hairpin
exchanger (MOC for tube and
shell)
Crude diesel 1 Hairpin CS Multi tube hairpin
production exchanger (MOC for tube and
shell)
Crude kero. CR 2 Hairpin CS Multi tube hairpin
exchanger (MOC for tube and
shell)
Crude diesel CR 2 Hairpin 5Cr1/2 Multi tube hairpin
exchanger Mo (MOC for tube and
shell)
Crude hot RCO 1 Hairpin 410SS Multi tube hairpin
exchanger (MOC for tube and
shell)
Diesel product cooler 1 Hairpin Adm Multi tube hairpin
brass (MOC for tube and
& CS shell)
Kerosene product 1 Hairpin Adm Multi tube hairpin
cooler brass (MOC for tube and
& CS shell)
Column overhead 2 Shell & Adm Horizontal (MOC
condenser tube brass for tube & shell)
& CS
Heavy naphtha cooler 1 Hairpin Adm Multi tube hairpin
brass (MOC for tube and
& CS shell)
Stabilizer overhead 1 Shell & Adm Vertical (MOC for
condenser tube brass tube & shell)
& CS
Stabilizer reboiler 1 Shell & CS Vertical (MOC for
tube tube & shell)
Stabilized naphtha 1 Hairpin Adm Multi tube hairpin
cooler brass (MOC for tube and
& CS shell)
TOTAL 16 ---- ----- ----

VESSELS
EQUIPMENT QUANTITY TYPE MOC DESCRIPTION L B/D H
IDENTIFICATION REQUIRED
Desalter 1 Horizontal CS 2 electrodes; 1 no. 2.44 1.83 -----
 cylindrical entrance bushing; m m
insulater; 1 mixing
valve; etc

Desalter transformer 1 10 KVA ----- Mounted on the ----- ---- ----

top of the desalter

Overhead naphtha 1 Horizontal KCS 2 no. 20 mm wide 3.9 1.22 5

accumulator cylindrical long slots facing m m m3
walls for inlet; 1
no. Vertex breaker

Flushing oil drum 1 Vertical CS Ordinary flat 1.2 0.6 0.5

cylindrical bottom tank with a m m m3
vent

Fuel gas KOD 1 Vertical CS Trsphrcl head and 2.2 0.6 0.75
cylindrical Trsphrcl bottom m m m3

Demister PAD 1 York 431 SS316 Demister pad for ---- ---- ----
or Eq fuel gas KOD

Closed blow down drum 1 Horizontal CS Underground vessel 3m 1,2 3.4

cylindrical with internal cooling m m3
coil/heating coil
Furnace decoking vessel 1 Vertical ----- Vertical cylindrical ---- ----- ---
cylindrical vessel for collecting
coke
TOTAL 7 ---- ------ ------ ---- ---- ---

STORAGE TANKS
EQUIPMENT QUANTITY TYPE M DESCRIPTION L B
IDENTIFICATION REQUIRED O
C
Kerosene storage tank 2 Vertical CS Conical bottom, 7.8 m 8.5 m
cylindric conical fixed roof
al
Diesel storage tank 2 Vertical CS Conical bottom, 8.0 m 9.0 m
cylindric conical fixed roof
al
RCO storage tank 2 Vertical CS Conical bottom, 7.5 m 8.25 m
cylindric conical fixed roof,
al with internal steam
coil

Naphtha storage tank 2 Vertical CS Conical bottom, 9.0 m 9.95 m

cylindric floating roof
 al
TOTAL 8 ---- ---- ----- --- ----

CHEMICAL INJECTION TANKS

EQUIPMENT QUANTITY TYPE MOC DESCRIP L B
IDENTIFICATIO REQUIRED TION
N
Corrosion inhibitor 1 Vertical IS2062 Flat bottom 1.45 m 1.75 m
tank cylindric
al

Agitator for corrosion 1 Vertical ----- Inhibitor ---- ----

inhibitor tank solution
mixing
agitator

Demulsifier tank 1 Vertical IS2062 Flat bottom 1.0 m 1.0 m

cylindric
al

Agitator for 1 Vertical ----- Demulsifier ---- ----

demulsifier tank solution
mixing
agitator

Ammonia solution 1 Vertical MSGls Flat bottom 1.45 m 1.75 m

tank cylindri lined or
cal phenoli
c resin

Injection water tank 1 Vertical IS2062 Flat bottom 2.225 2.5 m

cylindri m
cal

Demineralised water 1 Vertical FRP- Flat bottom 1.50 m 1.75 m

storage tank cylindri isophth
cal alic
resin

PACKAGE ITEMS
EQUIPMENT QUANTITY TYPE MOC DESCRIPTION
IDENTIFICATION REQUIRED
Furnace 1 Vertical Shell: CS; Radiative &
Radiant convective heating
tube: coil for crude;
 5%Cr; convective heating
Convection coil for steam;
tube: CS castable
insulation;
insulation bricks;
etc
Fuel gas burners 3 FG ------ UV Scanner, pilot
burner, BMS. etc
Steam generating 2 ---- -----
boiler
Demineralised water 1 Ion ---- To generate boiler
plant exchange feed water
Boiler feed pump 2 ------ ----- Capacity: 0.6
m3/hr;head:80 m
Blower for boiler 2 ----- ----- -----
Cooling tower 1 Induced ---- -----
draft
CW Pumps for ckt 1 2 ---- CI & CI Capacity: 280
m3/hr;head: 27 m
Cooling tower fans 1 ----- ----- Capacity: 300
m3/hr; range:10
0
C
CW 2 ---- ---- Capacity:20
Pumps for ckt 2 m3/hr;head:50 m
Raw water pumps 2 ---- CI & Capacity:18
3
Bronze m /hr;head:40 m
Loading arm 3 ----- ---- Separate arms for
naphtha & RCO,
common arm for
diesel & kerosene
Weigh bridge 1 ---- ---- Common weigh
bridge for all
products
Air conditioning system ----- ----- ----- ------
Exhaust fan ------ ------ -------- -----
 Effluent Treatment
Plant (ETP)
SOURCE OF EFFLUENTS:

1) Stripped Sour Water & De-Salter Brine:

In refinery operations, water that comes out from the process units will contain
large amount of H2S and Ammonia. H2S rich water is called Sour Water.

2) Water from Crude Tanks Drains:

High chloride water separated in crude tanks.

3) Slops from Units:

An off-spec liquid hydrocarbon, which is generated during start-up and shutdown

of the process units or during emergency and which has minimum water content,
is known as Slop Oil.

4) Spent Caustic Steam:

Caustic is utilized in various processes in the refinery, mainly in Meraux units for
removal of H2S and mercaptanes from Kerosene to achieve desired quality.

5) Sanitary Sewage:

Sanitary sewage generated in the refinery is also taken into the treatment
process.
6) Other Waste Water Streams:

Floor equipment washes, process condensates, cooling tower blow-down; De-

mineralization plant Regeneration waste and contaminated rainwater comprises
the other wastewater streams

Effluent is primarily water with hydrocarbon. Hydrocarbon mixed with water is

characterized with two types of oil:
1. Free oil
2. Emulsified oil
The treatment philosophy is largely based on oil water separation through specific
gravity differences of two phases. This separation is carried out in stages by either
coalesce of small oil droplets into larger droplets or through reducing the specific
gravity by nucleating the micro bubbles to emulsified oil thereby allowing the oil
droplets to rise to the surface, facilitating separation. The entire treatment scheme
for Tatipaka GCS is designed to treat 500 M3 per day with average load of 21
M3 per day.

Treated Water Quality (as per CPCB/SPCB):

Parameter O.W.S. Contaminated Spent Caustic Sanitary &
(Oily water Rain Water Canteen
sump) wastes

Tot. S.S. 200mg/l 200mg/l 18mg/l 250mg/l

Sulphides 100mg/l 10mg/l 4327mg/l -n/a-
Phenols 50mg/l 10mg/l 4327mg/l -n/a-
Oil + Grease 5000mg/l 3000mg/l 6125mg/l --- ---
C.O.D. 1000mg/l 200mg/l 17500mg/l 350mg/l
B.O.D./5days 500mg/l 30mg/l 6862mg/l 200mg/l
Ammonia 30mg/l 5mg/l 2mg/l -n/a-
Parameter Allowable limit

TSS 20

Temperature Not more than 5oC above intake water

body temp.

Sulphides 0.5

Phenols 1

PH Value 6.0-8.5

Oil & Grease 10

Color& Odor Clear & no unpleasant smell

C OD 250

BOD/5days 15

Ammonia 5
Effluent Water Characteristics:

Process Description:

Oil Water Sumps (OWS):

The Raw effluent feed from the underground sewer is collected in the OWS sump.
The sump possesses 2 auto level switches, which indicate the effluent level, &
there are 4 transfer pumps, which works based on the level of the sump. The
effluents are then transferred to the wash tank.

Wash Tank:
The effluent transferred from the OWS sump through the pump is collected in the
wash tank of 200 cubic meter capacity. The inlet of wash tank line will be
connected to an on-line dosing system. The dosing of de-oiler chemical is done on-
line to achieve de-emulsifying of oil from the effluent. The sludge separated is
transferred to the existing chemical sludge sump through sludge transfer pump.

Balancing Tank:

The effluent is transferred from wash tank to balancing tank of 200 cubic meter
capacity. In a balancing tank a separate slop oil overflow line is provided to collect
the slop oil in the slop oil sump. The sludge is transferred to chemical sludge sump
through sludge transfer pump.

Tilted Plate Interceptor:

The outlet of the balancing tank i.e oily water is connected to two TPI feed pumps
to transfer the effluent to tilted plate interceptor. These pumps transfer the
equalized raw effluent for further treatment.

Flash Mixer:

The outlet of the TPI treated effluent then passes through flash mixer. The flow
from the TPI to the flash mixer is under gravity over flow. The TPI created
effluent is then subjected to coagulation of solids with the help of alkali and alum
dosing.

Flocculation Tank:

The over flow of the flash mixer tank, flows into theflocculation chamber by
gravity.
Here polyelectrolyte is dosed for flocculating the alum-oil suspended solids flocs
and creating large agglomerates.
Dissolved Air Flotation Unit:

The effluent from the flocculation tank is fed to the central feed well and a part of
it is fed to the DAF and it is pressurized & saturated with air. This is then recycled
to the central feed well. Due to sudden de-pressurization, the dissolved air is
released into fine air bubbles.
These bubbles will adhere to the flocks and makes it lighter and so it floats on the
surface of DAF. Then this is removed by means of skimmer. A small amount of
sludge is periodically drained. The capacity of DAF unit is 20m3.

Filter Feed Sump:

The treated effluent from DAF unit is collected in the filter feed sump though
gravity flow pipelines.
The effluent is then transferred to a dual media filter in the down stream process
through transfer pumps.

Polishing System:
This system consists of a vertical mount mild steel epoxy coated vessel with 2
medias anthracite followed by sand each of about 300 mm thickness.
The treated effluent, which possesses traces of organic and suspended solids, is
removed by dual media filtration.

Backwash Sump:

The DM filtration unit is designed for a continuous filtration process. When DP

increases more than 1kg/cm2 filter will be taken for backwashing.

Guard pond and Treated Effluent Pump:

A guard pond is provided to store the treated effluent after the filtration. The
effluent from the pound is pumped by high pressure pump (P-570A/B) for
underground disposal in old reservoir.
There are few other sections whose proper functioning is required for efficient
working of ETP. They are

Sludge and Oil Scum Handling Section:

Sludge is generated throughout the treatment process. The sludge’s are basically
generated from different sources.
● Titled plate interceptor(TPI)
● Dissolved air floatation unit(DAF)
Sludge is collected in sludge collection sump from this sump the sludge is sent to
centrifuge for de-watering. The sludge cake is obtained from centrifuge after de-
watering of sludge which is transferred to sludge drying bed.

Slop Oil Handling Section:

Slope oil i.e. floating oil generated during the separation process is collected in
separate sump having a capacity of 7.5 m3. Slope oil is collected from the
following three units.
● Wash and Balancing Tank
● Tilted Plate Interceptor(TPI)
● Dissolved Air Floatation Unit(DAF)
The slope oil collected in this sump is lifted to oil storage tank by two screw
pumps.

Chemical Handling System:

The chemical required for the entire treatment process are prepared for dosing I
appropriate strength on the incoming raw effluent water. Four type of dosing
chemical has been designed for the system.
a. De-oiling
b. Poly aluminum chloride
c. Polyelectrolyte (DAF System)

Treated Effluent Storage and Disposal:

After polishing of effluent water in DMF that treated effluent is stored in guard
pond which is having the capacity of 180 m3. The treated effluent water is injected
into effluent disposal well by reciprocating pumps.

Chemical Dosing:

A. POLYALUMINIUM CHLORIDE-100-150ppm(25kgs/day)
B. DE-OILER-8 to 10 ppm
C. POLYELECTROLYTE-2 to 5 ppm

DESIGN CAPACITY-750M3/DAY

AVERAGE LOAD OF 31M3/Hr

List of equipment:
● OWS sump: 40 cum cap, residence time-2 hrs
● Wash tank:200cum cap, residence time-10hrs
● Balancing tank:20cum cap, residence time-10hr
● TPI Separator:20cum cap, residence time-10hrs
● DAF:20cum cap, residence time-17mins
● Dual medial filter:4 cum cap x2nos, operating pr(2.5kg)
● Chemical dosing: Alum, polyelectrolyte &de-oiler
● Guard pond :180 cum cap, residence time-12 hrs
● Sludge handling: 8cum cap, sludge drying bed.
 GAS DEHYDRATION UNIT(GDU)
There are several problems concerning pipelines, although similar, the problems
are unique for gas, oil and multiphase flow pipelines. For gas pipelines the main
problem is water in the gas.
Water is a problem in the gas phase, both in gas processing and in pipeline
transport.
The main problems with water in gas are:
· Corrosion
· Liquid water formation
· Hydrate formation
In pipelines where it is known that the gas is wet, the problem can be countered.
If it is known in the design phase the pipeline can be designed with more
corrosion resistant materials or increased material thickness. If the problem
occurs during production, the problem can be minimized by injecting inhibitors
into the gas.

In dry gas pipelines the problems ought not to occur, but can occur in case of
insufficient dehydration. If not discovered the problems are more serious here,
because the pipelines are not designed for these conditions. When discovered
inhibitors can be added until adequate dehydration is available again. Liquid
water in the pipeline is a problem, not only concerning liquids in compressors,
but also a problem because the liquid water can create liquid plugs and increase
corrosion.

Prevention
Because of the potential dangers from gas hydrates they must be prevented.
There are several methods to prevent gas hydrate formation, they are:
· Gas dehydration
· Raising the temperature
· Reducing the pressure
· Adding inhibitors
Gas dehydration is the most efficient way to prevent hydrate formation, but
there may be practical limitation to the use of dehydration, e.g. one central
dehydration unit. Gas dehydration will be treated further in section 3. If the gas
stream cannot be dehydrated, one of the other prevention methods must be used.
Raising the temperature of a pipeline is very impractical, likewise is reducing
the pressure, because such a reduction will reduce the pipeline flow. The only
practical solution is therefore to ad inhibitors to the gas.

Inhibitors
Inhibitors acts as antifreeze in the gas, the usual inhibitors are:
· Alcohols
· Glycols
Methanol and monoethylene glycol (MEG) are the most commonly used
inhibitors, low doses are often injected continuously in pipeline where hydrate
formation is a problem. Higher doses of especially methanol are used
temporally to dissolve hydrate plugs. MEG is more viscous than methanol but
has the advantage of being easier to regenerate from the gas than methanol,
because methanol regeneration is usually not feasible. MEG is the most
commonly used glycol, because it is more efficient at a given mass
concentration than diethylene glycol (DEG). DEG may nevertheless be used as
inhibitor in the pipeline, but only if DEG also is the glycol used in the
dehydration process afterwards.
There are other possible inhibiters that prevent hydrate formation they are:
· Salts
· Ammonia
· Monoethanolamine
Salts are very rarely used because of the risk of corrosion and deposits.
Ammonia is corrosive, toxic and can form solid deposits of carbonates obtained
with carbon dioxide and water. Monoethanolamine is only attractive if it after
pipe transport is used (and thereby recovered) for gas sweetening.

Removing the water from the gas offshore is essentially because it decreases the
problems associated with water in the gas. This makes the dehydration process
an essential part of the offshore gas treatment.

Dehydration methods

The methods used for gas dehydration are absorption, adsorption, membrane
processes and refrigeration. The methods may be used by themselves or be
combined to reach the desired water contents.
In dehydration by absorption water is removed by a liquid with strong affinity
for water, glycols being the most common. The lean (dry) glycol removes the
water from the gas in an absorption column known as a contactor. After the
contactor the rich (wet) glycol must be regenerated before it can be reused in the
contactor. The regeneration is done by distilling the glycol thus removing the
water. With glycol absorption it is possible to lower the water contents down to
approximately 10 ppmvol, depending on the purity of the lean glycol.

Dehydration by adsorption is done with a two-bed system, where the beds are
filled with adsorbents e.g. silica gel. The gas is lead through one of the
adsorbers, where water is removed. Meanwhile the other adsorber is regenerated
by blowing hot dry gas through it, this gas is then cooled, and the water
condenses. The Water is separated off and the gas is lead back to the wet gas,
the efficiency of the adsorption process depends on the adsorbent used.

In membrane processes the gas passes through a membrane that separates of the
water. Membrane processes yields water content between 20-100 ppmvol. The
problem with membrane processes are that they only become economically
viable compared to glycol absorption at flows below 1.5·106 Nm3/d.

Gas dehydration by refrigeration is a low-cost dehydration method. Water

condenses when the gas is cooled; the water is then removed in a separator. The
separation method can be conducted numerous times. The method is most
efficient at high pressure. The amount of water removed in the refrigeration
process is often insufficient. Because of the low cost the refrigeration process
are often used before the other dehydration processes.

Water absorption

The basis for gas dehydration by absorption is the absorbent; there are certain
requirements
for absorbents for gas dehydration:
· Strong affinity for water to minimize the required amount of absorbent.
· Low affinity for hydrocarbons to minimize hydrocarbon loss during
dehydration.
· Low volatility at the absorption temperature to minimize vaporization losses.
· Low solubility in hydrocarbons, to minimize losses during absorption.
· Low tendency to foam and emulsify, to avoid reduction in gas handling
capacity and
minimize losses during absorption and regeneration.
· Low viscosity for ease of pumping and good contact between the gas and
liquid
phases.
· Large difference in volatility and boiling point compared to water to minimize
vaporization
losses during regeneration.
· Good thermal stability to prevent decomposition during regeneration.
· Low potential for corrosion.

The most critical property for a good dehydrator is off course the high affinity
for water. The other criteria are used to evaluate potential absorbents practical
applicability in the industry. In practice glycols are the most commonly used
absorbents for dehydration.

Glycols used for dehydration

Glycol is a common name for diols; with the two alcohols these substances have
a high affinity for water. In dehydration 1,2-ethandiol also known as
Monoethylene glycol (MEG) and the small polymers of MEG (diethylen glycol
(DEG), triethylen glycol (TEG) and tetraethyl glycol (TREG)) are the most
commonly used for absorbents.
Higher polymers than TREG is usually not used for dehydration because they
become too viscous compared to the smaller polymers.

When TEG decomposes it becomes MEG and DEG, therefore it will not
influence the dehydration process, only give a slightly larger glycol loss because
MEG and DEG are more volatile than TEG.

The glycol dehydration process

The dehydration process can be divided into two parts, gas dehydration and
glycol regeneration.
In dehydration water is removed from the gas using glycol and in regeneration
water is removed from the glycol, before it can be reused for dehydration.

Dehydration
Dehydration always consists of an inlet scrubber and a contactor. Sometime it
might be preferable to lower the gas inlet temperature before the dehydration, so
an inlet cooler might also be used.

Regeneration

The main function in the glycol regeneration system can be divided into three:
1. Achieve the optimal pressure and temperature conditions for regeneration of
the
rich glycol.
2. Glycol regeneration.
3. Readjust glycol temperature and pressure for optimal dehydration conditions
in the contactor.

Besides these three main points there are some additional features to be
considered
when designing a dehydration plant.
· Installing a flash separator before the regeneration column. This separator
removes
most of the hydrocarbons in the dissolved in the glycol.
· Filtering the rich glycol if there is solid particles or liquid hydrocarbons in the
glycol
· Integrating the heat exchangers, so the lean glycol is cooled by heading the
rich
glycol, thus minimizing the energy consumption.
· Glycol make up to replace the glycol loss, e.g. in a storage tank.
Because of these considerations the design of the regeneration process varies
with the design of the plant. The integration of heat exchangers is especially
important, because this reduces the overall energy consumption of the plant.

Process description
The process is described by the equipment used in the glycol plant.

Inlet cooler
An inlet cooler may be used because dehydration is more efficient at low
temperatures. Another benefit of inlet cooling is that some water (and
hydrocarbons) in the gas will condense, and be removed in the inlet scrubber,
instead of in the contactor. An inlet cooler is used when the inlet gas
temperature is higher than the desired temperature in the contactor. It is also a
helpful tool in simulation if the temperature in the contactor needs to be
optimized.

Inlet scrubber
The inlet scrubber removes free liquid and liquid droplets in the gas, both water
and hydrocarbons. Removing liquid water in the scrubber decreases the amount
of water that has to be removed in the contractor. This decreases the size of the
contactor and the glycol needed in it, to reach the required conditions for the
outlet gas. Liquid hydrocarbons are also a problem in the contactor because they
increase the glycols tendency to foam, thereby decreasing the contactors
efficiency and increasing the glycol loss in the contractor and from the
regeneration system. Another problem is that hydrocarbons can be accumulated
in the glycol polluting it and thereby decreasing the dehydration efficiency.

Contactor
The contactor is the absorption column where the gas is dried by the glycol. The
lean glycol enters at the top of the contactor while the rich glycol is collected at
the bottom of the contactor and sent to regeneration. The wet gas enters the
contactor at the bottom, while the dry gas leaves at the top. The required water
dew-point of the dry gas dictates the lean glycol temperature and purity. This is
illustrated in Figure 3-2. The glycol temperature into the contactor must be 3 to
11 °C (5 to 20 °F) higher than the gas entering the contactor to minimize
hydrocarbon condensation into the glycol.
At contactor temperatures below 10 °C (50 °F) TEG becomes too viscous, thus
reducing the column efficiency. The contactor temperature may be as high as 66
°C (150 °F), but glycol vaporization loss is often deemed unacceptably high
above 38 °C (100 °F). The glycol flow into the contactor is dictated by the
water content in the gas and numbers of trays in the column. A usual glycol
flow is 0.017 to 0.042 m3 Lean TEG per kg water in the gas (2 to 5 gal TEG/lb
Water). Contactor columns with four to six trays usually operate with 0.025 m3
TEG/kg Water (3 gal/lb), in larger columns with eight or more trays the flow is
usually reduced to 0.017 m3/kg (2 gal/lb).
Flash valve
After the contactor column the pressure is reduced to the regeneration pressure
by a flash valve. The pressure drop over this valve depends on the pressure in
the contactor and the pressure loss in the pipes and equipment until the
regeneration column. Two places in the system unwanted gas is vented off the
system, in the flash separator and the regenerator. To prevent blowback the
pressure in these units must be higher than where they vent to. The slightly
higher pressure also acts as a propellant in transporting the gas from the
dehydration system.

Flash separator
It is a good idea to install a separator after the flash valve. Because of the
decreased pressure hydrocarbons absorbed in the glycol will be released.
Without a separator the gas in the glycol will be released together with water in
the regenerator. In the regenerator the water vapour is usually just vented to the
atmosphere, thus increasing the plants emission of hydrocarbons. With a flash
separator the hydrocarbon rich gas, can be used as process gas in the plant. The
pressure in the flash separator must be above the pressure in the system that the
gas is vented too; the separator pressure will therefore differ between plants.

Filters
Filters are only necessary if there is a problem with solid particles or liquid
hydrocarbons in the glycol. Solid particles in the glycol accumulate, increasing
the wear on the equipment and can create plugs in heat exchangers. Solid
particles can easily be removed with sock filters,
which can be made of cloth fabrics, paper or fibreglass. Liquid hydrocarbons
like condensate and BTEX can be removed from the glycol by activated carbon
filters.

Heat exchangers
The numbers of heat exchangers vary with the design of the process plant.
Because of the large temperature difference between the contactor and
regenerator column, rich glycol needs to be heated while lean glycol must be
cooled. With proper design of heat exchangers between the rich and lean glycol
most of the energy can be conserved. Rich glycol may be heated before and/or
after the flash separation. Heating before the flash separator increases
hydrocarbon recovery along with glycol loss. Heating before the flash separator
is preferable if hydrocarbon contents in the rich glycol after the separation are
too high.
Besides the heat exchangers the glycol is heated in the regenerator boiler. The
lean glycol temperature may also need to be adjusted before it enters the
contactor, this can be done with the dry gas or a cooler.

Regenerator
The regenerator is a distillation column, where glycol and water is separated.
The rich glycol is preheated in heat exchangers before it is feed to the
regenerator column. At the top of the column is a partly condenser, this provide
reflux thus improving the separation between water and glycol. The condenser
also minimizes glycol loss from the regenerator. The remaining water vapour
leaves the condenser and is vented to the atmosphere. The temperature in the
condenser is given as 98.9 °C (210 °F).

The energy required to separate glycol and water is supplied by the reboiler at
the regenerator
column. The reboiler temperature is dictated by the glycol used for the
dehydration as described. For TEG the recommended maximum temperature in
the reboiler is 204 °C (400 °F). The Lean glycol is taken from the reboiler and is
transferred to a storage tank before it is recycled or is recycled directly from the
reboiler. The pressure in the regeneration system is just above atmospheric
pressure, this is to ensure that no air can enter the system from the atmospheric
vent.
The operating conditions for the regenerator influence the purity of glycol. At
204 °C TEG yields a lean glycol concentration of 98.6 wt%. If this purity of
glycol is inadequate it can be improved by using more advanced regeneration
techniques.
Some simple ways to increase the lean glycol purity is to add a stripping gas to
the regenerator or regenerate by vacuum distillation. Stripping gas can be added
to the regenerator boiler or in a stripping column after the regenerator column.
By adding stripping gas to the regenerator boiler, the TEG purity can be
increased up to 99.6 wt%. Vacuum distillation yields TEG purities up to 99.98
wt%.

Stripping column
Glycol purities up to 99.9 wt% can be achieved by using a stripping column
after the regenerator. The stripping gas from the top of the stripping column is
routed to the regenerator boiler, like when stripping without the stripping
column. The stripping gas is usually nitrogen, dry gas or flash gas from the flash
separator. The water can be removed from the stripping gas by cooling it well
below waters dew-point. If hydrocarbon rich gas is used the gas from the
regenerator must be dried or used as process gas.
To achieve 99.9 wt% pure glycol (or 99.6 wt% without the stripping column),
the stripping gas flow must be 28.3 Nm3 gas/m3 TEG (4 scf gas/gal TEG).
Cool stripping gas can be used in the stripping column, because the glycol needs
to be cooled after the regenerator. If on the other hand stripping gas is added
directly to the regenerator boiler it might be preferable to preheat the gas, to
keep a uniform temperature in the boiler.

Glycol storage tank

This is an optional instalment that ensures a constant glycol flow to the
contactor column. Because there will be a loss of glycol in the dehydration
system, a storage tank can act a buffer to prevent insufficient glycol flow and be
used to measure the glycol contents in the system.

Glycol circulation pump

Because of the pressure difference between the regenerator and the contactor,
the glycol pressure needs to be increased. This is done with the glycol
regeneration pump. The glycol is cooled below 80 °C before pumping to protect
the pump.

Process plant
A possible design of a dehydration plant is
The efficiency of a dehydration process is evaluated by the water contents in the
gas after the dehydration. The water contents after the dehydration is often
given as the water dew-point, this is to ensure that no water will condense in the
pipeline. The water Gas dehydration dew-point is therefore more practicable
because it is directly comparable with the pipeline operating conditions.
The glycol dehydration process can be divided into two parts. First lean glycol
dries the wet gas, thereby making the glycol rich. In the second part of the
process water is removed from the rich glycol making it lean once again. In the
second part of the plant pressure and temperature is changing to achieve the
optimal operating conditions both in the contactor and the regenerator. The
changing of pressure and temperature creates a wide range of possibilities of the
final design of the plant.
 Quality Control Lab
In this laboratory the quality and characteristics of crude and distillates are tested.
Sample (test sample collected before entering the storage tanks) is tested for its
purity based on its composition and properties for any change.
The various equipment in the laboratory and their functioning are:

1.Reid vapor pressure apparatus- (to determine vapor pressure)

Reid vapor pressure (RVP) is a common measure of the volatility of gasoline. It is

defined as the absolute vapor pressure exerted by a liquid at 37.8 °C (100 °F) as
determined by the test method ASTM-D-323. The test method measures the
vapor pressure of gasoline, volatile crude oil, and other volatile petroleum
products, except for liquefied petroleum gases. RVP is stated in kilopascals and
represents a relative pressure to the atmospheric pressure because ASTM-D-323
measures the gauge pressure of the sample in a non-evacuated chamber. All
values are in SI units and are regarded as standards. Imperial units are for
information only.
The matter of vapor pressure is important relating to the function and operation
of gasoline-powered, especially carbureted, vehicles. High levels of vaporization
are desirable for winter starting and operation and lower levels are desirable in
avoiding vapor lock during summer heat. Fuel cannot be pumped when there is
vapor in the fuel line (summer) and winter starting will be more difficult when
liquid gasoline in the combustion chambers has not vaporized. Thus, oil
refineries manipulate the Reid Vapor Pressure seasonally specifically to maintain
gasoline engine reliability.
The Reid vapor pressure (RVP) differs slightly from the true vapor pressure (TVP)
of a liquid due to small sample vaporization and the presence of water vapor and
air in the confined space of the test equipment. That is, the RVP is the absolute
vapor pressure and the TVP is the partial vapor pressure.
2. Hydrometer-(for measuring density)

A hydrometer is an instrument used for measuring the relative

density of liquids based on the concept of buoyancy. They are
typically calibrated and graduated with one or more scales such as specific
gravity.
A hydrometer usually consists of a sealed hollow glass tube with a wider bottom
portion for buoyancy, a ballast such as lead or mercury for stability, and a narrow
stem with graduations for measuring. The liquid to test is poured into a tall
container, often a graduated cylinder, and the hydrometer is gently lowered into
the liquid until it floats freely. The point at which the surface of the liquid touches
the stem of the hydrometer correlates to relative density. Hydrometers can
contain any number of scales along the stem corresponding to properties
correlating to the density.
Hydrometers are calibrated for different uses, such as a lactometer for measuring
the density (creaminess) of milk, a saccharometer for measuring the density of
sugar in a liquid, or an alcoholometer for measuring higher levels of alcohol
in spirits.
The hydrometer makes use of Archimedes' principle: a solid suspended in a fluid
is buoyed by a force equal to the weight of the fluid displaced by the submerged
part of the suspended solid. The lower the density of the fluid, the deeper a
hydrometer of a given weight sinks; the stem is calibrated to give a reading.
3.ASTM distillation unit – (the quality of the product is tested)

The basic test method of determining the boiling range of a petroleum product by
performing a simple batch distillation has been in use as long as the petroleum
industry has existed. It is one of the oldest test methods under the jurisdiction of
ASTM Committee. Since the test method has been in use for such an extended
period, a tremendous number of historical data bases exist for estimating end-use
sensitivity on products and processes.
The distillation (volatility) characteristics of hydrocarbons have an important
effect on their safety and performance, especially in the case of fuels and
solvents. The boiling range gives information on the composition, the properties,
and the behavior of the fuel during storage and use. Volatility is the major
determinant of the tendency of a hydrocarbon mixture to produce potentially
explosive vapors.

The distillation characteristics are critically important for both automotive and
aviation gasolines, affecting starting, warm-up, and tendency to vapor lock at high
operating temperature or at high altitude, or both. The presence of high boiling
point components in these and other fuels can significantly affect the degree of
formation of solid combustion deposits.

Volatility, as it affects rate of evaporation, is an important factor in the application

of many solvents, particularly those used in paints. Distillation limits are often
included in petroleum product specifications

.4. Copper corrosion apparatus.

This is a qualitative method that is used to determine the level of corrosion of

petroleum products. In this test, a polished copper strip is suspended in the product
and its effect observed.
The method is well suited for specification settings, internal quality control tools
and development and research on aromatic industrial hydrocarbons. It also detects
the presence of harmful corrosive substances, like acidic or sulfur compounds,
which may corrode the equipment. The value of this test is reported in SI units.
This test can be used for testing gasoline, solvents, natural gasoline, kerosene,
diesel fuel, distilled fuel oil and lubricating oil, among other products, using test
baths. At elevated temperatures, a copper strip that has been polished is immersed
in a sample, usually 30 ml. The strip is then removed and tested for corrosion and a
classification number is given. The number ranges from 1 to 4 after a comparison
with the ASTM copper strip corrosion standard is done.

5.Abel flash point apparatus- (to determine flash point)

Flash point is lowest temperature of the test portion, corrected to a barometric

pressure of 101,3 kPa, at which application of an ignition source causes the vapour
of the test portion to ignite and the flame to propagate across the surface of the
liquid under the specified conditions of test. Flash point values are not a constant
physical-chemical property of materials tested. They are a function of the
apparatus design, the condition of the apparatus used, and the
operational procedure carried out. Flash point can therefore be defined only in
terms of a standard test method. Abel closed-cup tester measures the flash point,
the lowest temperature at which the vapors of a sample ignite upon the application
of an ignition source.

6.Pensky marten apparatus- (to determine flash point)

The Pensky–Martens closed-cup flash-point test is a test for the determination of

the flash point of flammable liquids. It is standardized as ASTM D93, EN ISO
2719 and IP 34. A brass test cup is filled with a test specimen and closed with a lid,
through which an ignition source can be introduced periodically. The sample is
heated and stirred at specified rates depending on the material that is being tested.
This allows the development of an equilibrium between the liquid and the air
volume. The ignition source is directed into the cup at regular intervals with
simultaneous interruption of stirring. The test concludes upon observation of a
flash that spreads throughout the inside of the cup. The
corresponding temperature is the liquid's flash point.
The different flash point methods depend on the controlled conditions in the
laboratory and do not determine an intrinsic property of the material tested. They
are however useful to compare different substances and is therefore widely used
in road transportation and environmental safety regulations.
Closed cup testers give lower values for the flashpoint than open-cup testers
(typically 5–10 K) and are a better approximation to the temperature at which
the vapour pressure reaches the "lower flammable limit"
7. Smoke point apparatus (determine smoke point of diesel and naphtha)

The smoke point also known as Burning point of an oil or fat is the temperature at
which, under specific and defined conditions, it begins to produce a continuous
bluish smoke that becomes clearly visible. [1]Smoke point values can vary greatly,
depending on factors such as the volume of oil utilized, the size of the container,
the presence of air currents, the type and source of light as well as the quality of
the oil and its acidity content, otherwise known as free fatty acid (FFA) content.
The more FFA an oil contains, the quicker it will break down and start
smoking. The higher in quality and the lower in FFA, the higher the smoke
point. It is important to consider, however, that the FFA only represents typically
less than 1% of the total oil and consequently renders smoke point a poor indicator
of the capacity of a fat or oil to withstand heat.
8.Pour point apparatus – (to determine pour point)
The pour point of a liquid is the temperature below which the liquid loses its flow
characteristics. In crude oil a high pour point is generally associated with a
high paraffin content, typically found in crude deriving from a larger proportion of
plant material.

Measuring the pour point of petroleum products

Manual method:
ASTM D97, Standard Test Method for Pour Point of Crude Oils. The specimen is
cooled inside a cooling bath to allow the formation of paraffin wax crystals. At
about 9 °C above the expected pour point, and for every subsequent 3 °C, the test
jar is removed and tilted to check for surface movement. When the specimen
does not flow when tilted, the jar is held horizontally for 5 sec. If it does not flow,
3 °C is added to the corresponding temperature and the result is the pour point
temperature.
It is also useful to note that failure to flow at the pour point may also be due to
the effect of viscosity or the previous thermal history of the specimen. Therefore,
the pour point may give a misleading view of the handling properties of the oil.
Additional fluidity tests may also be undertaken. An approximate range of pour
point can be observed from the specimen's upper and lower pour point.
Automatic method:
ASTM D5949, Standard Test Method for Pour Point of Petroleum Products
(Automatic Pressure Pulsing Method) is an alternative to the manual test
procedure. It uses automatic apparatus and yields pour point results in a format
similar to the manual method (ASTM D97) when reporting at a 3 °C.[1]
The D5949 test method determines the pour point in a shorter period of time
than manual method D97. Less operator time is required to run the test using this
automatic method. Additionally, no external chiller bath or refrigeration unit is
needed. D5949 is capable of determining pour point within a temperature range
of −57 °C to +51 °C. Results can be reported at 1 °C or 3 °C testing intervals. This
test method has better repeatability and reproducibility than manual method
D97.
Under ASTM D5949, the test sample is heated and then cooled by a Peltier device
at a rate of 1.5±0.1 °C/min. At either 1 °C or 3 °C intervals, a pressurized pulse of
compressed gas is imparted onto the surface of the sample. Multiple optical
detectors continuously monitor the sample for movement. The lowest
temperature at which movement is detected on the sample surface is determined
to be the pour point.

Measuring the pour point of crude oils

Two pour points can be derived which can give an approximate temperature
window depending on its thermal history. Within this temperature range, the
sample may appear liquid or solid. This peculiarity happens because wax crystals
form less readily when it has been heated within the past 24 hours and
contributes to the lower pour point.
The upper pour point is measured by pouring the test sample directly into a test
jar. The sample is then cooled and inspected for pour point as per the usual pour
point method. The method usually gives higher pour point because the thermal
history has not been cancelled by a prolonged thermal treatment.
The lower pour point is measured by first pouring the sample into a stainless-
steel pressure vessel. The vessel is then screwed tight and heated to above 102 °C
in an oil bath. After a specified time, the vessel is removed and cooled for a short
while. The sample is then poured into a test jar and immediately closed with a
cork carrying the thermometer. The sample is then cooled and then inspected for
pour point as per the usual pour point method.
9.Dean and stark apparatus – (to determine associated water content)

Two types of Dean-Stark traps exist – one for use with solvents with a
density less than that of water and another for use with solvents with a
density greater than that of water.
The Dean–Stark apparatus typically consists of vertical cylindrical glass tube, often
with a volumetric graduation along its full length and a precision stopcock at its
lower end, very much like a burette. The lower end of a reflux condenser fits into
the top of the cylinder. Immediately below the joint between the condenser and
the cylinder is a sloping side-arm that joins the cylinder to a reaction flask. The
lower end the side-arm turns sharply downward, so that the side-arm is
connected to the reaction flask by a vertical tube.
The reaction flask is heated. Boiling chips within it assist with the calm formation
of bubbles of vapor containing the reaction solvent and the component to be
removed. This vapor travels out of reaction flask up into the condenser where
water being circulated around it causes it to cool and drip into the distilling trap.
Here, the immiscible liquids separate into layers (water below and solvent above
it). When their combined volume reaches the level of the side-arm, the upper,
less-dense layer will begin to flow back to the reactor while the water layer will
remain in the trap. The trap will eventually reach capacity when the level of the
water in it reaches the level of the side-arm. At this point, the trap must be
drained into the receiving flask. The process of evaporation/ condensation/
collection may be continued until it ceases to produce additional amounts of
water.
More rarely encountered is the model for solvents with a density greater than
water. This type has a tube at the bottom of the side-arm to allow the organic
solvent at the bottom to flow back into the reaction vessel. The water generated
during the reaction floats on top of the organic phase.
This piece of equipment is usually used in azeotropic distillations. A common
example is the removal of water generated during a reaction in boiling toluene.
An azeotropic mixture of toluene and water distills out of the reaction, but only
the toluene (density: 0.865 g/ml) returns, since it floats on top of the water
(density: 0.998 g/ml), which collects in the trap. The Dean-Stark method is
commonly used to measure moisture content of items such as bread in the food
industry.
This equipment can be used in cases other than simple removal of water. One
example is the esterification of butanol with acetic acid catalyzed by sulfuric acid.
The vapor contains 63% ester, 29% water and 8% alcohol at reflux temperature
and the organic layer in the trap contains 86% ester, 11% alcohol and 3% water
which is reintroduced. The water layer is 97% pure.

.
10.Gum content Tester: (to determine existent gum content)

Gum formed during fuel storage can deposit on induction system surfaces, intake
valves, stems and guides. To test for gum content, a 50mL sample is evaporated in
an aluminium block bath for a specified period under controlled conditions of
temperature and flow of air (aviation and motor gasolines) or steam (aircraft
turbine fuel).
Evaporates aircraft turbine fuel and motor and aviation gasoline samples under
controlled conditions in accordance with ASTM specifications. Consists of a high
temperature evaporation bath with 100mL test beakers and, for aircraft turbine
fuels, a steam generator and steam super heater.
To test for gum content, a 50mL sample is evaporated in an aluminium block bath
for a specified period under controlled conditions of temperature and flow of air
(aviation and motor gasolines) or steam (aircraft turbine fuel).
11.Kinematic viscometer- (to determine viscosity)

Kinematic viscosity of liquids (either fuel or lubricating oil) is measured using

Kinematic Viscometer at specified temperatures using specified apparatus.
Eg- (STANHOPE-SETA; Model: 83700-3)
This unit has six calibrated precision capillary viscometer tubes inside a cylindrical
glass oil bath, which are interchangeable and may be selected from a range of nine
tubes, measuring viscosities between 3 and 2000 mm2/s.
A six-channel timer is fitted for measuring flow times for a fixed volume of fuel to
flow under gravity through a capillary of the viscometer.
The kinematic viscosity is the product of measured time and calibration constant of
the viscometer tube used in viscometer.
A cooling tube fitted in the bath is used for tests below and slightly above ambient,
and also to quickly lower the bath temperature when needed
12.Total Sulphur Analyzer – (to determine sulphur content)

Eg-
The Model 6200T Total Sulfur Analyzer utilizes proven UV fluorescent
technology to continuously detect sulfur found in inert gas streams. An internal,
quartz catalytic converter is employed to convert the sulfur, when mixed with
scrubbed ambient air, into SO2 via high temperature oxidation. An internal
vacuum pump is employed to draw both the sample and the ambient air into the
converter. The converted sample gas is fed to the fluorescence chamber where it is
then exposed to ultra-violet radiation. The measurement process in the reaction cell
is described by the following equation: SO2 + hu1 > SO2 * SO2 * > SO2 + hu2
Where hu1 is the incident UV energy at 214nmand hu2 is the resultant
fluorescence, which is directly proportional to the SO2 concentration in the
reaction cell. The fluorescence emission is in turn sensed by the photomultiplier
tube (PMT) and amplified to provide an analog output. The result is a continuous
measurement of total sulfur (i.e. H2S, CS2 , COS, mercaptans, etc.) as SO2 from
0-50 ppb to 0-20 ppm.
 - PRODUCTS -
QUALITY PARAMETERS & REQUIREMENTS

The products are

1) NAPHTHA
2) SUPERIOR KEROSENE OIL
(S.K.O.)/MTO
3) HIGH SPEED DIESEL (H.S.D.)
4) LOW SULPHUR HEAVY STOCK
(L.S.H.S)
Quality parameters - NAPHTHA
 SUPERIOR KEROSENE OIL

• Parameter description Unit Requirement

• Acidity-Inorganic mg.KOH/g Nil

• Burning Quality:
• a) Char value mg/kg oil 20(max)
• b) Bloom on chimney ---- Not darker
than
gray
• Color-Saybolt ---- 10(min)
• Distillation:
• a) Recovery below 200C % Vol 20(min)
• b) FBP ºC 300(max)
‘ • Flash point ºC 35(min)
• Smoke point mm 18(min)
• Copper strip corrosion ---- Not worse than
(3h at 50ºC) one
• Total sulphur %mass 0.25
• Parameter description Unit Requirement
• Acidity-inorganic mg. KOH/g Nil
• Acidity-total mg. KOH/g 0.20
• Ash content % mass 0.01(max)
• R. carbon residue on 10% distillate %mass 0.30(max)
• Cetane number ---- 48(min)
• Pour point ºC 3(winter)15(summer)
• Copper strip corrosion (3h at 100oC) ---- Not worse than 1
• Distillation
• 85% vol. recovery ºC 350(max)
• 95% vol. recovery ºC 370(max)
• Flash point
• Abel ºC 35(min)
• Pensky-Martens ºC 66(min)
• Kinematic Viscosity Cst 2.0-5.0
• Sediments % mass 0.05(max)
• Density at 15ºC Kg/dm3 0.820-0870
• Total Sulphur % mass 0.05(max)
• Water content % vol 0.05(max)
• CFPP ºC 6(max-winter)
• Colour Iodine <0.01
 QUALITY PARAMETERS-LSHS
• Parameter description Unit Requirement

• Acidity-inorganic mg. KOH/g Nil

• Ash content % mass 0.1(max)
• Gross cal. Value Kcal/kg ----
• Relative density at 15ºC Kg/dm3 ----
• Flash point (Pensky-martens) ºC 66(min)
• Kinematic viscosity Cst 80(max)
• Sediment % mass 0.25(max)
• Water content % vol 1.0(max)
• Pour point ºC 60(max)
• Total Sulphur % mass 1.0(max)
• Trace Elements
• Na ppm 50(max)
• V ppm 200(max)
• Al + Si ppm 80(max)
 QUALITY POLICY

O.N.G.C. Tatipaka Mini-Refinery & Gas Collecting Station (G.C.S.) has

established and maintained an Environmental Management System (E.M.S.)
as per the International Standards Organization I.S.O.-14001 with the
following overall objectives:

1) To meet all the environmental legislative requirements.

2) To meet mission objectives of the plant and organization in general.

3) To prevent pollution arising out of its activities, products and services.

4) To continuously improve its environmental performance.

SAFETY POLICY OF THE REFINERY

It is ONGC’S policy to provide safe and healthful working conditions and to

enlist the active support of all staff in achieving these ends.

OBJECTIVES

In pursuance of the safety policy, the following are set:

1. To ensure the protection of the employees against occupational risks,

accidents, health hazards and dangerous situations.

2. To establish safety and health standards in the working environment.

3. To integrate safety and health measures the design, construction,

 maintenance and operation of oil field installations.

4. To provide safe and healthful working conditions, appropriate safety and

personal protective equipment

5. To establish standards of training, provide adequate facilities for

imparting training and ensure that employees receive adequate on – the
– job – safety and survival training.

6. To create an awareness of occupational safety and health at every level.

7. To promote participation of employees in the improvement of working

conditions and of the environment.
 GLOSSARY

• LN : Light Naphtha

• HN : Heavy Naphtha

• HSD : High Speed Diesel

• SKO : Superior Kerosene Oil

• LSHS : Low Sulphur Heavy Stock

• RCO : Reduced Crude Oil

• CR : Circulating Reflux

• OWS : Oily Water Sump

• CBD : Closed Blow Down

• GCS : Gas Collecting Station

• O/H : Over Head

• DM : De mineralized

• KGP : Krishna-Godavari Project

• KOD : Knock Out Drum

• CW : Cooling Water

• ACC : Atmospheric Crude Column

• CF : Crude Furnace

• EDP : Effluent Disposal Plant

• ETP : Effluent Treatment Plant

• SKO : Superior Kerosene Oil