Zahid Ali: - Refinery Limited

Internship Report
Technical Services Department - TSD

Crude Distillation Unit-CDU & Vacuum Distillation Unit-VDU
PAK-ARAB REFINERY LIMITED

(A Pakistan-Abu Dhabi joint Venture)
Technical Services Department
ZAHID ALI
BS CHEMICAL ENGINEERING
GHULAM ISHQ KHAN INSTITUTE OF ENGINEERING SCIENCES AND
TECHNOLOGY
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Contents
Acknowledgements: ........................................................................................................................ 5
Introduction of PARCO MCR: ....................................................................................................... 7
Vision statement: ............................................................................................................................ 7
MISSION STATEMENT: .............................................................................................................. 8
Primary objectives: ......................................................................................................................... 8
Divisions of Parco: .......................................................................................................................... 8
Parco stands for? ............................................................................................................................. 9
COMPANIES OF PARCO: ............................................................................................................ 9
PAK – ARAB PIPELINE COMPANY LIMITED (PAPCO): ....................................................... 9
TOTAL PARCO PAKISTAN LTD (TPPL): ............................................................................... 10
PARCO PEARL GAS (PVT) LTD: ............................................................................................. 10
What is crude oil? ......................................................................................................................... 11
How crude oil is formed? .............................................................................................................. 11
Component of curded oil: ............................................................................................................. 11
Paraffin’s: .................................................................................................................................. 12
Naphthenes ................................................................................................................................ 12
Aromatics .................................................................................................................................. 13
Olefins ....................................................................................................................................... 13
Miscellaneous compounds: ........................................................................................................... 14
Salts: .......................................................................................................................................... 14
Sulphur: ..................................................................................................................................... 14
Metals: ....................................................................................................................................... 14
Sand Mineral Matter and Water: ............................................................................................... 15
The presence of impurities in the crude oil:.................................................................................. 15
Sulfur: ........................................................................................................................................ 15
Corrosion: .................................................................................................................................. 15
Odor:.......................................................................................................................................... 15
Salt:............................................................................................................................................ 15
Nitrogen Compounds: ............................................................................................................... 16
Hydrocarbons Gaseous:............................................................................................................. 16
HSE orientation:............................................................................................................................ 17
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FIRE DRILL: ................................................................................................................................ 17

FIRE FIGHTING EQUIPMENT: ................................................................................................ 18
PPEs: ............................................................................................................................................. 19
Safety helmet: ............................................................................................................................ 19
Safety Shoes: ............................................................................................................................. 19
Ear Protection plugs: ................................................................................................................. 19
Safety Goggles: ......................................................................................................................... 19
Work permit system: ..................................................................................................................... 19
Cold work permit: ..................................................................................................................... 20
Hot work permit: ....................................................................................................................... 20
Electrical isolation and de isolation permit: .............................................................................. 20
Confined space permit:.............................................................................................................. 20
Radiography permit: .................................................................................................................. 21
Excavation permit: .................................................................................................................... 21
Fire management system: ............................................................................................................. 21
PREVENTION: ......................................................................................................................... 21
Fire prevention includes; ........................................................................................................... 21
DETECTION: ........................................................................................................................... 22
SUPPRESSION: ....................................................................................................................... 22
FIRE FIGHTING AND EMERGENCY RESPONSE:............................................................. 23
Unit-100 ........................................................................................................................................ 24
Crude distillation unit: .................................................................................................................. 24
Processing Objective:.................................................................................................................... 24
Feeds: ............................................................................................................................................ 24
Products: ....................................................................................................................................... 24
Processing conditions: .................................................................................................................. 24
Process: ......................................................................................................................................... 25
Desalter: ........................................................................................................................................ 25
Why desalting is done? ............................................................................................................. 25
Types of desalting: .................................................................................................................... 26
Desalting by settling:........................................................................................................................... 26
Chemical desalting: ............................................................................................................................. 26
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Electro-chemical desalting: ................................................................................................................. 26

Method of desalting:.................................................................................................................. 27
Pre-flash vessel: ............................................................................................................................ 28
Furnace:......................................................................................................................................... 29
Distillation unit: ............................................................................................................................ 30
Overhead section:.......................................................................................................................... 30
Kerosene section: .......................................................................................................................... 31
Diesel section: ............................................................................................................................... 31
Bottom section: ............................................................................................................................. 32
Vacuum distillation unit:............................................................................................................... 32
Vacuum distillation tower: ........................................................................................................ 32
Reduced crude flashing: ................................................................................................................ 33
Vacuum residue handling: ............................................................................................................ 34
Product condensation: ................................................................................................................... 34
Heat exchange: .............................................................................................................................. 35
Root cause of vacume heater (110-H1) stack detoriation: ............................................................ 36
Flue Gases ................................................................................................................................. 36
Liner Deterioration .................................................................................................................... 36
Carbonation ............................................................................................................................... 36
Weather ..................................................................................................................................... 37
Construction Techniques ........................................................................................................... 37
Pinch analysis................................................................................................................................ 38
Case study ..................................................................................................................................... 39
Unit description ......................................................................................................................... 39
PA application ........................................................................................................................... 40
Improvement: ............................................................................................................................ 41
HEN Design .............................................................................................................................. 43
Cost computation....................................................................................................................... 44
Conclusion:................................................................................................................................ 46
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Acknowledgements:
I would like to thank Almighty ALLAH who selected me and provided me this Opportunity to
perform 6 weeks training at Pak Arab Refinery Limited. First and foremost, I would like to
express my deepest gratitude to:
Engr Muhammad Shahid

Engr Asad Rana
Ma’am Khalida
All Shift Supervisors
For their uninterrupted supervision, adjuvant guidance and extravagant encouragement during
the experimental, theoretical and writing up stages of my work.
I would like to express my special thanks to Pak Arab Refinery Limited (PARCO), for
providing such an utmost learning platform which is admirable.
I would like to extend my admiration and deepest thanks to my beloved Parents for their
endearing Guidance, financial support & amiable supervision went a long way towards my
success at that stage. Finally, I would like to thanks all friends and all management of MCR
for sharing their practical & theoretical knowledge.
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ABSTRACT:
PARCO is largest player of Business in Refining of crude oil in Pakistan. Having such an
enthusiastic, energetic and having passionate team progressing by leaps and bounds to become the
premier Pakistani organization with a Global outreach.
I worked as an Internee at crude distillation unit (CDU), vacuum distillation unit (VDU), Engr. M.
Shahid was my mentor and he taught me about CDU/VDU unit and exclusively explained about
the whole process. Visited plant several time, spent time in field and worked upon calculating
capacities and efficiencies of machines.
Overall in TSD I learnt many new things from the staffs especially from Ma’am Khalida, she is
really an amazing lady and she helped me a lot in library and also guided in every sort of work.
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Introduction of PARCO MCR:

PARCO, a joint venture between Government of Pakistan and the Emirate of Abu Dhabi was
incorporated as a public limited company in 1974. The Government of Pakistan holds 60% of the
share holding while 40% of the shares are held by Emirate of Abu Dhabi.
The major business activities include Crude Oil Refining and Transportation, Storage and
Marketing of petroleum products. With a refining capacity of 100,000 Barrels Per Day, combined
storage capacity of over one million tons, a marketing joint venture with TOTAL (France) and a
technical support venture with OMV (Austria); PARCO is the strategic fuel supplier for Pakistan.
The organization encompasses Pakistan's second largest refinery and 2000 km of cross country
pipeline network, including that of its subsidiary PAPCO. In 2010, the company set up a Diesel
Hydro Desulfurization Unit to ensure that Diesel produced by the refinery meets international
Euro-II standards. PARCO also commissioned a Biturox plant in 2012, which is expected to
produce road paving bitumen.
With continued support of the Emirate of Abu Dhabi and Government of Pakistan, PARCO over
the years has been able to implement a number of energy projects that have contributed
significantly in enhancing the country’s economic growth, saving foreign exchange, transferring
technology and providing employment
PARCO`s performance is reflected not only in its technical and financial results, but can also be
judged by its other achievements and awards e.g. Company has maintained its AAA and A1+ long
and short term credit rating by Pakistan Credit Rating Agency (PACRA) for the seventeenth year
running. The company is amongst the first in Pakistan with three simultaneous international
certifications: ISO 9001:2008 (Quality Management System), ISO 14001:2004 (Environmental
Management System) and OHSAS 18001:2007 (Occupational Health and Safety Management
System). PARCO has also received Environment Excellence Awards for the last several years and
is rated among the top 10 organizations in Pakistan for outstanding achievement in Environment
Management.
Vision statement:
For PARCO to remain among tomorrow's corporate winners, it may not only need to have a clear
vision but also a passion for translating that vision into reality. The big challenge is therefore, not
only trying to figure out what future will be the right one, but to choose a future that will give
definite competitive advantage to the Company over the long-term and to create a cause for action
besides charting a course on how to get there.
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MISSION STATEMENT:
To enhance and establish a professionally sound corporate identity.
 To implement an Integrated Investment Programmed which takes cognisance of the

existing bottlenecks and long-term petroleum needs of the country.
 To operate the existing Pipeline System in a manner that establishes it as a center of

excellence in Pipeline and Refining Activities in-the Country.
 To provide a lead to the indigenous Petroleum Industry in finding of solution to Technical

and Managerial problems.
 To develop appropriate Human Resources for undertaking of large Energy Projects in the
Country.
Primary objectives:
 Crude Oil Refining and allied facilities
 Oil pipeline system, storage and allied facilities.
Divisions of Parco:
PARCO has six Divisions:
 Corporate Affairs
 Finance
 Technical Services
 Pipeline
 Refinery
 Marketing & Commercial
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Parco stands for?

Professional and progressive corporate outlook
Aggressive technical thinking and advanced planning
Reliability of service
Consistency in performance
Organized and systematic development
COMPANIES OF PARCO:
The companies of Parco are
 PAK-ARAB pipeline company limited (PAPCO)

 Total Parco limited (TPL)
 Parco pearl gas limited
PAK – ARAB PIPELINE COMPANY

LIMITED (PAPCO):
Pak – Arab Pipeline Company Limited (PAPCO) – is an excellent
example of Public-Private partnership. Shell (26%), PSO (12%) and TOTAL PARCO Marketing
Limited (formerly known as Chevron Pakistan Limited) (11%) joined hands with PARCO (51%)
to build and operate a US$ 480 million cross-country pipeline system for transporting High Speed
Diesel from Karachi ports to up-country locations. PAPCO was commissioned in March 2005,
comprising 786 Km of 26” die cross-country pipeline, storage tanks, pumps and other allied
facilities. PAPCO has proven immensely successful as the main fuel carrier for the country.
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TOTAL PARCO PAKISTAN LTD (TPPL):

TOTAL PARCO PAKISTAN LTD (TPPL) was established in
2001 – a joint venture between PARCO and TOTAL of France – for marketing of consumer
petroleum products through its network of retail outlets across Pakistan. After the acquisition of
Chevron Pakistan Limited (renamed as TOTAL PARCO Marketing Limited) by TPPL, today, the
TOTAL PARCO network is a 50:50 joint venture with765 retail fuel outlets, plus a lubricants
blending and marketing business, making it the 3rd Largest Oil Marketing Company in Pakistan.
PARCO PEARL GAS (PVT) LTD:

PARCO Pearl Gas (Private) Limited (PPGL) is a wholly owned
subsidiary of PARCO. PPGL is the largest LPG marketing company in Pakistan, selling around
90,000 metric ton of LPG per annum in cylinders and bulk. It has a nation-wide network of
distributors and has expertise in addressing industrial applications through its Industrial and
Commercial solutions. The product is marketed nationally under brand names of Pearl Gas, Super
Gas and Super Gas Bulk. Our vast portfolio covers all the product segments in the market. PPGL
has been working towards providing energy solutions, keeping in view all possible dynamics and
dimensions in the market
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What is crude oil?

Crude oil, commonly known as petroleum, is a liquid found within the Earth comprised of
hydrocarbons, organic compounds and small amounts of metal. While hydrocarbons are usually
the primary component of crude oil, their composition can vary from 50%-97% depending on the
type of crude oil and how it is extracted. Organic compounds like nitrogen, oxygen, and sulfur
typically make-up between 6%-10% of crude oil while metals such as copper, nickel, vanadium
and iron account for less than 1% of the total composition.
How crude oil is formed?

The beginning of crude oil formation happened millions of years ago. Oil is a fossil fuel that has
been formed from a large amount tiny plants and animals such as algae and zooplankton. These
organisms fall to the bottom of the sea once they die and over time, get trapped under multiple
layers of sand and mud.
As time goes by, heat and pressure

began to rise as the organisms get
buried deeper and deeper below the
surface. Depending on the amount of
pressure, heat and the type of
organisms, determines if the
organisms will become natural gas
or oil. The more heat, the lighter the
oil. If there is even more heat and the
organisms were made up of mostly
plants, then natural gas is formed.
Once the oil and natural gas is

formed, it migrates through pores in
the rock until it gets trapped under cap
rock and clay where the oil can no longer get through. This is where we find oil today!
Component of curded oil:

Crude oil is a mixture of comparatively volatile liquid hydrocarbons (compounds composed
mainly of hydrogen and carbon), though it also contains some nitrogen, sulfur, and oxygen. Those
elements form a large variety of complex molecular structures, some of which cannot be readily
identified. Regardless of variations, however, almost all crude oil ranges from 82 to 87 percent
carbon by weight and 12 to 15 percent hydrogen by weight.
Based on the molecular structure of hydrocarbons they are divided on following classes
 Paraffin
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 Naphthene
 Aromatic
 Olefins
Paraffin’s:
Paraffin hydrocarbon, also called alkane, any of the saturated hydrocarbons having the general
formula CnH2n+2, C being a carbon atom, H a hydrogen atom, and an integer. The paraffin’s are
major constituents of natural gas and petroleum. Paraffin’s containing fewer than 5 carbon atoms
per molecule are usually gaseous at room temperature, those having 5 to 15 carbon atoms are
usually liquids, and the straight-chain paraffin’s having more than 15 carbon atoms per molecule
are solids. Branched-chain paraffin’s have a much higher octane number rating than straight-chain
paraffin’s and, therefore, are the more desirable constituents of gasoline. The hydrocarbons are
immiscible with water. All paraffin’s are colorless.
Naphthenes
Naphthenes are a class of cyclic aliphatic hydrocarbons obtained from petroleum. Naphthenes have
the general formula CnH2n. These compounds are characterized by having one or more rings of
saturated carbon atoms. Naphthenes are an important component of liquid petroleum refinery
products. Most of the heavier boiling point complex residues are cycloalkanes. Naphthenic crude
oil is more readily converted into gasoline than paraffin-rich crudes are.
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Aromatics
This sense is usually third in order of occurrence in crude oil. The simplest and lowest boiling
compound in the aromatic series is benzene (C6H6). These compounds are similar to naphthenes
in that they have a structure but differ in that only one hydrogen atom is attached to each carbon
atom in the ring instead of two. The following illustrates the general structure of aromatic
compounds.
Olefins
This series occurs very rarely in crude oil because these compounds are generally the products of
the decomposition of other types of hydrocarbons The greatest concentration of olefins is found in
the products from Thermal and Catalytic Cracking Units Olefins are paraffin’s hydrocarbons
which are deficient in hydrogen atoms so that they contain double bonds in their structure The
double bonds are responsible for the reactivity which is characteristic of olefins
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Miscellaneous compounds:
Salts:
These are predominantly chloride salts, such as, sodium chloride, magnesium chloride, and
calcium chloride The salts may break up chemically to form acids and corrode the steel in the top
and overhead sections of the crude column Salts may also be responsible for plugging equipment
such as heat exchangers and fractionator trays
Sulphur:
Sulfur compounds comprise the largest portion of the impurities found in crude oil. If the sulfur
content of a crude is high, it is called a "sour crude" The number and type of sulfur compounds
found in crude oil is as numerous as the hydrocarbons themselves The lightest sulfur compound is
hydrogen sulfide (H2S) which along with being very corrosive is also a deadly gas. Mercaptans
are the general name for a class of paraffinic hydrocarbons where a hydrogen atom has been
replaced by an -SH radical (bisulfide)
Thiophene
Metals:
The common metals found in crudest Oils are arsenic, lead, vanadium. nickel, and Iron Most of
the metals in the crude charge Will exit the crude column with the reduced crude. Most of the
metals Will eventually remain with the asphalt products from the vacuum column Arsenic and lead
are especially bad 'poisons" to catalytic reforming catalysts while vanadium, nickel and iron Will
deactivate catalytic cracking catalysts
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Sand Mineral Matter and Water:

These compounds are in suspension in the crude oil charge They are grouped together in the crude
oil analysis as "Base Sediment and Water" (B.S &W) and this figure will normally be less than 0.5
wt.% of the total crud
The presence of impurities in the crude oil:
Sulfur:
Difficulties with oils that contain sulfur compounds arise in only three main ways: corrosion, odor
and poor explosion characteristics of gasoline fuels.
Corrosion:
corrosion by finished products presents little difficulty because most products are used at low
temperatures. The main bulk of the corrosive sulfur compounds can by removed by treatment with
alkalis or the sweetening treatments. In presence of air and moisture the sulfur gases produced
during the burning of oil may cause corrosion, as in steel stacks, ducts, and engine exhaust pipes
and mufflers.
Real difficulties arise when high sulfur oils are heated to temperature 300 0F or higher for copper,
or 400 0F for steels.
Odor:
Odor is most obnoxious with low boiling or gaseous sulfur compounds, as H2S or SO2 in flue
gases, mercaptans up to even six carbons atoms (B.P. of about 400 0F), sulfides up to 8 carbons
atoms (about 350 0F), and among disulfides only methyl disulfide (B.P. 243 0F). This odor is not
obnoxious in sweetened products except in certain extremely high- sulfur gasoline.
Percentage of S in crude oil ranges from nearly 0.1 for high API- gravity crude oils as high 5
percentages in a few very heavy crude oils Generally crude with greater than 0.5% S require more
extensive processing than those with lower sulfur content .
Salt:
Salt carried into the plant in brine associated with crude oils is a major cause of the plugging of
exchangers and coking of pipe still tubes.
If salt content expressed as NaCl, is greater than 10 lb./1000 bbl., it is generally necessary to desalt
the crude before processing.
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Nitrogen Compounds:
The nitrogen compounds in petroleum are not of major importance, but they do tend to cause a
reduction in the activity of the catalysts used in catalytic cracking and they may assist in the
formation of so- called "gum" in distillated or diesel fuel oil.
Crude containing in amount above 0.25 % by weight require special processing to remove the
nitrogen.
Hydrocarbons Gaseous:
The amount of gaseous hydrocarbons dissolved in crude oil is almost totally a function of the
degree of weathering that the oil has undergone or the pressure at which it is collected .
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HSE orientation:
The Policy deals with Health, Safety, Environment and Quality of every activity going on
which affects the performance of PARCO.
 Health: Minimize effluents, emissions of gases, and proper treatment of

waste
 Safety: To ensure safety, one should follow standards
 Environment: PARCO follows National Environment Quality Standards (NEQS)
under Ministry of Environment of Pakistan.
 Quality: Product Quality, teamwork, innovations
The objective of HSEQ Department is to create awareness of safety to the employees and
keep regulating the practices as defined in the Standard Operating Procedures Manual
(SOPM). HSE Department concentrated on the following areas in our orientation session:
 Awareness to PARCO Health, Safety, Environment and Quality Management Systems

 Importance of conformance with HSEQ Policy, Procedures, requirements of HSEQ
Management System and benefits of improved personal performance
 Awareness of HSE Hazards and Risks
 Awareness of possible emergencies and emergency procedures
 Importance and use of Personal Protective Equipment
 Permit to Work System
 Material Safety Datasheets
 Firefighting
 First Aid
During the orientation we were provided safety shoes, safety goggles, safety helmet earplugs
and overall which we placed in the cabinets reserved for internees. Every morning we
changed our dress and put on these PPEs to enter the plant area otherwise no one is allowed to
enter. Workers ought to have safety gloves otherwise they will not be allowed to work at any
point in the plant.
FIRE DRILL:
HSE Engineers along with the fire department conduct a weekly fire drill with sole purpose
of keeping the firefighting skills alive to treat any unwanted emergency of any type on the
plant. Every Monday at 10:30 a.m. HSE department give briefing on parts of fire extinguisher,
use of fire extinguisher and wind direction. Right at 11 am the fire alarm is activated and
utility operator starts the designated water pump for this particular firefighting session. All the
firemen in morning shift along with other employees and the internees as per the schedule
participate in this practice.
The firefighting practice is carried out at the ground adjacent to Waste Water Treatment
Plant. The firefighting convoy comprises of a fire fighting truck, an ambulance and a jeep for
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HSE Engineers. Initially fire is ignited on a mini oil storage tank and then top fire extinguishing
system is demonstrated where foam is sprinkled all over the tank surface. Now the difficulty
level is raised and in the absence of top extinguishing system the fire on the oil is extinguished
by the foam injected at the bottom which covers the surface and kills the fire.
Another fire is lighted on the spilled oil and this time a special high flow nozzle is used which
carpets the oil surface with thicker layer of foam. Simultaneously the fire extinguishers are
also used. Finally the atmosphere is cooled by showering the water from the pipeline coming
through the fire truck taking the feed from the fire line already networked in the plant. The
firefighting water for extinguishing contains 97 % water and 3 % Foam.
In all this demonstration we understood all the main firefighting systems which are helpful to
overcome the serious fires at the different areas of the plant. In case of burns the ambulance
contains fire blankets, polymer jackets which are used to cover the body and put out the fire if
there still remains any. It is also equipped with a stretcher, oxygen cylinder and mask along
with First Aid Box. Initially the patient is taken to dispensary in PARCO and then to any
nearby hospital.
FIRE FIGHTING EQUIPMENT:

To keep supplying the water one of the 5 pumps of firewater is used to maintain the pressure
at 4 to 5 kg/cm2. There are three fire trucks in fire department. Numerous fire extinguishers
are placed at many plant sites which are more likely to be on fire. A fire extinguisher has a
pipe which is held in hand and the top lever is pressed which blows compressed gas to the
fire. The appropriate use is to blow in the direction of wind and at a safe distance from fire.
HSE gave orientation on health, safety and environment. Including different topics
 Mandatory PPE’s
 WPS- work permit system
 ERP- emergency response plan
 Waste treatment
 Fire management system
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PPEs:
They are the equipment’s that are necessary to wear when working in the field for personal safety
from hazards
Necessary PPEs are
 Helmet
 Goggles
 Jacket
 Trousers
 Safety shoes
Safety helmet:
Safety helmet is used for protection against head injury. Its useful life is affected by heat, cold,
chemical and sunlight. The unit consist of shell and suspension which work together. Helmet
provides limited protection; it reduces the effect of force of falling objects.
Safety Shoes:
Safety shoes protect feet from injury caused by acids, oil, bases or any other falling object. The
unit consist of anti-slip PVC sole, steel tow caps impact resistant up to 200 joules are fitted with
rubber protection strips, which eliminate pressure across toes .
Ear Protection plugs:

Ear plugs are used to protect ears from noise up to 22 db. It is advised to plug in ear protection
plugs before visiting plant area.
Safety Goggles:
Safety Goggles have impact resistance lenses and strong frames to protect you from flying
particles, encountered like chips, or sparks of high inertial energy at work with machine or during
transport. Lens is also resistant to chemical attack and also can absorb 99.9% of UV radiation.
If a person is working without these PPEs it should be reported
Work permit system:

A permit-to-work system is a formal written system used to control certain types of work that are
potentially hazardous. A permit-to-work is a document which specifies the work to be done and
the precautions to be taken. Permits-to-work form an essential part of safe systems of work for
many maintenance activities. They allow work to start only after safe procedures have been defined
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and they provide a clear record that all foreseeable hazards have been considered. A permit is
needed when maintenance work can only be carried out if normal safeguards are dropped or when
new hazards are introduced by the work. Examples are, entry into vessels, hot work and pipeline
breaking.
Work permit system is designed to allow the safe working environment, to ensure the safety of
worker and to adopt necessary protocol to do any work
Work permit system are of following types
 Cold work permit

 Hot work permit
 Electrical isolation and de-isolation permit
 Confined space entry permit
 Radiography permit
 Excavation permit
 Road closure/vehicle entry/mobile machine permit
Cold work permit:
Cold Work Permit. Cold work permits are used in hazardous maintenance work that does not
involve “hot work”. Cold work permits are issued when there is no reasonable source of ignition,
and when all contact with harmful substances has been eliminated or appropriate precautions taken
Hot work permit:

Hot work is a process that can be a source of ignition when flammable material is present or can
be a fire hazard regardless of the presence of flammable material in the workplace. Common hot
work processes 1involve welding, soldering, cutting, brazing burning and the use of powder-
actuated tools or similar fire producing operations outside of designated hot work areas.
Electrical isolation and de isolation permit:
An electrical permit to work is the statement that the circuit or item to be worked on is safe to work
electrically.
A permit applied at any time work is to be performed on or near the electrical equipment that is in
an energized state. Maybe the subset of permit to work system but must include additional safety
requirement and approvals.
Confined space permit:

Confined space entry permit is used to specify the precautions to be taken to eliminate the exposure
to dangerous fumes and oxygen depleted zone before the person is permitted to enter the zone. The
permit should confirm that space is free from dangerous fumes.
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Confined space include chambers, tanks, vessels, furnaces, ducts, sewers, manholes and ovens.
Many accidents have occurred where inadequate precautions were taken before and during the
work involving the entry to confined space.
Radiography permit:
The radiation permit, typically colored yellow, outline necessary control measures to minimize the
risk of exposure to radioactive sources including the site inspection, the control on source
exposure, access or containment barriers and the radiation monitoring.
Excavation permit:
Any employer in Manitoba who proposes to make an excavation that is more than 1.5 meters deep,
in which a worker is required or permitted to enter must provide notice of excavation to the
Workplace Safety and Health Branch (WSH) not more than 48 hours before the day the
excavation work is scheduled to begin.
Employers must not begin any excavation work without a valid excavation registration number
and serial number for the excavation project from the WSH branch.
Fire management system:

In PARCO the major threat to the plant is fire which could be very dangerous in such types of
plants. So HSE has some regulations for which they perform their job against fire.
PREVENTION:
Prevention is a method by which fire are prevented & minimized.
Fire prevention includes;
 Hot work permit procedure
 Testing & inspection of fire equipments
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 Lightening arrestors
 Housekeeping
 Non static charge producing clothes(i-eNylone)
 Hazardous area classification
 Floating roof tanks
DETECTION:
It needs to be detected and tackled in minimum time, so that it should be it controlled. An effective
fire detection system helps to detect fire at initial stages;
 Heat detectors
 Smoke detector
 UV/IR flame detectors (ultra violet /infra red detectors)
 HSSD (high sensitive smoke detectors)
 Hydrocarbon detectors
 Hydrogen sulphide detectors
 Vigilance employees
SUPPRESSION:
It includes the following sections;

 Fm-200(Hepta fluoro propane gas) fire suppression system installed in CR-1,SS-1&SSB
sections.
 Deluge valve system (Auto & Semi Auto system)
 Automatic system (at product pumps)
 Semi auto system (at fin fan, cooler, TLG, area’s)
 Fm-200 is ozone & human friendly gas. It is imported from United States in cylinders. It
is filled about a pressure of (140-145) kg/cm2 in cylinders.
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FIRE FIGHTING AND EMERGENCY RESPONSE :
After suppression they do a job of fire fighting and have an emergency response with the help of
 MAC(Manual call point)
 Telephone
 Radio communication
 FAP (Fire alarm panel)installed in buildings
 LMS panel(Local monitoring system)
 Synoptic board
 Out side agencies
In order to avoid from any serious losses of human life during any explosion at process area’s six
assembly points are arranged at six different places. People working at process areas are advised
to gather at these assembly points during any serious explosion at process area’s. A fire alarm is
also managed to aware the people from any serious incident.
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Unit-100
Crude distillation unit:

The crude oil distillation unit (CDU) is the first processing
unit in virtually all petroleum refineries. The CDU distills
the incoming crude oil into various fractions of different
boiling ranges, each of which are then processed further in
the other refinery processing units. The CDU is often
referred to as the atmospheric distillation unit because it
operates at slightly above atmospheric pressure.
Processing Objective:
The crude Distillation Unit is designed to process 100,000
BPSD (662.44 m3/hr.) of either Arabian light crude oil or a
70/30 volumetric blend of upper zakham and Murban crude
oils.
Feeds:
The feed used for crude distillation units are either 100% Arabian light or a blend of 70 LV%
upper zakhum and 30 LV% Murban crude oil.
Products:
 Reduced crude
 Diesel
 Kerosene
 Naphtha and overhead gases
Processing conditions:
The degree of fractionation between the products from crude column is such that the gap between
the 95% ASTM distillation temperature of the lower boiling fraction and the 5% ASTM distillation
temperature of the higher boiling fraction will not be less than the following
Unstabilized straight run Naphtha/Kerosene: 20°F – 10°F
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The side stream products from the crude column will strip to meet the following flash point
requirement.
Process:
 Pre-heating
 Desalting
 Flash zone
 Heating through exchangers
 Heater
 Distillation unit
In CDU the crude is divided into different products by fractionation using atmospheric distillation.
The side cuts of distillation column are divided into different section as follow
 Reduced crude section

 Diesel section
 Kerosene section
 Naphtha pump around
 Crude column overhead products
The description and working of major equipment’s used in CDU is as follow
Desalter:
In a refinery, crude oil containing high levels of salt will go through a desalter before being fed to
the atmospheric distillation tower.
Removal of salts is important for reducing corrosion in the distillation tower and downstream
processing units. If not removed, the salt will form acids when heated that will result in corrosion.
Also, the salt can form deposits on heat exchanger surfaces over time, resulting in fouling.
Desalting also removes suspended solids such as sand, dirt, and rust particles picked up in
transport.
Why desalting is done?

Salts in crude oil are mainly in the form of magnesium, calcium, and sodium chlorides, sodium
chloride being the most abundant. These salts can be found in two forms: dissolved in emulsified
water droplets in the crude oil, as a water-in-oil emulsion, or crystallized and suspended solids.
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The negative effect of these salts in downstream processes can be summarized as follows: salt
deposit formation as scales where water-to-steam phase change takes place and corrosion by
hydrochloric acid formation. Hydrochloric acid is formed by magnesium and calcium chlorides’
decomposition at high temperatures (about 350 °C) as follows
CaCl2 + 2H2O → Ca(OH)2 + 2HCl
MgCl2 + 2H2O → Mg(OH)2 + 2HCl
In addition, other metals in inorganic compounds present in reservoir dirt and sand produce catalyst
poisoning in downstream processes such as hydrotreaters and cat crackers because of they are
chemically adsorbed on the catalyst surface.
The objective of desalting process is to remove chloride salts and other minerals from the crude
oil by water-washing. Depending on the desired salt content in the desalted crude oil, a one- or
two-step process could be applied. For refining purposes, a salt concentration < 2PTB (pound of
salt measured as NaCl per thousand barrels) is desired. By desalting, a considerable percentage of
suspended solids (sand, clay, or soil particles, or even particles product from corrosion of pipelines
and other upstream equipment’s) are removed.
Types of desalting:
There are three types of desalting methods used in refinery to remove salts and other from the
crude.
 Desalting by settling
 Chemical desalting
 Electro-chemical desalting
Desalting by settling:
Crude is stored in settling tanks for a long time in which molecules of water coalesce and settle
down by gravity. This process is not usually preferred because it takes a lot of time and a lot of
storage tanks if the production capacity is more
Chemical desalting:
Water and chemical surfactant (demulsifies) are added to the crude, heated so that salts and other
impurities dissolve into the water or attach to the water, and then held in a tank where they settle
out.
Electro-chemical desalting:
Washing of the salt from crude oil with water oil and water phases are separated in a settling tank
by adding chemicals to assist in breaking up emulsion or by the application of electrostatic field
to collapse the droplets of saltwater more rapidly.
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Method of desalting:
In most crudes. approximately 95% of the
total salt content IS found in the BS&W
(Base Sediment and Water) of the crude The
salt occurs in the form of highly
concentrated brine droplets dispersed
throughout the crude These droplets are
extremely small and are difficult to contact
with the fresh water added to the crude. The
desalting process consists of diluting this
high salt content brine with incoming fresh
water to produce a low salt content water
In order for the incoming water to effectively

contact the concentrated brine or BS&W, an
emulsion must be formed to disperse the
water throughout the crude and obtain
Intimate Contact with the brine droplets.
After demulsification and settling, the BS&W which remains in the crude IS a diluted water instead
of a concentrated brine
Emulsification is that process of Size reduction in which two or more Immiscible liquids are
intimately mixed one is the dispersed or discontinuous phase and the other is the dispersing or
continuous medium. The particle Size of most common emulsions is approximately I to 10 microns
in diameter Such particles are not visible to the eye but are easily resolved under a microscope
The production of emulsions emphasizes the principle of subjecting the liquid mixture to vigorous
shearing action, rather than to an impacting action often stressed in equipment for size reduction
of solids. The emulsion is produced by passing the liquids at high velocity through a small orifice
or between fixed surfaces. This is accomplished by means of a mixing valve upstream of the
electric desalters or by Injecting water at the start of the exchanger train that precedes the desalter
Obviously. the greater the pressure drop across the mixing valve, the greater will be the mixing or
shearing action. The greater the pressure drop the smaller the particle sizes and the tighter or more
stable the emulsion
The ease of producing an emulsion as well as its stability are influenced by such factors as
interfacial tension, electrical charge on the Individual globules, and the viscosity of the film at the
liquid interface
The process of demulsificatlon or breaking the emulsion IS accomplished by coalescing the small
particles of emulsion together so that they form droplets of sufficient size to permit separation by
gravity settling
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This IS accomplished in electrical desalting by passing the emulsion through an electrical field.
The particles of water are polarized (one side IS negative, the other side positive), and are oriented
along the lines of force in the electrical field. The attraction of opposite charges forms large
droplets which settle out
Pre-flash vessel:
Pre-flash column is one of the major part of a Crude Distillation Unit.
As the name suggests, its job is to flash, that is to vaporize the lighter (volatile) portion of the crude
oil before it enters the furnace. The basic principle of this vaporization is the
sudden decrease of pressure Which makes a large chunk of the volatile portion of the crude to get
vaporized and is directed to the main distillation column bypassing the furnace.
The remaining heavy portion is heated in the furnace and finally introduced in the main distillation
column.
The advantage of having the pre-flash drum is to reduce the load in the furnace resulting in saving
of Fuels. Had it not been there we would have to heat the entire crude before introducing it to the
crude distillation columnJust upstream the preflight vessel
The desalted crude oil flows from the top of the 2nd Stage Desalter, 100-V6 to the Flash Drum, 100-V8
With heating up to 190°C through a series of the following heat exchangers
100-E9 Desalted Crude-Cold Diesel Product Exchanger

100-E11A/B: Desalted Crude-HVGO Exchanger No. I
100-E12A/B: Desalted Crude-Circulating Diesel Exchanger No.2
100-E13: Desalted Exchanger-HVGO Exchanger No.2
100-E14: Desalted Crude-Hot Diesel Product Exchanger
Through the flash drum level control valve, 100-LV-036 flashed vapor is separated in 100-V8 and sent to
the crude column through the flash drum pressure control valve 100-PV-037 Approx. 2.2wt%and approx.
5.7 wt% of crude will be vaporized In Arabian Light Crude case and Upper Zakum-Murban Crude case,
respectively.
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Furnace:
An industrial furnace or direct fired heater is equipment used to provide heat for a process or can
serve as reactor which provides heats of reaction. Furnace designs vary as to its function, heating
duty, type of fuel and method of introducing combustion air. However, most process furnaces have
some common features. Fuel flows into the burner and is burnt with air provided from an air
blower. There can be more than one burner in a particular furnace which can be arranged in
cells which heat a particular set of tubes. Burners can also be floor mounted, wall
mounted or roof mounted depending on design. The flames heat up the tubes, which
in turn heat the fluid inside in the first part of the furnace known as the radiant section
or firebox. In this chamber where combustion takes place, the heat is transferred
mainly by radiation to tubes around the fire in the chamber. The heating fluid passes
through the tubes and is thus heated to the desired temperature. The gases from the
combustion are known as flue gas. After the flue gas leaves the firebox, most furnace
designs include a convection section where more heat is recovered before venting to
the atmosphere through the flue gas stack.
The radiant section is where the tubes receive almost all its heat by radiation
from the flame. In a vertical, cylindrical furnace, the tubes are vertical. Tubes
can be vertical or horizontal, placed along the refractory wall, in the middle,
etc., or arranged in cells.. Tube guides at the top, middle and bottom hold
the tubes in place. The convection section is located above the radiant
section where it is cooler to recover additional heat. Heat transfer takes place
by convection, and the tubes are finned to increase heat transfer.
The heater in CDU and VDU is rectangular type heater with forced draft and
heater is supplied with 5% excess air for complete burning of the fuel. The fuel used for the burning
are of three types fuel oil, fuel gas and waste gases of overhead section of vdu.CDU heater has 24
burners which can be ignited all at a time or partially according to the requirement.
Flashed crude then enters the Crude Heater, 100-HI, through eight passes.It is Important to have
individual pass flow Indication to ensure sufficient flow through each pass. Low flow through a
heater pass will result In eventual coking and overheating of the tubes in that pass. This would
result In a tube failure and a major fire. The heater outlet temperature controlling the fuel gas and
fuel oil control valves to the burners of the heater
Stable and efficient firing of the crude heater IS an important process variable. The temperature
(heater outlet) cascaded to the fuel pressure control is only part of the firing system. The second
part is the draft control of the heater. For safety and efficient operation a firebox should never be
allowed to become positive In pressure as this will cause an unsafe condition generally referred to
as "blowout"
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Distillation unit:
At 350 0C, and about 1 bar, most of the fractions in the crude oil vaporize and rise up the column
through valves in the trays, losing heat as they rise. When each fraction reaches the tray where the
temperature is just below its own boiling point, it condenses and changes back into liquid phase.
A continuous liquid phase is flowing by gravity through 'down comers' from tray to tray
downwards. In this way, the different fractions are gradually separated from each other on the trays
of the fractionation column. The heaviest fractions condense on the lower trays and the lighter
fractions condense on the trays higher up in the column. At different elevations in the column,
with special trays called draw-off trays, fractions can be drawn out on gravity through pipes, for
further processing in the refinery.
The Crude Column, 100-V9, has a total of 40 trays and divided into the following sections
Naphtha Pumparound (3 trays)

Naphtha/Kerosene Fractionation (9 trays)
Kerosene Pumparound (3 trays)
Kerosene/Diesel Fractionation (9 trays)
Diesel Pumparound (3 trays)
Diesel/Reduced Crude Fractionation (7 trays)
Flash Zone
Reduced Crude Stripping (6 trays)
All sidedraws are taken from total accumulator trays. A portion of each sidedraw stream is pumped on
flow control and returned hot as internal reflux to the column below each draw
The remaining part of sidedraw IS cooled and returned to the column several trays above the draw
tray as the external reflux. None of the circulating reflux streams are to be considered as
temperature control for the crude column, although they remove heat from the column The
circulating streams enable operating with higher heater outlet temperatures for better and more
complete removal of light ends from the crude oil while keeping the heater outlet temperatures
below cracking temperatures. The circulating streams Increase the Internal reflux to Improve
fractionation and thus improve the split or gap the 95% and 5% of the column products. The gap
is normally the control point for the sidecut products. and IS achieved by adjusting the circulating
external reflux flow controller.
Overhead section:
At top of the column, vapors leave through a pipe and are routed to an overhead condenser,
typically cooled by air fin-fans. At the outlet of the overhead condensers, at temperature about
40ºC, a mixture of gas, and liquid naphtha exists, which is falling into an overhead accumulator.
Gases are routed to a compressor for further recovery of LPG (C3/C4), while the liquids (gasoline)
are pumped to a hydrotreater unit for sulfur removal.
A fractionation column needs a flow of condensing liquid downwards in order to provide a driving
force for separation between light and heavy fractions. At the top of the column this liquid flow is
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provided by pumping a stream back from the overhead accumulator into the column.
Unfortunately, a lot of the heat provided by the furnace to vaporize hydrocarbons is lost against
ambient air in the overhead fin-fan coolers. A clever way of preventing this heat loss of condensing
hydrocarbons is done via the circulating refluxes of the column. In a circulating reflux, a hot side
draw-off from the column is pumped through a series of heat exchangers (against crude for
instance), where the stream is cooled down. The cool stream is sent back into the column at a
higher elevation, where it is being brought in contact with hotter rising vapors. This provides an
internal condensing mechanism inside the column, in a similar way as the top reflux does which
is sent back from the overhead accumulator. The main objective of a circulating reflux therefore
is to recover heat from condensing vapors. A fractionating column will have several (typically
three) of such refluxes, each providing sufficient liquid flow down the corresponding section of
the column.
Kerosene section:
The lightest side draw-off from the fractionating column is a fraction called kerosene, boiling in
the range 150-232 °C, which falls down through a pipe into a smaller column called 'side-stripper'.
The purpose of the side stripper is to remove very light hydrocarbons by using steam injection.
The stripping steam rate, or reboiled duty is controlled such as to meet the flashpoint specification
of the product. Similarly, to the atmospheric column, the side stripper has fractionating trays for
providing contact between vapor and liquid. The vapors produced from the top of the side stripper
are routed back via pipe into the fractionating column.
The kerosene that IS withdrawn from total accumulator tray separates Into three flows. The first
flow is pumped by the Kerosene Circulation pump 100-P7A/B and returned hot as internal reflux
to the crude column below the accumulator tray.
The second flow, circulating kerosene, is also pumped by 100-P7A/B and is used as a heating
medium for the Crude-Circulating Kerosene Exchanger, 100-E4 Then, the circulating kerosene is
returned, three trays above the draw tray as external reflux to the lower section
The remaining part of the flow enters the Kerosene Stripper, 100-V 10, The light end vapors are
steam stripped from the liquid and both are returned through the stripper vapor line to the crude
column at a point above the reflux return. The kerosene product pumped by the Kerosene Product
Pump, 100-P9A/B, is cooled and coalesced with the following equipment before being routed to
the Kerosene Merox Unit, U-801, or simultaneously to the diesel/fuel oil blending system.
Diesel section:
The second side draw-offs from the main fractionating column are diesel fractions, boiling in the
range 232 – 360 0C, which are ultimately used for blending the final diesel product
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The diesel that is withdrawn from total accumulator tray separates Into three flows. The first
flow is pumped by the Diesel Circulation pump, 100-P6A/B on flow control, 100-FV-078, and
returned hot as Internal reflux to the crude column below the accumulator tray.
The second flow, circulating diesel, IS also pumped by 100-P6A/B and IS used as a heating
medium for the Debutanizer Reboiler, 411-EI l, in the Gas Concentration Process Unit. It is then
passes through different exchangers for heat transfer.
Then, the circulating diesel is returned to the crude column on flow control, 411-FV-I I l, three
trays above the draw tray as external reflux to the lower section
The remaining part of the flow enters the Diesel Stripper, 100-V11. The light end vapors are steam
stripped from the liquid and both are returned through the stripper vapor line to the crude column
at a point above the reflux return. The diesel product pumped by the Diesel product pump 100-
P8A/B is cooled. coalesced, and salt dried with the following equipment being routed to the diesel
blending system
Bottom section:
The heated crude enters the crude column flash zone. In this section some of the charge flashes to
vapors and begins traveling up the column through the down flowing internal reflux which begins
cooling the hot vapors. The rest of the charge remains a liquid and falls to the bottom of the column
where it is steam stripped to remove the light components. These light components are carried up
the column by the steam until they reach the section of the column where they are cooled to the
point of condensing into a liquid. The bottom material that has been steam stripped is generally
referred to as "reduced crude" The reduced crude is directed to the suction of the Reduced Crude
Pump, 100- P5A/B and pumped to the Vacuum Heater, 110-HI.
Provision has been made to allow operation of the Crude Distillation Unit without the Vacuum
Distillation Unit, U-110 In this case the reduced crude IS cooled through the following heat
exchangers with the flashed crude, and then sent to the fuel oil blending system where it IS further
Vacuum distillation unit:

To recover additional distillates from long residue, distillation at reduced pressure and high
temperature has to be applied. This vacuum distillation process has become an important chain in
maximizing the upgrading of crude oil. As distillates, vacuum gas oil, lubricating oils and/or
conversion feedstock’s are generally produced. The residue from vacuum distillation - short
residue - can be used as feedstock for further upgrading, as bitumen feedstock or as fuel
component. The vacuum distillation unit is working at the pressure of 0.07kg/cm^2
Vacuum distillation tower:

In order to maximize the recovery of gas Oil present. reduced crude from the atmospheric
distillation unit further processed in a Vacuum Distillation Unit.
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At atmospheric pressure. reduced crude containing gas oils would be subjected to cracking
temperatures long before meaningful quantities. could be flashed off. By reducing the pressure.
desired quantities of specification material can be flashed off below cracking temperatures.
The maximum performance or the ability 10 lift the maximum gas Oil products depends on the
lowest absolute pressure that can be maintained in the flash zone consistent with maximum non-
cracking from the heater to the flash zone.
Experience has that for most stocks. the optimum flash zone temperature is approximately 399 co.
Although there are some stocks. usually with high characterization factor (UOP K), That require
lower temperatures. Also there are Others. usually IOW COP K stocks, that can tolerate as high as
427'C.
Vacuum distillation unit can be divided into four sections
 Reduced crude flashing

 Vacuum residue handling
 Product condensation
 Heat exchange
Reduced crude flashing:

The reduced crude is charged through the vacuum heater into the vacuum column in the same
manner that whole crude is charged to the Crude Distillation Unit. Whereas the flash zone pressure
of the crude column may be as high as .07 kg/cm2the pressure in a vacuum column is much lower.
The heater outlet temperature is generally used for control even though the pressure drop along the
transfer the makes the temperature at that point less meaningful than the flash zone temperature.
Heater outlet and flash zone temperatures are generally varied to meet the vacuum residue
specification.
If the flash zone temperature is too high, the reduced crude can stand to crack and produce gases
which overload the ejectors and break the vacuum. When this occurs, it is necessary to lower the
temperature. If a heavier bottoms product is still required. an attempt should then be made to obtain
a better vacuum to allow the lower flash zone temperature to create the same lift.
Slight cracking may occur without breaking the vacuum, this is sometimes indicated by positive
results from the Oliensis Spot Test. The Oliensis Spot Test is a simple laboratory test which
purports to indicate the presence of cracked components by the separation of these components
when a 20X solution of asphalt in naphtha is dropped on a filter paper. Some crudes always yield
a positive Oliensis asphalt. regardless of process conditions. If a negative Oliensis is demanded,
operations at the high and lowest temperature should be attempted.
Since the degree of cracking depends on both the temperature and the time during which the oil
is exposed to that temperature. the liquid level of the vacuum column bottom should be held at
50%, and its temperature reduced by recirculating some cooled vacuum residue as quench from
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the outlet of the vacuum bottoms/crude exchangers (I 00-E 17 / 19) to the bottom of the column.
It will often be observed that when the bottoms level rises, the column vacuum falls because of
cracking due to increased residence time.
The flash zone temperature will vary widely depending upon the crude source, vacuum bottom
specifications and the quantity of product taken overhead. Temperatures from below 315°C
(600ºF) to over 427°C (800°F) have been used in commercial operations.
Vacuum residue handling:

Vacuum residue must be handled more carefully than most refinery products. The vacuum bottoms
pump which handle very hot, heavy material have a tendency to lose suction. This problem can
be minimized by recycling some cooled vacuum bottoms to the column bottom and so reducing
the tendency of vapor to form in the suction line.
vacuum residue leg at the bottom of the column is small in diameter that the vacuum will have a
low residence If the residence was not low. the vacuum residue would turn quickly to coke; it is
also important that vacuum bottoms pump glands be sealed in such a manner as to prevent the
entry of air. Limitation of pump suction to a level of about 371 is also suggested
Since most vacuum residues are solid at ambient temperatures. all vacuum residue handling
equipment must either be active. or flushed with gas oil when it IS shut down. The vacuum residue
coolers should always be flushed out with gas oil immediately after the vacuum residue now
Product condensation:
The vapor rising from the flash zone is the gas oil product. and no further fractionation is required.
It is only desired to condense these vapors as efficiently as possible. This could be done in a shell
and tube condenser. but these are inefficient at low pressures, and the high pressure drop through
such a condenser would raise the flash zone pressure. The most efficient method is to contact the
hot vapors with liquid product which has been cooled by pumping through heat exchangers.
If the HVGO circulation is high enough to condense all the vapors, the HVGO temperature on the
accumulator tray will be so low that inefficient heat exchange will result. In order to obtain a
suitably high heavy vacuum gas oil temperature on the accumulator tray, it is necessary to reduce
the circulation rate until some of the vapors escape uncondensed. These uncondensed vapors are
condensed by circulating cooled LVGO in the upper section of the column, called the contact
condensing section.
The HVGO circulation rate IS chosen to maximize heat exchange efficiency with the crude. One
way of doing this on an operating unit IS to observe the temperature of the crude leaving the
flashed crude-HVGO exchangers no.4(100-E18), while lowering the HVGO circulation rate by
5%. If the crude temperature rises. the effect of the higher HVGO temperature on the accumulator
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tray has been greater than the effect of reduced circulation, and a further trial can be made. If the
crude temperature drops, a 5% change in the opposite direction can be tested.
The cooled HVGO product IS pumped to the Diesel ax unit. storage tank and blending systems on
the HVGO accumulator tray level control.
The LVGO section is a final contact condenser. The circulation rate should be adequate to keep
the vapor temperature to the ejectors about 44ºC. A high circulation rate will provide a margin
against upset.
Heat exchange:
In order to reduce the cost of operating the Vacuum Distillation Unit in combination with the Crude
Distillation Unit, as much heat as possible is recovered from the hot product streams by heat
exchanging them with cold crude streams. The LVGO, the HVGO, and the vacuum bottoms heat
exchange with the cold crude charge before the crude enters the crude column. A record should be
kept of heat exchanger inlet and outlet temperatures and heat transfer duty, so that fouling can be
recognized and corrected before the capacity of the unit is affected
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Root cause of vacume heater (110-H1) stack detoriation:

The smokestack & venting system of an industrial facility is much more complex than most people
think. Factory owners & managers generally understand the importance of regular plant
maintenance, but industrial chimneys often don’t get serviced as often as they should. Due to their
height, construction, and function, industrial chimneys will inevitably face deterioration. With
proper (and regular) maintenance, these structures can serve for years beyond their intended life
span of 25 to 30 years.
Industrial chimneys & smokestacks will begin to deteriorate as soon as they are constructed. After
a few years of regular use, the deterioration of these structures is exponential. Early on,
deterioration is hard to detect, especially from outside of the structure. In subsequent years,
deterioration accelerates rapidly often turning minor maintenance requirements into major repairs.
A specialized industrial chimney technician can detect early signs of degradation and find a
solution before it becomes a major or dangerous issue.
There are five major types of deterioration: flue gases, liner deterioration, carbonation, weather,
and construction techniques.
Flue Gases:
Corrosive chemicals and combustion byproducts will attack the concrete & materials the stack is
constructed of. These flue gases can bleed into the annular space between the chimney liner and
the shell causing corrosion-induced cracks, delamination, or spalling.
Liner Deterioration:
Industrial chimney liners & coatings protect and insulate the structure. Metal liners have either an
interior acid-resistant coating or exterior insulation. If the acid-resistant coating fails or the
insulation becomes damaged, holes or cracks can develop in the liner, making the chimney shell
vulnerable to chemical and thermal threats. This can cause concrete industrial chimneys to crack
or spall.
Carbonation:
Although carbonation is not a major threat early in the life of an industrial chimney, it can pose
serious problems close to the end life of the structure. When concrete is exposed to carbon dioxide
continuously, the pH of the material declines, reducing the protection of the steel rebar inside of
the structure. After two decades of use, as much as 1.5 inches of concrete will have been carbonated
which is troublesome as reinforcing steel is embedded 1.5 inches inside of the concrete. When this
steel rusts, it expands 12 – 14 times its original size, causing the outer concrete to spall & break
off.
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Weather:
Weather actually plays a very critical role in the deterioration of industrial chimneys. Wind, rain,
fluctuating ambient temperatures, lightning, and other environmental factors can hasten the
deterioration of these tall structures.
Construction Techniques:
The materials & techniques used to construct a smokestack can also affect how quickly a structure
deteriorates. Many industrial chimneys over 200 ft are built in 7 to 10 foot sections and the joints
can wear out way before the other components of the structure, allowing corrosive elements to
attack these now-vulnerable parts. Steel stacks also suffer from small cracks caused by wind
loading or thermal stress during construction.
The root causes of the detoriation of 110-H1 heater stack is the fuel used for the heating. The fuels
used here are
 Fuel oil
 Fuel gas
These fuels contain subsequent amount of Sulphur which is very corrosive and is the major cause
for this detoriation which is found in sour gas in waste gases and gasoil as H2S. Corrosion due to
H2S is mainly electrochemical in nature. The products of dissociation of the H 2S gas are aggressive
and can catalyze electrochemical reactions, especially the dissolution of Fe. As the temperature in
the heater can be around 360oC and at elevated temperature the corrosion ability of H2S increases
significantly to severals mm per day which increase the corrosion rate
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Pinch analysis:
Pinch Technology provides a systematic methodology for energy saving in processes and total
sites. The methodology is based on thermodynamic principles. Figure 1 illustrates the role of Pinch
Technology in the overall process design. The process design hierarchy can be represented by the
“onion diagram” [2, 3] as shown below. The design of a process starts with the reactors (in the
“core” of the onion). Once feeds, products, recycle concentrations and flowrates are known, the
separators (the second layer of the onion) can be designed. The basic process heat and material
balance is now in place, and the heat exchanger network (the third layer) can be designed. The
remaining heating and cooling duties are handled by the utility system (the fourth layer). The
process utility system may be a part of acentralised site-wide utility system.
A Pinch Analysis starts with the heat and material balance for the process. Using Pinch
Technology, it is possible to identify appropriate changes in the core process conditions that can
have an impact on energy savings (onion layers one and two). After the heat and material balance
is established, targets for energy saving can be set prior to the design of the heat exchanger
network. The Pinch Design Method ensures that these targets are achieved during the network
design. Targets can also be set for the utility loads at various levels (e.g. steam and refrigeration
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levels). The utility levels supplied to the process may be a part of a centralised site-wide utility
system (e.g. site steam system). Pinch Technology extends to the site level, wherein appropriate
loads on the various steam mains can be identified in order to minimise the site wide energy
consumption. Pinch Technology therefore provides a consistent methodology for energy saving,
from the basic heat and material balance to the total site utility system.
Case study:
Unit description:
The problem is stated as follows:
Small section of the Para-xylene separation unit (Fig. 4) of the Company has been considered to
be analysed according to the preference of the process department. The description of the process
is the following; Part of the bottom product of the distillation column which is the pure Para-xylene
should be cooled down through the air fan cooler in order to be stored in the storage tank (Stream
number 3 ), and the rest should be heated up in the reboiler in order to come back to the column
(Stream number 5). In addition, there are other hot and cold streams, which are involved in the
analysis that comes from other units of the plant which are;
Stream number one is recirculation solvent in Eluxy process unit, Stream number two is the feed
of Eluxy unit, which comes from Reformate & Aromatic separation unit, stream number six, which
is Para-xylene for purification and removing Toluene, and finally stream number four, which is
again Para-xylene. In Fig. 4 each stream specified by a number and after cooling or heating process
their names changes by adding an “A” character after the aforementioned numbers. “H” and “C”
also represents heater and cooler respectively
Fig. 4. Schematic view of the considered unit
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To summarize; there are three hot process streams “NH” to be cooled down and three cold process
streams “NC” to be heated up. In Table 1 which based on the stream’s properties of the existing
case, all required data for starting the analysis has been listed.
Table 1. Streams table for existing case
PA application :
As it mentioned before, the first step for applying PA is to list all considered hot and cold streams
with their properties, then computing the energy (flux) requirements for each stream by means of
(1). Hot streams should be cooled down therefore, computed flux via (1) is called maximum
cooling load “Qmax,C” which is equal to 22.12 MW according to the streams properties which
have been listed in Table 1. In a contrary, cold streams should be heated up and same computation
is called maximum heating load “Qmax,H” which is equal to 16 MW.
Next step will be drawing two composite curves by means of Matlab code for hot and cold streams,
which is shown in Fig. 5. For the beginning ΔTmin considered equal to 30 degrees but as stated
before, it is rare to have the same amount of preselected value for the first plot of composite curves.
Aforementioned Matlab code provides a useful tool to perform pinch analysis and draw composite
curves for more streams which only needs few properties as input. In Fig. 5, Q min,h and Q min,c
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are stands for minimum loads. Variation of ΔTmin will change the amount of recovered heat as
well as external utilities loads. If the difference between minimum and maximum load is
significant, it is worth applying PA. In the first attempt, the idea is shifting cold composite curve
to the left in order to recover more heat and decrease an external heat load as much as possible
(Case 1).
By choosing ΔTmin equal to 16.5 °C which can be obtain either by calculation or graphically, the
heating duty of the external utilities are becoming zero, cooling load decreases and heat recovery
zone increases ( Fig. 6 ) . Therefore, with this ΔTmin, maximum heating load (16 MW) required
for heating up cold streams have been recovered from the heat available of hot streams.
Fig. 6. Composite curve with modified ΔTmin (case 1)

An interesting question is how much natural resources are needed to produce this much (16 MW
= 504576 GJ/year = 12051.59 toe) of heat load? By considering natural gas as a fuel and taking
into account the heating value of natural gas in Iran equal to 8600 Kcal/m3, it is possible to
compute how many cubic meters per hour of gas is needed in order to produce 504576 GJ/year
heat flux ;
The result shows that, 14×106 m3/year (1600 m3/h) of natural gas is needed to produce such
amount of heat flux. Considering the price of natural gas equal to 2650 Iranian Rial (IRR) for each
m3 , the amount of annual cost saving will be 3.71×1010 (IRR). This amount is equal to 1.4 million
dollars according to the exchange rate of Iranian central bank.
In section 3.3, another stream will be added to the existing case in order to recover more available
heat inside the system.
Improvement:
it is evidence from Fig. 6, the amount of cooling load that should be rejected to the extern is equal
to 6 MW which could be still useful for heating purposes. The possible suggested option was
heating up an additional water stream which is used in desulfurization unit. The source and target
temperature of this stream and other properties which needed to perform PA have been written in
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the last row of Table 2. By adding this new stream, number of cold streams increases to 4 but
number of hot streams remain fixed (case 2).
Table 2. Streams table with additional water fluid (case 2)
Fig. 7 shows the upgraded composite curve according to streams that have been listed in Table 2.
By simply looking to the composite curves, it is clear that there is still possibility to recover more
heat by increasing the mass flow rate of last stream.
Fig. 7. Upgraded composite curves (case 2)

The idea is increasing mass flow rate gradually, up to the point that heating load starts to change
from being zero; Therefore, the corresponded mass flow rate will be the upper bound. By following
the procedure, maximum mass flow rate of water, which keeps the heating load equal to zero, will
be equal to 57.9 kg/s. By updating last row of Table 2 with new value of mass flow rate, final
composite curve for this improved case (case 3), can be drawn (Fig. 8). In this case, the minimum
cooling load has reached to 3.9 MW.
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In Table 3 one can see the amount of minimum cooling load, the recovered heat in each
modification and the corresponded cost saving due to heat recovery in million dollars per year.
Table 3. Summary of modifications
Note that for all cases ΔTmin is equal to 16.5 °C and minimum heating load according to the
composite curves is equal to zero.
HEN design and investment cost computation:

HEN Design:
The primary goal of HEN is to devise an efficient (economically or thermodynamically) heat
exchanger network to optimize the exchange of heat between hot and cold process streams with
known initial and final temperatures , heat capacities, and flow rates [4, 5].
So far, the PA for computing the amount of recovered heat has been performed, and it's the time
for designing a proper heat exchanger network according to the rules which mentioned in section
2.2.
Fig. 9 is the designed heat exchanger network corresponds to the last modification of this case
study (case 3)
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As it was expected from composite curves, there is no external heat utility in the HEN since heating
load was equal to zero, and there is only one cooler that should reject 3.9 MW of flux to the
environment. Heat duty, inlet and outlet temperature of each heat exchanger can be computed by
performing heat and obtaining heat transfer area.
Next section is devoted to perform investment cost calculation of the HEN and computing payback
time due to the saving of the resource consumption.
Cost computation:
For any heat exchanger with a hot and cold stream, the heat requirement is calculated as:
In addition, the overall heat transfer equation for the exchanger must be solved simultaneously:
Where U is the overall heat transfer coefficient which is a function of the flow geometry, fluid
properties and material composition of the heat exchanger, A is the heat transfer area, and ΔT LM
is the log-mean temperature difference which is computed as follows:
In which; ΔT 1 = (T hot,in - T cold,out ) and ΔT 2 = (T hot,out - T cold,in )

The log-mean temperature difference between the fluids is in general a function of the fluid
properties and flow geometry as well. Heat exchanger design requires consideration of each of
these factors. Since in both shell and tube side hydrocarbon passes, the typical overall heat transfer
coefficient value for shell and tube heat exchanger could be estimated in a range of 50 to 300
[W/m2K][23]. Equation (4) implies that, the higher the amount of U is, the lower the heat transfer
area [24]. However, high value of “U” requires higher investment cost due to its dependency to
the material composition of the heat exchanger. By considering the value of overall heat transfer
coefficient equal to 175 [W/m2K] and solving(2), (3) and(4), computation of heat transfer area
will be straight forward. It is also possible to find out an investment cost of equipment according
to the computed heat transfer area by means of curves and tables so called cost curves and
installation’s cost table which gives quick and rough estimation for investment costs. Fig. 10 shows
cost curve related to the sell and tube heat exchanger.[25]
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Table 4 shows calculated heat duties, heat transfer area and investment costs (purchasing plus
installation) related to each heat exchanger according to the last improvement (case 3). Note that
investment costs have been computed according to the table of price which constructed at 1998.
In order to adjust process plant construction costs from one period to another, Chemical
Engineering Plant Cost Index (CEPCI) has been used [26], to correct the past price;
Where; C1 and C2 are the prices, I1 and I2 are price indexes for past and present respectively.
Since this study deals with HEN which includes heat exchangers, piping, valves, etc., it can be
considered small part of the plant and composite index can be used to perform the computation ;
From Table 4, total cost of the network is equal to C1 = 1.55 × 106 $ and from CEPCI, annual
average price index for past and present year can be extracted; I1, (1998) = 389.5, I2,(2013) =
566.4
The amount of updated total cost can be computed via (5) and it is equal to C2 = 2.25 × 106 $.
Now by looking to Table 3 and considering cost of recovered heat for case 3 which is actually
resource saving due to PA application, it is possible to compute payback time of the investment
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cost(C2) in order to construct HEN. Result shows the payback time of the investment is
approximately equal to 17 months.
Conclusion:
One of the most important roles in many industrial processes is reducing energy consumptions.
Saving and optimizing the energy usage is a promise to meet the goal of an optimum energy cost
and to gain more profitability.
In this paper, a very small scale of a real condition in a petrochemical plant has been analysed from
the heat recovery point of view as well as economic aspect of the modification.
The result of first evaluation in terms of composite curve shows that by reducing the value of
minimum temperature difference, the amount of recovered heat increases and on the other hand,
external utilities duty decreases (Fig. 5 and Fig. 6 with 30 °C and 16.5 °C ΔTmin respectively).
The idea was to add another stream in order to recover more heat inside the system. For this
purpose, the 48 °C water stream has been selected to be heated up. Next step was increasing the
mass flow rate of water stream while minimum heating load remains zero. Then with the new mass
flow rate of additional stream (case 3), HEN has been designed and heat transfer area is calculated.
Finally, the investment and payback time have been computed, which is almost 17 months in this
case.
In the next study, it is possible to draw a curve like Fig. 3 specifically for this case study, which
shows the relationship between variation of energy and utility cost with different ΔTmin
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Vacuum distillation unit:
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Crude distillation unit:
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Acknowledgements:
sI would like to thank Almighty ALLAH who selected me and provided me this Opportunity to
perform 6 weeks training at Pak Arab Refinery Limited. First and foremost, I would like to
express my deepest gratitude to:
Engr Muhammad Shahid

Engr Asad Rana
Ma’am Khalida
All Shift Supervisors
For their uninterrupted supervision, adjuvant guidance and extravagant encouragement during
the experimental, theoretical and writing up stages of my work.
I would like to express my special thanks to Pak Arab Refinery Limited (PARCO), for
providing such an utmost learning platform which is admirable.
I would like to extend my admiration and deepest thanks to my beloved Parents for their
endearing Guidance, financial support & amiable supervision went a long way towards my
success at that stage. Finally, I would like to thanks all friends and all management of MCR
for sharing their practical & theoretical knowledge.
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Vacuum distillation unit:............................................................................................................... 32

Vacuum distillation tower: ........................................................................................................ 32
Reduced crude flashing: ................................................................................................................ 33
Vacuum residue handling: ............................................................................................................ 34
Product condensation: ................................................................................................................... 34
Heat exchange: .............................................................................................................................. 35
Root cause of vacume heater (110-H1) stack detoriation: ............................................................ 36
Flue Gases ................................................................................................................................. 36
Liner Deterioration .................................................................................................................... 36
Carbonation ............................................................................................................................... 36
Weather ..................................................................................................................................... 37
Construction Techniques ........................................................................................................... 37
Pinch analysis................................................................................................................................ 38
Case study ..................................................................................................................................... 39
Unit description ......................................................................................................................... 39
PA application ........................................................................................................................... 40
Improvement: ............................................................................................................................ 41
HEN Design .............................................................................................................................. 43
Cost computation....................................................................................................................... 44
Conclusion: 46
50

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Internship Report

Technical Services Department - TSD

PAK-ARAB REFINERY LIMITED

Technical Services Department

FIRE DRILL: ................................................................................................................................ 17

Electro-chemical desalting: ................................................................................................................. 26

Engr Muhammad Shahid

Introduction of PARCO MCR:

 To implement an Integrated Investment Programmed which takes cognisance of the

 To operate the existing Pipeline System in a manner that establishes it as a center of

 To provide a lead to the indigenous Petroleum Industry in finding of solution to Technical

 Oil pipeline system, storage and allied facilities.

 Marketing & Commercial

Parco stands for?

Aggressive technical thinking and advanced planning

Organized and systematic development

 PAK-ARAB pipeline company limited (PAPCO)

PAK – ARAB PIPELINE COMPANY

TOTAL PARCO PAKISTAN LTD (TPPL):

PARCO PEARL GAS (PVT) LTD:

What is crude oil?

How crude oil is formed?

As time goes by, heat and pressure

Once the oil and natural gas is

Component of curded oil:

Sand Mineral Matter and Water:

The presence of impurities in the crude oil:

 Health: Minimize effluents, emissions of gases, and proper treatment of

 Awareness to PARCO Health, Safety, Environment and Quality Management Systems

FIRE FIGHTING EQUIPMENT:

Necessary PPEs are

Ear Protection plugs:

If a person is working without these PPEs it should be reported

Work permit system:

Work permit system are of following types

 Cold work permit

Hot work permit:

Confined space permit:

Fire management system:

It includes the following sections;

FIRE FIGHTING AND EMERGENCY RESPONSE :

Crude distillation unit:

Unstabilized straight run Naphtha/Kerosene: 20°F – 10°F

 Reduced crude section

The description and working of major equipment’s used in CDU is as follow

Why desalting is done?

CaCl2 + 2H2O → Ca(OH)2 + 2HCl

MgCl2 + 2H2O → Mg(OH)2 + 2HCl

In order for the incoming water to effectively

100-E9 Desalted Crude-Cold Diesel Product Exchanger

Naphtha Pumparound (3 trays)

Vacuum distillation unit:

Vacuum distillation tower:

Vacuum distillation unit can be divided into four sections

 Reduced crude flashing

Reduced crude flashing:

Vacuum residue handling:

Root cause of vacume heater (110-H1) stack detoriation:

Fig. 4. Schematic view of the considered unit

Table 1. Streams table for existing case

Fig. 6. Composite curve with modified ΔTmin (case 1)

Fig. 7. Upgraded composite curves (case 2)