Escolar Documentos
Profissional Documentos
Cultura Documentos
CONTENTS
Chemical Handling Area U-900 .................................................................................................................... 1
Introduction ........................................................................................................................................1
Design Capacity & Users ...................................................................................................................1
Process Discription ............................................................................................................................2
Equipments & Data Sheets ...............................................................................................................2
Daily Checkups ...................................................................................................................................2
Plant & Instrument Air System U-910.......................................................................................................... 3
Introduction ........................................................................................................................................3
Design Capacity & Users ...................................................................................................................3
Process Description ...........................................................................................................................4
Daily Checkups ...................................................................................................................................4
Compressor PACKAGE (Elliott USA)...................................................................................................5
Air Dryer Package ...............................................................................................................................6
Equipment Data Sheets.....................................................................................................................7
Flare System U-915 ...................................................................................................................................... 8
Introduction ........................................................................................................................................8
Design Capacity & Sources ...............................................................................................................8
Process Description ...........................................................................................................................9
Equipment Specifications ............................................................................................................... 10
Daily Checkups (Main+Acid)........................................................................................................... 10
Fuel Oil & Fuel Gas System U-920 ............................................................................................................. 11
Introduction ..................................................................................................................................... 11
Design Capcity & Users, Sources ................................................................................................... 11
Process Description ........................................................................................................................ 13
Equipment Specifications ............................................................................................................... 13
Dail Cehckups ................................................................................................................................. 13
Water System U-920................................................................................................................................... 14
Introduction ..................................................................................................................................... 14
Design Capacity............................................................................................................................... 14
Process Description ........................................................................................................................ 14
Cooling Tower Treatment................................................................................................................ 16
Equipment Data Sheet ................................................................................................................... 17
Daily Checkups ................................................................................................................................ 17
Fire Water System U-926 ........................................................................................................................... 18
Introduction ..................................................................................................................................... 18
Design Capacity............................................................................................................................... 18
Introduction ..................................................................................................................................... 20
Design Capacity............................................................................................................................... 20
Quality of Effluent............................................................................................................................ 20
Chemical Summary ......................................................................................................................... 21
Process Description ........................................................................................................................ 22
Equipment Specification................................................................................................................. 24
Steam, Feed Water & Condensate Handling System U-940 .................................................................... 25
Intoduction ...................................................................................................................................... 25
D.M.W. B.F.W. & Steam Conditions ............................................................................................... 25
Steam Gernerator ........................................................................................................................... 25
Process Description ........................................................................................................................ 26
Equipment Specification................................................................................................................. 31
Daily Checkups ................................................................................................................................ 31
Suggestions/recommendations................................................................................................................. 32
Department: U&OM
ii.
Caustic soda handling system: 50 BeO is received in 900-TK1 A/B through 10 metric
ton tank Lorries and diluted to 25 BeO. Afterwards supplied to various refinery users
and they further diluted to 10o or 3oBe as required.
98% sulfuric acid handling system: sulfuric acid is stored in a horizontal vessel (900V1) and supplied to users as per requirement.
Acid User
Utility, Boiler Makeup Water System,
Cooling Water System, Spent Caustic
Section
Caustic User
Utility, ETP
K-MX, LPG-MX, CCR
NHTR, AMINE
D-MAX, K-MX(ELEC)
50 BeO caustic specific gravity = 1.510, 25 BeO caustic specific gravity = 1.175
Demineralized water specific gravity = 0.998
50 BeO caustic = 50 % concentrated, 25 BeO caustic = 18.68 % concentrated
1% of tank level = 0.9 m3
Department: U&OM
Process Discription
Caustic System
The 50wt% caustic unloading pumps (900-P1A/B) shall transfer the caustic to 25oBe caustic tanks
(900-TK1A/B) which have demineralized water in advance to dilute 50wt% caustic to 25oBe caustic.
The 50wt% caustic unloading pumps shall circulate the caustic solution for mixing.25oBe caustic is
transferred to each user by 25oBe caustic pump (900-P2A/B) which is running normally.
Service
Type
Capacity
Head
m3/hr
R.P.M.
Power
kW
900-P1A/B
Unloading Pump
Centrifugal
24
35.1
2915
11
900-P2A/B
Caustic Pump
Centrifugal
13.3
44.9
2915
7.5
900-P3A/B
Centrifugal
900-P4A/B
Centrifugal
6.47
925P53A/B
Diaphragm
0.02
Tag No.
Service
Type
2915
29.4
2915
7.5
MLL
m3
110
3.9
900TK1A/B
Fixed
Rood
5.8
4.2
900-V1
Horizontal
Vessel
3.45
6.9
Daily Checkups
900-TK1A/B & 900-V1 Level in % mm, Caustic & Acid Pump Discharge Pressure, Caustic & Acid
Exported % or mm.
Department: U&OM
Drying Methods
There are three general methods of drying: Chemical drying, Refrigeration, and Adsorption. Selection
of air drying equipment is based upon required dew point, quantity of air to be dried, pressure of the
incoming air, and excess air capacity of compressor station.
Description
Temperature (oC)
Pressure (kg/cm2G)
Max
Normal
Min
Plant Air
42
8.7
7.7
6.5
Instrument Air
50
8.5
7.0
3.5
Department: U&OM
Process Description
Plant & instrument air unit consists of following sections
i.
ii.
Air from atmosphere passes through pre-filter and enter in compressor through a control valve which
control density of air entering. 910-C1/A/B two compressor package has 1 steam turbine driven and
1 motor driven centrifugal compressors. After 1st stage pressure increase up to 1.5kg/cm2 and inter
stage cooler cool air to 45oC then after 2nd stage pressure raise to 5.2kg/cm2 and again inter stage
cooler cools air to 45oC. After 3rd stage air compress up to 8.7kg/cm2 and temperature to 109oC and
after cool cools air to 48oC. A diesel compressor DIS390SS can also use as backup in case of both
compressor failure.
The compressors discharge pressurized air to a common Main Air Receiver (910-V1). From this point,
instrument air is passed through Air Dryer Package (910-ME1), while plant air is not dried as bypass
the dryer package and distributed to plant air header through PCV control valve which maintain
header pressure. Air to be used for instrument air is dried using two 100% pressure sewing type
instrument air dryers, one operating and one spare and they are switch after 1month. An instrument
air receiver (910-V2) is located downstream of the air dryers.
The Air Receivers provide reservoir of instrument air in the case of the failure of air compressors. The
total holding time of the vessels is approximately 5 minutes with a pressure transition, when this
pressure is reached the standby compressor will start automatically and re-pressurize the receiver to
7.5 kg/cm2G.
Daily Checkups
Air Filter P, Air Density, Pressure, Vibrations LS+HS Side, Seal Air Pressure, Compressor Temp.
Pressure Each Stage, I.A. Header Pressure, Lube Oil pressure, temp., cooled temp., Filter P, Return
Temp., Oil Bearing Temp. Pressure, Steam Turbine Flow + Speed.
Department: U&OM
iii.
iv.
v.
vi.
vii.
Suction Filter: Used to filter any dust particles from air. 22cmH2O pressure drop
across filter generate alarm to clean it.
Inlet Valve: Also density control valve, installed to control density of air. Higher density
of air increases compressor load, lower density cause low pressure zone which can
cause surge.
Unloading Valve: Known as anti-surge valve, PCV installed at outlet of compressor
maintain the outlet pressure and discard excess pressure.
1st & 2nd Stage Intercooler: Plate type heat exchanger installed to cool down
compressed air from each stages by Cooling water.
After Cooler: Counter current heat exchanger installed to cool down compressed air to
required supply temperature by cooling water.
Lube Oil System: The lubrication system supplies oil to compressor bearings and
gears. It is cooled down by cooling water (80oC to 30/40oC).
Seal Air System: Installed to separate oil and compressed air in compressor.
Department: U&OM
Pressure swing adsorption processes rely on the fact that under high pressure, gases tend to
be attracted to solid surfaces, or "adsorbed". The higher the pressure, the more gas is adsorbed;
when the pressure is reduced, the gas is released, or desorbed. PSA processes can be used to
separate gases in a mixture because different gases tend to be attracted to different solid surfaces
more or less strongly. Each train comprises of two beds, one in service and other on regeneration.
Service and regeneration sequence is controlled by PLC based automatic timing sequence (5min)
controller which diverts the air flow by changing the valve position. The cycle can be classified into
following steps.
i.
ii.
iii.
iv.
v.
vi.
Drying: Compressed air passes through bed from bottom while regeneration valves
are closed. Moisture from air is removed by adsorbent and air exit from top and
routed to instrument air receiver 910-V2 through NRVs.
Depressurization: Depressurizing vessel by closing air inlet valve and outlet valve and
opening valve installed towards silencer vent.
Regeneration: During regeneration air is routed from top to bottom and saturated bed
is regenerated and air is vent through vent.
Pressurize: After regeneration silencer valve is closed and air from top pressurize
vessel.
Parallel Drying: For about 5sec both adsorber starts drying before switching.
Switch over: After regeneration air inlet valve is opened for drying and vent closed.
Department: U&OM
Service
910-ME1
910-ME1V1A/B/C/D
910-ME1V2A/B
910-ME1V3A/B
Dryer Trains
Design
Pressure
kg/cm2
11.25
Air Dryer
Design
Temperature oC
Capacity m3
Weight
kg
120
4790
11.25
5/120
1.8
950
Pre-Filter
11.25
5/120
0.055
150
After-Filter
11.25
5/120
0.055
150
Values
Capacity
Pressure
1.019kg/cm2
Temperature
50/5oC
Relative Humidity
85%
Discharge Conditions
Pressure
10.08kg/cm2
SHP
871kW
R.P.M.
2970
Filter
0.014kg/cm2
34.5 45oC
4.4 3.4kg/cm2
29, 10, 59.7 m3/hr
Department: U&OM
ii.
iii.
iv.
v.
vi.
i.
A knockout drum to remove any oil and/or
water from the relieved gases.
A water seal drum to prevent any flashback of the flame from the top of the flare
stack.
An alternative gas recovery system for use during partial plant startups and/or
shutdowns as well as other times when required.
A steam injection system to provide an external momentum force used for efficient
mixing of air with the relieved gas, which promotes smokeless burning.
A pilot flame (with its ignition system) that burns all the time so that it is available to
ignite relieved gases whenever needed.
The flare stack, including a flashback prevention section at the upper part of the flare
stack.
Department: U&OM
Process Description
Main flare system
Flaring gas and/or liquid is routed to the main flare knockout drum 915-V1 via main flare header. The
main flare knockout drum pumps 915-P1A/B transfer any slop oil collected in 915-V1 to the light slop
tank 945-TK47. From 915-V1 the vapor passes to main flare (stack) 915-ME1, and passes through
the water seal drum provided at the bottom of the flare stack and the dry gas seal in the flare stack,
then is combusted at the flare tip
Smokeless steam
To prevent generation of smoke from the main flare, MP steam is injected into the main flare. The
flare tip is provided with a steam ring to promote smokeless operation.
Department: U&OM
Equipment Specifications
Tag No.
915-V1
915-V2
Service
K.O.Durm
Main
Flare
K.O.Drum
Acid
Tag No.
Diameter
Length
5.5
18
1.22
Service
Material
D.P.
D.T.
Weight
kg/cm2
oC
ton
SA516Gr.70
3.5
338/5
97
3.9
316L SS
3.5
210/5
2.5
Type
Capacity
m3/hr
915P1A/B
915P2A/B
Tag No.
915-ME1
inch
Ton/hr
48
112
950
112
48.607
Pressure
S/D
Kg/cm2
R.P.M.
Power
kW
0.27/5.54
7.5
0.29/5.50
7.5
Specifications
Smokeless Flare DP 3.5kg/cm2,
DT 338oC
Elevated Flare DP 3.5kg/cm2,
DT 210oC, Steam Traced,
Insulation
10
Department: U&OM
Destination (Consumers)
i.
ii.
Crude heater, Vacuum heater, Charge heater in NHT, Product fractionator feed
heater, Thermal cracking heater in Diesel Max Unit , Visbreaker heater
Utility boilers
Refinery fuel oil is normally make-up by Diesel Max residue, i.e. primary fuel oil, and
Visbreaker residue is used as first alternate fuel oil.
Fuel oil product will be temporary used, i.e. at refinery start-up operation, and
blended fuel is used as other alternate fuel.
Purge gas from the catalytic section of the DieselMax Process Unit
Treated gas from the Amine Treating Process Unit
Net gas from the Platforming Process Unit
Natural gas from outside of the refinery
On-spec LPG from LPG sphere
11
Department: U&OM
Destination (Consumers)
i.
ii.
iii.
iv.
v.
vi.
Crude heater, Vacuum heater, Visbreaker heater, Charge heater NHT, Reactor charge
heater, Product fractionator feed, Thermal cracker heater in the DieselMax Process
Unit, Charge heater, No.1 Interheater, No.2 Interheater in the CCR-Platforming
Process Unit
Utility boilers
Purge gas to flare headers
Dry seal for flare stacks
Incinerator, 820-H3/H4 in the Sulfur Recovery Unit
SCOT line heater, 820-H51/H52
Description
Temperature oC
Pressure (kg/cm2G)
165-175
12
Fuel Gas
42
5.7
12
Department: U&OM
Process Description
Make-up oil runs down continuously and maintains refinery fuel oil tanks (920-TK1A/B) level in
almost constant tanks capacity is 1,600m3.
Equipment Specifications
Tag No.
Service
Type
m
920TK1A/B
Fixed
Rood/Steam
13.5
12.2
Traced
Service
Type
Capacity
920P1A/B/C
Tag No.
920-E2
Service
RFO Heater
Centrifugal
Type
Shell & Tube
1600
Head
m3/hr
32
153
Area
MLL
m3
RFO
Storage
Tag No.
Sp.
Gravity
0.98
11.45
R.P.M.
Power
kW
2950
Shell
75
Tube
m2
DP
DT
DP
DT
88
33
220
47.5
426/252
Dail Cehckups
920-TK1A/B Level, Temp. Status (F/S), Steam Coil, 920-P1A/B/C Discharge Pressure, P Stainer,
920-ME1A/B Pressure, RFO Header Pressure.
13
Department: U&OM
Design Capacity
U-925s different sections designed on basis of their requirement in refinery.
i.
ii.
iii.
iv.
With Effluent system are Cooling Water Blowdown, Side Stream Filter Back Wash Water 27 m3/hr
and Potable Water Filter Back Wash Water 27 m3/hr.
Process Description
Raw Water
A total of six wells is provided, raw water requirements of 100m3/hr each. Water from the wells is
pumped up normally to Raw Water Tanks (925-TK1A/B) and for fire water make-up to Fire Water Tank
(926-TK1) by well pumps (925-P1~P6). Raw Water Tanks serve as a secondary source of firewater.
Raw water stored in a raw water tanks is pumped to the following users by the raw water supply
pumps (925-P7A/B/C).
i.
ii.
iii.
Plant Water Make-up (Plant water is used mainly of Boiler Make-up Water
Treating System feed, Cooling Water Make-up, utility hose stations and other
miscellaneous users.)
Make up of Potable Water
Sulfur Solidification (as cooling medium)
Potable Water
Raw water is treated by the potable water filter system (925-ME1) and potable water chlorination
system (925-ME3). The treated water is stored in a potable water tank (925-TK2) as potable water.
Potable water is pumped to users by a refinery potable water pump (925-P9A/B).
14
Department: U&OM
Cooling Water
The tower is of the induced draft, cross-flow type and is designed for a capacity of 10,000 ton/hr with
a cooling 45C to 34.5C based on the wet bulb temperature of 29.5C. The tower consists of four
cells and four induced draft fans equipped with motors.
Cooling water is pumped to the various users by the cooling water circulation pumps (925-P10A/B/C)
and returned to the cooling tower from the users. Cooling water circulation system has side stream
filter system (925-ME2), Chemical Feed System (925-ME4) and Chlorination System (925-ME5).
Cooling Water Circulation Pumps (925-P10A/B/C) Two pumps are turbine (condensing turbine) driven
and the other is motor driven.
Side Stream Filter System (925-ME2A/B/C) Used to remove suspended solids from cooling
water. The filters will be backwashed automatically. Side Stream Filter System is sized for 405 m3/h
and it is approximately 4% of the normal circulation cooling water. Type of the system is Valve-less
Self Backwash Gravity.
Condensate Pumps for Surface Condenser (925-P12A/B) Two motor driven pumps are provided.
Surface condenser to keep its liquid level, flow is sent to cold condensate.
15
Department: U&OM
16
Department: U&OM
Service
Type
m3
Liquid
MLL
m
Raw Water
Fixed Roof
28.8
14.63
9500
1.0
PortableWater
Cone Roof
9.2
9.8
640
1.0
Capacity
Head
R.P.M.
Power
m3/hr
Tag No.
Service
Well Pumps
Submersible
100
70
2950
RawWaterPump
Centrifugal
400
5.5 P
1500
kW
34.35
B.H.P.
110
PortableWaterPump Centrifugal
45
C.W. Circulation
Centrifugal
6870
Pump
Cooling Tower Data Sheet
5.3 P
2925
13.8
4.5 P
598
1140
925P1/2/3/4/5/6
925-P7A/B/C
925-P9A/B
925P10A/B/C
Type
13.89
10,000 ton/hr
3124.44m3
Fan
10m3/hr
5.4kg/cm2, 1.4kg/cm2
Filter Medium
Daily Checkups
i.
ii.
iii.
iv.
Chemical Pit Level & Stocks, H2SO4, Chlorine Pressure & Flow
Cooling Water & Portable Water (Fan In-service/Sump Level, Process/Utilities Flow,
C.W.S & C.W.R Temperature & Pressure, pH, Side Stream Filter Service/C.W. Flow)
Cooling Water Turbines (HP & Condenser Vacuum, temp. pressure flow, Lube oil
pressure, temp. CWS to cooler)
Surface condenser Level, temp. CW outlet temp, P12A/B discharge pressure, MP
Steam pressure, C.C. temperature
17
Department: U&OM
Design Capacity
The fire protection system is designed on basis of the following criteria:
i.
ii.
System Description
The fire water tank (926-TK1) is a fixed roof tank with effective fire water capacity is 13,626 m3. On
the other hand, the raw water tanks (926-TK1A/B) are also fixed roof tanks, with fire water volume
usable, per tank is 4,542 m3).
Four centrifugal fire water pumps, two electric motor driven (926-P1A/B) and two diesel engine driven
(926-P1C/D) are provided for the refinery. The two motor driven pumps are operated in case of the
largest fire water demand, while the two diesel engine driven pumps are as standby.
Two centrifugal electric motor driven jockey pumps, unit operating 926-P2A/B are provided, to
continuously maintain the pressure in fire water distribution piping.
Cut-in Sequence
Pressure difference and time difference for fire water pumps are used as consequent operation of
multi fire water pumps. The following operation sequence is used.
18
Department: U&OM
The pressure of fire water distribution main piping is maintained at 10.5 kg/cm2G by the jockey pump
(926-P2A). When fire water distribution piping pressure falls to 9.5 kg/cm2G, the first electric motor
driven pump (926-P1A) will be put into operation automatically with no time delay, the second electric
motor driven pump (926-P1B) will be put into operation automatically, with 10 seconds time delay.
Diesel engine driven pump, 926-P1C, shall start automatically on the following condition; on low
pressure on the fire main header, on electric power failure, on time delay after the signal given to P1A.
Equipment Specification
Tag No.
Service
Type
926-TK1
Tag No.
926P1A/B/C/D
926-P2A/B
Fire Water
Cone Roof
38.2
14.63
Tank
Service
Type
Capacity
Main Fire Water
Pumps
Jockey Pump
Liquid
m3
16760
Head
m3/hr
Centrifugal
1136
108.5
Centrifugal
24
104
MLL
m
1.0
R.P.M.
Power
kW
1490
19
Department: U&OM
Design Capacity
The system is composed of the following eight major systems:
i. Clean water sewer system
ii. Oily water collection system (The design capacity of the process waste water lift station inlet
is 2,620 m3/hr, tankage waste water lift station inlet is 460 m3/hr each.
iii. Slop oil recovery system (The skimmed oil circulation rate is 8 m3/hr.)
iv. Spent caustic neutralization system (The capacity is 180 m3/hr.)
v. Closed aromatics waste system
vi. Waste water treatment plant(The design capacity of WTP is 170 m3/hr x 2 train)
vii. Oily sludge handling system (The design capacity is 17 m3/hr with 2 % as dry solids
contents as oily sludge thickener feed and 20 % dry solid cake at dehydrator outlet)
viii. Bio-sludge handling system (The design capacity of bio-sludge handling system is 2.2 m3/hr
average with 1 % as dry solids contents as bio-sludge thickener feed and 17 % dry solid
cake at dehydrator outlet.)
ix. Sanitary waste treatment plant (The design capacity of sanitary waste treatment plant is
7.5 m3/hr total which is capable of treating an average daily flow rate of 144 m3.)
Quality of Effluent
Parameter
Temperature
39
pH Value
6-9
6-9
BOD5 at 20C
mg/l
300
30
CODcr
mg/l
750
150
Suspended Solids
(TSS)
Chromium,
Hexavalent
mg/l
50-100
30
mg/l
0.1
Chromium, Total
mg/l
0.5
Lead
mg/l
< 0.1
0.1
mg/l
0.05
NH3-N
mg/l
10
TDS 3500
Benzene
mg/l
<1
0.05
20
Department: U&OM
Phenol
mg/l
<6
0.3
Sulphide
mg/l
<5
1.0
mg/l
30 - 2000
10
200 as CaCO3
Toxic Metals 2
mg/l
Sanitary effluent feed :
Alkalinity
BOD5
TSS
BOD5
TSS
300 mg/l
300 mg/l
20 mg/l
30 mg/l
Chemical Summary
Name
Emulsion Breaking
Polymer
Sulfuric Acid
Caustic Soda
Ferric Chloride
DAF Polymer
DAP
Oily & Bio Sludge
Polymer
Hypochlorite
Specifiaction
NALCO EC ST9302
40% wt H2SO4
18.7% NaOH
40% wt FeCl3
40% wt Polymer
Purpose
Slop Oil emulsion
breaker
pH Control
pH Control
Coagulating Agent
Sludge Accumulator
Nutrient
40% wt Polymer
Sludge Accumulator
12.5% wt as Cl2
Bacteria Killer
Service
930-TK6A/B &
TK7
930-ME22 & V7
930-ME22
930-ME22
930-ME4A/B
930-ME5A/B
930-ME51 &
ME61
930-TK72
21
Department: U&OM
Process Description
Oily water collection system
Process Waste Water Lift Station (930-ME2) (Bar Screen Skimmer for Process & UTY)
Tankage Waste Water Lift Station (930-ME9A/B)
22
Department: U&OM
The API effluent water stored in the equalization tank (930-TK2) transfers at constant flow rate to the
flash mixing basin. Then the ferric chloride as coagulant and DAF polymer are injected by a injection
pump to make flocs. The caustic soda or the sulfuric acid is also dosed to adjust pH. The DAF effluent
is recycled to mix plant air in V-11.
Suspended solids in the waste water collected by the fine bubbles and are accumulated at the
surface of DAF basin as scum. The scum removes by the DAF skimmer and then transfers to the oily
sludge handling system. The DAF bottom sludge removes by the DAF scraper and then transfers to
the oily sludge handling system.
Biological aeration/Clarifier section
The treated effluent from the DAF basins flows by gravity to two biological aeration basins, to reduce
the biological oxygen demand (BOD5) to the acceptable limit of effluent.
The air supplies to the biological aeration basins by air blowers through air diffusers to maintain a
dissolved oxygen (DO) level. The clarifiers (930-ME27A/B) separate the biological solids from the
effluent from the aeration basin. The sludge scraper mechanism installed in the clarifier collects
surface scum is also routed to a bio sludge treatment.
Sand filter section
The clarified water flows by gravity to the rapid gravity type dual media filters which are of rectangular
design and of concrete. The filters are normally repeating the service and back washed by automatic
sequence. Four filters are in operation under full plant flow.
Sanitary Waste Treatment plant
Two packaged rotating biological contactors receive sanitary waste water from the office, buildings,
toilets, and kitchen facilities. The sanitary effluent treat at the aeration section and flows to the
clarifier section. The treated sanitary effluent flows by gravity into a hypochlorite contact tank.
Oily Sludge & Bio Sludge Polymer
Oily sludge from API separator is sent to centrifuge with injection of oily sludge polymer which help to
separate oil from water & Biosludge sent to belt press machine with injection of biosludge polymer
which eject water from sludge then both properly dumped.
23
Department: U&OM
Equipment Specification
Tag No.
Service
Type
Liquid
MLL
m3
Open Roof
49.2
14.6
25400
W.W.
13.87
Fixed Roof
19
14.6
4100
W.W.
13.87
Cone Roof
5.8
5.2
130
1425
930-TK1
930-TK2
930TK6A/B
930-TK5
930P1A/B
930P2A/B
930P3A/B
930P15A/B
930P17A/B
930P18A/B
930P19A/B
930P23A/B
930P24A/B
930P28A/B
Tag No.
930-C1A/B
930C2A/B/C/D
930-C4
Diversion
Tank
Equalization
Tank
Slop Oil Tank
130
Head
m3/hr
Slop
0.95
1.05
Slop
0.95
R.P.M.
4.52
11.59
4.52
Power
kW
W.W. to API
Separator
Submersible
4.59
36
1496
45
W.W. to TK1
Submersible
12.7
89
1465
132
Treated Water to
Saim Nala
Submersible
200
72.4
2950
56.3
Centrifugal
192.3
17
1450
Acid Injection to
V-7
Centrifugal
8.8
1.75
1500
1.5
Circulation Pump
Centrifugal
120
3.5
2950
22
Centrifugal
180
23
1470
22
Centrifugal
28.5
2895
3.7
Centrifugal
28.5
2895
3.7
Diaphragm
1.9
3.1
1500
3.6
Spent Caustic
Transfer Pump
Slop Oil Heater
Transfer Pump
TK7 to Heater
Transfer Pump
Spent Caustic To
ETP
Service
Type
Capacity
Pressure
R.P.M.
Equalization Tank
Rotary Gear
4.59NMPH
kPa g
1496
Aeration Basin
Rotary Gear
1950
40.7
1950
930-TK60
Rotary Gear
400
39.2
2791
24
Department: U&OM
B.F.W.
Pressure
Temp.
2
oC
kg/cm
58
121/115
pH=8.5-9.5, Cond. < 5S/cm
O2 <0.005cc/l (0.007mg/l)
Type
HP
MP
LP
Steam
Pressure
kg/cm2
42.2
10.5
3.5
Temp.
oC
390
205
160
Steam Gernerator
High Pressure Steam is mainly generated by HP steam Boilers of utility area and also by Waste Heat
Recovery Steam Generators of 300-V12 & 820-E1.
MP Steam is mainly generated by process waste heat Boilers in the Refinery, and also by exhaust
/extraction of HP Steam turbines. 300-C1.
LP Steam is generated by HP/MP Steam turbine exhaust and extraction from 284-C1.
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Department: U&OM
Process Description
Boiler Makeup Water Treating Section
The Plant is designed to produce demineralized water from 8.5 kg/cm2g design pressure Plant water
at a flow rate of 94 m3/h, with a shift volume of 1200 m3, at a battery limit pressure of 3.5 Kg/cm2g.
Activated carbon adsorption principles 940-50A/B
The activated carbon explicates its adsorption capability by means of its porous structure obtained
firing vegetable matter, such as coconuts, or mineral coal. Plant water pumped by 940-P7A/B is
transfer to Demin Trains and its flow is controlled by control valve to trains. Water enter from top and
all possible suspended solid are removed and water leaves from bottom to cation exchanger. For
regeneration water flows from bottom to top.
Cation Exchanger 940-V51A/B
It means to remove cations from water, replacing them by hydrogen ions, flowing the water through a
bed of cationic resin in hydrogen cycle.
Weak acid resins When a dissolved strong acid salt, such as Calcium Sulfate, crosses a weak acid
resin
Strong acid resins To exchange a dissolved weak acid salt like Sodium Bicarbonate
During the Regeneration, carried out, in this package, with sulphuric acid (1.5 & 3%), the cations fixed
on the resin are removed.
Decarbonator 940-V52A/B
Instead of treat the weak hydrochloric acid on strong anion resins, it is possible to"decarbonate" the
decationized waters. This process uses the Henry's law with which it is easy to strip away from
decationized water the dissolved excess of carbon dioxide.
10 ppm as CO2 obtained.
And residual
26
Department: U&OM
according to the
Deanionized water (normally coming after an anionic unit) have an excess of OH Ions that normally
links themselves with Na ions that leaked from the cationic resins. The resultant NaOH base will give
the deionizated water a pH above 7.
During the Regeneration, carried out with sodium hydroxide 3%, the anions on the resin are removed
27
Department: U&OM
Deaerator Section
The Deaerator receives all recovered condensate (Hot condensate & Cold condensate) plus
Demineralized water required to make up of losses for steam stripping, blow down and so on. Hot
condensate is received to the side of Deaerator shell, while Demineralized water and cold condensate
are received from top of the Deaerator shell. The water is heated up with the saturated steam flashed
from the condensate recovery system and from the continuous blow down tank, plus supplementary
make up from the LP steam system through control valve 940 PV 026 A.
B.F.W. System
Boiler Feed Water Pump (940 P1 A/ B/ C) takes water from Deaerator and pumped to the Utility
Boilers (940 B1 A/ B/ C) and steam generators of process area. Boiler Feed Pumps 940 P1 A / B
are steam turbine driven, while 940 P1C is motor driven.
Boiler Section
This D type TITAN M Boiler Plant is supplied by MACCHI, Italy. Each Boiler produces 65 tons/h
Super-heated steam at 43.5 Kg /cm2 pressure and 390 C for Pak Arab Refinery. Boilers are Water
tube, Forced Draft with natural circulation and are suitable for Fuel Gas & Fuel Oil firing.
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Department: U&OM
29
Department: U&OM
Economizer
The economizer is fully drainable type, equipped with horizontal bare tubes and installed at Boiler
outlet in flue gas path. Economizer possesses double fins tubes.
The flue gas path is directed vertically, from top to bottom, while tubes are placed horizontal.
Soot Blowers
The Boiler and economizer are equipped with steam soot blowing facilities to keep the external
surface of Boiler clean, Super-Heater & economizer during the operation with Fuel Oil. All soot blowers
are driven by electric motors and are arranged to obtain automatic sequence control for routine
operations or to be remotely operated without automatic sequence.
Each Boiler is equipped with: Two rake soot blower on economizer, One retractable soot blower on
Super-Heater section, Two rotary soot blowers on Boiler-Bank.
Boiler Stack.
Each Boiler is equipped with 26 meters high self - standing type stack, and it is composed by several
rolled and flanged shell.
I.B.D. Drum
The steam-generating unit is equipped with one atmospheric intermittent blow down drum (940 V2),
common for three Boilers. It performs following functions: To receive the drain of C.B.D. tank and to
reduces its water temperature before draining to the waste water system, to receive the drain of soot
blower system of all the three Boilers, To receive IBD from all three Boilers, when IBD is applied, and
reduces its water temperature before draining to the waste water system.
C.B.D. Drum
The steam-generating unit is equipped with one continuous blow down drum (940 V1), common
to the three Boilers, in order to the following functions: To receive high temperature & high pressure
continuous blow down from all three Boilers steam drum, To flush this water into steam and water,
steam pressure is level to the Deaerator pressure, to send the flashed steam to Deaerator for
deaeration, To send remaining water to IBD drum.
Parameters
pH
Conductivity @ 25oC
Phosphate
C.B.D.
9.4 - 10.5
< 600 us/cm
5-15ppm
Chemical Dosing
Elimin-OX can economically remove small amount of dissolved oxygen. Eliminox is dosed by 940 P53
A / B (reciprocating pump) by adjusting its strokes. Dosing solution is prepared in dosing tank 940 ME
3A by adding 6.0 litters Eliminox and remaining portion filled with Demin water.
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Department: U&OM
Tri-Sodium Phosphate is dosed by 940 P60 A / B / C & D (reciprocating pumps) by adjusting their
strokes. One pump is for each Boiler and pump P 60 - D is on back up for all three pumps. TSP keep
salts that are prone to settle at high temp. In suspended form.
Cyclohexane Amine maintain the condensate pH in the range of 8.09.5. It is volatile and distils in
steam to dissolve readily in the condensate. Being alkaline, it neutralizes the carbonic acid present in
steam condensate and thus overcome low pH values and corrosion. Amine is dosed by 940 P54 A / B
(reciprocating pump) by adjusting its strokes. Dosing solution is prepared in dosing tank 940 ME 3B,
by adding 4litres amine and remaining portion filled with Demin water.
Equipment Specification
Tag No.
Service
Type
Diameter
Height
Capacity
m3
Liquid
MLL
m
940TK1A/B
DMW Tank
Cone Roof
14.5
13.4
2200
1.0
940-TK5
Blowdown Tank
Pit
42.2
1.3
2200
1.0
Tag No.
Service
12.73
Diameter
Length
Design
Pressure
Design
Temperature
Insulation
Kg/cm2
oC
mm
940-V1
CBD
940-V2
IBD
940-V3
LC.Recovery
2.3
6.7
3.5
260/121
75
940-V4
MC.Recovery
1.6
1.8
260/150
75
940-V5
HC.Recovery
1.2
3.6
13
285/186
75
Tag No.
Service
Type
Capacity
Head
m3/hr
R.P.M.
Power
kW
940-P1A/B
BFW Pump
Centrifugal
133
608
2980
360
940-P2A/B
DMW to Deaerator
Centrifugal
85
203
(10kg/cm2)
2980
100
940-P3A/B
Condensate to Deaerator
Centrifugal
122
52
2945
34
940-P4A/B
DW Regeneration Pump
Centrifugal
70
75
940-P5A/B
Neutralization Pump
Submersible
73
Daily Checkups
i.
ii.
iii.
iv.
B.F.W. Flow, Pre-Heater O/L temperature, I/O Economizer temperature & pressure,
Combustion Air temperature & pressure, Fuel Gas, Steam Drum pressure & level,
Super-Heater U/S & D/S temperature
Analyzer (CBD, O2, pH, Conductivity), Phosphate Control, Pump Stocks
F.D. Fan Turbine (Flow, Speed, HS & LS temperature pressure)
B.F.W Condensate Recovery, 940-P1A/B/C Flow, temperature, pressure
Analyzer (pH, Conductivity, HC), Eliminox & Amine Stocks, 940-P2A/B & P3A/B
discharge pressure
31
Suggestion/Recommendation
Department: U&OM
Suggestions/recommendations
Proper sitting arrangement must be made for the Trainees, and each trainee should be
assigned a technical or managerial task for better training
Boiler soot blowing method must be changed because in most of times chain stuck and soot
blowing stops. Steam soot blowing must be change with air because steam and soot blower
temperature can cause steam to condense, so water sludge will ejected and after sometime it
can erode tubes of boiler
Overflow line at Equalization Tan (930-TK2) in case of level instrument failure
Cooling Tower I.D. fans must have variable speed drivers or variable pitch fans in order to
improve energy utilization
Health of cooling tower louvers should be inspected as few stones and debris were found
broken on ground probably from the top louver
Installation of air pre-heater in furnace to increase efficiency of combustion
Instead of converting HP steam to MP steam or MP-LP by BFW injection, install a heat
exchanger that would heat up boiler feed water to lower its temp. & pressure
Installation of Flare Gas Recovery System that takes gases from knockout drum and
compress them to liquefy them. After liquefaction pump liquid to CDU and flare noncondensable gases
Synchronization of Excel based sheet with supervisors cabins to keep interact them with
process, they have to contact with DCS operator to handle any problem
32