A VOCATIONAL TRAINING REPORT

Duration :June 2, 2011 to June 30,2011

Submitted By: MANISHA GUPTA Z.H.C.E.T, ALIGARH MUSLIM UNIVERSITY

PREFACE
Industrial training is the beginning of students journey in the corporate world. Not only does it provide insights about the industry concerned, it also bridges the gap between theory and practical knowledge. We were fortunate that we were provided with an opportunity of undergoing Industrial training at INDIAN OIL CORPORATION Ltd., Mathura, one of the leading refineries in India. The experience gained during this short period was fascinating to say the least. It was a tremendous feeling to observe the operation of different equipments and processes. It was overwhelming for us to notice how such a big refinery is being monitored and operated with proper co-ordination to obtain desired results. During our training we realized that in order to be a successful process engineer one needs to possess a sound theoretical base along with the acumen for effective practical application of the theory. Thus, we hope that this industrial training serves as a stepping-stone for us and helps to be successful in future.

Acknowledgement
I feel immense pleasure and privilege to express my deep sense of gratitude, indebtedness and thankfulness towards those who generously helped me colour the mosaic of this training with their knowledge, expertise and memories. I shall remain ever grateful to all the persons of I.O.C.L, who have helped, inspired and encouraged me and above all made me an ever more experienced person. We would like to express our deep sense of gratitude to Mr R.K. Prasad (Training Manager) and Mr J. Bhilware for granting us permission to undergo training at IOCL, Mathura refinery over a period of one month and for providing us with necessary inputs as and when needed. For their invaluable guidance, kind cooperation, inspiration and encouragement during all the stages of my training, I would like to thank to our co-ordinator Mr S. Khan & all senior production managers. In spite of their busy schedule, they were always eager to help us out and share their vast experiences with us. We would also like to heartily thank the shift engineers and operators who in spite of their arduous task took time out to explain each and every detail of the processes and also provided us with invaluable technical advices about every aspect of the plant. We are really thankful to the staff for cooperating with us immensely. We are thankful to the following departments and their staffs for their insights on the industry. Last but not least, I would like to convey my hearty and blossom thanks to my friends and fellow mates who have directly or indirectly helped me in the compilation of this report. After the completion of the training program, I found it to be of immense help, not only in supplementing the theoretical knowledge, but also by gaining highly practical knowledge regarding the actual work carried out in a Refinery Plant. At the end, I again express my gratitude to all those who helped me in any way to complete my training successfully.

Manisha Gupta

CERTIFICATE

This is to certify that Ms Manisha Gupta, a student of Aligarh Muslim University has completed her summer vocational training with our organization for a period of one month, starting from 01/06/2011 to 30/06/2011.

Chief Manager (MS & Training)

INTRODUCTION
Only three decades ago, Indian looked to the world for help in its quest for oil. Then slowly, but surely the scenario changed. Indian oil company(Estd.1959)played a leader role in this transformation. Today, Indian oil owns and operates 6 refineries at Digboi, Guwahati, Haldia, Barauni, Mathura and Gujarate amongst the countrys twelve refineries, with a combined crude oil refining capacity of over 24 million tones which is about 47% of the total refining capacity in India. Indian oils seventh grassroots refinery is coming up at Karnal in Haryana with a capacity of 6 million tones per annum. Indian oils first product pipeline in the Guwahati-Siliguri sector carned itself the honors of being the first petroleum product pipeline to be constructed on the eastern side of suez canal.Indian oils pipeline length progressively grew to todays level of over 3800 km maintaining an uninterrupted flow of crude oil to refineries and petroleum products to the consuming centers across the length and breadth of the country.Currently, Indian oil is executing its longest ever petroleum product pipeline ,all of 1454 km, originating from Kandla in Gujarat and terminating at Bhatinda in Punjab. Whats more, Indian oil reaches a wide spectrum of customers through its marketing wing .it sells over 32 million tones of petroleum products annually through a country wide marketing network. Indian oil commands a market share of about 57% on the whole. it is interesting to note that Indian oil runs a retail outlet at the worlds highest point kaza in Himalayas as well.Indian oil is the only oil refining and marketing company in India India which has a full fledged research and development center. nearly 600 of the lubricant formulations developed at this center have been commercialized thereby indegenising over 95% of the lubricant marketed by Indian oil. This center has mastered the complete know how of FCC catalyst evaluations and manufacturing in India with its own formulation apart from giving support services on fccs to Indian refineries.

MATHURA REFINERY
Mathura refinery standing bold on the outskirts of Mathura on Delhi-Agra highway, has been the harbinger of technological advancement in this region in perfect harmony with the environment. Nurturing technology amidst the greens has been a pioneering experiment of a modern industry and Mathura refinery takes pride in successfully accomplishing this arduous task since its inception. A torch bearer of north west India: Mathura refinery has been the focal point of development in industrial and transportation sector for almost the entire northwest India since its commissioning in Jan 1982. This 7.5 million tone refinery is indias latest and most modern refinery. Also, it has the wide adaptability of processing over 30 types of crude oil. This ranges from indigenous Bombay offshore crude to imported crudes of Australian origin in the east and Nigeria and Venezuela in the far west. Mathura refinery has the distinction of having single largest capacity crude distillation unit which has the unique engineering marvel of 67 m high crude distillation column. The crude to the refinery is received from salary in west coast through a dedicated cross country 1078km pipeline . Products from this refinery are dispatched through rail, road and Mathura-Delhi-AmbalaJalandhar pipeline .the contribution of Mathura refinery in meeting the petroleum products demand of north west India is about 68%. Indian Oil Corporation Limited or IOC is Indias largest commercial enterprise and the only Indian company to be among the worlds top 200 corporations according to Fortune magazine. It is also among the 20 largest petroleum companies in the world. It was established in 1959 as Indian Oil Company Limited which was merged with Indian Refineries Limited in 1964 to form IOC as it is today. Indian Oil Corporation has four divisions: Marketing Division with Headquarters at Bombay; Refineries and Pipelines Division with Headquarters at New Delhi; Assam Oil Division with Headquarters at Digboi; and Research and Development Centre at Faridabad. Indian Oil Corporation Limited is India's largest commercial enterprise with a turnover of Rs.2, 85,337 crore and a net profit of Rs.2, 950 crore in 2008-09. Indian Oil alone accounts for 56 % petroleum product market share among PSU companies, 42% National refining capacity and 68% downstream pipeline throughput capacity. Indian Oil group owns and operates 10 of Indias 18 refineries with a current combined rated capacity of 54.2 Million metric tonnes (MMTPA). These include subsidiaries viz. Chennai Petroleum Corporation Ltd and Bongaigaon Refinery & Petrochemicals Ltd. It owns and operates the countrys largest network of cross-country crude and product pipelines, with a combined length of 7,730 km with a combined capacity of 54.2 MMTPA.

The LPG bottling plant situated within Mathura refinery premises bottles nearly 7 million cylinders per annum for catering to domestic market. Major fertilizes industries at Kanpur, Panipat, Nangal, Bhatinda and Kota are supplied with naphtha or furnace oil/ heavy petroleum stock as fertilizer feed stocks from Mathura refinery. Also, thermal power plants of Nangal, Obra and Badarpur get fuel oil supply from this refinery. Apart from this, Mathura refinery is privileged to provide the necessary energy to the pulsating capital, New Delhi and also boost the standards of the farmers belonging to the crop rich lands of Punjab and

Haryana. The other important product, bitumen, has paved the transportation sector in this region on to road worthiness. To keep the environment clean and green. Mathura refinery recovers nearly 10,000kgs of sulphur everyday as a by-product from crude oil. The various products of Mathura Refinery are: S.No 1 2 3 PRODUCTS Liquid Petroleum Gas Naptha Aviation Turbine Fuel USED AS Domestic purpose Fertilizer as feed Civil and Defence purpose Domestic purpose Transportation purpose Fuel for industries Transportation purpose Agro equipments Road paving High polymers Chemical industries

aviation

Superior Kerosene Oil 4 High speed diesel oil 5 Furnace oil &heavy petroleum stock 6 Petrol (leaded and unleaded) 7 Light diesel oil 8 Bitumen 9 Propylene 10 Sulphur 11 PROCESSING UNITS OF MATHURA REFINERY: S.No. 1 2 3 4 5 6 7 8 9 10 S.No. 11 12 13 14 15 16 17 18

Name of Processing Units Atmospheric & Vacuum Distillation Unit(AVU ) Visbreaker Unit (VBU) Fluidized Catalytic Cracking Unit (FCCU) Continuous Catalytic Reforming Unit (CCRU) Propylene Recovery Unit (PRU) Hydrogen Generation Unit ( HGU ) Once Through Hydrocracker Unit (OHCU) Sulphur Recovery Unit (SRU) Bitumen Blowing Unit (BBU) Diesel Hydro Desulphurization Unit (DHDS) Name of Treatment Units Merox (Mercaptan Oxidation) ATF CRLPG SRLPG VBN FCCG Amine Recovery Unit (ARU) Sour Water Stripping Unit (SWSU)

OFFSITE FACILITIES: The offsite facilities at Mathura Refinery have 8 numbers of crude oil storage tanks having storage capacity of 430000 KL Crude Oil and 68 numbers of product tanks. There are 7 numbers of pumping station, a blending station and connecting pipelines. There are 6 numbers of LPG Horton spheres each of 1500 m capacity and two nos. of Propylene Bullets. The offsite operation is controlled from the centralized DCS control room at OM&S.

VISION: >A major diversified, transnational, integrated energy company, with national leadership and a strong environment conscience, playing a national role in oil security& public distribution.

MISSION: > To achieve international standards of excellence in all aspects of energy and diversified business with focus on customer delight through value of products and services, and cost reduction. > To maximize creation of wealth, value and satisfaction for the stakeholders. > To attain leadership in developing, adopting and assimilating state-of- the-art technology for competitive advantage. >To provide technology and services through sustained Research and Development. >To foster a culture of participation and innovation for employee growth and contribution. >To cultivate high standards of business ethics and Total Quality Management for a strong corporate identity and brand equity. >To help enrich the quality of life of the community and preserve ecological heritage through a strong environment conscience. balance and

EFFFLUENT TREATMENT PLANT OM&S-II

The main objectives of ETP are:

 Recovery of Oil Reduction of BOD Removal/recovery of suspended solids and other chemical constituents like phenol, sulfides, etc. Waste water collection system of Mathura Refinery consists of: Industrial Sewer (IS) or Oily Water Sewer (OWS): In this sewer, process oily water from units, equipments, sample points, pump house drains, electric desalter drains, loading gantries, tank drains, etc. comes. Salty Waste Water Sewer (CS): A separate underground RCC pipe network is provided for collection of crude oil tank drains and drain from crude oil booster pump station. The wastewater through this network flows by gravity and also joins the IS Sump of the ETP. Storm Water Sewer (SS) or Contaminated Rain Water (CRW) Sewer: In this sewer rain water from tank farm dyked area comes. Domestic Sewer (DS): In this sanitary sewage from toilets and lavoratories provided in the refinery come.

Alkaline Waste : The alkaline waste or spent caustic streams from Merox Units and from AVU come by two separate above ground pipelines which join together before entering the spent caustic storage tanks provided in the ETP. These wastewater streams reach ETP under their own system pressure. Sour Water: Normally, the sour water from cracking & desulphurisation units goes to the Sour Water Stripper (SWS), but in case of shutdown of the SWS, it is diverted to the spent caustic storage tanks of the ETP through an above ground pipeline under its own system pressure. Cooling Tower Blowdown : The blowdown from cooling towers is taken to ETP through above ground pipeline, which terminates into the Cooling Tower Blowdown (CTBD) Sump of ETP. This stream can be pumped to Guard Ponds or Surge Reservoirs if contaminated with oil.

WASTEWATER POLLUTANTS:
BOD (Biochemical Oxygen Demand)

BOD is expressed as oxygen required for decomposition of organic chemicals biologically and indicates biologically oxidisable organic matter in the water. It is not a pollutant in itself. Presence of BOD is not desirable as it consumes Dissolved Oxygen required for aquatic life. COD (Chemical Oxygen Demand) COD is expressed as oxygen required for decomposition of organic chemicals chemically (oxidants like Potassium Dichromate) and indicates total oxdisable organic matter. It indicates presence of toxic chemicals/ biorefractory chemicals in the water. TSS (Total Suspended Solids) Its presence creates problems for aquatic animals which respirate through gils. Therefore, it is important to be controlled. Oil & Grease Presence of Oil & Grease in water contributes to BOD/ COD. It is detrimental to all organisms. Further, it imparts odour to the water and not desirable from aesthetic point of view. Phenol Chlorination of the water containing phenols produces odourous & objectionable tasting Chlorophenols. Sulphide Sulphide compounds are highly toxic and cause corrosion in pipelines & pumping systems. There are mainly 4 types of treatment: a) b) c) d) Physical treatment Chemical treatment Biological treatment Tertiary treatment

The major operations in the processing scheme are: A. B. Free Oil Removal Emulsified Oil Removal

C. D. E. F.

Sulphide Treatment Biological Treatment Tertiary Treatment Sludge Thickening & Centrifuge Operation

Pollutant and their treatment method: POLLUTANT Free oil Emulsified oil Sulphides Organics (BOD / COD) Settable Solids Microbes (Bacteria, Algae, etc.) Suspended solids TREATMENT METHOD Gravity separation Chemical destabilization and flotation Chemical oxidation Biological oxidation & Sedimentation Sedimentation Disinfection by Chlorination Sedimentation & Filtration

a)Physical treatment:
In this treatment, physical process in API separators separate suspended solids and free oils. Here the velocity of water is slowed down considerably. At such low velocities solids settles at the bottom and free oil floats on the water surface. The oil is then skimmed off by scrapper and sent to slop tanks. After drain of water from tank and heating to 700 C, slop oil will be pumped to tanks in IFO, where from it will be processed in units with crude. In the equalizer basin, at inlet, treated water from chemical treatment section also comes and joins with water from API outlet. Here both hydraulic as well as organic loads of both streams are absorbed and equalized. Oil skimming facility is provided here to remove free float oil. Waste water from here goes to single stage high rate trickling filter. Oily sludge from oil separators will be pumped to oily lagoons. After removing supernatant, sludge will be removed manually and disposed off.

b) Chemical treatment:
Chemical treatment is required for caustic as it has high concentration of sulfides that cannot be removed by biological or physical treatment plant. Spent caustic from caustic storage tank

is first sent to PH tank, then it is further sent to the reactor tank where H2O2 dose is given by using dosing pump at the rate of 60-70 lit/day. Whole reaction mixture is sent to flocculation tank. Then floe formed out of chemical reaction is settled at clarifier cum thickener (CCT), where from the clear water goes to equalizer basin inlet. The settled/thickened chemical sludge is withdrawn at frequent interval in a sump and pumped to sludge drying beds. Chemical sludge after drying beds will be disposed off manually.

c) Biological treatment:
Naturally occurring bacteria eat away or oxidize impurities causing reduction of sulfides, phenols, BOD/COD and oil using proper aerator. The excess and dead bacterium is periodically removed from the system. Biological treatment takes place in two steps: A)Bio Tower The bio tower is a type of attached growth process. This system of biological treatment is usually used for degrading complex organic toxic compounds. The bio tower consists of a bed of plastic media to which micro-organisms are attached and through which wastewater is percolated. Plastic media used in bio tower provide more surface area for growth of microorganisms. Plastic media also has more void volume, which helps to circulate the air within media. The bio tower is constructed with an under drain system for collecting the treated wastewater and any biological solids that may have detached from the media. This under drain system is important both as a collection unit and as a porous structure through which air can circulate freely. The collected liquid is passed through a settling tank where the solids are separated from the treated wastewater. To maintain the hydraulics of the system, part of the wastewater is recirculated back to the filter along with the fresh incoming waste. This helps in maintaining a minimum required water flow through the medium to ensure that the medium is maintained wet at all times. A population of micro-organisms attached to the media degrades the organic material present in the wastewater. The organic matter from the liquid is adsorbed on to the biological film. In the outer portions of this biological film layer, the organic material is degraded by aerobic micro-organisms. The required oxygen is available from the air circulating in the medium. As the micro-organisms grow, the thickness of the slimy layer increases, and the diffused oxygen is consumed before it can penetrate the full depth of the slime layer. Thus, an anaerobic environment is established near the surface of the media. As the slime layer increases in thickness, the adsorbed organic matter is metabolized before it can reach the micro-organisms near the media face. As a result of having no external organic source available for cell carbon, the micro-organisms near the media face enter into an endogenous phase of growth and lose their ability to cling to the media surface. The liquid then washes the slime off the media, and a new slime layer starts to grow. This phenomenon

of losing the slime layer is called sloughing and is primarily a function of the organic and hydraulic loading on the bio tower. The hydraulic loading accounts for shear velocities, and the organic loading accounts for the rate of metabolism in the slime layer. B)Activated Sludge Treatment (Aeration Tanks): The process basically consists of continuously mixing of waste water and activated by motor operated aerators. Here decomposition takes place. The mixed liquor is then sent to the final clarifier where bacteria mass is separated from water and bio-sludge is recycled. The metabolic reactions are: Food + Microbes + Nutrients + O2 New cells + CO2 + H2O + NO2 + Energy. The process basically involves two unit operations i.e. contacting and liquid solid separation. Numerous factors influence the performance of the Activated Sludge Process. Some of the factors are: -- Variability in Waste Water Flow and Quality. -- Sludge Retention Time -- Hydraulic Retention Time. -- Organic Loading (F/M ratio) -- Macronutrient Levels -- Mixed Liquor Suspended Solids (MLSS) concentration. -- Mixing and Aeration Intensity/ Pattern -- Mixed Liquor Temperature -- Mixed Liquor pH Value -- Mixed Liquor Dissolved Oxygen levels -- Influent Waste concentrations -- Physical characteristics of sludge

d) Tertiary treatment:
A. Chlorination

It is a disinfecting agent and when chlorine is added to water undergoes two reactions: Hydrolysis reaction: CI2 + H2O HOCI + H + + CI

Ionization Reaction: HOCI H + + OCI-

Hence chlorine acts as a more effective disinfectant at a neutral to slightly acidic pH rather than at an alkaline pH. Chlorine reacts with the enzymes of the bacterial cells and denatures them resulting in bacterial kill. Factors affecting germicidal efficiency are pH, temperature, contact time & mixing efficiency. B. Filtration

The clarified outlet from the secondary clarifier is generally expected to contain some suspended solids, along with some residual organics in the form of BOD and COD, colour matter and odour. These need to be reduced further by tertiary treatment, which comprises of pressure filtration using Dual Media Filters (DMF) and Activated Carbon Filters (ACF). DMF consists of a pressure vessel filled with layers of various grades of sand and anthracite as the filtering media. Water at high pressure is passed downwards through the media. The fine suspended solids get entrapped in the anthracite and sand media layer. Over a period of time the suspended solids accumulates in the surface layers of the media thereby causing pressure drop to develop across the filter. When the pressure drop reaches a value of 0.8 - 0.9 kg/cm2 the filter is backwashed for 10 -15 minutes to clean the top layer. The filtration cycle can be continued after the backwash cycle. The residual COD, colour and odour remaining at the outlet of DMF is subjected to adsorption on activated carbon by filtering the same in Activated Carbon Filters (ACF). The ACF is also subjected to backwash as in the case of DMF with loss of head across the filter. SLUDGE THICKENING AND CENTRIFUGE OPERATION Biological sludge generated from Activated Sludge Process (ASP) is thickened for volume reduction. Thickening is done by gravity separation in a sedimentation tank called thickener and by high-speed centrifuge operation. The thickened sludge is stabilized in drying beds. The weathered sludge from the drying beds is used as bio manure in the green areas of the plant. The volume of oily sludge generated from API/ TPI Oil Separators, DAF & basins of ETP is reduced by heat application followed by oil recovery. The sludge after oil recovery is further thickened by centrifuge operation and the residual sludge is transferred to secured landfill site. Polyectrolytes are used to increase efficiency of the centrifuge operation.

Functions Of Individual Equipment For Waste Water Treatment API Separators: Physically separate free oil, sludge and solids. Equalization Ponds: Helps in supplying consistent quality and quantity of waste water to biological section. Trickling filters: Helps in reducing BOD/COD, sulfides, phenols and oils in contact with algae grown on stone media. Aeration tanks: Helps in further reduction of above mentioned pollutants in contact with bacteria and continuous aeration. Final Clarifier: Retaining biological sludge from recycle. Slop Sumps: Receiving API, clarifier, IS and guard basin slop for pumping to slop oil tanks. Sludge Sumps: Receiving sludge from API Separator bottom and pumping to oily sludge lagoon. Drying Beds: Drying of biological and chemical sludge. Guard Basin: Storage during peak flow situation. Polishing Ponds: provide resistance time for finishing touch with natural aeration.

ATMOSPHERIC AND VACUUM UNIT (AVU)

Originally the Atmospheric and Vacuum distillation Unit was designed to process 6.0 MMTPA of Imported Middle East crude (i.e. a mixture of Light Arabian (LA) crude and North Rumaila (NR) crude in the proportion of 1:1).

Atmospheric and Vacuum unit (AVU) of Mathura Refinery is designed to process 100% Bombay High Crude and 100% Arab Mix crude (consisting of Light and Heavy crude in 50:50 proportion by weight) in blocked out operation @ 11.0 MMTPA. AVU consists of following sections: Crude Desalting section Atmospheric Distillation section Stabilizer section Vacuum Distillation section

CAPACITIES
Crude Distillation Unit Vacuum Distillation unit Naphtha stabiliser : : : 11.0 MMTPA 3.4 MMTPA 1.0 MMTPA

TYPES OF CRUDE
Low Sulphur Indian : Nigerian Bombay high. : Girasol, Escravos ,Farcados, Bonny light High Sulphur Imported : Arab Mix, Kuwait ,Dubai, Ratawi, Basra etc

PRODUCTS EX CDU/VDU MAIN COLUMNS

Short Name Gas LPG NAP HN KERO ATF LGO HGO VD LVGO LDO HVGO V. SLOP VR

Long Name Fuel gas Liquefied Petroleum Gas Naphtha Heavy Naphtha Kerosene Aviation Turbine Fuel Light Gas Oil Heavy Gas Oil Vacuum Diesel Light Vacuum Gas Oil Light Diesel Oil Heavy Vacuum Gas Oil Vacuum slop Vacuum Residue

Cut range C C1 C2 C3-C4 C5-120 120-140 140-270 140-240 240/270-340 320-370 370+ 370-380 380-425 425-550 550-560 560 +

Usage Internal Fuel Domestic Fuel MS Component HSD component Domestic Fuel Aeroplanes fuel HSD Component HSD Component HSD Component Feed to OHCU/RFCCU Fuel Feed to OHCU/RFCCU IFO Component Bitumen /HPS

Steps of operation in AVU process

CDU CRUDE RECEIVING CRUDE PREHEATING (FIRST STAGE) DESALTING OF CRUDE CRUDE PREHEATING (SECOND STAGE) PREFRACTIONATOR DISTILLATION CRUDE PREHEATING (THIRD STAGE) RAISING TEMPERATURE WITH FIRED HEATERS

 ATOMOSPHERIC DISTILLATION NAPHTHA STABILISATION PRODUCT ROUTING AFTER HEAT RECOVERY VDU FEED TEMPERATURE INCREASE WITH FIRED HEATER VACUUM DISTILLATION PRODUCT ROUTING AFTER HEAT RECOVERY

PROCESS FLOW DESCRIPTION

FEED SUPPLY
Crude oil is stored in eight storage tanks (eight tanks each having a nominal capacity of 50,000 m3 whereas remaining other 2 tanks are of 65,000 m3 nominal capacity). Booster pumps located in the off-sites are used to deliver crude to the unit feed pumps. Filters are installed on the suction manifold of crude pumps to trap foreign matter. For processing slop, pumps are located in the off-site area, which regulate the quantity of slop into the crude header after filters. Provision to inject proportionated quantity of demulsifier into the unit crude pumps suction header with the help of dosing pump is available.

SYSTEM DESCRIPTION:
Crude Oil is heated up to 136 -141 C in the first train of heat exchangers operating in two parallel sections up to the desalter which is connected in series. Desalting temperature as required can be maintained manually by operating the bypass valve of heat exchangers.

A two-stage desalter has been designed for 99% salt removal. It is designed to use stripped sour water for desalting which is being taken ex stripped sour water unit. Provision to use DM water/ services water is also provided. The electric field in the desalter breaks the emulsion and the outlet brine from the 1st stage desalter is sent to ETP on level control. The crude after leaving the desalter is preheated to 250 to 265 C. The preheated crude is further heated and partially vaporized in Atmospheric Furnace (four furnaces with four pass each). Heater is a box type vertical furnace with up-firing burners. 7 nos. in each section are provided on the floor with FG and FO firing facilities. Each crude furnace has fourteen burners.

FURNACE OPERATION:
1. CDU Fired Heater 2. VDU Fired Heater Like any conventional process heater, these heaters are also having two distinct heating section: (I) a radiant section, which houses the burners and forms the combustion chamber or fire box: and (ii) a convection section which receives heat from the hot flue gases leaving the radiant section and is therefore placed above the radiant section.

CDU Fired Heater:

The convection section has 8 rows of tubes with 8 nos. tubes in each. The two rows of shock tubes, i.e. the two rows just above the radiant section are plain tubes without studs. The rest six rows are of extended surface type having cylindrical studs. All the convection bank tubes are of 152 mmx8mm dimension and 5Cr 1/2 Mo material of construction. Of these 64 tubes in the convection section, 4 nos studded tubes are for the service of superheating MP steam for strippers; and the rest 60 nos. tubes are for crude oil service. Crude oil to be heated enters the convection section in four passes. From outlets of the convection bank, it passes through

crossovers provided inside the furnace into bottom coils of the radiant section. Steam flow is of single pass to superheating coils. Provision exists to vent out MP steam ex- super heating coils of furnaces to atmosphere through silencers. In the radiant box, 84 nos. tubes are arranged horizontally along the height of the two sidewalls. The tubes are of 152x8mm dimension and 5 Cr 1/2 Mo material of construction. There are 21 tubes in each pass and the pass flows are up the radiant section to the heater outlet from top of radiant box to join the 900mm dia. Transfer line going to crude fractionator. Heater tubes rest on wall-supported hangers and are arranged in such a fashion as to facilitate free expansion. The floor of furnace is elevated above grade and the hot air duct (supplying combustion air to burners) runs across the length of the furnace below the furnace floor. The skin temperature of tubes is limited to 550 0C.

VDU Fire Heater:

Like any conventional process heater, these heaters are also having two distinct heating section: (I) a radiant section, which houses the burners and forms the combustion chamber or fire box: and (ii) a convection section which receives heat from the hot flue gases leaving the radiant section and is therefore placed above the radiant section. The Max box temp should be maintained less than 801 0 C. The convection section has 13 rows of tubes with 8 nos. tubes in each. The top three rows are for the service of superheating LP steam for vacuum column and the rest 10 rows are for RCO service. The three rows of shock tubes, i.e. the three rows just above the radiant section are plain tubes without studs. The next seven rows are of extended surface type having cylindrical studs. Provision exists to vent out MP steam ex- super heating coils of furnaces to atmosphere through silencers. There are 5 rows of tubes in arch zone and 9 rows of tubes in radiation zone for each pass for heating the RCO.The tubes material of construction is 9Cr 1Mo.

The floor of furnace is elevated above grade and the hot air duct (supplying combustion air to burners) runs across the length of the furnace below the furnace floor. The skin temperature of tubes is limited to 542 0C. The furnaces are of balanced draft type with forced draft (FD) fans to supply combustion air and induced draft (ID) fan to take suction of the flue gases through air-preheating system and discharge the same to stack.

CRUDE DISTILLATION UNIT :

The column is provided with 56 trays of which 8 are baffle trays in the stripping section. Heated and partly vaporized crude feed coming from fired heater enters the flash zone of the column at tray no. 46 at 355 C/365 C. bottom product, called RCO. MP steam having some degree of superheat is introduced in the column below tray no. 46 at approximately 3.5 kg/cm2 (g) and 290 C for stripping of RCO. Steam stripping helps to remove lighter constituents from the bottom product (RCO). Hydrocarbon vapours liberated by flashing moves up along with the steam in the column for further mass transfer at trays in the upper section. Reduced crude oil product is collected at the bottom of the column and the overhead vapours are totally condensed in Overhead air Condenser and train condenser. This condensed overhead product is separated as hydrocarbon and water in the reflux drum. Water is drawn out under inter-phase level control and sent to sour water drums. Hydrocarbon vapours flash in this zone and get liberated. Non-flashed liquid moves down which is largely

STABILIZER:
Unstabilized Naphtha containing Fuel Gas, LPG and Naphtha is sent to stabilizer under cascaded flow control. LPG is pumped to MEROX for treatment.

Fuel Gas generated during BH/AM operation is routed to Fuel Gas Amine treatment Unit to remove H2S before being routed to the plant Fuel Gas Distribution Header.

VACUUM DISTILLATION UNIT :

Hot RCO from the atmospheric column bottom at 355 C is mixed with slop recycle from Vacuum Column, heated and partially vaporized in 8-pass vacuum furnace and introduced to the flash zone of the vacuum column. The flash zone pressure is maintained at 115-120 mm of Hg. Steam (MP) is injected into individual passes and regulated manually. Three injection points have been provided on each pass. This is to maintain required velocities in the heater, which is Fuel Gas, Fuel Oil or combination fuel fired. Each cell is provided with 10 burners fired vertically upshot from furnace floor along the centerline of the cell. The vaporized portions entering the flash zone of the column along with stripped light ends from the bottoms rise up in the vacuum column and is fractionated into four side stream products in 5 packed sections. The hydrocarbon vapours are condensed in the Vac Slop, HVGO, LDO and LVGO sections by circulating refluxes to yield the side draw products. Vacuum is maintained by a two-stage ejector system with surface condensers. The condensed portion from the condensers are routed to the hot well from where the non-condensable are sent to the vacuum furnace lowpressure burners or vented to the atmosphere. Oil carried over along with the steam condensate is pumped to the vacuum diesel rundown line by overhead oil pumps.