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Slide1
ChennaiPetroleumCorporationLimited(AGroupcompanyofIndianOil)
Refining Process, Refinery Configuration& Design Aspects
Slide2
REFINERY PROCESSES
REFINERY CONFIGURATION
PROJECT DESIGN ASPECTS
PRESENTATION PLAN
Slide3
STEPS IN REFINING PROCESS
w SEPARATION PROCESS
w CONVERSION PROCESS
w FINISHING
REFINERY PROCESS - Overview
Slide4
REFINERY PROCESSING STEPS
Crude oil
Objective
Examples
Improving the qualities of products by:
Blending products of different qualities to get an optimal mix
Treating products (typically with hydrogen) to remove impurities
Gasoline blending Hydro-treating
SeparationSeparation ConversionConversion Finishing
Breaking up a mixture into its components
Distillation/fractionation
Extraction
- Fundamentally changing the chemical structure of a product by:
Breaking down molecules
Combining molecules
Rearranging structure
Coking Cracking Alkylation (combining) Isomerization
(rearranging)
Slide5
SEPARATION PROCESS
Slide6
DISTILLATION COLUMN
Slide7
Separation of components from a liquid/vapor mixture via distillation: Depends on the differences in boiling points of the
individual components
Depends on the concentrations of the components present
Hence, distillation processes depends on the vapour pressure characteristics of liquid mixtures.
DISTILLATION PRINCIPLE
Slide8
The Dew-point is the temperature at which the saturated vapour starts to condense.
The Bubble-point is the temperature at which the liquid starts to boil.
Relative volatility is a measure of the differences in volatility between 2 components, and hence their boiling points. It indicates how easy or difficult a particular separation will be.
DEW POINT , BUBBLE POINT AND RELATIVE VOLATILITY
Slide9
Column
Column internals9 Trays9 Packing
Reboiler
Condenser
Reflux Drum
MAIN COMPONENTS OF DISTILLATION
Slide10
Temperature
Pressure
Draw off and reflux rates
Pump around
Stripping steam rate
OPERATING VARIABLES
Slide11
CRUDE- FEED PREPARATION
Effect of Bottom, Sediments & Water:
Deteriorates equipment performance Shorter run length High Energy Consumption
This can be achieved only by proper feed preparation.
Impurities in crude: Inorganic salts Acids
Desalting helps to remove these impurities
Slide12
PREHEAT TRAINS & FURNACE
Pre-heat trains:
Utilize the heat available in the products and PA
Reduces the fuel consumption in the furnace
Furnace:
Natural draft
Forced Draft
Balanced Draft
Slide13
ATMOSPHERIC DISTILLATION
Slide14
VACUUM DISTILLATION
Slide15
VACUUM DISTILLATION
Vacuum distillation can improve a separation by:
Prevention of product degradation
Reduced mean residence time especially in columns using packingrather than trays.
Increasing capacity, yield, and purity.
Reduced capital cost, at the expense of slightly more operating cost.
Slide16
CRUDE DESALTER
Slide17
CRUDE FURNACE
Slide18
CRUDE ATMOSPHERIC COLUMN
Slide19
Lube Oil Base Stocks
SPINDLE LIGHT NEUTRAL INTERMEDIATE NEUTRAL 500 NEUTRAL HEAVY NEUTRAL BRIGHT STOCK
Slide20
LUBE PROPERTIES
Properties /Components
Viscosity ViscosityIndex
Pour Point
Paraffins Low High High
Naphthenes Medium Medium Medium
Aromatics High Low Low
Slide21
LUBE PROCESSING STAGES
S.NO PROCESS PROPERTY CONTROL
1 Vacuum Distillation Viscosity, Flash Point
2 Solvent Extraction/ Viscosity Index
3 Solvent Dewaxing / Iso-Dewaxing
Pour Point
4 Hydrofinishing Colour / Oxidation Stability
Slide22
FurfuralExtraction
Unit
FurfuralExtraction
Unit
NMPExtraction
Unit
NMPExtraction
Unit
MEKDewaxUnit
LubeHyFiUnit
Atm.DistlColumnAtm.DistlColumn
VacuumDistillatnColumn
PDAUnit
LUBE PROCESSING BLOCK
Crude
RCO
Vac. Distl
Vac. Residue
Extract
Extract
Pitch
DAO
Raffinate DWO LOBS
Slack Wax
Slide23
FEED CHILLING
FILTERSSOLVENTRECOVERYFROM WAX
SOLVENTRECOVERYFROMFOOTS OIL
DEOILED WAXSTORAGE
PRODUCTSTORAGE
HY.FIUNIT
NH3 REFRIGERATION
INERT GAS
FOOTS OIL
WAX PROCESSING
Slide24
CONVERSION AND TREATING PROCESS
Slide25
CONVERSION AND TREATING PROCESS
Conversion Process:
9Thermal processes
9Catalytic processes
Treating Process
9Catalytic processes
9Chemical treating process
Slide26
THERMAL (VISBREAKER UNIT)
Mildthermaldecomposition(visbreaking)
Reductionofviscosity&pourpointoffeed
DesirableReaction Cracking
SomepolymerizationcondensationreactionalsooccursCokeformation
Slide27
THERMAL (VISBREAKER UNIT)
CRACKEDRESIDUEVACUUM
FLASHER
STEAMVISBREAKER
FEED VACUUMFLASHED
HVGO
LVGO
GAS+SLOPS
GO
STABNAPHTHA
GAS
STEAM
HEATER SOAKERFRACTIONATOR
GAS
Stabiliser
300 c
426 c
440 c
380 c
7.7 kg/cm2
39
26
96 c
160 c0.95 kg/cm2
210 c
9.8 kg/cm2
25 mmhg130 c
300 c
Slide28
(Thermal) Delayed coking
Slide29
Reactor DesignBetter performance and operational flexibility can be achieved:
Choice of catalyst
Choice of feed
Operating conditions
Reactor configuration
Synergy with other units
Better internals
CATALYTIC (REACTORS)CATALYTIC (REACTORS)
Slide30
REACTOR INTERNALS
Catalystunloadingnozzle
Aluminaballs
Catalyst
Debrisbasket
Distributornozzle
Outletnozzle
Inletnozzle
Screen
Slide31
REACTOR INTERNALS
Outletnozzle Screen
Catalystunloadingnozzle
Aluminaballs
Catalyst
Debrisbasket
Distributornozzle
Inletnozzle
Quench
Catalyst
Slide32
CHEMISTRY:
Dehydrogenation
Isomerisation
Dehydro cyclization
Hydrocracking
CATALYTICREFORMING
Slide33
DEHYDROGENATION:
C7H14 >C7H8+3H2Methylcyclohexane Toluene
RON: 73.8 119.7
ReactionishighlyEndothermic
Promotedbylowpressureandhightemperature
Occuronmetalsite(Platinum)
FastestreactioninReforming
CATALYTICREFORMING
Slide34
+ 3H2
Reaction is mildly Exothermic
Occur on acid site(Al2O3 and HCL)
Second fastest reaction in Reforming.
C
Methy Cyclo Pentane Cyclo Hexane BenzeneRON - 89.3 RON - 110 RON - 120
Naphthene AromaticNaphthene
CATALYTICREFORMING
ISOMERISATION:
Slide35
C
Toluene119.7
+ 3H2
n-HeptaneRON 0.0
Reaction is Endothermic
Promoted by low pressure and high temperature
Occur on acid and metal site
Slowest reaction in Reforming
-C-C-C-C-C-C-C-
ParaffinAromatic
CATALYTICREFORMING
DEHYDROCYCLISATION:
Slide36
Naphtha Hydrotreating & Cat. Reforming
Naphtha
Impurities: S,N,Metals
Risk of poisoningCCR catalyst
Naphtha Hydrotreating Hydro treated
Naphtha
Impurities:Nil or low
No Risk of poisoningCCR catalyst
Low octane number
Continuous CatalyticReforming
ReformateHigh OctaneNumber: 102
HydrogenRich gas
Slide37
NHT CCR
Slide38
CCR REACTOR-REGENERATOR
Slide39
NHT ISOM
NHT Section - Main reactions
Hydrorefining reactions removal of impurities Desulfurization Denitrification
Hydrogenation reactions saturation of the olefins and diolefins
Demetallation reactions removal of metallic impurities
ISOM Section - Main reactions
Benzene hydrogenation to form cyclohexane Isomerization (eg. N-pentane to i-pentane)
Slide40
Surge Drum
D
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R
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Feed Heater
H
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NHDTSeparator
N
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Light IsomerateStorage
Heavy Isomerate
L
P
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S
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p
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L
P
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S
t
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LPG Product
To Isomerate Storage
To FCCC5/C7+ Cut
Recycled H2 To R1
FeedNaphtha
C1
F1R2R1
C2K2 A/B
C4
C13
C16C17
R3R4
C19
C22
C29 C30
F
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D
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Surge Drum
K1A/BMake-up H2 compressor
NHT ISOM
Slide41
HYDROCRACKER BLOCK
Reaction Chemistry
Hydro-treating Reactionsa) Demetallizationb) Desulfurizationc) Denitrificationd) Olefins Saturatione) Aromatics Saturation
Hydrocracking Reactions
Catalyst (Ni3S2)CnH2n+2 + (x-1) H2 x C n/xH2n/x +2 + Heat
Slide42UCO (to FCCU)
Off-gas to PSA (for
H2 recovery)VGO feed
Feed preheating
and filtration
Furnace
Product stripper
Light end recovery section
Fractionator
Fuel gas (to header)
LPG (to storage)
Light Naphtha (to MS pool / HGU)
Heavy Naphtha (to Diesel pool / CRU)
Kerosene / ATF
Diesel..
HP gas separator
LP gas separator
Recycle gas compressor
(RGC)Amine treating
Recycle gas
Furnace
Gas
Liquid hydrocarbon
Heavierhydrocarbons
Lighter hydrocarbons
Lighter hydrocarbons
Make-up H2 from HGU
3600C
Reactors172.5 Kg/cm2
3780C
Make-up H2 compressorQuench H2
Make-up H2.
HYDROCRACKER
Slide43
CPCL HYDRO CRACKER
Slide44
FLUIDCATALYTICCRACKINGUNIT
FlueGas680C Flue Gas
Slide Valve
Regenerator650C
Spent CatalystSlide Valve
Regenerated CatalystSlide Valve
Catalyst circulation 10 MT/min
Air43000
nm3/hr Raw OiL 120 m3/hr 370C
Stripping Steam
Reactor500C
Products to Main Column
Slide45
FINISHING PROCESS
Slide46
DHDT UNIT (Hydrodesulphurization)
Slide47
DHDT REACTOR
Reactor Dimensions
Height,m 31.3
Width,m 4.4
Parameters SOR EOR
Reactor Inlet Pressure, kg/cm2g 77.7 79.6
Reactor Inlet Temp, C 331 375
Reactor Outlet Temp., C 351 388
Reactor Outlet Pressure, kg/cm2g
75.0 75.0
Slide48
SULFUR RECOVERY UNIT
Step 1:H2S + 1 O2 SO2 + H2O + HeatStep 2:2H2S + SO2 3/n Sn + 2 H2O + HeatOverall reaction of Claus Process 3H2S + 1 O2 3/ n Sn + 3 H2O + Heat
Chemical Reactions
Slide49
Sulphur Recovery Block
AmineRegn.(ARU)
2-stageSWSUnit
Tail GasTreating
ThermalConverter
CatalyticConverters
SulphurA
c
i
d
G
a
s
lean amine
rich amine from process units
rich amine to ARU
S
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p
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r
R
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o
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e
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y
U
n
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t
Sour water from process units
stripped water
Lean amine
Slide50
CPCL SRU
Slide51
1. REFINERY PROCESSES
2. REFINERY CONFIGURATION
3. PROJECT DESIGN ASPECTS
PRESENTATION PLAN
Slide52
Refinery ConfigurationKey Considerations & Available Options
Slide53
V
a
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D
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t
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l
a
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LPG
PROPYLENEPBFS/MEKFS
MS
NAPHTHA
ATF
DIESEL
LUBEOILBASESTOCKS
PARAFFINWAX
ASPHALT
FO
AmineTreating
Amine/MeroxTreating
DHDS/DHDT
Extraction Dewaxing LubeHDT
Hydrocracker
FCCU
LPGTreating
PropyleneRecovery
MeroxTreating
Visbreaking
Biturox Unit
AmineRegeneration
SulphurRecovery
Ref.FuelGasSystem
A TYPICAL REFINERY CONFIGURATION
NaphthaSplitter
ATFTreating
NHT/ISOM
HexanePlant
HydrogenGeneration
CatalyticReforming
GAS
LPG
LT.NAP Naphtha(4590C)
Naphtha(90130C)
ATF
Diesel
LUBEDistillates
VGO
UCO
Hydrogen(H2)
LongResidue
A
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Isomerate
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Reformate
CrackedGasolineC
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N
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a
HY.NAP
HEXANE
COKE
SULPHUR
SK
DelayedCoking
ShortResidue
WaxDeoiling&WaxHydrofinishing
SK
LCGO HCGO
LPG
CRUDEOIL
STORAGE
H2
H2
Slide54
Global Economic Downturn & Recovery
Slide55
Global Oil Outlook
Slide56
India - Net Oil Import Dependence
Reference: IEA WEO 2009
Slide57
Projects Classification
Slide58
Drivers for New Projects Identification
Supply Demand Balance
Change in the market scenario
Impact of products Slate / demand (Zero FO export, Dieselization, etc.)
Stringent Product Specifications
Environmental improvement / regulations
Profitability through capacity expansion
Diversification into new areas
Achieving overall economics of scale in operations
Slide59
Impact of Product Demand
Reference: OPEC WOO 2010
Global Product Demand 2009 to 2030
Slide60
Stringent Product SpecificationsGASOLINE Euro-III Euro-IV Euro-VSulphur, ppm 500 150 50 10RON, min 88 91 91 95MON, min - 81 81 85RVP (max), Kpa 60 60 60 60Benzene (max), vol% 5/3 1 1 1Aromatics (max), vol% - 42 35 35Olefins (max), vol% 21 21 18
DIESEL Euro-III Euro-IV Euro-VSulphur, ppm 500 350 50 10Cetane Number 48 51 51 5195% recovery, C 370 360 360 360Flash Point (Abel), C 35 35 60
Product Spec Changes Mean More Complex Refineries
Slide61
Drivers for Revamp Projects Identification
Capacity Expansion
Quality Improvement of products
New Technology Implementation
Slide62
Crude Feed Selection
High Sulphur Crudes (Dubai-Brent crude spread)
Heavy Crudes
High TAN crude
High nitrogenous / mercuric crude
Tar Sands, Oil Shales
Slide63
Over half of worlds oil supply is heavy & sour crude
New refineries built with capability to handle heavy crudes.
Marker Crude Dubai rose higher than Brent in Dec 08 due to Rise in demand for sour crude OPEC production cuts, etc.
Not only is sour crude seeing more demand growth, it also outstrips light, sweet crude in production growth.
Share of sour, heavy crude is likely to increase vis-a-vis light, sweet crude.
Trend in Crude ProcessingHeavy/Sour Crudes
Slide64
The Total Acid Number (TAN) is the amount of potassium hydroxide in milligrams that is needed to neutralize the acids in one gram of oil
TAN >1.0 leads to NAC (naphthenic acid corrosion)
Share of High TAN crude in overall oil production Current - 20% In next five years - 25%
Acidic Crudes Characteristics Yield low S Gas Oil Low Cetane value
Handling of Acidic Crudes Blending with non-acidic crudes & Specialized Metallurgy & Chemical
Injection for corrosion abatement
E.g.) Penglai (Australian), Duri (Indonesian), Marlim (Latin America), etc.
Processing of Opportunity CrudesHigh TAN Crudes
Slide65
High Pour Crudes need to be blended with normal crude for pipeline transportation.
Pricing benchmark of these crudes need to be considered for economic viability.
Processing of high pour crudes also require Coker facilities within the refinery.
For example: Handil (Indonesian), Rajasthan crude
Processing of Opportunity Crudes
High Pour Crudes
Slide66
Topping Refinery
Skimming Refinery
Cracking (hydro/catalytic) Refinery
Coking refinery
Integrated Refinery
Lube Refinery
Types of Refineries
Slide67
Primary Processing Units Distillation Blending
Secondary Processing Units Catalytic Cracking Hydro-cracking Catalytic Reforming Isomerization / Alkylation, etc
Bottom Upgradation Units Visbreaking Delayed Coking
Treating Units Hydrotreating
Processing Units in Oil Refineries
Slide68
Units Capacity (MMTPA)
Crude / Vacuum Distillation Unit(65% Arab Light and 35% Arab Heavy) 6.0
Full Conversion Hydrocracker 1.95Diesel Hydrotreater 1.63Delayed Coker Unit 1.36Hydrogen Unit 0.07Naphtha Hydrotreater 1.0CCR Reformer Unit 0.5Isomerization Unit 0.3Sulphur Recovery Unit 2 x 180 MTPD
BORL Configuration, Bina, M.P
Slide69
Refinery Configurations
S.No SECONDARYUNITS RESIDUNITS
1 VGOHDT+PetroFCC DCU
2 OHCU+ConvFCC DCU
3 FullConv.HCU+DHT(Integrated) DCU
4 VGOHDT+PetroFCC SDA+SlurryHCU(50%DAO)
5 OHCU+PetroFCC SDA+SlurryHCU(50%DAO)
6 FullConversionHCU SDA+SlurryHCU(50%DAO)
7 ConventionalFCC DCU
8 FullconversionHCU DCU
9 VGOHDT+PetroFCC SDA+SlurryHCU(60%DAO)
10 OHCU+PetroFCC SDA+SlurryHCU(60%DAO)
11 FullconversionHCU SDA+SlurryHCU(60%DAO)
Cases Studied
Slide70
EuroVGASOIL
COKE
KERO
VGOHDT
FCCPC
DCU
POLYPROPYLENE
ALKYLATION
EuroVGASOLINE
LPG
DHT
NHT/CCR/ISOM
CDU/VDU
PPU
FCCNap.Splitter
EuroIVGASOLINE
EuroIVGASOIL
BITUMEN
Sample Block - VGO HT + PFCC + DCU
Slide71
EuroVGASOIL
COKE
KERO
HCU
ALKYLATION
EuroVGASOLINE
LPG
DHT
NHT/CCR/ISOM
CDU/VDU
EuroIVGASOLINE
EuroIVGASOIL
SDA SlurryHCU BITUMEN
Sample Block - FC HCU + DHDT + Slurry HCU
Slide72
Raw water & Drinking water system Compressed air system Fuel gas system Fuel oil system Condensate Recovery system Nitrogen System Cooling towers DM water treatment plants Generation & Distribution of steam Generation & Distribution of Power Flare system
Refinery Power & Utilities
Slide73
Slide74
Refinery IntegrationBenefits
DistributionProductsProcessingTreatingSupply
Asset Utilization
Environmental Concerns
Slide75
Integration with PetrochemicalsPetrochemical Sector: 13% annual growth projected
Major Petrochemicals : Ethylene, Propylene, Butadiene, PVC, HDPE, BTX, etc.
Crude Oil
Associated Gas
LPGEthane Methane
PropyleneEthylene C4s
Naphtha
PyGas TolueneBenzene Xylene
Naphtha
AromaticsOlefins
Slide76
Cases Studied
Case-1: VGO HDT, FCC-PC, DCU, AC and PC
Case-2: OHCU, FCC-PC, DCU,AC and PC
Case-3: OHCU, DCU, AC and PC (in this case OHCU bottoms are routed to Naphtha Cracker)
Case-4: VGO HDT, FCC-PC, LC Fining, AC and PC
Case-5: Part MRDS, DCU, FCC-PC, AC, and PC
Integration with Petrochemicals
Slide77
CDU / FCCU / OHCU / DCU
HEAVY NAPHTHA HDT CCR
HY.
NAPHTHAREFORMER SPLITTER
LT. REFORMATE
HY. REFORMATE
SULFOLANE EXTRACTION UNIT
BENZENE TOLUENE EXTRACTION
TRANS ALKYLATION
XYLENE FRACTIONATION UNIT
XYLENE ISOMERISATION
PARA XYLENE SEPARATION
PARA XYLENE 800 TMT
BENZENE 340 TMT
Integrated Refinery with Aromatics complex
Slide78
Vac. GASOILS / Crk. GASOILS
VGO
DHDT
UNIT
ETHYLENE
CRACKER
UNIT
SWING UNIT
MEG UNIT
ETHYLENE
LLDPE / HDPE
Integrated Refinery with Petrochemical Block
HDPE UNIT HDPE
MEG
DEG
362 TMT
400 TMT
700 TMT
135 TMT
HY. NAPHTHA
FCC OFF GAS
Syn. Diesel/
Naphtha
PART DIESEL FROM DHDT
CPCL NAPHTHA
1200 TMTPA
668 TMTPROPYLENE
Slide79Slide79of64
FCCU PC
CRACKED LPG
PROPYLENE RECOVERY UNIT
PROPYLENE POLY PROPYLENE UNIT
POLY PROPYLENE
PROPYLENE EX-CRACKER
1120 TMT
668 TMT
432 TMT
FCC Unit with Petrochemical Block
Slide80
Gasification: A commercially proven process that convertshydrocarbons such as heavy oil / petroleum coke, and coal intohydrogenandcarbonmonoxide(synthesisgas).
4 CH + 2 H2O + O2 4 H2 + 4 CO(Fuel) (Water) (Oxygen) (Hydrogen) (Carbon Monoxide)
SyngasGasification Technology
Competitive with unconventional & alternative resourcesExtensive commercial applicationGenerate value added productsFeedstock and product flexibility
Refinery Power Integration
Slide81
Gasification MultipleSegmentOptions
PetCoke/ Coal
SNG thruMethanation
Syngas Hydrogen / Power / Steam
Power
Fuels by F-T Synthesis
ChemicalsSulphur
Slag
Slide82
Refinery Power IntegrationCoke from Coker Unit can be Gasified to produce Syngas & Power / Hydrogen
Slide83
Project Execution Methodology
Conceptualization of Project
Project Formulation
Preliminary FeasibilityReport (PFR) Stage
Licensor Selection
Process Package Preparation
Detailed Feasibility Report (DFR)
Final Investment Approval from Board
Project Implementation Phase
Mechanical Completion of the unit
Pre-Commissioning & Commissioning stage
Unit Start-up & Stabilization
Carry out PGTR
Project Completion
Phase-I Phase-II
Slide84
PFD REVIEW
P&ID REVIEW
ENGINEERING KICKOFF
HAZOP & 3D MODELING
ORDERING/FABRICATION
ERECTION/CONSTRUCTION
P&ID CHECK/INSPECTION
PRE-COMMISSIONING
START-UP & PGTR
FLUSHING/LEAK TEST
P&ID CHECK/INERTING
1ST DRYOUT
CAT. LOADING
2ND DRYOUT
FINAL INERTING
FEED CUT-IN
Phase-II Breakdown Structure
Slide85
Parameters Studied during the Project Evaluation
Various Refinery Configurations will be evaluated based on
Economic Feasibility Capex & Opex of projects Yield of Distillates Refinery Margins Plot Plan Availability
Financial Appraisal Net present value Internal Rate of Return
Slide86
Financing Assumptions D/E ratio, interest rate, repayment tenor, moratorium period, etc. Macro-economic assumptions
The net GRM for the project worked out by deducting Operating Costs
Net incremental cash flows to the project worked out by deducting Tax Outgo Capital investment Net working capital from the net benefit Financial viability of the project established by computing post-
tax IRR and NPVNet Incremental Cash Flows = [ Incremental GRM ] less [ Opex +Income Tax +
Core Capital Investment + Increase in Net Working Capital ]
Financial Appraisal
Slide87
1. REFINERY PROCESSES
2. REFINERY CONFIGURATION
3. PROJECT DESIGN ASPECTS
PRESENTATION PLAN
Slide88
PROJECT DESIGN ASPECTS
Slide89
Design Aspects
Unit/Equipment Design Philosophy (Margin & Turndown)
Battery limit philosophy for units
Vacuum Design
Instrumentation Philosophy
Metallurgy of Equipments (e.g. DSS for Water Coolers)
Piping Material Specifications
Energy efficiency / integration systems
Adherence to Standard Design & Codes
Slide90
Codes & StandardsBIS Bureau of Indian standards
ASME American Society for Mechanical Engineers
API American Petroleum Institute
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
AISI American Iron and Steel Institute
AWWA American Water Works Association
SSPC Steel and Structure Painting Council
MSS-SP Manufacturer Standardization Society - Standard Practice
NACE National Association for Corrosion Engineers
BS British Standard Specification
Slide91
Codes & Standards
ASME Codes For Mechanical devices such as pressure vessels, boilers (e.g.) ASME Section 8, B 31.3 : Standards of process piping
API Standards Designed to help users improve the efficiency and cost-effectiveness
of their operations (e.g.) API 610 : centrifugal pumps (e.g.) API 682 : mechanical seals (e.g.) API 6D : Pipeline Valves (e.g.) API 560 : Fired Heaters (e.g.) API 616 : Gas Turbines (e.g.) API 617, 618 : Compressors
Slide92
Other Codes & Standardscontd.
IS (Indian Standard) Codes For civil works and construction (e.g.) IS-456 for Plain & Reinforced Concrete
TEMA Standards For Heat Exchangers
Slide93
Sl# Parameter Minimum Normal /Average
Maximum /Design
(A) METEOROLOGICAL DATA1 Elevation above mean sea level, m 3.52 Barometric pressure, mbar3 Ambient temperature, C tmin =18 tnor = 35 tmax =454 Relative humidity, % @ tmin @ tnor 80% @ tmax5 Rainfall data (mm) (a) for 1-hour
period(b) for 24-hour period
100450
6 Wind data (a) wind velocity
(b) wind direction
180 km/hr (as per IS:875 Part-III).North East & South West
(B) DATA FOR EQUIPMENT DESIGN 1 Design dry bulb temperature, C 382 Design wet bulb temperature, C 293 Low ambient temperature for MDMT, C NA4 Design air temperature for air cooled exchangers
where followed by water cooling, C40
5 Design air temperature for air cooled exchangers where not followed by water cooling, C
42
6 Coincident temperature and relative humidity for Air Blower / Air Compressor design.
80 % at 45 o C
7 Min. Design temperature for equipment 65 o C
Meteorological Design Data
Slide94
Plant Life
Default plant operating life as 15 years with 5% salvage value will be considered for economic calculations.
The default plant equipment design life shall be taken as follows:a) 30 years for heavy wall reactors and separatorsb) 20 years for columns, vessels, heat exchanger shells and similar
services.c) 12 years for piping, furnace tubes, High Alloy exchanger tube bundles.d) 5 years for Carbon Steel / Low Alloy heat exchanger tube bundles.e) 15 years for reactors removable internals
Slide95
Sl Parameter Minimum Normal Maximum Mech Design
1 VERY VERY HIGH PRESSURE (VVHP) STEAM Pressure, kg/cm2g 90 95 95 104/FVTemperature, oC 495 505 505 505
2 VERY HIGH PRESSURE (VHP) STEAMPressure, kg/cm2g 44.8 48 54.9 58.0/FVTemperature, oC 379 425 435 440
3 HIGH PRESSURE (HP) STEAMPressure, kg/cm2g 29.5 30.5 32.5 36.0/FVTemperature, oC 270 280 290 300
4 MEDIUM PRESSURE (MP) STEAM Pressure, kg/cm2g 9.5 10.5 12.5 15.0/FVTemperature, oC 200 220 240 280
5 LOW PRESSURE (LP) STEAM Pressure, kg/cm2g 2.7 3.5 4.0 7.0/FVTemperature, oC Saturated 170 190 240
6 CONDENSATE RETURN Pressure, kg/cm2g 5.0 13Temperature, oC 140-150 210
7 SERVICE WATERPressure, kg/cm2g 6.0 10.5Temperature, oC Amb. 65
8 COOLING WATERSupply Pressure, kg/cm2g 4.5 8.0Return Pressure, kg/cm2g 2.5 8.0Supply Temperature, oC 33 65Return Temperature, oC 45 65
9 DEMINERALISED WATER Pressure, kg/cm2g 7.0 8.0 9.0 14..0 Temperature, oC Amb. Amb. Amb. 65
Utility Conditions @ Unit Battery Limits
Slide96
Sl Parameter Minimum Normal Maximum Mech Design10 BOILER FEED WATER (MP/HP)
Pressure, kg/cm2g 19.0/38.0 29.0/55.0Temperature, oC 105-110 150/150
11 PLANT AIR Pressure, kg/cm2g 5.0 6.0 6.5 10.0Temperature, oC Amb. Amb. Amb. 65
12 INSTRUMENT AIRPressure, kg/cm2g 5.0 6.0 10.0Temperature, oC Amb. Amb. 65
13 FUEL GAS Pressure, kg/cm2g 2.5 3.0 3.8 7.0Temperature, oC 40 65
14 REFINERY FUEL OILSupply Pressure, kg/cm2g 10.0 12.0 17.5Return Pressure, kg/cm2g 2.5Temperature, oC 80 165-200 220 250
15 SURFACE CONDENSATE (EX TURBINE)Pressure, kg/cm2g 6.0 15.0Temperature, oC 40 100
16 NITROGENPressure, kg/cm2g 5.0 6.0 7.0 9.5Temperature, oC Amb. Amb. Amb. 65
Utility Conditions @ Unit Battery Limits
Slide97
WATER SYSTEMSBackflush arrangement shall be provided for All cooling water consumers Only overhead condensers Cooling water consumers with water line sizes greater than NB.
Back flush lines to be provided with same size as main cooling water line when main line size is 6. One size lower to be provided for main line size > 6 For much higher line sizes e.g 14 and above to be decided based on case to case basis
Slide98
Water Qualityl Parameter Cooling Water
make up ( from TTP of ETP)
Cooling Water DM Water
BFW
PH 7.2-7.5 7.2-7.7 6.8-7.2/8.3-8.5 8.5-9.5
Turbidity, NTU < 2
Slide99
Water Qualitycontdl Parameter Treated Raw Water as DM water
Make upDesalinated water as DM water
make upPH 7 - 7.8 7-7.8Turbidity, NTU 15 NATotal suspended solids, Total dissolved solids, NA mg/l 350 Conductivity micromho/cm NA 493Mo Alkalinity, 240 (as CaCO3)mg/l 2.9 (as CaCO3)mg/lCa Hardness as CaCO3, 176 mg/l 1.3 mg/l (as Ca)Total Hardness as CaCO3, Total cation/anion asCaCO3, 608 NATotal Silica as SiO2, 40 0.1Colloidal Silica as SiO2, mg/lSodium as Na, 344 (as CaCO3) mg/l 135.3 (as CaCO3) mg/lPotassium as K, mg/lChlorides as Cl, 172 mg/l 142-220 mg/lFree chlorine,Sulphates as SO4, 121 mg/l 12.5 mg/lPoly phosphates as PO4,Nitrates as NO3, NA mg/l 0.2 mg/lTotal Iron as Fe, 0.3 mg/l NACopper + Iron, Mg , Hardness NA mg/l 4.5 mg/lZinc as Zn, Zinc Sulphate as Zn, Boron, mg/l NA 1 mg/lDissolved Fe, mg/ lOil content, KmnO4 value at 100 oC, 20 mg/l NAHydrazine (residual), Morpholine (residual),
Slide100
Compressed Air & Nitrogen System
Sl Parameter Plant Air Instrument Air
1 Dew Point at atmospheric pressure water-free (-)40oC
2 Oil Content, ppm nil nil
Sl Parameter Inert Gas Nitrogen1 Dew Point at atmospheric pressure (-) 100oC
2 Oil Content, ppm nil3 Nitrogen purity, vol% 99.99
4 Oxygen content, vol ppm 3 (max)
5 Carbon dioxide content, vol ppm 1 (max)
6 Carbon monoxide content, vol ppm nil
Slide101
Liquid fuel system for the project shall be one of the following. No liquid fuel system applies to the project. Existing liquid fuel system in Refinery III shall cater to the project,
After Augmentation, if required. Alternately, new liquid fuel system shall be provided.
Fuel gas system for the project shall be one of the following. No fuel gas system applies to the project. Existing fuel gas system in Refinery III shall cater to the project,
After Augmentation, if required. New fuel gas system for the total project:
(a) Integrated to existing facility (b) Independent of existing facility
Refinery Fuel Systems
Slide102
9 Burner turndown requirements have to be met at liquid fuel pressures at burner not less than the normal anticipated return header pressure. The fuel oil system shall be designed for a recirculation rate of 2:1.
9 Fuel gas liquid knockout drums and tracing for piping shall be separate for each process unit.
9 In-line strainers in burner piping are recommended for each unit. These shall be located not more than 20 meters upstream of the burner manifold and shall be 1 on-line + 1 spare strainer with mesh sizes 100 for Fuel Oil, Fuel Gas and atomising steam.
9 In-line strainers for FO, FG and atomising steam to be provided on common header supplying to all heaters within each unit.
9 Hot liquid fuel temperature shall be assumed to drop by 5oC between unit battery limits and burner manifold.
Fuel Systems
Slide103
Sl Parameter Case-1 Case-2 Case-3 (Note-C)
1 Name PG VR BH VR+VAC.DIESEL
UCO+VR
2 Crude stock 3 Density @ 15oC, kg/m3 930 - 1030 978 852-8574 Sulfur content, wt% 4 (Note-1) 0.84 0.275 Nitrogen content, wppm 3700 1000 (max.) 3006 Nickel content, wppm 18 37 Vanadium content, wppm 200 5 118 Sodium content, wppm 80 129 Copper content, wppm
Slide104
Case A Case B Case C Case D Case E Case F Case GCOMPONENTMOLE % Normal
OperationRefinery Start
up case
Max FG production
H2O 0.81 0.13 1.29
0.86
0.43 0.31 0.69
H2 35.35 80.1 0.0 45.49 34.48 74.96 25.63
C1 29.43 8.01 0.0 25.95 26.35 11.41 32.6
ETHYLENE 0.45 0.24 0.0 0.0 0.79 0.18 0.32
C2 16.08 4.04 9.43 15.06 13.29 6.23 20.64
PROPYLENE 1.21 0.64 0.0 0.0 2.11 0.47 0.85
C3 7.96 2.59 44.08 6.06 8.53 3.09 9.44
IC4 1.99 0.93 9.09 1.48 3.06 0.76 2.23
1BUTENE 0.50 0.26 0.0 0.0 0.87 019 0.35
NC4 3.22 1.63 36.07 2.59 5.36 1.24 5.43
1C5 06 0.17 0.04 0.77 1.05 0.13 0.27
NC5 1.32 0.79 0.0 0.94 2.31 0.57 0.87
C6+ 0.78 0.31 0.0 0.78 0.83 0.34 0.5
H2S Note-1 Note-1 Note-1 Note-1 Note-1 Note-1 Note-1
NH3 0.00 0.00 0.00 0.00 0.01 0.00 0.00
N2 0.30 0.16 0.0 0.0 0.53 0.12 0.21
TOTAL 100.00 100.00 100.00 100.00 100.00 100.00 100.00
MW 20.004 8.2533 48.79 16.717 22.537 8.9845 22.66
KGM/HR 354.51 667.9 0.353 275.5 203 914.7 507.4
KG/HR 7091.5 5512 17.2 4605 4575 8218 11498
LHV, Cal/kg 11798 14544 10964 12184 11648 14120 11613
Fuel Gas Specifications
Slide105
Refinery Flare systemFlare systems for the project shall be:
Existing Refinery flare system will be used, if found adequate. Alternately, new flare header shall be provided for the project.
Single flare for all released streams Normal flare for hydrocarbons and Acid gas flare for released acid gases Separate high-pressure flare header for flared hot, hydrogen rich
gases Hydrocarbon drain from the Flare K.O. drum will be routed by gravity flow
to the CBD. In addition, pump-out facility will be provided for the Flare K.O. drum.
Philosophy of relieving flammable vapors shall be: Vapor releases of all molecular weights to be connected to flare system Vapor releases below molecular weight of vented to atmosphere Hot hydrogen-rich gases (>300C) vented to atmosphere Other:
For adherence to OISD standard # 106, individual units shall be provided with a flare knock-out drum whenever significant liquid relief is anticipated from the pressure relieving devices, apart from the main knock-out drums at the flare stack. Unit designer / contractor shall specify a horizontal unit flare KOD, sized to separate out liquid droplets down to a size of 400 .
Slide106
# Flare system Built- up back pressure,kg/cm2g
Superimposed back pressure at unit battery limits, kg/cm2g
Built-up back pressure at PSV outlet,kg/cm2g
1 Normal flare 0.2 default = 1.5 default = 1.72 Acid Gas flare 0.2 default = 0.5 default = 0.73 High Pressure flare
# Contingency Low pressures< 70 kg/cm2g
High pressures> 70 kg/cm2g
1 Steam generating / consuming equipment under IBR
5% (as per IBR)
5% (as per IBR)
2 Fire case 20% as per designer
3 Thermal relief 25% as per designer
4 Operational failures 10% as per designer
Maximum flare backpressure shall be considered for sizing of pressure relief devices
Overpressure (as percentage of set pressure) for sizing relief valves
Refinery Flare system
Slide107
Liquid Pumpout & Drain Systems
Congealing hydrocarbon drains: Combined with non-congealing hydrocarbon drains. Provided with combined cooling and heating coil
Steam generator blowdown drains: Flash MP and HP blowdowns for recovery of LP Steam. The LP steam vessel
liquid to be cooled in a CW exchanger to 40 deg C and route to Cooling tower sump through cooling water sump/pumps.
Non-congealing hydrocarbon drains: Buried Closed Blowdown drum shall be: Standard size of 10m3 to cater to only residual drains. Individually sized for each unit for single largest equipment inventory. Provided with cooling coil Connect equipment to closed blow down (CBD) network leading to a CBD drum.
CBD drum will be located in a pit and the same will be sand filled. Design CBD system for 200oC.
Caustic drains:All bulk caustic inventory drains shall leave process unit under own pressure or be pumped out. For residual caustic drains such as unpumpable vessel bottoms, level gage drains, etc., one of the following shall be adopted:
Provide underground caustic CBD system with buried vessel and pumpout. Collect residual drains by temporary facility like drums and jars. Provide caustic drains to nearby neutralization pit outside the unit area.
Slide108
Acidic drains:(a) Amine systems Bulk amine drains shall be only lean amine, displaced to amine storage tank. All rich amine streams shall be routed to amine regeneration section under own pressure or under inert gas pressure or displaced with water. Residual amine drains shall be connected to a buried amine closed blowdown system located in the Amine Regeneration section. Amine-bearing drains from Amine Wash sections shall be routed to this buried vessel or collected through temporary facilities. Individual units handling amine will be provided with separate buried amine closed blowdown system from where amine stream will be pumped to regeneration unit.
(b) Sulphuric acid systems When consumed only in non-process areas, temporary facilities will be defined. Sulphuric acid storage and unloading facilities near cooling tower (existing).
(c) Process sour waters1. Process sour waters shall normally be routed to identified sour water strippers. Residual drains or during intermittent situations where unavoidable, these may be drained to oily water sewer. The effluent treatment plant designer shall be advised to incorporate provisions to receive the single largest parcel of such sour water.2. Flare water seal drum sour water to be sent to sour water stripper.
Liquid Pumpout & Drain Systems
Slide109
FLUSHING OIL SYSTEMS
Normal flushing oil (FLO)- No flushing oil tank and pumps will be provided in outside battery limits.- OSBL flushing oil header will be provided with mainly CDU/VDU Gas oil, which will have hot or cold gas oil to the header. The main header also will have alternate source of FLO. - For external flushing of pumps API seal plans, or for purging instruments in congealing service, the FLO pressure will be boosted. For this purpose, a separate vessel with (1+1) screw pumps will be provided independently with in the respective unit. The connection for make up flushing oil to vessel will be provided from maintenance Flushing oil header.
Heavy flushing oil (HFLO)Straight run Vacuum Gas Oil from CDU/VDU will be taken as Heavy Flushing Oil for external flushing of hot, heavy fluid handling pumps API seal plan. To maintain the temperature of VGO about 80-110 C, the separate vessel with steam coil will be provided with in the unit. A separate set of screw pumps (1+1) will be provided to pump the flushing oil to necessary pressure level for pump seal flushing.
Operating condition Mechanical DesignSl# Stream
P, kg/cm2g
T, oC P, kg/cm2g T, oC
1.2.
Flushing Oil (Gas Oil)Heavy Flushing Oil (VGO)
6.0-16.04.0-6.0
40-10370-80
27.027.0
141100
Slide110
Energy integration
Improvement in overall energy efficiency shall call for unit-level and total plant-level optimization of energy. Designer of a particular unit shall indicate the following at the outset of design activities:
(a)The total energy consumption expressed as equivalent fuel oil (Btu/bbl or FOE
(b)The preferred temperatures for hot feeds and products from an energy (c)integration standpoint, if these are significantly different from that stipulated in unit BEDB.
(c)Energy shall be preferentially recovered into process streams. Steam generation shall be considered thereafter to recover excess available energy. Steam generation levels shall be chosen to preferably match the corresponding steam level demand within unit.
(d) Low-level energy recoverable for external consumption, say, for Boiler Feed Water preheat serving other units.
Slide111
Vacuum Design
Vacuum design conditions shall be stipulated for:
(a) Equipment operating normally under vacuum conditions
(b) Equipment that are subjected to vacuum conditions during start-up, shutdown, regeneration or evacuation.
(c) Liquid full vessels that can be blocked in and cooled down
(d) Distillation columns and associated equipment that can be subjected to vacuum conditions through loss of heat input.
(e) All steam users consuming steam during normal operation.
(f) Pressure vessels containing liquids having vapor pressure at minimum ambient temperature less than atmospheric pressure.
Vacuum design conditions are not to be specified for the eventuality of blocking in after equipment steam-out or operator maloperation.
Slide112
EQUIPMENT DESIGN PHILOSOPHY%turnup %turndown
Process Towers (atmospheric or above) 10%Process Towers (vacuum) 10%Fired Heaters (potentially coking services) 15%*
Fired Heaters (clean services) 15% *Heat exchangers (fouling service): overdesign on duty 10%
Heat exchangers (fouling service): overdesign on flow 10%
Heat exchangers (clean service): overdesign on duty 10%
Heat exchangers (clean service): overdesign on flow 10%
Tower overhead exchangers: overdesign on flow & duty and reboilers
20%
Pumparound exchangers: overdesign on flow 20%
Recycle compressors 10% Make-up compressors 10% minimum
Pumps in general 10%Reflux and pumparound pumps 20%3-phase separators (in and out flowrate) 10%2-phase separators(in and out flowrate) 10%Crude preheat exchangers 15%
Slide113
Selection Of Mechanical Design Conditions
Equipment and piping systems shall be designed for the most stringent coincident temperature and pressure conditions, accommodating the maximum expected working pressure and temperature without causing a relieving condition
A pressure system protected by a pressure relief device connected to the flare system, shall have a mechanical design pressure, calculated at the location of the relieving device, as the higher of the following:
I)For operating pressures above 70 kg/cm2g, mechanical design pressure shall be as per designer, subject to a minimum of 77 kg/cm2g.II)For operating pressure up to and including 70 kg/cm2g, design pressure shall be the highest of the following:Maximum operating pressure (kg/cm2g) x 1.1Maximum operating pressure + 2.0 kg/cm2
Vessels operating under vacuum shall be, in general, designed for an external pressure of 1.033 kg/cm2abs and full internal vacuum, unless otherwise specified
Slide114
For a full liquid system at the discharge of a centrifugal pump, the mechanical design pressure shall be as under:
Pdes = Pmax suction + Pmaxwhere,Pmax suction = Maximum pressure at suction vessel bottom during suction system relieving conditions (as per 8.2.1.2)Pmax = Pump differential pressure at pump shutoff head with maximum operating density. If not known:Pmax = 1.2 x H x max : constant speed pumpPmax = 1.1 x 1.2 x H x max: variable speed pumpPmax = 1.3 x H x max : high head multistage pump
For a full liquid system at the discharge of a positive displacement pump, the mechanical design pressure shall be the higher of:
Pdes = Prated discharge + 2 kg/cm2Pdes = 1.1 x Prated discharge
Selection Of Mechanical Design Conditions
Slide115
For shell-and-tube heat exchangers, the low pressure (LP) side shall be preferably specified with a design pressure at least equal to 10/13 of high pressure (HP) side design pressure, in order to avoid having to install a pressure relief device on the LP side
For systems operating at or above 0oC, the mechanical design temperature shall be the higher of the following:
Tdes = 65CTdes = Tmax + 20CTdes = Trelief (excluding fire relief temperatures)
For systems operating below 0C, the mechanical design temperature shall be equal to the lowest anticipated operating temperature.
Selection Of Mechanical Design Conditions
Slide116
Furnace - Design Aspects
Slide117
FURNACE
TYPES OF FURNACE Cylindrical furnace
Low plot space Low cost Higher heat flux For clean services
Box furnace High plot space High cost Even heat flux For fouling services
Slide118
FURNACE
TYPES OF FURNACE Natural Draft
Air for combustion enters due to pressure difference Forced Draft
FD fan is used to supply air, usually air gets heated up in convection zone.
Balanced Draft
FD fan is used to supply air and ID fan is used to suck the fluegas and heat is exchanged between air and flue gas through an external heat exchanger (APH)
Slide119
FURNACE
TYPES OF FURNACE Single fired heater
Common pattern in heaters For low fouling / sensitive fluid Peak flux >80% of average flux
Double fired heater For high fouling service Low residence time Fire on both side of coil Uniform heat flux & peak flux < 20% of average flux
Slide120
Fired HeatersSelection of fuelFired heaters shall be designed for continuous operation with:
100% firing on either fuel oil or fuel gas or any combination of both, unless constrained to reject use of fuel oil from reasons of process or acid gas dew point. 100% firing on fuel gas for heaters less than 1.5 MMKcal/hr.
Target efficienciesAchievable fired heater efficiencies depend on service, furnace heat duty, process temperatures and quality of fuel. Highest target efficiencies shall be pursued by a unit designer, as found economically justified. Options such as cast tube and glass tube air preheaters, steam generation and superheat, etc., shall be evaluated. Target efficiency shall be: 92% on fuel gas fired heaters only 90% on combination firing heaters (with either fuel oil or fuel gas or dual fuel mode)
Excess Air Fuel Oil Fuel GasNatural Draft 25 % 20 %Forced Draft 20 % 15 %
Slide121
Fired HeatersHeater stackStacks shall be individually mounted on each heater unless there are considerations such as grade-mounted APH or combined APH system for a group of heaters.
Minimum fired heater stack heights shall be the higher of indicated heights in respective unit BEDB Part-A documents or as calculated from the formula below:
H = 14 (Q)0.3(Minimum stack height as per TNPCB / MoE&F to be provided, SOx / NOx nozzles to be provided)
where, H: stack height, metresQ: total SO2 emission, kg/hr
Slide122
Middle of Radiant Section Convection Section
Furnace Burner
HEX - Design Aspects
Slide123
FURNACEOPERATION
Draft inside the furnace
Air ingression
Arch pressure slightly positive Stack damper
Combustion air control thro Air registrars
Excess air : 5-10% for gas and 10-15% for fuel oil
Monitored & controlled by Arch zone O2 analyser
Skin temperature
Stack temperature
Slide124
FURNACE
INTERLOCKS
Process fluid low / no flow
Fuel oil / gas - ring pressure low
Arch pressure high
APH interlocks
FD fan trip
ID fan trip
Arch pressure high
SPECIAL OPERATION Economiser
Steam Soot blowing
Steam air Decoking Steam spalling
Temperature cycling
Coke burning Convection water wash
Slide125
Standard fired heater piping & instrumentation(a) Low-low fuel oil supply pressure shuts down fuel oil supply and return
(b) Low-low fuel gas pressure shuts down fuel gas supply but keeps pilots running.
(c) Low-low heater pass flow shuts down fuel oil and fuel gas but keeps pilots running.
(d) Low Low pilot gas pressure shuts down the pilot gas supply
(e) Low-low differential pressure between atomising steam and fuel oil shuts down fuel oil supply and return.
(f) Emergency shutdown shuts down fuel oil and fuel gas as well as pilots.
(g) Emergency coil steam, manual or automated, depending on criticality.
(h) Draft gage connections at: Burners Below convection Above stack damper Below stack damper
(i) Flue gas sampling connections at: Below convection section Below stack damper
(j) On-line analysis with location as per (g), connections mounted at the same plane: O2 analyser NOx analyser SOx analyser SPM analyser CO analyzer HC
analyser
(k) Temperature measurement connections below convection section, below stack damper, at hearth level.
(l) Skin thermocouples shall be considered for measuring temperature of furnace tubes.
Slide126
HEX - Design Criteria
9 Material selection9 Thickness Calculations
Shell, Channel, Covers, Tube sheets9 No of shell passes9 Velocity of the fluid9 Pressure Drop9 Tube Pattern9 Consideration of Fluids through Tubes9 Easy maintenance
Tube size, U- Tube, Cover header, Fluid choice
Slide127
Tube Metallurgy with Carbon steel
Tube MOC with Stainless Steel
HEX Material of Selection
Slide128
HEX - Codes & Standards
Typical TEMA TypeHeat
Exchangers
Slide129
Codes & StandardsWhich type of TEMA Heat Exchanger?
Slide130
HEX - Design Aspects
Preferred Sizes for Shell && Tube HEX
Tube Metallurgy CS / Low Alloy High alloy/SS/BrassTube Diameter 25 mm 25 mmTube Thickness 2.5 mm 2.0 mmTube Length 6.0 m
Criteria for selection of TEMA Type
Shell side Fouling Resistance
Tube side Fouling Resistance (Hr-m2-C/kcal)
TEMA type
> 0.0002 > 0.0002 Floating head 0.0002 > 0.0002 Floating Head> 0.0002 0.0002 U tube bundle 0.0002 0.0002 Fixed tube
sheet/ U-tube bundle
Slide131
HEX - Design Aspects
Tube Pitch Selection
PitchPattern
PitchAngle
ShellSideFluid
FlowRegime
Triangular 30 Clean All
RotatedTriangular
60 Clean Rarelyused
Square 90 Fouling Turbulent
RotatedSquare
45 Fouling Laminar
Slide132
HEX Sample Datasheet (Pg 1/2)
Slide133
HEX Sample Datasheet (Pg 2/2)
Slide134
PUMPSDESIGN
Selectionoftypeofpumps Sparingofpumps
Specificationofpumpseals
Specificationofdrives
Minimumflowbypass(MFB)provisions&controls
# Operating pumps Rated capacity per pump Spare pumps
2 50% of total normal flow 1
3 33% of total normal flow 1
4 25% of total normal flow 2
Slide135
Steam Turbine drives
When to select a steam turbine drive?Steam turbine drives shall be specified in extremely critical services where even short-term failure of a drive can result in a shutdown from where an operational recovery is difficult, time-consuming or has a large economic penalty, such as irreversible catalyst poisoning.Steam turbine drives shall also be specified for the following drives, that, among other considerations, shall ensure that a power failure does not automatically lead to a steam failure:
(a) Cogeneration / Steam generation plant BFW pumps yes no(b) Cogeneration / Steam generation plant FD Fan yes no(c) Cooling water pumps yes no(d) Compressor lube oil & seal oil pumps yes no(e) Hot well pumps yes no(f)Emergency evacuation pumps yes no
Slide136
PUMPS Sample Datasheet
Slide137
IBR RequirementsScope of IBRSteam generators / steam users shall meet IBR regulations. Major IBR requirements are summarized below:a) Vessels: Any closed vessel exceeding 22.75 litres (five gallons) in capacity which is used exclusively for generating steam under pressure and include any mounting or other fittings attached to such vessels, which is wholly or partly under pressure when steam is shut-off.b) Piping: Any pipe through which steam passes and if:
i) Steam system mechanical design pressure exceeds 3.5 Kg/cm2 g ORii) Pipe size exceeds 254 mm internal diameter
c) The following are not in IBR scope:i) Steam Tracingii) Heating coilsiii) Tubes of tanksiv) Steam Jackets
d) All steam users (heat exchangers, vessels, condensate pots etc.) where condensate is flashed to atmospheric pressure i.e. downstream is not connected to IBR system are not under IBR and IBR specification break is done at last isolation valve upstream of equipment.e) All steam users where downstream piping is connected to IBR i.e.condensate is flashed to generate IBR steam are covered under IBRf) Deaerator, BFW pumps are not under IBR and IBR starts from BFW pump discharge.
Slide138
INSTRUMENTATION
InstrumentationPhilosophyforallequipments&pipelines
E.g.)PackedTowersForcolumndifferentialpressureindicationtwoseparatePTshallbeprovidedanddifferentialpressureshallbederivedinDCS.
Localdifferentialpressureindicationforeachbed: yes no Localdifferentialpressureindicationfortotalsection: yes no ControlRoomdifferentialpressureindicationforeachbed: yes no ControlRoomdifferentialpressureindicationforcriticalbeds: yes no ControlRoomdifferentialpressureindicationfortotalsection: yes no 1+1Basketstrainersinlinesgoingtopackedbeds: yes no Singlebasketstrainersinlinesgoingtopackedbeds: yes no
Slide139
Utility Line InstrumentationUTILITY local
PIDCSPI
PAL/PAH
localTI
DCSTI
TAL/TAH
DCSFI
FAL/FAH
DCSFQ
MP STEAM 9 9 9 9 9 9 9 9 9
LP STEAM 9 9 9 9 9 9 9 9 9
Condensate 9 9 9 9
CW supply 9 9 9 9 9 9 9 9
CW return 9 9 9 9
Instrument Air 9 9 PAL 9 9 9
Plant Air 9 9 9Inert Gas 9 9 9 9 9 9Fuel Gas 9 9 9 9 9 9 9 9 9Fuel Oil 9 9 9 9 9 9 9 9 9DM Water 9 9 9 9 9 9Service Water 9 9 9
Flare 9
Slide140
Block & Bypass Valve Size for Control Valve ManifoldControl Valve SizeLine
SizeBlock & By paas Valve
0.5 0.75 1 1.5 2 3 4 6 8 10 12 14 16
0.5 BlockBypass
0.50.5
0.75 BlockBypass
0,750.75
0.750.75
1 BlockBypass
11
11
11
1.5 BlockBypass
1.51.5
1.51.5
1.51.5
1.51.5
2 BlockBypass
22
22
22
22
3 BlockBypass
22
22
33
33
4 BlockBypass
33
33
43
44
6 BlockBypass
44
64
66
8 BlockBypass
66
66
86
88
10 BlockBypass
88
88
108
1010
12 BlockBypass
1010
1010
1210
1212
14 BlockBypass
1210
1412
1414
16 BlockBypass
1412
1614
1616
Notes:1.All sizes are nominal sizes in inches.2.Bypass pipe diameter shall
be same as bypass valve.3.Bypass valve will be globe
valve upto 8" size and gate valve above 8".
Slide141
Control Valve Sample Datasheet
Slide142
PIPING & INSULATION Insulationthicknessforheatconservation,personnelprotection,electrically
tracedlines&coldinsulation
MaterialUsage CellularGlassforprocesstemperaturesupto350C. RockWoolforprocesstemperatureupto550C CalciumSilicateforprocesstemperaturesfrom551 760C.
AdherencetostipulationsofOISDstandard#118formin. interequipmentspacingandinterdistancebetweenprocessunitandoffsites
Steamtracingforpipinghandlingcongealingservicesshallbe: Steamtracingwithinunitbatterylimits,electrictracingforoffsitesupto
150C
Steamtracingwithinunitbatterylimits,electrictracingforoffsitesupto250C
Steamtracingforbothbatterylimitsandforoffsites LPSteamuptovacuumgasoils,MPSteamforheavyresidues MPSteamforallcongealingservices
Slide143
Environmental Parameters
Sulphur Recovery for reduced sulphur emissions
Flare gas recovery unit to recover hydrocarbons
Usage of low sulfur fuel in all process heaters/boilers
Incorporation of Low NOx Burners/DeNOx Technology
Continuous Ambient Air Monitoring & Stack Monitoring
Segregated collection of solid wastes.
Oil sludge treatment is done through chemical, mechanical and
bio-remediation routes.
Slide144144
Environ Impact Assessment Study
Slide145145
IsoplethsShowingMeasuredSPMConcentrations
-15000 -10000 -5000 0 5000 10000 15000
X Direction (East) Distance, m
-15000 -10000 -5000 0 5000 10000 15000
-15000
-10000
-5000
0
5000
10000
15000
Y
D
i
r
e
c
t
i
o
n
(
N
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)
D
i
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a
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,
m
-15000
-10000
-5000
0
5000
10000
15000
1234567891011121314151617181920212223242526272829303132333435363738
394041
0
50
100
150
200
250
300
Pollutant: SPM
Unit: ug/m3
0 1000 2000
Scale
m
Slide146146
Min Max AvgSl.No. Parameter g/m31 SPM 18 287 70 234
2 RSPM 15 147 34 70
3 SO2 6 40 7 124 NOx 3 15 3 7
5 H2S 1 23 1 4
6 NH3 5 57 6 34
7 HC and VOC 10 14 -
Ambient Air Quality Data
Fugitive Emissions from the Work Zone Area of MRC Benzene < 1 ppm (OSHA)
Slide147147
Environment Noise & WaterParameter Residential Commercial Industrial Inside the
Plant Area
Noise levels(dBA)
46 - 82 72 - 79 66 - 79 77 - 84
Standard(dBA)
55 65 75 85
Water Environment
Surface WaterGround WaterBacteriological Quality
Slide148148
Risk Analysis Study
HeatRadiationEffectsduetoBLEVE(CDUVDU)
37.5kW/m2(315m)
12.5kW/m2(591m)
4.0kW/m2(1032m)
Slide149
Individual & Societal Risk Factors due to that project are studied & analysed
Risk Analysis Study
Slide150
REFINERY PROCESSING STEPSCRUDE- FEED PREPARATIONPREHEAT TRAINS & FURNACEATMOSPHERIC DISTILLATIONVACUUM DISTILLATIONVACUUM DISTILLATIONCRUDE DESALTERCRUDE FURNACECRUDE ATMOSPHERIC COLUMNLube Oil Base Stocks REACTOR INTERNALSREACTOR INTERNALSCATALYTIC REFORMINGCATALYTIC REFORMINGCATALYTIC REFORMINGCATALYTIC REFORMINGCPCL HYDRO CRACKERSULFUR RECOVERY UNITRefinery ConfigurationKey Considerations & Available OptionsGlobal Economic Downturn & RecoveryGlobal Oil OutlookIndia - Net Oil Import DependenceProjects ClassificationDrivers for New Projects IdentificationImpact of Product Demand Stringent Product SpecificationsDrivers for Revamp Projects IdentificationCrude Feed SelectionTrend in Crude ProcessingProcessing of Opportunity CrudesProcessing of Opportunity CrudesTypes of RefineriesProcessing Units in Oil RefineriesRefinery ConfigurationsRefinery - Integration BenefitsIntegration with PetrochemicalsIntegration with PetrochemicalsGasification Multiple Segment OptionsRefinery Power IntegrationPlant LifeWATER SYSTEMSWater QualityWater QualitycontdCompressed Air & Nitrogen SystemFURNACEFURNACEFURNACEFURNACEFURNACEHEX - Design CriteriaHEX Sample Datasheet (Pg 1/2)HEX Sample Datasheet (Pg 2/2)PUMPSPUMPS Sample DatasheetINSTRUMENTATIONControl Valve Sample DatasheetPIPING & INSULATIONEnvironmental ParametersIsopleths Showing Measured SPM ConcentrationsEnvironment Noise & Water
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