Date post: | 03-Apr-2018 |
Category: |
Documents |
Upload: | hemalatha-mardi |
View: | 258 times |
Download: | 2 times |
of 31
7/28/2019 inplant training report.pdf
1/31
INPLANT TRAINING
REPORT
BHARAT PETROLEUM CORPORATION
LIMITED KOCHI REFINERY
SUBMITTED BY
HEMALATHA MARDI
P:504
ELECTRONICS AND COMMUNICATION ENGINEERING
NIT CALICUT
TENURE: 23
RD
MAY- 3
RD
JUNE
7/28/2019 inplant training report.pdf
2/31
AKNOWLEDGEMENT
Firstly I would like to thank god almighty for giving me this opportunity. I
express my sincere gratitude to Mr Sabu Jose and Mr Ramesh K. for their
invaluable assistance and support.
I would like to thank Mr Anish P.V, Mr Rajeev M.C, Mr Raveendran Pillai, Mr
Jacob C.V, and Mr Prathish K Babu for their time and effort.
I also appreciate the effort and risk BPCL KR has taken in including us in the
daily busy schedule of its working hours.
I whole heartedly thank all the engineers and technicians who regardless of
their busy routine have found enough time to educate us and exposingourselves in the real working of an industry. BPCL KR has done a great role in
integrating our theoretical knowledge with work experience.
7/28/2019 inplant training report.pdf
3/31
INDEX
Company profile Introduction Process description CDU I CDU II FCCU DHDS Analyzers Control systems HART management systems TFMC Truck loading unit Wagon loading Conclusion
7/28/2019 inplant training report.pdf
4/31
COMPANY PROFILE
Kochi Refinery was incorporated as a public limited company in
September 1963, with technical collaboration and financial participation
from Phillips petroleum company, USA. The refinery was commissioned
on 23rd
September 1966, with a crude processing capacity of 2.5 MMTPA
.In addition to the crude distillation unit (presently CDU1), the units
commissioned initially included a Vacuum Distillation, Visbreaker,
Bitumen, Naphtha and Kerosene Hydro de-Sulfurisation and reformer
units .Many new process units were added including secondary
processing facilities, Aromatics Recovery and Diesel De-Sulfurisation
units. Many of the processing units and associated facilities have
undergone several modifications, including expansion and
modernization projects.
The capacity was first expanded from 2.5 to 3.0 MMTPA in September
1973.The production of liquefied petroleum gas(LPG) and aviation
turbine fuel (ATF) were commenced after this expansion. Bombay high
crude was first processed in CDU1 in 1975.
Crude processing capacity of KR was further enhanced to 4.5 MMTPA by
revamping the crude unit in 1984, along with the addition of secondary
processing facilities including a 1.0 MMTPA Fluid catalytic cracking unit
(FCCU).Installation of the FCC unit was necessitated due to the ever-
increasing price of crude oil and increased demand for middle distillates
and lighter products. The FCC unit facilitates conversion of heavier
hydrocarbon streams with lower demand to high value products like
LPG, Gasoline and Diesel.
7/28/2019 inplant training report.pdf
5/31
The crude processing capacity of the refinery was further increased to
7.5 MMTPA in the year 1994 with the addition of a new 3.0 MMTPA
Crude Distillation Unit (CDU-2). The FCC Unit capacity was also increased
to 1.4 MMTPA along with this, to match the crude capacity. A Vacuum
Distillation Unit (VDU-2), Naphtha Stabiliser, Sour Water stripping unit
and LPG treatment facilities were also included as a part of the
installation of CDU-2. Subsequently a Sulphur Recovery Unit (SRU) for
desulfurisation of refinery fuel gas was commissioned in 1995 as a part
of the capacity expansion project.
All the process units of the refinery are currently monitored and
controlled using state-of-the-art Distributed Control System
(DCS), with associated instrumentation and other facilities. The earlier
Pneumatic control system used in some of the process units and utilities
were changed over to DCS in stages. DCS was first commissioned in CDU-
1 block in November 1988 by changing over from pneumatic system.
Older DCSs of CDU-1 and FCCU blocks and ARU along with CPP-1 were
upgraded in June 2001.A plant wide network connecting DCSs of all the
process units and other areas of the refinery, was commissioned along
with the up gradation. A real time database system for storage,
distribution and displaying of process data and other information was
also commissioned with this .
Raw Material Linkages
Indigenous CrudeBH Crude
LS CrudeLabuan- Malaysia
Bonny light - Nigeria
7/28/2019 inplant training report.pdf
6/31
Marib Light Yemen
MS CrudeMasila YemenMurban UAE
Essider- Libya
HS CrudesArab Mix- Saudi
Iran Mix- Iran
Dubai- UAE
Important Milestones in Growth:
Formed in joint sector with the financial & technical participationbetween Phillips Petroleum Company, USA and Duncan Brothers,
Calcutta.
Construction completed in 29months at a cost of Rs. 27 crores Commissioned on September 23, 1966 as a 2.5 MMTPA refinery. Crude oil refining capacity expanded to :
o 2.5 MMTPA to 3.3 MMTPA in 1973o 3.3 MMTPA to 4.5 MMTPA in 1984o 4.5 MMTPA to 7.5 MMTPA in 1994
Installation of secondary processing facilities (1MMTPA FCCU) in1984.
Capacity augmented to 1.4 in 1994 & 1.75 with oxygen plant facilityin 2005.
7/28/2019 inplant training report.pdf
7/31
INTRODUCTION
Instrumentation Engineering has found major application in all sectors of
the plant with it playing a vital role in optimization of labour, resource and
time. The advent of electronic hardware, that replaced mechanical
hardware, has led to greater accuracy, reduced response times and lesser
maintenance. This in turn has augmented margins because of reduced cost
of production and better product quality with very little production and
quality analytic delay.
The purpose of the industrial visit was to acquaint the apprentice with all
the major manifestations of instrumentation engineering on the premises
of the refinery. I met Mr Sabu Jose who briefly described the role of the
instrumentation engineering in the field of refinery. Then I was asked to
report to Mr Ramesh K, who scheduled our tenure at the refinery for the
remaining 10days at the refinery. He assigned us to different people for the
allotted time slot, as per their expertise in the refinery, to augment our
understanding of concepts imbibed within the confines of the classroom.
We visited the following places:
Captive power plant (control room) CDU I Stack and blending analyzers TFMC and offset
However I realised that two weeks would not suffice to see entire plant in
detail, let alone indulge in its intricacies. As such I have attempted to put my
best foot forward and tried to garner as much knowledge and experience from
our guides and instructors. This is a brief report of what I learnt over the
course of the two week I was here at the refinery.
7/28/2019 inplant training report.pdf
8/31
PROCESS DESCRIPTION
CDU- crude distillation unit
FCCU- fluid catalytic cracking unit
ARU- aromatic recovery unit
DHDS- diesel hydro desulphurisation unit
CRUDE OIL
TANK
CDU I
4.5 MMTPA
CDU II
3 MMTPA
FCCU
1.75 MMTPA
DHDS
2.54 MMTPA
ARUREFORMATE FROM CDU I
23
PRODUCTS
7/28/2019 inplant training report.pdf
9/31
CDU-1 BLOCK
CDU-1 consists of crude distillation unit, LPG recover unit, Naphtha splitter unit(NSU), Naphtha Hydro desulphurization unit (NHDS), Reform unit, kerosene
hydro desulphurization unit (KHDS), visbreaker unit.
I. Crude Distillation Unit (CDU-1)
7/28/2019 inplant training report.pdf
10/31
7/28/2019 inplant training report.pdf
11/31
temperature, converts sulphur compounds into H2S, which can be easily
removed from the system.
V. Reformer unitThe reformer unit was originally designed to boost the octane number of
straight run naphtha to be sold as gasoline. The main function of the
reformer unit is to produce benzene & other aromatic products from the
C60C90 cut of desulphurized naphtha. Toluene is another major
constituent of the reformate. Hydrogen formed is separated and
recycled in the reactors. The main chemical reactions within this unit
are:
o Dehydrogenation of naphtha into aromaticso Isomerization of paraffin and naphtheneso Dehydro-cyclisation of paraffin into aromaticso Hydro cracking
Reformer unit is semi regenerative unit.
VI. Kerosene hydro desulphurization unitThe unit produces aviation turbine fuel (ATF) or jet fuel (JP5). This unit is
also used for producing mineral turpentine oil (MTO) desulphurization of
kerosene2 stream from CD for blending in diesel pool is another function
of the KHDS unit.
VII. Visbreaker unitVacuum residue obtained from imported crude in the FPU has high
viscosity. The visbreaker unit is used specifically to reduce this viscosity.
Visbreaker, basically is a thermal cracking process wherein long chain
hydrocarbon molecules in heavy feed stock are broken into smaller
molecules having lower viscosity, thereby leading to a reduction in the
velocity. This results in conserving valuable distillate products.
7/28/2019 inplant training report.pdf
12/31
There are two alternate products for visbreaking:
o Coil visbreaking- feed stock is cracked at high temperature (480-500
OC) in a furnace with sorter residence times to achieve this
conversion.
o Soaker technology- the feed stock is heated to relatively lowertemperature (440-460
OC) and holding the charge in a soaker drum
for larger residence times (20-25min) to achieve the required
conversion.
7/28/2019 inplant training report.pdf
13/31
CDU II BLOCK
Crude from storage is preheated, mixed with stripped water desalted againpreheated and split into two for preheating. Its finally heated and flashed into
the atmospheric column
Atmospheric column overhead vapours pass through accumulator and
overhead steam is sent to naphtha stabilizer, HGO, LGO, kerosene, HN are
withdrawn with side streams.
HN is routed to gas oil stream, kerosene to storage after stream stripping; gas
oil steam is also routed to storage RCO from crude column bottom is sent to
VDU. Cooling and condensation of vapours is then performed.
I. Naphtha stabilizer:In this unstabilized naphtha is sent to CDU or to LAN/HAN storage.
II.
Naphtha caustic wash:It removes H2S and mercaptan from stabilized naphtha. It is done by
separating hydrocarbons and cautic phases from a mixture of naphtha
and caustics.
III. LPG amine treatment unit:It was designed to remove H2S from LPG. This is done passing feed
through amine absorption column and then processing in a regenerating
boiler. LPG from absorption column is sent to wash drum, then to
storage through a sand filter.
IV. Vacuum distillation unit (VDU):In this unit VGO feed from FCCU is produced, hot RCO is heated, fed to
fractionating column. Slope oil is collected in hot well, vacuum diesel
along with CDUs gas oil is sent to combined diesel pool. VGO obtained is
stored in VGO storage of the FCCU. Slope distillation is partly recycle rest
is routes with VR which is routed to LSHS storage.
7/28/2019 inplant training report.pdf
14/31
V. Sulphur recovery unit (LOCAT SRU):It removes H2S from refinery fuel gas by converting it into elemental
sulphur. LOCAT is an oxidation process. Unit is an oxidation process. Unit
can process fuel gas from HP & LP source.
VI. Amine absorption unit (AAU):It was installed as an alternative to LOCAT SUR. Centralized facility for
regeneration for DEA in the DHDS block is made use of H2S is absorbed
which is sent to DHDS amine unit.
VII. Aromatic refinery unit (ARU):Aromatic viz. benzene & toluene are extracted from reformate using
salfolane as solvent. Utility system for the supply of plant air, instrument
air, cooling air is a part of ARU.
7/28/2019 inplant training report.pdf
15/31
FLUIDIZED CATALYSED CRACKING UNIT (FCCU)
The FCCU was commissioned in 1985. It converts the atmospheric residue from
CDU I into additional middle distillates, motor spirit and LPG. There are many
process units under FCCU. A substantial portion of the atmospheric residue
(RCO) which varies from 30 to 45% of the crude throughout depending on the
type of crude, was converted to FO by visbreaking or yielded as low sulphur
heavy stock during earlier periods.
Feed to the unit is the VGO (Vacuum gas oil) generated from FPU (feed
preparation unit) and vacuum distillation unit in CDU II.The functionality of the
FCCU can be divided into:
7/28/2019 inplant training report.pdf
16/31
1. Feed preparation unit (FPU)The purpose of the feed preparation unit is to make feed of required
quality to be processed in FCCU. In this unit, RCO is distilled undervacuum into four different units mainly vacuum diesel oil (VDO),Light
Vacuum gas oil (LPGO), Heavy vacuum gas oil (HVGO) & Vacuum residue
(VR).
2. Bitumen unitIn this unit, bitumen is produced from VR from vacuum column during
asphalt bearing crude run. Normally VR from BH run is not used for
bitumen make due to its low asphaltene content. VR from FPU is cooled
to around 220oC and charged to which air from an air compressor is
supplied through a distributer.
3. Fluidized catalytic cracking unit (FCCU)FCCU converts VGO in to higher value products such as LPG, Gasoline
and diesel by cracking of heavier hydrocarbon molecules of VGO to
lighter components. Silica-alumina catalyst in powder is used forpromoting the cracking reactions. The reaction takes place at a high
temperature and at a pressure above atmospheric pressure.
4. Gas concentration unit (GCU)In the GCU, LPG is recovered from both the overhead gas an liquid
streams and in the process, gasoline is stabilized. The unit consists of a
primary absorber and a sponge absorber for recovering LPG from fuel
gas, a stripper for removing H2S from the liquid stream to fuel gas, and a
debutanizer for separating LPG and gasoline. Sponge absorber uses LCO
circulating reflux stream as the absorption medium. Fuel gas is routed to
the refinery fuel gas system after removing H2S.
7/28/2019 inplant training report.pdf
17/31
DIESEL HYDRO-DESULPHURIZATION PLANT (DHDS)
Diesel is currently, the most highly consumed petroleum product in India.Sulphur in diesel results in SO2 and other particulate matter that pollute the
atmosphere. DHDS remedies this and it consists of:
I. Hydrogen generation unit:The HGU is designed to produce hydrogen of 99.99% purity. Hydrogen is
produced from naphtha using steam reforming. Naphtha having a
sulphur content of 1000ppm is desulphurized in a pre-desulphurization
section is to reduce the sulphur level in the feedstock. This is achieved
by the reaction of sulphur compounds in naphtha with hydrogen in a
catalytic reactor.
II. Diesel hydro desulphurization unit:The DHDS unit is designed to desulphurize diesel/VGO in blocked out
mode operation. It is designed to reduce the sulphur content of dieselblend stock.
III. Sulphur recovery unit:The SRU converts and separates H2S contained in the sour gas and acid
gas streams from sour water stripping unit and amine regeneration unit
in the form of elemental solid sulphur.
IV. Amine regeneration unit:Di ethanol amine is the primary feed to this unit, which rich in H2S.
V. Sour stripping unit:The main function of the sour water stripping unit is to treat sour water
generation unit is to treat sour water generated from the DHDS/
hydrogen unit.
7/28/2019 inplant training report.pdf
18/31
ANALYZER
The industry standards today demand very high standards both for the sake ofhigh quality products and for environmental safety. Analyzer is that
component of the refinery that achieves this. An analyzer is a device that
performs chemical analysis on samples or sample streams. Its purpose of
commission is to ensure the quality of end products. It reduces the
inadequacies in quality control methods prevalent in earlier industrial practices
which cause heavy delay in the delivery of products and losses due to sub
standard quality. The BPCL refinery relies mainly on online analyzer.
The main characteristics of an online analyzer are:
1. Continuous operation for long periods with minimal skilled attention andmaintenance.
2. It must withstand the hostile environment in which the product isformed/treated.
3. It should not pose a threat to the safety to the chemical process.4.
It must have very efficient sampling system.
NIR analyzer
NIR analyzers are used for measuring properties of MS & HSD work on the
same principle. PROSPEC III is the model used. A representative sample from
the blend header is taken and introduced to the flow cell of the analyzer. Near
the infrared rays of wavelength 800nm-1700nm are transmitted through the
sample to obtain the absorption spectrum. The monochrometer consists of the
lamp assembly, the filter wheel assembly and the grating wheel assembly.
White light from a Tungsten-halogen bulb travels through the lenses, through
the slit, through a fibre wheel and is incident upon holographic diffraction
grating. The filter wheel houses several filters that are used for wavelength
calibration. The concave holographic diffraction grating has equally spaced
lines per mm on its surface and dispenses the light into continuum of
wavelengths.
7/28/2019 inplant training report.pdf
19/31
Oxygen analyzer
1. Paramagnetic oxygen analyzer:It consist of a thin pipe called bypass pipe at the center, a heating
resistance wire is wound around it. There is a tap in the center which is a
Wheatstone bridge together with fixed resistors R1 & R2. Also strong
magnetic field is provided to the left half by means of a permanent
magnet. Thus if a measuring gas which is on the left side of the bypass
pipe contains O2 molecules which are highly paramagnetic are sucked
into the central part of the magnet which has the largest field strength
and it flows from left to right in the bypass pipe.
However, O2 molecules which have reached the center of the magnetic
field are heated by the resistance wire. Thus their paramagnetism is
reduced and their proclivity to being sucked into the magnetic field is
reduced. Therefore they are gradually pushed to the right from the gas
flowing in from the left. The strength of this magnetic wind is
proportional to the O2 content. The magnetic wind cools down in both
the halves at different rates. The difference is directly proportional to
the O2 content and is measured using the electric bridge circuit.
2. Zirconia probe oxygen analyzer:Zirconia sensor works on the principle of Nernst equation which states
that the voltage developed across the zirconia cell is
E=0.0496T log10 [P1 (O2)/P2 (O2)]
Where,
E= sensor output (V)T=absolute temperature (K)
P1 (O2)=ref partial pressure
P2 (O2) =sample gas partial pressure
From this it is clear that as O2 concentration in the sample gas decreases
the emf developed in the sensor increases.
7/28/2019 inplant training report.pdf
20/31
CONTROL SYSTEMS
I. Programmable logic controller (PLC)A programmable logic controller (PLC) or programmable controller is a
digital computer used for automation of electromechanical processes,
such as control of machinery on factory assembly lines, amusement
rides or lighting fixtures. PLCs are used in many industries and machines.
Unlike general-purpose computers, the PLC is designed for multiple
inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
Programs to control machine operation are typically stored in battery-
backed or non-volatile memory. A PLC is an example of a hard real time
system since output results must be produced in response to input
conditions within a bounded time, otherwise unintended operation will
result
Programmable logic controllers are microcomputers developed to
handle Boolean operations. A PLC produces ON/OFF voltage output andcan actuate elements such as electric motors, solenoids, fans etc. The
basic operation of a PLC can also execute operations such as counting,
delays and timers. PLC initiates relay actions through software
Features:
The main difference from other computers is that the PLCs are armoured
for several conditions (such as dust, moisture, heat, cold) and have the
facility for extensive input/output (I/O) arrangements. These connect
the PLC to sensors and actuators. PLCs read limit switches, analog
process variables (such as temperature and pressure), and the positions
of complex positioning systems. Some use machine vision. On the
actuator side, PLCs operate electric motors, pneumatic or hydraulic
cylinders, magnetic relays, solenoids or analog outputs.
7/28/2019 inplant training report.pdf
21/31
The input/output arrangements may be built into a simple PLC, or the
PLC may have external i/o modules attached to a computer network that
plugs into the PLC.
System scale:
A small PLC will have a fixed number of connections built in for inputs
and outputs. Typically, expansions are available if the base model has
insufficient I/O. Modular PLCs have a chassis(also called a rack) into
which are placed modules with different functions. The processor and
selection of I/O modules is customized for the particular application.
Several racks can be administered by a single processor, and may have
thousands of inputs and outputs. A special high speed serial I/O link isused so that racks can be distributed away from the processor, reducing
the wiring costs for large plants.
User interface:
PLCs may need to interact with people for the purpose of configuration,
alarm reporting or everyday control. A human machine interface (HMI) is
employed for this purpose. HMIs are also referred to as MMIs (man
machine interface) and GUIs (graphical user interface).
A simple system may use buttons and lights to interact with the user.
Text displays are available as well as graphical touch screens. More
complex systems use programming and monitoring software installed on
a computer, with the PLC connected via a communication interface.
Communications:PLCs have built in communication ports, usually 9-pin RS-232, but
optionally EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually
included as one of the communication protocols. Other options include
various field buses such as DeviceNet or Profibus. Other communications
protocols that may be used are listed in the list of automation protocols.
7/28/2019 inplant training report.pdf
22/31
7/28/2019 inplant training report.pdf
23/31
II. Distributed control systems (DCS)It refers to a control system usually of a manufacturing system, process
or any kind of dynamic system, in which the controller elements are not
central in location (like the brain) but are distributed throughout the
system with each component sub-system controlled by one or more
controllers. The entire system of controllers is connected by networks
for communication and monitoring.
DCS is a microprocessor/computer based digital system used for basic
control of various process parameters like flow, pressure, level,
temperature etc. the system gathers process data from various sensors
in the field, operate on these data such as a scale compare, calculate etc.as per preconfigured algorithms and send signals back to final control
elements in field for achieving process control.
7/28/2019 inplant training report.pdf
24/31
HART MANAGEMENT SYSTEMS
HART is an acronym for highway addressable remote transducer. The HARTprotocol makes use of the Bell 202 frequency shift key (FSK) standard to
superimpose digital signals at a low level on top of the 4-20 mA. This enables
two way communications to take place and makes it possible for additional
information beyond just the normal process variable to be communicated
to/from a smart field instrument. The HART protocol communicates without
interrupting the 4-20mA signal and allows a host application (master) to get
two or more digital updates per second from a field device. HART has been
adopted by most of the major manufacturers of process control field
equipment. It is an open standard that is administered by the HART communications foundation. As the digital FSK signal is phase continuous,
there is no interference with the 4-20mA signal. The relative simplicity of the
HART protocol makes it easy for both end users and suppliers to gain
experience and benefits from the enhanced two-way communication
capability of smart field instruments using this technology. The digital signal is
made up of two frequencies 1200 Hz and 2200 Hz representing bits 1 and 0
respectively. Sine waves of these two frequencies are superimposed on the
direct current (dc) analog signal cables to provide simultaneous analog and
digital communications.
HART devices can operate in one of two network configurations-
Point to point Multidrop
Point to point
In point-to-point mode, the traditional 4-20mA signal is used to communicate
one process variable, while additional process variables, configurationparameters, and other device data are transferred digitally using the HART
protocol. The 4-20mA analog signal is not affected by the HART signal and can
be used for control in the normal way. The HART communication digital signal
gives access to secondary variables ad other data that can be used for
operations, commissioning, maintenance and diagnostic purposes.
7/28/2019 inplant training report.pdf
25/31
Multidrop
The multidrop mode of operation requires only a single pair of wires and if
applicable, safety barriers and an auxiliary power supply for upto 15 field
devices. All process values are transmitted digitally. In multidrop mode, all field
device polling addresses are >0, and the current through each device is fixed to
a minimum value (typically 4mA).
7/28/2019 inplant training report.pdf
26/31
TANK FARM MANAGEMENT CENTRE (TFMC)
The major equipments consist of storage tanks, LPG spheres, pumps,pipelines, automatic and manual valves and blending systems. Instrumentation
system includes:
Tank gauging systemsFor monitoring level temperature and water level of products in tanks.
Tank gauging systems are provided by 3companies. The Honeywell
ENRAF (radar and servo types), Emerson SAAB (radar type) and SBEM
(servo and mechanical types). The radar systems use a 10GHz signal.This signal will be transmitted into the tank and gets reflected back from
the top level. The time difference will give the current level. In the servo
type a dispenser is used. The weight of the dispenser, according to the
Archimedes principle, will give a measure of the level of the tank.
Blending instrumentation which includes flow meters using orifice platesensors, differential pressure transmitters, coriolis mass flow meter,
pressure transmitters and control valves with I/P converter and
blending analyser.
LPG sphere safety system utilizing thermal fuses, pressure switches,solenoid valves etc.
Gas monitoring system, LPG sphere deluge valve/sprinkler control paneletc.
Major control systems in TFMC control room are:
Foxboro (Invesys) DCS -It integrates the tank gauging systems, blending systems etc.
GE- Fanuc PLC-For achieving safety interlocks.
Console interlocks switches-To trip the sphere interlocks manually.
Console bypass switches-For the purpose of checking and calibration of level instruments.
Console hardware annunciator-
7/28/2019 inplant training report.pdf
27/31
Digital indicators such as ROP positions, safety circuit pressure
low, sphere level high is provided with hardware annunciation
with hooter in addition to the DCS indicator.
ENRAF/ENTIS ATG system terminal-for maintenance and operational functions. Also for gauge
operations such as rising and lowering displacers, checking
alarms, configuring of ATGs etc.
SBEM ATG system terminal ENRAF/ENTIS ATG system terminal Gas monitoring systems-
For detecting gas leaks. There are three systems used in KRL:
o Detection instruments systems-installed at pump housearea and truck loading area
o Dil udyog system-installed at LPG spheres,benzene/toluene area
o Pentax system-installed at all other areas controlled byTFMC
It monitors sphere safety and controls the actuation of delugevalves.
7/28/2019 inplant training report.pdf
28/31
TRUCK LOADING UNIT
All the petroleum products produced from BPCL Kochi refinery are distributedvia truck loading units. The petroleum products are classified as white oil and
black oil. These products include LPG, diesel, motor spirit, LSFO, HSD etc. the
truck loading unit is divided into two areas with gantry in each area. In one
area all white oil are handled and it is known as white oil loading area, whereas
in the second area all the black oils are handled and it is known as black oil
loading area. There are 12bays at white oil loading area. Each bay has a
platform with 3loading arms. In some cases only 2loading arms are provided.
Black oil loading area consists of 8bays. Each bay is provided with one or two
loading arms. Each loading arm is provided with a mass flow meter, digital
control valve (DCV) and local controller. Each bay is provided with a card
reader. Control valves are provided for controlling flow and they are operated
through batch controller. All lines are provided with strainers and deaeraters
to remove foreign materials and air or gas residue. Batch controllers are locally
located in the gantry and have display and keyboard for user interphase. Each
batch controller gets flow data from mass flow meter, temperature data fromRTD and truck earthing status from earthing relay. DCV is controlled by batch
controller through two solenoid valves (one NO and one NC). Mass flow meter
is connected to pressure transmitter which gives pressure reading for mass
flow meter pressure compensation. As mentioned above, each bay is provided
with a card reader. When the card issued to truck driver from the control room
is shown to the correct bay, the data from the control room will be
downloaded to the batch controller to start the loading. During and after
loading the field operation like flow, temperature, total quantity loaded etc
will be sent back to the control room for report generation and billing purpose.
LPG bottling plant: It has a capacity of 9800 cylinders per shift. The plant is
designed for producing 14.2 kg domestic LPG cylinders and 19kg industrial LPG
cylinders with center valves. This is one of the busiest and most profitable
stations in the facility. There are four sections in the bottling plant filling
7/28/2019 inplant training report.pdf
29/31
section, hot air sealing section, evacuation section and evacuation & purging
section.
Truck loading computer system
Entire operation is controlled by a computer system in the control room and a
microprocessor based batch controller in field. The control room provides the
following:
Indication of all parameters Status of all loading points Stopping of loading Alarm displays and annunciation Graphic displays and indications Logging and reporting Self-diagnostic measurements Configuration displays
7/28/2019 inplant training report.pdf
30/31
7/28/2019 inplant training report.pdf
31/31
CONCLUSION
An overall brief study of the functioning of the various units of the BPCL KochiRefinery was carried out. The ease in successful execution of analysis, control
and error correction with the advent of electronic hardware and competent
software over the erstwhile mechanical hardware, was demonstrated to us by
our guides.
The tenure, though very short, helped us realize the implications of real time
analysis and apt responses to various issues that arise in the various stages of
the functioning of the plant. It is only through such an exposure, that we
realize the significance of accuracy in measuring and controlling a parameter
and the magnitude of the aftereffects of minor deviations.
The flaws within the prevalent system of education were accentuated by the
training, which is dogmatic in nature and rendering is ill-equipped to solveproblems, thus serving little purpose in the world extraneous to the college.