CHAPTER 1

GENERAL

1.1 INTRODUCTION

The Crude Distialltion Unit of Bongaigaon Refinery and Petrochemicals Ltd is designed to
process 1.35 million tonnes per year of crude oil mix comprising Naharkatiya-LakwaRudrasagar in 68:19:13 ratio by weight. The Unit ia also capable of handling any of the
following feeds:

i)Lakwa and Rudrasagar crudes in 60:40 ratio by weight.

ii)Naharkatiya crude alone.

Subsequent necessary modifications in the units have been done for processing of low
sulphur imported light Crude. Because of this, the units are capable of processing low
sulphur Ravva Crude as well.

The unit consists of the following sections:

Topping,Stabilization and Naptha Splitters. The product of the unit are Fuel Gas, SR Naptha,
LPG, Reformer feed Naptha, Kero component, kero-I, Kero-II, Gas Oil and Reduced Crude
oil. Fuel Gas is used as a fuel in the process heaters. Other unit products are either further
processed or blended to produce finished products.

1.2 STREAM FACTOR:

The on-stream hours for the operation of the Crude Distillation Unit is 8000 hours per
year.

1.3 DESIGN DATA:

The Crude Distillation Unit has been designed to process 1.35 MMTPA of Assam crude. The
unit is also capable of handling low sulphur crude like Ravva crude, Bonny light crude,
Labuan crude etc.

Table 1.1 Typical Feed Characteristics

Sl. No

Characteristics

Units

1
2
3
4
5
6
7
8
9
10
11
12

Density @15oC
API gravity
RVP @ 38oC
Pour point
BS&W
Salt content
Sulphur, total
Nitrogen, total
Asphaltene
Ash content
Wax content
Viscosity @40Oc

gm/cc
Kg/cm2
o
C
Vol%
Ptb
Wt%
Wt%
Wt%
Wt%
Wt%
Cst

Assam
crude
0.8722
30.64
0.33
30.0
1.0
25.0
0.25
0.047
0.26
0.002
10.8
5.96

Ravva crude
0.8443
35.9
0.21
27.0
< 0.1
4.1
0.05
0.03
0.19
< 0.01
9.6
3.97

Table 1.1 (contd.)

13
14

Charc. Factor KUOP

Yield Pattern (Typical)
C1 - C4
C5 - 110OC
110 - 145OC
145 - 180OC
180 - 240OC
240 - 270OC
270 - 370OC
370OC+

11.37

11.9

1.12
9.16
5.31
7.05
8.05
4.63
26.34
38.30

1.20
9.30
6.70
5.60
9.50
10.30
24.50
32.80

Wt%

3
CHAPTER 2

PROCESS DESCRIPTION

2.1 GENERAL

Crude distillation unit is designed to process 1.35MMTPA of Assam Crude Oil produced
by Oil India Limited ONGC.

Design Tput

4050 MT/day

Minimum Tput

2100 MT/day

Maximum Tput

4200 MT/day

Crude oil pumped from the Crude oil pump house is preheated through a series of heat
exchangers up to a temperature of about 210-227 deg.C and further heated to about 357-359
deg .C in a two pass furnance and flashed into main fractionator column. Gas oil, kero-II and
kero-I are drawn from tray 9, 15, 23 resp. Naptha is condensed in a total condenser and a part
is refluxed. The balance is again heated by kero-I and kero-II run down stream before
entering the stabilizer column.
For uniform loading in the column and to recover maximum heat, three circulating refluxes
namely top circulating reflux(tray 35-37),kero-I CR(tray 23-25)and kero-II CR(tray 15-17)
are used.

Kero-II CR is used as heating medium for stabiliser reboiler.The purpose of stabilizer is to

stabilize naptha and to produce liquefied petroleum gas(LPG).
LPG withdrawn from Stabiliser reflux drum is first washed with caustic and then washed
with water and then sent to Horton sphere for storage.
The stabilized naptha is further split into light naptha(50-110)deg.C and heavy naptha (110180) deg.C in Splitter-I. Heating medium for splitter-I is Kero-I CR.
Splitter-I bottom is further split into reformer feed naptha (110-147) deg.C and Kero
component.Reboiler heating medium for splitter-II is Reduced Crude Oil from main
fractionator column.
Aquous ammonia is injected in overhead vapour in main fractionator to combat corrosion due
to hydrochloric acid vapour.
Side strippers are used for kero-I ,kero-II and gas oil for stripping lighter ends. Stripping
steam superheated to about 400deg. C is used as stripping media in all three strippers.

2.2 FEED SUPPLY

Crude oil is received by pipeline and stored in four floating roof storage tanks TK-1A/B/C/D
each having a nominal capacity of 20,000 cubic m.The total Crude Oil storage is for 20 days
consumption at design throughput.
Feed pumps are located in offsites Pump house to take suction from the tanks and deliver

rude oil to the Unit. Normally only one feed pump will run. Failure of the feed pump will
cause a drop in discharge line pressures which will be indicated in the control room audiovisually, hence the spare feed pump will start automatically. There is a provision also for
stopping any of these feed pumps through a push button and selector switch.
Temperature Indicator, Flow Recorder and a Flow Integrator are provided on the feed line
within the battery limit ahead of the crude preheat exchanger train.

2.3 FEED PREHEATING

Crude oil is first preheated in a series of eleven Heat exchangers viz E-31,E-33,E-4,E-2,E3,E-5,E-34,E-7,E-8 and E-35 by exchanging heat with process streams.The crude oil in
exchanger E-31,exchanges heat with K-I on tube side ; in E-32, crude exchanges heat with
K/C on the tube side;in E-33,with gas oil on the tube side; in E-4 with TCR on the shell
side;in E-2 with RCO on the shell side;E-3 with gas oil on shell side;in E-5 with RCO on the
shell side;in E-34 with Kero-IICR on the shell side;E-7 with gas oil on the shell side;in E8with RCO on the shell side;in E-35 with gas oil on the shell side. Crude coming out from E35is at a temperature of 227 deg.C.
Any exchanger can be bypassed and isolated on both shell and tube side whenever needed for
maintenance.The heat Exchangers are provided with Thermal Safety valves relieving to oily
water stream on the streams receiving heat,to protect against over pressure due to expansion
under blocked condition.Local TGs are provided at the inlet and outlet of exchanger streams.

2.4 DESALTER

The Crude Desalter is a process vessel that removes water and thereby salt from the
crude. The wash water is mixed with crude witd into the Crude Desalter. Demulsifying
chemicals are also added at this stage to prevent formation of new emulsion and to assist in
breaking down any emulsions that exist with the crude. Thus, Desalter vessel, in addition to
allowing a certain residence time for the crude oil that allows separation of the water with the
help of gravity, also provides an electrostatic field to assist the balance of water particles to
coalesce under the electrical charge and thus separates from the crude oil. The effluent water
is withdrawn from the vessel under interface Level Control and the desalted and dehydrated
crude is withdrawn from the vessel under backpressure.

2.4.1 Crude Desalting

Crude oil brings salts along with it. Particularly those of sodium, Magnesium etc.,metals like
Arsenic, Vanadium etc and mud. Although these are present only in small amounts, their
presence can result in serious problem in down stream equipments viz. heat exchangers,
heaters and columns. Hence the need of their removal is important before processing.

At high temperatures, Magnesium chloride decomposes and forms Hydrochloric acid, which
corrodes trays in the top section of column and tubes of overhead Condensers etc. The
presence of calcium and Sodium salts can cause plugging of heat exchangers and heater
tubes; thereby rapidly reducing heat transfer coefficients. The presence of Arsenic acts as a
poison to Platinum catalysts that may be used in down stream process units.
Presence of these salts also promotes coke formation in heater tubes which results in
increased pressure drop as well as less heat transfer rates. The excessive coke formation
result in escalation of hot spots on heater tubes which can have serious and disastrous
consequences for heater tubes. At high temperatures, salts in crude oil show a tendency to
deposit along heat exchange surface of the equipment.
Caustic injection in crude is done to neutralize acids present in crude and convert them into
salts. These salts are then removed by Desalter water in Desalter. Brine is also associated with
crude as emulsions. To break these light emulsions, Demulsifier is added. In fact both caustic
solution and Demulsifier is added into the crude before the preheat train.
Desalter utilises electronic elements at 415 volts to coalesce and separate water from oil for
reducing the salt content in crude oil so that it is within acceptable and specified limits in
desalted crude. When oil water mixture enters the high voltage electric field, it separates into
two phases in Desalter. The oil phase floats on top and overflows. While water with its
dissolved salts, metals, mud and Iron oxides settles down at the bottom. Thus oil from
Desalter flows to the rest of the preheat train.

2.4.2 Desalter Vessel Description

This is a single stage Desalter unit.Performance of it is as follows:

Electrical power requirement

415V/50 hertz/ 3 phase

Power Demand

75Kva(max)

Operating Temperature/Pressure

125-140 degC/29-34 kg/cm2g

Salt content of thedesalted crude

20/35/45

Length

2850 mm

Fig. 2.1 CDU Desalter PFD

2.5 FURNANCE
Crude Oil from preheating exchangers is further heated and partially vaporized in
furnace F-1, the temperature rising from 227 deg .C to 355 deg. C. The heater is a vertically
cylindrical furnance having convection and a radiation section with 11 nos. of burners
vertically mounted on the floor. The heater coil is of alloy steel in radiation section and
carbon steel in the convection section.
The crude feed to heater splits in two parallel streams and passes through first the
convection section and then the radiation section. The two parallel streams together at the
outlet of the radiation section go to the flash zone of the main column. The feed flow is
controlled by FRC. In case of any interruption FALCO gets low flow signals and sounds an
alarm in the control room. This shuts down fuel gas, fuel oil and shut down valves.
The transfer temperature is controlled by the Temperature Controller . A Selector switch is
provided to select the temperature control either on oil or on gas firing. Fuel oil supply to the
heater is available at a pressure of about 10 kg/cm2g and a temperature of 80 deg.C. Fuel gas
supply is available at a pressure of 3.5 kg/cm2g Interruption in any will be sensed by PALCO
which will shut off the corresponding valves.
2.6 CRUDE DISTILLATION COLUMN
The Crude Distillation Column has three sections: the bottom stripping section having 4
trays, the middle section having 21 trays and the top section having 13 trays. The trays are
numbered from bottom to top. The trays are of bottle cap & valve type.

10

Feed coming from the furnace enters the column in the flash zone under tray 5. The flash
zone temperature is maintained at 358 deg .C .Stripping steam is introduced at the bottom of
the column to remove lighter fractions from the bottom product i.e reduced crude oil.
Fractionator flash zone temperature and pressure is normally maintained at about 350
deg. C and 1.3 Kg / sqcm respectively.
In Crude distillation column (C-I) ,the crude oil fractionates into number of distillates and
bottom product .

Table 2.1 CDU Product and its tops distillation ranges:

PRODUCT
Fuel gas
LPG
SRN
RFN
Kero comp
Kero-I
Kero-II
SRGO
RCO

RANGES
0-50 deg.C
60-65 deg.C
55-100 deg.C
110-145 deg.C
145-180 deg.C
180-240 deg.C
240-270 deg.C
270-370 deg.C
350 or 370 deg.C

The overhead vapors from the crude column goes to the overhead condenser at about 142
deg. C and the condensate is collected in the reflux drum. A part of hydrocarbon
condensate from the reflux drum is sent to the crude column as top reflux and the balance
quantity goes to Stabilizer feed.
The three side products i.e. Kero-I, Kero-II and Gas oil are withdrawn from the C-I

11

column from tray #23, tray #15 and tray#9 respectively. The withdrawal product temperatures
are about 225 deg.C, 260 deg.C,309 deg.C resp. From C-I the side products flows out into
the side strippers C-2,C-3 and C-4.Superheated steam i injected in all the three strippers to
strip off the light ends back to main fractionator. The three circulating refluxes namely- TCR,
K-I,K-II are provided to remove heat and maintain the desired temperature profile in the
column.
2.7 STRIPPERS
Kero-I, Kero-II and Gas oil are the distillate streams which are stripped by steam in the
respective Strippers C-2, C-3 and C-4 to remove the lighter ends carried over. The
strippers have got four trays each. The trays are of valve type. Kero-I, Kero-II and GaOil are
withdrawn from tray 23,15 and 9 respectively of the crude column and enter into the top tray
of the respective Stripper column.
Stripping steam is introduced into the bottom of each stripper .The flash points of the
distillate streams are controlled by adjusting the rate of the stripping manually .The steam
rates are indicated by flow metres .The bottom temperatures of Kero-I, Kero-I and Gas oil
strippers are normally maintained at 186 deg.C, 238deg.C and 279deg.C.
The vapors from the strippers C-2,C-3 and C-4 are returned to the vapor space of tray 25,17
and 11 of the crude column respectively.
K-I is withdrawn from C-2 bottom, cooled in a stabilizer feed exchanger. It is further cooled
in E-21 and finally sent to storage. K-II is withdrawn from C-3 bottom cooled in stabilizer
feed exchanger, further cooled in E-22 and then to storage. Gas oil is withdrawn from C-4
bottom , cooled in crude heat exchanger then finally routed to HSD storage.

12

2.8 STABILIZER

The Crude Column overhead product (IBP- 180deg.C cut) is stabilized by removing the gas
fraction up to C4 in the stabilizer column C-5.The Stabilizer column has 30 bubble caps
valve trays . The tray material is of carbon steel and valves are of Cr steel.
The feed to the stabilizer is preheated in K-I heat exchanger E-9A and K-II heat exchanger E10 and E-29 to 126 deg.C and enters the stabilizer column at 126 deg. C. The overhead vapor
at about 53 deg. C goes to the condenser E-15. The condensed liquid is collected in the reflux
drum V-2 at 45deg.C. Any water condensed is collected in the water leg of V-2 at the same
temperature. Water is manually drained.
The reflux drum level is controlled by LIC. The stabilizer reflux pump takes the suction from
V-2 and sends a part as reflux to the top of C5 to maintain the temperature of the column at
65-67 deg.C and pressure 9.5 kg/cm2g. The other part is sent as LPG followed by caustic
wash, water wash and then storage. The stabilizer bottom temperature is maintained by
reboiler E-11 where outlet is regulated at 205 deg.C.

2.9 NAPTHA SPLITTERS

A heart cut of 110-145 deg.C is obtained from stabilized naptha by distillation in two splitter
columns. This cut is later used as reformer feed.

13

2.9.1

First Naptha Splitter

The stabilized naptha is split in the 1st Naptha Splitter C-6 into an overhead light naptha
and a bottom product. The 1st Naptha Splitter C-6 has 30 bubble caps valve type trays.
The tray material is of carbon steel . Stabilized naptha from the bottom of the Stabilizer is fed
to C-6 at tray 15.
The overhead vapors at a temperature of 94-98 deg.C are condensed in E-16. The condenser
liquid is taken from the reflux drum and a part is sent to the top of the column as reflux and
balance is routed through cooler E-20 to SRN storage. C-6 bottom temperature is maintained
by reboiler E-12 where K-I CR is used as the heating medium. The 1 st Naptha Splitter bottom
is fed to the second splitter C-7.

2.9.2

Second Naptha Splitter

The 1st Splitter bottom is further fractionated in the second Naptha Splitter C-7 into an
overhead 110-145 deg.C cut and bottom 145 -180deg.C cut.110-145deg.C cut is sent to
storage as reformer feed while 145-180 deg.C cut is used as Kero component and routed to
Kero I storage.
The bottom products from the 1st Splitter is fed to 2nd Splitter at tray 15 at a temperature of
170deg.C.The overhead vapors at a temperature of 145-148 deg.C are condensed in E-17.
The condensed liquid is collected in the reflux drum V-4 at a temperature of 80 deg.C. The
reflux pump takes suction from the reflux drum and sends a part to the top of C-7 as reflux
and the balance is sent through E-32 where Kero component is used for

14

preheating the crude and cooled in E-19 and routed as Kero component to storage C-7
bottom.

2.9

LPG CAUSTIC WASH

Caustic is injected into crude to convert all the chlorides eg. MgCl2, CaCl2 etc. present in
the crude into NaCl which is carried away with crude column bottoms. This prevents HCl
vapors to go up the crude column overhead system and cause corrosion. The rate of caustic
injection is determined by the crude feed rate and salt content in the crude.
Caustic solution is received from utilities section in the caustic solution drum. Service water
and plant air connections are provided in the drum. Dilute caustic solution is injected by the
dosing pump into the crude stream just ahead of the crude preheat exchangers. Enough
residence time is allowed in the vessel, so that LPG and caustic solution separate into two
distinct layers of hydrocarbon and water. A ratio of 1:1 between caustic circulations to LPG is
preferably maintained.

2.10 LPG WATER WASH

LPG water wash removes the carried over caustic along with the LPG water wash
bycirculation pumps that circulate the water in wash water vessel. Normally volumetric ratio
of 1:1 in between LPG and water is maintained. Differential pressure is maintained at
1kg/cm2g.LPG from the water wash vessel overflow to the LPG coalesce in which carried
over water with LPG is removed. LPG is sent through the pressure control valve. Pressure of
the LPG product is maintained at 16 kg/ cm2g.

15

CHAPTER 3
OPERATION OF CDU
3.1

INTRODUCTION

There is a large amount of preparatory work performed by the operating crew to operate the
plant efficiently. A planned check of all units not only ensures smooth start up but also
acquaintance with the operations of various sections comprising of varied variety equipments
to run them. Start up is critical and includes operation of each equipment .Operation includes
proper inspection of vessels ,columns ,piping and instruments.
3.2 FUNCTIONAL TESTS
All motors and pumps including dosing pumps will undergo functional test to check their
performance.
3.2.1 Motors
Each motor should be checked and started to ensure that it has the correct direction of
rotation .The motor speed should be checked to ensure that rpm is correct. After a short run
each bearing should be felt to ensure that it is free and not overheated.
3.2.2

Pumps

Generally the pump is opened and checked to ensure that it contains no foreign material.
Cleanliness of suction line and installation of fine strainer should be ensured.

16

3.3.3

Instruments

( i ) Control Valves:
We should make certain that the debris are not lodged in the control
valve.Each control valve installation should be checked for full travel of the
valve.It should also be ensured that each control valve is at proper position
( close or open) at right air pressure.
( ii) Differential pressure transmitters and receivers:
Ordinarily these should be calibrated locally against a water column and the
calibration checked at the receiver ,which may be recorder or indicator.
( iii) Tightness test:
The purpose of this test is to check the tightness of flanges, joints, manholes
etc. This test will be done with steam. Before conducting this test, all the
safety valves should be placed in position and properly lined up only after
testing.
3.4 OPERATING PROCEDURE
The Crude Distillation Unit is steam purged in sections to free all vessel and piping of air.
After displacing air from the system, the hydrocarbon feed will be taken in the unit.

17

Unit charge pump located in offsites takes suction from crude oil tanks and delivers into the
crude distillation column. After building up adequate level in the column, circulation is
established.
Heater is fired and transfer temperature gradually raised to normal value of 355 deg.C.
Various product streams are withdrawn and circulating reflux is adjusted according to the
temperature in the column.
Overhead naptha product is routed to stabilizer where lighter ends up to butane are
removed. The stabilized naptha

is routed to 1 st splitter.C5-110deg.C cut is obtained as

overhead and sent to naptha storage. The bottom product is routed to 2 nd splitter which also
works in a similar manner. Heating medium of reboiler will be reduced crude.110-145 deg.C
cut is obtained as overhead product of 2nd splitter and pumped to storage as Reformer feed.,
the bottom product is 145-180deg.C cut which is routed to Kero-I storage tank. After
stabilising the unit ,the injection of chemicals is started.
3.5 EQUIPMENT OPERATING PROCEDURE
Fig. 3.1 Centrifugal Pump

1) CENTRIFUGAL PUMPS:
A centrifugal pump is a rotodynamic pump that uses a rotating impeller to
increase the velocity of a fluid. Centrifugal pumps are commonly used to move
18

liquids through a piping system. The fluid enters the pump impeller along or near to
the rotating axis and is accelerated by the impeller, flowing radially outward into a
diffuser chamber, from where it exits into the downstream piping system.
A centrifugal pump works by the conversion of the rotational kinetic energy,
typically from an electric motor or turbine, to an increased static fluid pressure. This
action is described by Bernoulli's principle.

The rotation of the pump impeller

imparts kinetic energy to the fluid as it is drawn in from the impeller eye (centre) and
is forced outward through the impeller vanes to the periphery. As the fluid exits the
impeller, the fluid kinetic energy (velocity) is then converted to (static) pressure due
to the change in area the fluid experiences.
Centrifugal pumps are used in the crude distillation unit except Crude oil charge
pump, Stabilizer feed pump and stabilizer reflux pump. All mechanical jobs are
completed. Cooling water provision and steam is opened for any dead cooling in the
pumps. Then oil level is checked and flushing is done if oil is dirty or contains any
foreign material. The suction valve is opened and motor is energized .Pump is started
and stopped immediately. Discharge pressure is checked and opened slowly.
2) HEAT EXCHANGERS
A heat exchanger is a device built for efficient heat transfer from one
medium to another. The following are the various type of heat exchangers, in
CDU.

19
a)
b)
c)
d)

Heat Exchangers:
Reboilers:
Condensers:
Coolers:

 Operating steps:
Cooling medium vent valve is opened. Drain valve and flushing oil valves are
closed. Now cooling medium vent valve is opened, liquid is allowed to come out then
again closed. Then open the cooling medium outlet valve and fully open the inlet
valve also. Heating side vent valve is opened and all flashings are shut off. Finally the
normal inlet and outlet temperatures are checked
3.6 NORMAL OPERATING CONDITIONS
FURNANCE (EQUIPMENT NO: 11F-001)
Table 3.1 Operating variable Datas of furnace
SERVICE

CRUDE OIL

STEAM

Total duty
,MMKCal/Hr

19.3

0.2

Inlet pressure
,kg/sqcm

12.5

4.0

Outlet pressure
,kg/ sqcm

2.5

3.5

Inlet tempr , deg. C

220.0

155

Outlet tempr, deg .

C

358.0

350.0

Max. tube skin

tempr

580.0

550.0

20

Table 3.2 Construction details of furnace:

RADIATION

CONVECTIO

STEAM

SECTION

N SECTION

SUP
HEATER

A335 P5

A106 Gr.B

A213 T22

(5Cr-1/2 Mo)

CS

(2.25Cr1Mo)

TUBE
SIZE(O.D*THK)INC
H

6.625*0.28

6.625*0.28

4.5*0.24

TOTAL NO OF
TUBES

60

88

12

BARE

60

16

12

TUBE MATERIAL

FINNED

72

NO OF PASS

TUBE LENGTH

13

DESIGN PROCESS
FLUID TEMP

375

375

350

COIL DESIGN
PRESSURE KG/CMG

15.3

15.3

23

MAX DESIGN TUBE

TEMP DEG C

484

454

21

Table 3.3 Crude Column details:

352 deg.C
Flash zone temperature
1.2 Kg/cm2g
Flash zone pressure

148 deg.C
Column top temperature
0.9/1.9 Kg/cm2g
Column top
/bottompressure

Table 3.4 Draw-off temperature details of product:

Draw off temperatures:

Kero-I
216 deg.C
265 deg.C
Kero-II
301 deg.C
Gas oil
196 m3/hr
Top CR flow
105 deg.C
Return temperature
160 m3/hr
Kero I CR flow
172 deg.C
Return temperature
144 m3/hr
Kero II CR flow
209 deg.C
Return temperature
907 Kg/hr
Stripping steam flow

22

Table 3.5 Strippers (C-2/C-3/C-4 ) details:

Stripping steam flows:

Kero-I Stripper C-2
249 Kg/hr
Kero-II Stripper C-3
139 Kg/hr
Gas oil Stripper C-4
356 Kg/hr

Table 3.6 Stabilizer (C-5) temperature profile:

Column top temperature

Reboiler outlet temperature
Feed temperature

54 deg.C
167 deg.C
126 deg.C

Table 3.7 1st Naptha Splitter( C 6) temperature profile:

Column top temperature
Reboiler outlet temperature
Feed temperature

105 deg.C
172 deg.C
167 deg.C

Table 3.8 2nd Naptha Splitter( C 7) Temperature profile:

Column top temperature

Reboiler outlet temperature
Feed temperature

154 deg.C
196 deg.C
172 deg.C

23

Fig 3.1 Various Operational equipments

Differential pressure transmitter

Differential pressure receivers

Centrifugal pump

Control valve

Heat exchanger

24

CHAPTER 4

QUALITY CONTROL OF CDU PRODUCTS

Samples are taken at regular intervals to see if the desired specifications are met or some
corrective solutions are necessary .Sometimes samples are taken to find out the effect of
certain changes brought about in the operating conditions. The samples have to undergo
chemical and physical tests.

4.1 TESTS ON LPG

Following tests are carried out:
1. Density test
2. Sulphur test
3. Weathering test( heaviness of the component)
4. Copper strip corrosion test

To ensure quality of LPG w.r.t to these tests , the samples are collected at every 4 hour
interval at field for checking its weathering .Whenever ,LPG is found marginally off spec,
stabilizer column parameters are adjusted to bring back the LPG quality to its normal level.
Also, as per LPG operations requirement ,lighter LPG is produced to correct LPG of Horton
sphere. If LPG sample during testing is found to be heavy , LPG run down ex-unit is stopped
immediately and parameters are normalized.
25

For copper strip corrosion, LPG samples are checked by laboratory. To ensure cu strip
quality , LPG samples are checked with lead acetate solution in every shift. In the LPG wash
section , replenishment of spent caustic with fresh caustic is done as per Lab.Report.
Whenever LPG fails in Cu strip, different parameters are adjusted. Also, the
recirculation caustic and water is replaced with fresh make-up based on cu strip.

4.2 TESTS ON SRN

1. Density test
2. Distillation range test

In distillation test , we check the IBP & FBP of the sample in accordance with our desired
specification in an auto distillation equipment.
4.3 TESTS ON KERO COMPONENT, KERO-I & KERO-II:

1. Density test
2. Distillation range test
3. Flash point test
4. Smoke point test

26
4.4 TEST ON RFN:
1.

Density test

2.

Distillation range test

RFN samples are tested daily once in laboratory for distillation and density. The quality of
product is also adjusted and accordingly product draw temp etc gets adjusted. Here its IBP
and FBP are very vital.
4.5 TEST ON SRGO
1. Density test
2. Distillation range test
3. Pour point test

SRGO samples are tested once in every shift at laboratory for recovery. Its recovery at 370
deg.C is very important.

5.6 TEST ON RCO

1. Density test
2. Distillation range test

27
Table 5.1 CDU Products test Results:

PRODUCT
1. LPG

CHARACTERISTIC
Evaporation temp. for 95% vol.
@ 760mm of HG pressure, deg.

VALUE
+ 2 ( (max)

C
Not worse than 1

2. Straight Run

Cu-corfrosion @ 38 deg. C for 1

hr., deg. C
Dist. Range, deg. C

Naphtha (SRN)

Density @ 15 deg. C, gm/cc

0.70 0.72

3.Reformer Feed

Dist. Range, deg. C

110 145

Naphtgha (RFN)
4. Kero Comp. (KC)

Density @ 15 deg. C, gm/cc

Dist. Range, deg. C

0.80 0.82
145 180

Flash Point, deg. C

>39

Density at 15 deg. C, gm/cc

Dist. Range, deg. C

0.80 0.82
180 240

Flash Point, deg. C

>47

Density at 15 deg. C, gm/cc

Dist. Range, deg. C

0.83 0.86
240 280

Flash Point, deg. C

>51

Density at 15 deg. C, gm/cc

Distillation, IBP Recovery @370
deg.C

0.85 0.87

Pour point, deg. C

69

Density at 15 deg. C, gm/cc

Distillation, IBP Recovery @
370 deg. C

0.86 0.88
10 15

Density at 15 deg. C, gm/cc

0.90 0.96

5. Kero-I

6. Kero-II

7. SR Gas Oil

8. Reduced Crude Oil

45 110

91 92

28
NOTE:
The product specifications as given above are the most desired. However, since, none of the
products are straight run finished products, rather blending components for making various
finished products, the necessary correction, by way of blending is done by OM&S before
dispatch.

Table 5.2 Typical Utilities Consumption per month:

Sl. No.
1.

UTILITIES

CONSUMPTION

Fuel Oil

988 MT

2.

Guel Gas

776 MT

3.

Steam (LP)

550 MT

4.

Steam (MP)

2500 MT

5.

Lube Oil

100 litres

6.

Caustic Solution

18 M3

7.

Ahuralan

45 kg

8.

Ammonia

250 kg

9.

Demulsifier chemical

As per dosing rate

Table 5.3 Chemicals used in CDU:

SL.NO
.

CHEMICAL

SPECIFICATION

TEST METHOD

1.

Ahuralan ESK-50

Proprietary item

-----

2.

Demulsifier
Chemical

Proprietary item

37

Table 5.3 (contd.)

-----

3.

Caustic

Strength 10%W

IS 252

4.

Ammonia

Proprietary item

----

Table 5.4 Standard yield (%) of Crude:

PRODUCT

ASSAM CRUDE RCO

RAVVA CRUDE
RCO

LPG

1.12

1.20

SR NAPHTHA

9.16

9.30

RF NAPHTHA
(RFN)

5.31

6.70

KERO
COMPONENT

7.05

5.60

KERO-1

8.05

9.50

KERO-II

4.63

10.30

SR GAS OIL

26.34

24.50

REDUCED
CRUDE OIL
(RCO)

38.30

32.80

( SRN)

NOTE:
The yield pattern may undergo changes from time to time depending upon change in feed,
product blend and market demand.

38

Study of Process and

Operations of Crude Distillation
Unit of IOCL-BGR

Kirti Vardhan

ABSTRACT

Crude distillation unit of BRPL has an annual crude processing capacity of 1.35 MMTPA.
The main products of CDU are LPG, Straight Run Naptha, Reformer Feed Naptha, Kero-I,
Kero-II, Kero component, Gas oil and Reduced Crude
Oil. It was commissioned in 1979.

This report discusses the various aspects of an operating refinery viz: process, operations,
maintenance , quality control , of crude distillation unit (CDU) of B.R.P.L ; supported by
various tables, data and figures.

During the project work, understood the working and operation

operations included operating procedures of distillation columns, pumps,
Furnaces, control valves and various instruments.

of this unit.

Plant