Pak-Arab Refinery Limited

REPORT
The Report describes about the activities and
learning during our one month on-job training at
Engineering Services Department of PARCO MidCountry Refinery.

Prepared By:
Abdur Rafay

(5587 - Trainee Engineer

Electrical)

Submitted to :
Mr. Muhammad Yasin

Chief Engineer

Mentor :
Mr. Afaq Khan Sherwani
Dated:

August 2nd, 2013

ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my

mentor Engineer Mr. M. Afaq Khan Sherwani as well as Chief
Engineer Mr. Muhammad Yasin and Engineer Danyal Khawaja who
gave me the golden opportunity to have this training session with
them. This session helped me in learning and understanding a lot
of things about the functions of ESD and its importance in the
refinery.
Secondly I would like to thank my parents, friends and other
employees in ESD whose efforts, prayers and well wishes enabled
me to successfully complete this training period.
Most of all I am thankful to Allah (S.W.T) for granting me the
will, power and passion to make the most of this period.

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CONTENTS

Brief Introduction of Engineering Services Department

Section 1

Study of Management of Change (MOC)

Study and preparation of Design package
Section 2

Study of Electrical Drawings

Section 3

Study of Electrical Design Specifications

Section 4

Study of Electrical Codes & Standards

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INTRODUCTION TO ENGINEERING SERVICES DEPARTMENT

ESD in PARCO comprises of two sections, namely, Engineering Services and
Information Technology (IT). Earlier Inspection department came under ESD
as well, which now is a separate department headed by a different manager.
The Engineering section is then further divided into three groups Mechanical,
Civil and Electrical and Instrumentation (E&I), as shown in the figure below.

Functions of ESD
There is a long list of functions of ESD but to summarize it can be said that
all the work related to documentation (Drawings, data sheets, specifications,
etc.) of old, ongoing and upcoming projects and changes or modifications
(Management of Change MOC) in any system, unit or equipment comes
under the aegis of ESD; HAZOP (Hazard Operability) studies and JSA (Job
Safety Analysis) of different jobs and tasks; Inspection and technical
evaluation of procured materials or services; Participation in the
development of TSR (Technical Study Report) and TRC (Technical Review
Committee); Budgetary estimates; Training of the staff; Technical assistance
of all other departments; Troubleshooting of complex abnormalities and
malfunctions; Acting as the custodian of CAD machines and SAP Project
System (PS) and many others are among the functions of ESD.

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SECTION 1

STUDY OF MANAGEMENT OF CHANGE (MOC) PROCEDURE:

(PAR-MCR-ESD/EG-SOP-011)

The MOC procedure defines the specific review authorization requirements

and the procedures through which changes are authorized and documented
MOC is applicable to all the changes either temporary permanent or
emergency made during all hours of operations within PARCO Mid Country
Refinery subject to prior approval of Managing Director PARCO on
change request form. Prior approval will also be required to make any
changes to this SOP through change approval form.

STUDY OF SOP ENGINEERING DESIGN PROCEDURE:

(PAR-MCR-ESD/EG-SOP-009)

To design the electrical and instrumentation related jobs against approved

CR in accordance with the applicable codes and
project specifications. The

procedure

standards and MCR

will be applicable for the

preparation of engineering design packages for all modifications and new

capital projects related to E&I engineering against approved change requests
and for other projects within MCR premises. Prior to the construction of any
new installation or modification in existing plant, a complete design

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package is required for the safe, smooth, reliable and cost

effective operation. Generally a design package comprising of basic and
detailed design documents includes following drawings and documents.
Requirement of each drawing/document varies depending upon the nature
and quantum of job.

A design package includes the documents listed below.

CR Form

Engineering Calculations

P&ID

Applicable Codes and

Equipment Data Sheets

Plot Plan

Layout Drawings

Area Classification Drawings

11 Scope of Work

Underground Facilities

12 Bill of Quantity (BOQ)

Drawings

13 AS BUILT Drawing

FLOW CHART OF MOC

Standards
10 Construction/Installation
Specs.

14 HAZOP Certificate

(PAR-MCR-ESD/EG-SOP-011-FCH-001)

This document is the pictorial representation of the flow of the Change

Request (CR). This document defines the responsibilities of Originating,
Technical Services, Engineering Services, Maintenance, Material, HSE/Finance
Departments and Vendor/Supplier as well. It covers both types of changes,
In-House and Out-Sourced.

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SECTION 2

STUDY OF ELECTRICAL DRAWINGS

Following is the list of Electrical drawing that is studied under this section:

D-000-1380-002

D-905-1381-015

D-000-1380-003

D-100-1381-016

D-905-1381-012

D-100-1381-011

D-905-1381-013

D-100-1381-001

D-905-1381-014

Study of single line Diagrams

In power engineering, a one-line diagram or single-line diagram is a
simplified notation for representing a three-phase power system. The oneline diagram has its largest application in power flow studies.
Electrical elements such as circuit breakers, transformers, capacitors, bus

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bars, and conductors are shown by standardized schematic symbols.

Instead of representing each of three phases with a separate line or
terminal, only one conductor is represented. It is a form of block
diagram graphically depicting

the paths for power

flow between

entities of the system.

Elements on the diagram do not represent the physical size or location of

the electrical equipment, but it is a common convention to
organize the diagram

with the same

left-to-right, top-to-bottom

sequence as the switchgear or other apparatus represented.

Study of Hazardous Area Classification drawing

Study of Hazardous Area Classification drawings of

Area 100 CDU

& VDU (PARCO MCR).

In a plant such as a refinery or chemical

process plant, handling of

large quantities of flammable liquids and gases creates a risk of leaks. In

some cases the gas, ignitable vapor or dust is present all the time
long periods. Other
of flammable

areas

substances

deterioration between

would

have

a dangerous concentration

only during process

maintenance

or for

upsets, equipment

periods, or during an incident.

Refineries and chemical plants are then divided into areas of risk of release
of gas, vapor or dust known as divisions or zones. The process of
determining the type and size of these hazardous areas is called area
classification. Guidance on assessing the extent of the hazard is given in the
NFPA 497 Standard or API 500 and according to their adaptation by other
areas gas zones is given in the current edition of (IEC 60079-10). For
hazardous dusts, the guiding standard is (IEC 61421-10).

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 Study of Power layout

Study of Power layout Area 100 CDU & VDU (PARCO MCR)
This drawing

shows

than lightening

the electrical power load in this area other

its associated cable route , the nature of load and

the its capacity.

Lighting Layout
Study of lighting layout of Area 100 CDU & VDU (PARCO MCR)
The details of electrical lightening its types and its associated cable routes in
the area is shown in this drawing
Earthing and lightning Protection Layout
Study of Earthing and lightning Protection Area 100 CDU & VDU (PARCO MCR)
A protective earth (PE), known as an equipment grounding conductor in the
US National
exposed

Electrical Code,

conductive

avoids this hazard by keeping the

surfaces

of a device

at earth potential. To

avoid possible voltage drop no current is allowed to flow in this conductor

under normal circumstances, but fault currents will usually trip or blow the
fuse or circuit breaker protecting the circuit. A high impedance line-to-ground
fault insufficient to trip the overcurrent protection may still trip a residualcurrent device (ground fault circuit interrupter or GFCI).
A lightning conductor is a metal rod or metallic object mounted on top of a
building,

electrically

bonded

using

a wire or electrical

to interface

with ground

engineered

to protect the building in the event of lightning strike.

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or earth through

conductor

an electrode,

If lightning hits the building it will preferentially strike the rod

and be conducted to ground through the wire, instead of passing
through the building, where it could start a fire or cause electrocution.

Cathodic Protection layout

Study of Cathodic Protection layout of Area 100 CDU & VDU (PARCO MCR)
Cathodic Protection (CP) is a technique used to control the corrosion of a
metal surface by making it the cathode of an electrochemical cell Impressed
current cathodic protection

(ICCP)

systems

is used

where there are

increased current requirements for corrosion protection, where the driving

voltage is greater than what can be obtained with galvanic
systems and where there may be a need for enhanced control
of system.
ICCP systems are extremely accurate and can be controlled to
deliver optimal protective current to the structure. Anodes are connected to
a DC power supply to deliver low-voltage electric currents and are controlled
by strategically placed reference electrodes. These reference electrodes are
connected to a monitoring system that observes and verifies the system
performance.
In PARCO MCR impressed current cathodic protection is used for
the protection of

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underground metallic structures

SECTION 3

STUDY OF ELECTRICAL SPECIFICATIONS

Technical design specifications of electrical facilities for PARCO MCR cover
the details of all electrical power systems installed at PARCO MCR
premises as described below.
General Specifications for Electrical Facilities (S-000-1380-001)

1. General Specifications of
Electrical power supply at

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Parco MCR
2.

3. Technical parameter of power

system
4.
5. Detail of Power distribution
system
6.
7. Transformer Sizing
8.
9. Cable Sizing (Underground &
above grade)
10.
11.

Emergency supply

12.
13.

Substation

requirements
14.
15.

Equipment layout and

Clearances
16.
17.

LV and HV Switch gear

18.
19.

Electrical cable

installation details
20.
21.

General specification of

electrical motors
22.
23.

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Allowable Voltage drops

 General Specification for telephone and Hotline system(S-000-1386001)

Telephone system used for communication in the PARCO MCR premises its
basic design parameters and specifications

General Specification for Cathodic Protection(S-000-1387-001)

Impressed current cathodic protection system at Parco MCR, its cable layout,
cable sizing and Transformer rectifier specifications.
Cathodic Protection (CP) is a technique used to control the corrosion of a
metal surface by making it the cathode of an electrochemical cell
Impressed

current cathodic protection

(ICCP)

systems

is used

where there are increased current requirements for corrosion protection,

where the driving voltage is greater than what can be obtained
with galvanic systems and where there may be a need for
enhanced control of the system.
ICCP systems are extremely accurate and can be controlled to
deliver optimal protective current to the structure. Anodes are connected to
a DC power supply to deliver low-voltage electric currents and are controlled
by strategically placed reference electrodes. These reference electrodes are

connected to a monitoring system that observes and verifies the system

performance.

SECTION 4

STUDY OF ELECTRICAL CODES & STANDARDS (OVER VIEW)

1. Study of Applicable Codes and standards at Parco MCR

2.
Study

of SOP

applicable

(PAR-MCR-ESD/EG-SOP-016) which defines

codes

and standards

the all

applied for the construction of

MCR project and also be consulted during engineering design this sop
shall be applicable to all the basic engineering

design of

changes/modifications, either Temporary/Permanent or Emergency made

during all hours of operations within PARCO Mid-country Refinery(MCR).
3. Study of Electrical Codes and standard for the classifications of
areas for
4. electrical installations in the petroleum refineries
5.

Study of

Recommended Practice for classification of locations for the

installation at petroleum facilities classified as Class 1, Division 1 and

Division 2(API 500):
The purpose of this recommended practice is to provide
guidelines for classifying

locations Class I, Division 1 and

Class I, Division 2 at petroleum

facilities for the selection

and installation of electrical equipment.

in the 2011 Edition of NFPA

Basic definitions given

70, National Electrical Code (NEC),

have been followed in developing this recommended practice.

This publication is only a guide and requires the application
sound

of

engineering judgment.

Recommendations for determining the degree

and extent of

locations classified Class I, Zone 0, Zone 1, and Zone 2 are addressed

in API 505.
Recommended Practice for Classification of Locations

for Electrical

Installations at Petroleum Facilities Classified as Class I, Zone 0, Zone 1

and Zone 2.

Study of IEC 60529 degrees of protection provided by enclosures :

The IP Code, Ingress Protection Rating, sometimes also interpreted

as International
degree

Protection

Rating classifies

and

rates the

of protection provided against the intrusion of solid

objects (including body parts

accidental

like hands

contact, and water

and

fingers), dust,

in mechanical casings and with

electrical enclosures. It is published by the International Electro-technical

Commission (IEC).
The digits (characteristic numerals) indicate conformity with the conditions
summarized in the tables below. Where there is no protection rating with
regard to one of the criteria, the digit is replaced with the letter X

Study of IEC 79-10 Electrical Installations for Hazardous areas:

IEC 60079-10-1:2008 is concerned with the classification of areas where

flammable gas or vapor or mist hazards may arise and may then be used as

a basis to support the proper selection and installation of equipment for use
in a hazardous area. It is intended to be applied where there may be an
ignition hazard due to the presence of flammable gas or vapor, mixed with
air under normal atmospheric conditions, but it does not apply to
a) mines susceptible to firedamp;
b) the processing and manufacture of explosives;
c) areas where a hazard may arise due to the presence of combustible
dusts or fibers
d) catastrophic failures which are beyond the concept of abnormality;
e) rooms used for medical purposes
f) domestic premises.

Study of NFPA 70 code for practical safeguard of persons and property

from hazards arising from the use of electricity :

The National Electrical Code (NEC) defines hazardous locations as those

areas "where fire or explosion hazards may exist due to flammable gases or
vapors,

flammable

liquids, combustible

dust, or ignitable fibers."

A substantial part of the NEC is devoted to the discussion of hazardous

locations. That's because electrical equipment can become a
source of ignition in these volatile areas. Articles 500 through 504, and 510
through 517

provide

classification

and installation

standards

for

the use of electrical equipment in these locations. The writers of the NEC
developed a

short-hand

as hazardous locations.
to explain

method
One

of describing

of the purposes

areas

classified

of this discussion

this classification system.

Hazardous locations are classified in three ways by the National Electrical

Code:

is

TYPE, CONDITION, and NATURE.