Learning Report

Submitted by-
Name: - JOYDEEP DAS
Designation: - Trade Apprentice- Attendant
Operator (Chemical Plant)
Trade Code: - 101
Training Institute: - BGR L&D
Trainee No.: - 9821335
  Refinery-I: - There are basically consists of two units in Refinery-I i.e. CDU-I (Crude
Distillation Unit-I) and DCU-I (Delayed Coker Unit-I).
 CDU-I: - Crude Distillation Unit is the primary unit of petroleum refinery; it is also
called the ‘Mother Unit’ of a refinery. Crude oil is used as the feed of this refinery.
Fractional distillation principle is used to separate various products from crude oil.
Products separate according to their boiling point in various columns. The various
products of this unit with their characteristics are listed below:

Product Characteristics Value

1. LPG Evaporation temperature for 95% +2 (max)
volume @760 mm of HG
pressure, C
Cu-corrosion @38C for 1 hr, C Not worse than 1
2. Straight Run Naptha Dist. Range, C 45-110
(SRN) Density @15C, gm/cc 0.70-0.72
3. Reformer Feed Naptha Dist. Range, C 110-145
(RFN) Density @15C, gm/cc 0.80-0.82
4. Kero. Component (KC) Dist. Range, C 145-180
Flash point, C >39
5. Kero-I Dist. Range, C 180-240
Flash point, C >47
Density @15C, gm/cc 0.83-0.86
6. Kero-II Dist. Range, C 240-280
Flash point, C >51
Density @15C, gm/cc 0.85-0.87
7. Straight Run Gas Oil Distillation, IBP Recovery 10-15
(SRG) @370C
Density at 15C, gm/cc 0.90-0.96

Different types of crude are used as feed viz. Assam crude, Ravva Crude and Imported
crude. Standard yield (%) of these crudes are-

Product Assam crude Ravva crude Imported crude

LPG 0.7 1.20 1.82
SRN 6.7 9.3 11.5
RFN 6.2 6.7 4.45
KERO COMPONENT 3.4 5.6 2.59
KERO-I 9.6 9.5 11.06
KERO-II 13.1 10.3 14.71
SR GAS OIL 18.3 24.5 18.87
RCO 42.0 32.8 35.0

Before processing of this crude oil are passed through desalter and demulsifier to remove
impurities from crude. The LPG produced in this unit is passed through caustic wash and water
wash before passing it to the loading area. The process flow diagram (PFD) of CDU-I is shown
below:

Fig.1: CDU-I Process Flow Diagram

 DCU-I: - The bottom product of the main fractionators column (C-01) of CDU-I is used
as feed in this unit. The product list of this unit are-
1. Sweet Fuel Gas
2. Treated LPG
3. Stabilized Coker Naptha
4. Coker kero
5. Light Gas Oil (LGO)
6. Heavy Gas Oil (HGO)
 7. Coker Fuel Oil (CFO)
8. Pet Coke
 Coker Furnace Section – It is a twin cell, box type, single bottom fired furnace with
radiation and convection section having four tube passes.
 Convection Section – 72 numbers of coils for radiation section besides 24
numbers primary feed coils and 8 numbers of coils for steam superheating.
 Radiant Section – there are 120 reaction coils (3 tubes in each pass)
There are a total of 48 burners (12 in each pass). Three types of burners are there-
i. Pilot burner
ii. Fuel Oil (Atomizing Steam)
iii. Fuel Gas
 Coke Chamber Operations – (cycle time ~ 36 hrs)
Operations to be done before filling of a coke chamber –
1. Pressure Testing- As chamber pressure slowly reaches 2.5 kg/cm2, it is maintained
by adjusting steam introduction and operating the drain valve and a thorough check of
top and bottom flanges and all other joints were carried out.
2. Vapour heating – When the average temperature attains 350C, the chamber is
ready for switchover.
3. Steam Cooling – continue steaming for ~ 2 hr at a rate of 4500 kg/hr
4. Low Range Water Cooling – increase low range water gradually to 10 m3/hr in
steps of 2 m3/hr at an interval of 30 minutes and simultaneously decrease steam in
steps of 500 kg/hr and then full close over a period of ~ 2.5 hr.
5. Deluge Water Cooling – at a rate of 145 m3/hr and continue watering till all skin
temperature come below 100C.
6. Draining
7. Coke cutting – The high pressure water header is created by running jet pump 14P-
012, which takes suction from decoking tank 14T-001.
Decoking is done in two ways:
i. Boring a hole downward through the coke bed
ii. Cutting and removing coke from the chamber
 The process flow diagram of DCU-I is shown below:

Fig.2: DCU-I Process Flow Diagram

 Refinery Wastewater Treatment Plant: -

The refinery wastewater includes phenol, sulphide, oil and grease etc. Oil may appear in waste
water as free oil, emulsified oil and as a coating on suspended matter. The sanitary sewage coming
from plant/BGR Township and canteen effluent is also treated along with the effluent from the
refinery WWTPs.
(a) Primary (Physical) treatment system:
i. Surge Ponds
ii. Tilted Plate Interceptors (TPI): For separation of free floating oil from effluent.
iii. Dissolved Air Flotation Units (DAF), two numbers: For removal of free and emulsified
oil.
iv. pH adjustment Section: To maintain pH within required level.
 v. Chemical (Polyelectrolyte & Alum) closing section: For coagulation and flocculation
to reduce TSS.
(b) Secondary (Bio) treatment facilities:
i. Trickling filter: For reduction of BOD load
ii. Aeration tanks (two numbers): For further reduction of BOD
iii. Clarifiers (two numbers): For settling and separation of Bio-sludge
iv. Guard ponds (four numbers): Storing of treated effluent for final quality tests prior to
sending to the tertiary treatment facilities.

\
Fig.3: WWTP and TTP process flow diagram
 Effluent Quality Standards
IS-2490 MINAS (R&P) MINASW (P/C)
pH 5.5-9.0 6.0-8.0 6.0-8.5
O&G 10 05 05
BOD 30 15 15
COD 250 125 125
Phenol 1 0.35 0.35
Sulphide 2 0.5 0.5
TSS 100 20 100
 TTP Design Parameters:
Inlet Outlet
pH 7.8-8.5 6.5-7.0
TSS 50 10
SiO2 (colloidal) 40 20
TTL Hardness 190 66
O&G 10 3
BOD 40 15

 OM&s (Oil Movement and Storage): - As the name suggest the basic functions of this
unit are receiving various products from the plant area, storing, blending and despatch.
 Overview of the tankage facility:
The principal activities of the Tankage facility are: -
i. Receiving of the products from refinery through dedicated rundown headers to the dedicated
tanks.
ii. Lubricity improver dosing for HSD. MFA/ correction dye dosing for MS. STADIS for ATF &
PPD dosing for HSD (winter), LDO, FO & LVFO.
iii. Dispatch of products through various modes viz. Pipeline (GSPL), Tank Truck Loading (TTL)
and Wagon Loading Gantry (WLG).
iv. Accounting of the product.
 Facilities of the BGR OM&S:
i. In BGR total 119 nos. of tanks are there. Total 87 numbers of tanks are under OM&S and
remaining tanks are under other units. Among these 13 nos. for HSD, 10 nos. for MS, 6 nos.
for SKO, 3 nos. for MTO, 2 nos. for B-max, 4 nos. for RFN/DSN, 6 nos. for RS Naptha, 6
nos. for DHDT feed, 4 nos. for CFO/RFO/FO, 7 nos. for ATF and 6 nos. for HCN.
ii. Dedicated Pipeline arrangements for various dispatch operations to TTL, WLG and Pipe line
transfer.
iii. TFMS facility is also available for accounting delivered to Marketing Division, TTL and Pipe
line division.
iv. 7 nos. loading bays for TTL. 2 bays dedicated for HSD, 1 for MS, 1 mixed bay, 1 dedicated
bay for SKO, 1 for ATF and 1 for black oil.
v. One BG tank wagon loading gantry and also Reformate/SKO and ATF unloading facility
(total nos. 50 of wagon loading gantry)
vi. CPC/RPC truck loading gantry.
 Types of Tanks:
Class A – petroleum having flash point below 23C
Class B – petroleum having a flash point between 23 and 65C
Class C – petroleum having a flash point between 65 and 93C

 Fixed Roof Tank

I. Cone Roof Tanks- This kind of tank roof shape is cone type. This type of tanks has a
variable vapour space between the oil surface and the roof of the tank. The roof is
solidly attached to the tank walls and is supported by columns, girders and rafters.
II. Dome Roof Tanks- This kind of tank r5oof shape is dome type. This type of tanks has
a variable vapour space between the oil surface and the roof of the tank. The roof is
solidly attached to the tank walls and is supported by columns, girders and rafters.
 Floating Roof Tanks – In this kind of tanks the roof rises and falls with the liquid
level in the tank. As opposed to a fixed roof tank, there is no vapour space in the floating
roof tanks. It is commonly used to store large quantities of petroleum products.

 Fixed cum Floating Roof Tanks – An IFR (Internal Floating Roof Tanks) is a tank
used to store liquids with low flash-points. This type of tanks incorporates the combined
advantage of both fixed and floating roof tanks.
Instrumentation
 Level Transmitters- To measure the level of the product in the tank
 Pressure Transmitters- attached to the tank bottom
 Temperature element – connected to the level transmitter and gives the temperature of the
product of tank
 Fire detection alarm system – Flame detectors are located on the tank top and bottom to
detect in case of fire
 Gas detection system – Flammable gas detectors are provided to detect any leakage of
product from the flanges of inlet and outlet manifold.
 Fire Protection
 Foam Connection – It consists of foam line mounted on the outside of tank shell
throughout the circumference with foam maker/ foam pourer and deflector connected to
the shield of tank. It serves the purpose of fire fighting in the rim seal of tanks by
discharging foam into the rim seal.
 Water Sprinkler & Pouring Line – It consists of one water lines mounted on the outside of
tank shell throughout the circumference and one water pouring/distribution nozzle at the
top of fixed roof tank, which serves the purpose of cooling the tanks when there is fire
incident.
 Foam Dam – It consists of a short vertical plate i.e. welded to the top pontoon plate at a
short distance from the seal with the height higher than the upper tip of the seal, to allow
the whole seal area to be flooded with the foam and extinguishes the fire effectively.
Tank Level Measurement – Tank level Measurement or Tank Gauging implies to
measure height of the product and/or water for quantity assessment.
Tank Gauging Procedure
I. Automated Radar Level Gauge/ Servo Gauge: - TFMS is installed on every tank for
instant &accurate tank product parameters. TFMS has been configured to measure
Tank level, Temperature, Gross volume and Ullage, Receipt/Dispatch Flow-Rates.
II. Manual Gauging: - It involves physical measurement of Tank Level using Dip Tape. A
well-calibrated metallic tape in good condition is to be used for accurate measurement.
Oil finding paste & water finding paste are to be applied on tape area for near accurate
measurement.
Tank Sampling –
i. Representative samples of petroleum products are required for the determination of
physical properties that are used to establish standard volume, prices and compliance with
commercial and regulatory specification.
ii. The treatment of samples from the time of collection until they are analyzed requires care
and effort to maintain their compositional integrity.
 Upper Level Sample – An upper sample is one taken at a level of 1/6 of the depth of
product below the top surface in a tank.
 Middle Level Sample – A sample taken at a level of ½ the depth of product below the top
surface in tank.
 Lower Level Sample – Sample taken at a level of 5/6 of the depth of product below the top
surface in a tank.
 LPG Area: - The basic functions of the LPG area can be broadly classified in five areas.
 i. Receiving: - It receives LPG from Refinery-I and II as well as INDMAX unit.
ii. Storage: - Three nos. of Mounded bullets with a capacity of 3000 cm ( length – 90 m
and Diameter – 7 m) and three Horton Spheres ( T-101, T-102 and T-103) with a capacity
of ( 32603) cm (Dia- 17.5 m) are there for LPG storage.
iii. Sampling: - Volatility test (called weathering test also) is one of the vital quality test of
LPG and this test is done in every shift for the receiving spheres and bullets. 100 ml of
LPG sample is collected from the sampling line and it is allowed to evaporate. When 5 ml
of the sample is left out, its temperature (in C) is noted and reported as weathering result.
Weathering result should be +2C maximum, as specified in BIS 4576-1999.
Copper Corrosion Test is also one of the vital quality tests of LPG. Though LPG comes
from unit after caustic wash and finally through CFC, presence of H2S is tested in the
storage vessel by Lead Acetate paper test and in case of indication of presence of H2S
results are communicated to production unit.
iv. Pump Operation: -
LPG Bullet Loading pumps – There are three LPG Bullet Loading pumps 52-P-101 A,B
&c, each pump having delivery capacity of 80 m3/hr.
LPG Bottling Pumps – There are two LPG Bottling pumps 53-P-001 A & B, which are
used for pumping LPG to LPG Bottling Plant.
Ethyl Mercaptan Dosing Pot – There are two numbers of Ethyl Mercaptan dosing pumps
52-P-102 A &B, each pump has a capacity of 1.5 Ltr/hr. The pumps are Swelore make,
reciprocating type.
v. Despatch: - There are two modes of LPG despatch –
 Pumping/transfer to LPG Bottling Plant
 Loading in LPG Bullet Tank Lorry (T/L)
There are four nos. of Loading Bays for loading of LPG Bullet Tank Lorry. Each
bay has Strainer, Vapour Eliminator, Mass Flow Meter, Set Stop Valve (Digital
Control Valve), Excess Flow Check Valve, DANLOAD, Card Reader, RIT.

 Different types of Instrument : -

1. Pump: - Pumps are in general classified as Centrifugal Pumps (or Roto-dynamic pumps) and
Positive Displacement Pumps. Centrifugal pump imparts velocity to the liquid resulting in a
pressure at the outlet whereas Positive displacement pumps captures confined amount of and
transfers it from the suction to the discharge part.
A centrifugal pump has two main components:
 I. A rotating component comprised of an impeller and a shaft.
II. A stationary component comprised of a casing, casing cover and bearings.
Start-up procedure-
i. Close the discharge line
ii. Open the suction line
iii. Casing line drain
iv. Close casing line
v. Check the lube oil, buffer oil, cooling water
vi. Check pump base
vii. Check earthing
viii. Check the shaft by rotating it and ensure its free rotation
ix. Start the pump
x. When the pressure becomes equal to the required discharge pressure, then open the
discharge line slowly
2. Furnace: - A furnace is a direct-fired heat exchanger that uses the hot gasses of combustion
to raise the temperature of a feed flowing through coils of tubes aligned throughout the heater.
Types of furnaces-
i. Natural draft furnace: - Here, damper regulates the air and maintain draft of the
furnace. It has no FD and ID fan.
ii. Induced draft furnace: - Draws gasses into the chimney
iii. Forced draft furnace: - It has blower. FD fan provides air to the forced draft
furnace. It has no ID fan.
iv. Balanced draft furnace: - It has highest efficiency. It has both FD and ID fan. Air is
input for FD and output for ID.
3. Breathing apparatus: - It is used in plant to take oxygen as breath during hazardous
condition. Plant air is used in breathing apparatus.
4. Wind vent and wind sock: - These are used for detection of air direction. Wind sock is
used in refinery plant. In case of gas leak, wind direction is checked by using wind sock.
5. Gas detector: - Gas detector is used to detect gas in a specific area specially in refinery
plant. By using gas detector, we can check whether gas is leaked or not.
6. DCP: - DCP stand for Dry Chemical Powder. It is used as a fire extinguisher.

7. Heat exchanger: - Basic function of exchanger is transfer of heat between hot and cold
media. Based on flow of liquid heat exchangers are classified in two types-
i. Parallel flow where hot and cold streams enter the exchanger at the same end and
travel to the opposite end in parallel streams. Energy is transferred along the length
 from the hot to the cold fluid so the outlet temperatures asymptotically approach each
other.
ii. Counter flow arrangement where the two streams enter at opposite ends of the heat
exchanger and flow in parallel but opposite directions. Temperatures within the two
streams tend to approach one another in a nearly linearly fashion resulting in a much
more uniform heating pattern.
Types of heat exchangers:-
i. Shell-and-Tube Heat Exchangers: They contain a large number of tubes packed
in a shell with their axes parallel to that of the shell. Baffles are commonly placed in
the shell to force the shell-side fluid to flow across the shell to enhance heat transfer
and to maintain uniform spacing between the tubes.
ii. Multipass Flow Arrangements: It is designed to increase the surface area for
convection relative to the fluid volume. With multiple tubes it is possible to arrange
flow in such a way so that one region will be in parallel and other in counter flow.
8. Compressor: - A gas compressor is a mechanical device that increases the pressure of a gas
by reducing its volume. The most common types of compressors are Centrifugal,
Reciprocating and Diaphragm compressors.
9. Valves: - The main purpose of a valve is to control the flow passing through it. The valves
can control the flow either by stating, stopping or throttling. Valves can be opened by rotating
in anticlockwise direction and can be closed by rotating in clockwise direction. Common types
of valves-
 Gate valve
 Globe valve [ whenever bypass line is there, globe valve is used]
 Check valve (NRV) [it allows unidirectional flow and does not return]
 Ball valve
 Control valve
 Switch valve
 Butterfly valve
 UV (dumped valve)
 XV (shutdown valve) etc.
10. Hydrazene & Morphene: - Hydrazene is used to remove oxygen. Morphene is used to
control pH level.
11. Level gauge: - It is used to measure the level of liquid.

12. Blind: - For positive isolation (100% isolation), blind is used. There are two types of blind
such as- spectacle blind and tail blind.
13. Orificfe: - Orifice is opposite to tail blind. It allows minimum amount to flow.

14. Pyrometer: - It is used for temperature measurement.