RASHTRIYA ISPAT NIGAM LIMITEDRASHTRIYA ISPAT NIGAM LIMITEDVISAKHAPATNAM STEEL PLANTVISAKHAPATNAM STEEL PLANTVISAKHAPATNAM STEEL PLANTVISAKHAPATNAM STEEL PLANT

BENZOL DISTILLATION PLANT

PRESENTATION PRESENTATION

ON

CFPS CRUDE BENZOL STORAGE TANKS BT-401/3 &

BT-401/4 CHANGING-AN INNOVATIVE APPROACH

P RAJESH VARMAJ SMANAGER(OPERATIONS)

CO&CCPCO&CCP VIZAG STEEL PLANT.

COKE & COAL CHEMICALS PLANTCOKE & COAL CHEMICALS PLANT

1. There are 4 Batteries.1. There are 4 Batteries.2. Each battery consists of 67 ovens.3. Coal is the main raw material.4. Coal is charged into the ovens and in

the absence of air it is heated up to 10000 10000 c.

5. In this process the lot of coke oven gas is generatedgas is generated.

6. This is the main raw material for manufacturing all the coal chemicals. g

COAL CHEMICALSThe main coal chemicals are:

1 T d t 1.Tar products :– Naphthalene– Phenol – Anthracene – Wash oil

Pitch– Pitch2.Benzol plant :– Benzene– Toluene– Light solvent oil– Heavy crude benzol– Heavy crude benzol– S O L – 1103.Ammonium sulphate “ PUSHKALA” fertilizer.

BENZOL PLANTBENZOL PLANT(OBJECTIVES)

• To recover Crude Benzol from Benzolised Oil.• To remove Impurities from Crude Benzol.p• To produce Pure Products such as benzene

,toluene ,xylene from Crude Benzol,toluene ,xylene from Crude Benzol

BENZOL PLANTBENZOL PLANT(SUB-SECTIONS)

• Benzol Distillation Section.• Hydro Refining UnitHydro Refining Unit.• Extractive Distillation Unit.• Crude & Finished Products Storage.

SOLAR OILCRUDE BENZOL MANUFACTURING PROCESS

BO FROM FGC

CONDENSERFGC

PROCESS

FGCCOOLERSCRUDEBENZOL CO GAS

C

STRIPPING COLUMN

CB- I COLUMN

CO GAS

DBO CB 2 DBO COOLER

CB- 2COLUMN DBO

TO FGC

HEAVYC OCRUDE BENZOL

BENZOL PRODUCTS MANUFACTURING.

CB

MAINREACTOR

STAGEEVAPORATOR

OFFGAS

PRE STRIPPER

BTXSRAFFINATE

H2

REACTOR

RC GAS( 95 % H2 )

B/T

N F M

AROMATICSSOL -110

C50

C50

C50

C50

BTXS

N F MBENZENE

1 2 4 5BTXSRAFFINATE

TOLUENEXS

(LSO + SB )NFM +

AROMATICS

TOLUENE

OVERVIEW OF THE PLANTOVERVIEW OF THE PLANT

• THIS PLANT COVERED UNDER EXPLOSIVE LICENSED PLANT.HAVING CLASS A PRODUCTS WITH FLASH• HAVING CLASS-A PRODUCTS WITH FLASH POINTS STARTS FROM -11OC

• BENZOL STORAGE TANK FARM COMPRISES OFBENZOL STORAGE TANK FARM COMPRISES OF 16 NOS OF VERTICAL TANKS AND 20 NOS OF HORIZONTAL TANKS

• THESE TANKS ARE GROUPED IN TWO DYKE WALLS

CRUDE &FINISHED PRODUCT STORAGE UNITSTORAGE UNIT

(EQUIPMENT)

Total Storage capacity• CB Tanks -4Nos -2800klCB Tanks 4Nos 2800kl.• PB Tanks -4Nos -2000kl.• PT Tanks -2Nos - 400kl.• LSO Tanks -5 Nos - 250kl• LSO Tanks -5 Nos - 250kl.• NA Tanks -2Nos - 100kl.• HCB Tanks -2Nos - 200kl.

THE VERTICAL TANKS SIZES (TOTAL 16 NOS)S NO

TANK Nos. TYPE OFPRODUCT STORAGE

Volume of the tanks

Diameter

of the tank in

Height of the tank in mtrs

Weight of the tank in tons

NO OF TANKS(Nos)

tank in mtrs

in mtrs

1 401(1,2,3,4) CRUDE BENZOL

700 m3 10.43 8.34 10+31 4

2 402(1,2,3,4) CG BENZENE

500 m3 8.53 8.7 8+25 4

3 403(1,2) NG TOLUENE

200 m3 4.73 5.88 3+8.5 2TOLUENE

4 405,407/1,407/2

406

3nos HCB

1No LSO

100 m3 4.73 5.88 3+10 4

406 1No LSO5 445 LSO 80 m3 4.73 4.5 3+8 1

6 404(IPS AREA NG 100 m3 4.73 5.88 3+8.5 1(TANK) TOLUENE

11

THE HORIZONTAL TANKS(TOTAL 20 NOS)

SNO TANK Nos Volume of tanks

NO OF TANKS(Nos)

TYPE OF PRODUCT STORAGEtanks TANKS(Nos) STORAGE

CFPS

408(1,2)409,412,417416(1,2)418

50 m3 10nos LSOSOL-110STILL BOTTOM OILHCB418

419(1,2)HCBSLOP TANKS

IPS 301(A,B),302(A,B)

100 m3 6nos CBBTXS)

395(A,B)BTXS

IPS 396(A,B)413

50 m3 3nos CG BENZENEXS fraction

IPS 397 25 m3 1no Toluene

12

TANKS LAYOUTTANKS LAYOUT

A VIEW IN ANOTHER ANGLEA VIEW IN ANOTHER ANGLE

FIRE FIGHTING FACILITIES FOAM FLOODING SYSTEM

FOR CRUDE BENZOL , PURE BENZENE, PURE TOLUENE & HEAVY CRUDE BENZOL TANKS.TOLUENE & HEAVY CRUDE BENZOL TANKS.

SHELL SPRAY SYSTEM FOR LIGHT SOLVENT OIL AND

NONAROMATICTANKSNONAROMATICTANKS ADDITIONAL FIRE WATER AND FOAM MONITORS

AT 7 METRES HEIGHT FROM GROUND LEVEL, ON BOTH SIDES OF THE STORAGE UNITBOTH SIDES OF THE STORAGE UNIT.

TWO WATER TANKS OF CAPACITY 500CU.M AND 1000 CU.M WITH A MAKE UP FLOW OF 350CU.M/HR EACHEACH.

CFPS TANKS ROOF DAMAGESTHE ROOFS OF THE TANKS ARE DAMAGING DUE TO CORROSION

THE REASONS OF CORROSION

• ROOF INSIDE MAINLY DUE TO SULPHUR CONTENT IN CRUDE BENZOL AND PRODUCTS WHICH ARE STORED.

• NITROGEN BLANKETING INSIDE TANK IS NOT THERE.• ROOF TOP CORROSION MAINLY DUE TO THE

NEARNESS TO THE COOLING TOWERS &THENEARNESS TO THE COOLING TOWERS &THE PRESENCE OF AMMONICAL MIST

VIEW OF THE DAMAGED ROOFVIEW OF THE DAMAGED ROOF

ROOF & SIDE PLATE DAMAGES OF 401/1OF 401/1

OPTIONS FOR ROOF CHANGINGCHANGING

OPTION 1 ROOF TOP PORTION & SIDE WALL OPTION -1 –ROOF TOP PORTION & SIDE WALL PLATES CHANGING IN POSITION (EARLIER PROCEDURE)PROCEDURE)

OPTION-2-TOTAL TANK REMOVAL FROM OPTION 2 TOTAL TANK REMOVAL FROM FOUNDATION & CHANGING WITH NEW FABRICATED TANK

OPTION-3-TOTAL PLANT SHUTDOWN, EMPTYING ALL CFPS TANKS & CHANGING ALL DAMAGEDALL CFPS TANKS & CHANGING ALL DAMAGED ROOFS

SINCE INCEPTION WE HAVE CHANGED TOTAL 12 NO. OPTION-1EARLIER PROCEDURE OF ROOF TOP PORTION CHANGING

TANK ROOFSSNO

TANK NO

1 ST TIME 2ND TIME

1 401/1 01/05/2002 TO 09/08/2002 (SIDE PLATE 1MTR WIDTH) 1/05/2011 TO 31/08/2011(SIDE PLATE1 401/1 01/05/2002 TO 09/08/2002 (SIDE PLATE 1MTR WIDTH) 1/05/2011 TO 31/08/2011(SIDE PLATE 1.8 MTS WIDTH)

2 401/2 01/12/2002 TO 01/03/2003 (SIDE PLATE 1MTR WIDTH) 01/05/2013 TO 31/07/2013(SIDE PLATE 1.8 MTS WIDTH) NOW )DEMACK SPECIAL PAINT PAINTED ON ROOF

3 401/3 01/12/2003 TO 25/12/2003 & 01/11/2004 TO 25/11/2004 NOW SIDE WALL DAMAGED3 401/3 01/12/2003 TO 25/12/2003 & 01/11/2004 TO 25/11/2004 (SIDE PLATE 1MTR WIDTH & INSIDE, OUTSIDE SAND BLASTING SPECIAL PAINTING)

NOW SIDE WALL DAMAGED

4 401/4 01/9/2006 TO 01/11/2006 (SIDE PLATE 1MTR WIDTH) NOW DAMAGED (NEW FABRICATED READY TO CHANGE SINCE 09/09/2014

5 402/1 02/02/2007 TO 30/04/2007 (SIDE PLATE 0.5MTR WIDTH)( )

6 402/2 05/09/2009 TO 10/11/2009 (SIDE PLATE 0.5MTR WIDTH)

WE HAVE CHANGED ALL THESE TANKS BY CUTTING THE TOP PORTIONPROCEDURE OF CHANGING

WE HAVE CHANGED ALL THESE TANKS BY CUTTING THE TOP PORTION OF ROOF AND SIDE WALL PLATE AROUND 500MM,1MTR OR 1.8 MTS AND REPLACED WITH THE NEW FABRICATED ROOF WITH THE HELP OF 955 CRANES BY TAKING SATEY PRECAUTIONS.CRANES BY TAKING SATEY PRECAUTIONS.

ADVANTAGESWITHOUT EFFECTING THE PRODUCTION THE ROOF CHANGING CAN BE DONECAN BE DONE.TOTAL SHUTDOWN PERIOD AFTER FABRICATION OF THE NEW ROOF IS 2 MONTHS

DISADVANTAGESMAY BE CHANCE OF UNSAFE CONDITIONS DUE TO INCITUCUTTING WELDING DONE ADJACENT TO TANKS IN OPERATIONCUTTING, WELDING DONE ADJACENT TO TANKS IN OPERATION.LOADING OF MATERIALS INTO TANKERS AND MATERIAL TRANSFERS IN AND OUT ALSO GETS AFFECTED.TOTAL ACTIVITY LINKED WITH FIREFIGHTING TEAM & AVAILABILITY OF CRANE.

ROOF CHANGING BY OPTION-1

• TO OVERCOME THE DISADVANTAGES AND ALLOWING FOR SMOOTH OPERATION OF UNIT WE CHOSE OPTION NO 2 -TOTAL TANK REMOVALOPTION NO 2 TOTAL TANK REMOVAL FROM FOUNDATION & CHANGING WITH NEW FABRICATED TANKWITH NEW FABRICATED TANK

CHALLENGES FOR NEW PROJECT

TO FABRICATE NEW TANKS A SAFE LOCATION NEAR TO• TO FABRICATE NEW TANKS A SAFE LOCATION NEAR TO DAMAGED TANKS ,HAS TO BE IDENTIFIED

• NO OF FIRE WATER LINES AND HYDROCARBON LINES OF OTHER TANKS RUNNING INSIDE THE DYKE WALL NEAR TO DAMAGED TANKS

• NO PROPER APPROACH ROAD FOR HEAVY CRANE• NO PROPER APPROACH ROAD FOR HEAVY CRANE MOVEMENT

• NO PROPER PLATFORM FOR HEAVY CRANE SUPPORTS• ADJACENT TANKS ALWAYS IN OPERATION WITH MATERIAL

TRANSFERS IN AND OUT • PLACEMENT AND POSITIONING OF CRANE FOR LIFTING OF• PLACEMENT AND POSITIONING OF CRANE FOR LIFTING OF

TANKS

NEW TANK FABRICATION PLACE IDENTIFICATION

FOR NEW TANK FABRICATIONFOR NEW TANK FABRICATIONAN OPEN AREA OPPOSITE TO TANK FARM AREA ABOUT 200TANK FARM AREA ABOUT 200 METERS AWAY FROM DAMAGEDTANKS AREA WAS CHOSEN IN ORDER TO MINIMIZE CRANE TRAVEL DISTANCE

BARRICADING OF THE TANK USING GI SHEETS TO ISOLATE FROM ADJACENT TANKSISOLATE FROM ADJACENT TANKS

FOR PROVIDING SMOOTH MOVEMENT OF CRANE BF SLAG LAID ON GROUND AND FILLED TO CERTAIN HEIGHT

DUMPER AT WORK DOZER LEVELLINGTHE SLAG PLATFORMDUMPER AT WORK DOZER LEVELLINGTHE SLAG PLATFORM PREPARED

WATER SPRAYING ON BARRICADES

BRAINSTORMINGBRAINSTORMING

NO OF FIRE WATER LINES ANDNO OF FIRE WATER LINES AND HYDROCARBON LINES OF OTHERTANKS RUNNING INSIDE DAMAGEDTANKS DYKE WHICH SHOULD’NTBE DISTURBED.

SO TWO BOX TYPE SUPPORTSWERE DESIGNED ,FABRICATEDAND PLACED IN BETWEEN PIPELINES

WITH THE NEW IDEA PLACEMENT AND POSITIONING OF CRANE

FOUR PIT TANKS WERE PROVIDED AROUND THE UNIT FOR COLLECTING ANY SPILLAGES OR LEAKAGES.ANY SPILLAGES OR LEAKAGES.

DYKE WALLS ARE PROVIDED TO CONTAIN THE MATERIAL IN CASE OFANY MAJOR LEAK FROM ANY TANK.

THE PREPARATORY ACTIVITIES

1. EMPTYING THE TANK TILL DEAD VOLUME.1. EMPTYING THE TANK TILL DEAD VOLUME.2. EMPTYING THE SURROUNDING TANKS.3. LIFTING THE CRUDE BENZOL BY GIVING WATER AND PUMPING IT.4 REPEATING THE PROCESS TILL NO BENZOL TRACES ARE FOUND IN4. REPEATING THE PROCESS TILL NO BENZOL TRACES ARE FOUND IN

THE MATERIAL BEING PUMPED OUT.5. REMOVING ALL THE COMMUNICATION LINES & BLANKING THE LINES.6. OPENING THE MANHOLES OF THE TANK.7. GIVING AIR & STEAM INSIDE THE TANK TO PURGE OUT THE VAPOURS.8. CHECKING OXYGEN CONTENT IN THE TANK AFTER PURGE OUT THE8. CHECKING OXYGEN CONTENT IN THE TANK AFTER PURGE OUT THE

VAPOURS.9. MANUAL CLEANING OF THE TANK. 10 AFTER CLEANING IS COMPLETED WASHING THE WALLS OF THE TANK10. . AFTER CLEANING IS COMPLETED, WASHING THE WALLS OF THE TANK,

TO REMOVE ANY DEPOSITS.

THE PREPARATORY ACTIVITIES THE PREPARATORY ACTIVITIES

• 11. BARRICADING THE TANK ON THREE SIDES WITH TARPOLIEN & GI SHEETS.

• 12.MAKING ARRANGEMENT FOR WATER SPRAYING ON THE BARRICADES.

• 13. FIXING WATER CURTAINS AT DIFFERENT PLACES.• 14. CHECKING THE WATER SPRAY ON BARRICADES AND THOROUGH C C G S O C S O OUG

WATERING ON CURTAINS.• 15. MAKING ARRANGEMENTS FOR RECIRCULATION OF WATER.• 16 CHECKING EXPLOSIVE MIXTURE INSIDE & SURROUNDING AREAS• 16. CHECKING EXPLOSIVE MIXTURE INSIDE & SURROUNDING AREAS

OF THE TANK.• 17.SURROUNDING TANKS ARE TO BE SPRAYED WITH SUMMER

COOLINGCOOLING.• 18 STOPPING OF ALL LOADING ACTIVITIES.• 19. STOPPING OF ALL TRANSFERS BY PRE/POSTPONING.

SEQUENCE OF ACTIVITES• PLACEMENT AND POSITIONING OF CRANE • REMOVAL OF DAMAGED TANK BT 401/3 FROM POSITION • DISMANTLING OF REMOVED TANK • REMOVAL OF DAMAGED TANK BT 401/4 FROM POSITION • DISMANTLING OF REMOVED TANK AND SHIFTING OF TANK SCRAP• TANK BASE TO BE CLEANED AND COAL TAR MASTIC COATING IN

BOTH TANKS AREA• ALLOWING TIME FOR TAR MASTICATION TO DRY UP• ALLOWING TIME FOR TAR MASTICATION TO DRY UP• PREPARING NEW FABRICATED TANK FOR SHIFTING • PLACE NEW TANKS IN PLACE ONE AFTER ANOTHER • CHECKING THE VERTICAL LEVEL AND HORZONTAL LEVEL S OF CHECKING THE VERTICAL LEVEL AND HORZONTAL LEVEL S OF

TANKS BY MECHANICAL • MOVEMENT OF CRANES OUT OF SITE• CONNECTING ALL COMMUNICATION LINES RELATED TO TANKS • PAINTING OF TANKS

VIEW OF THE CRANE USEDVIEW OF THE CRANE USED

DAMAGED TANK BEING LIFTED AND DISMANTLEDDISMANTLED

WATER RECYCLING PROCESSC C G OC SS

CLEANING OF TANK BASE AND SURFACE PREPARATION FOR COAL TAR MASTIC COATING

NEW FABRICATED TANK LIFTING

TANKS BEING PLACED IN POSITIONPOSITION

NEW CRUDE BENZOL TANKS BT-401/3 AND BT-401/4 IN POSITION

• WITH AN INNOVATIVE IDEA OF INSTALLING BOX TYPE SUPPORTS WE WERE ABLE TO COMPLETE THIS MASSIVE JOB OF TANK CHANGINGMASSIVE JOB OF TANK CHANGING WITHOUT ANY SHORTFALLS AND MISHAPSMISHAPS

• ALL THIS WORK GOT COMPLETED WITH THE COLLECTIVE EFFORTS OF OPERATION MECHANICAL AND MANYOPERATION, MECHANICAL AND MANY CONTRACT AGENCIES

P RAJESH VARMAMANAGER(OPERATIONS)

CO&CCP CO&CCP VIZAG STEEL PLANT.