SYED ALI SULTAN

BYCO Petroleum Internship Report

University of Engineering and Technology

10 JULY 2019
Acknowledgement
The internship opportunity I had with BYCO Petroleum Pakistan Limited was a great
chance for learning and professional development. Therefore, I consider myself as a
very lucky individual as I was provided with an opportunity to be a part of it. I am
also grateful for having a chance to meet so many wonderful people and
professionals who led me through this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude

and special thanks to the Mr. Haroon, General Manager who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my project at their esteemed organization
and extending during the training.

I express my deepest thanks to Mr. Owais Hussain, for taking part in useful decision
& giving necessary advices and guidance and arranged all facilities to make life
easier. I choose this moment to acknowledge his contribution gratefully.

I perceive as this opportunity as a big milestone in my career development. I will

strive to use gained skills and knowledge in the best possible way, and I will continue
to work on their improvement, in order to attain desired career objectives. Hope to
continue cooperation with all of you in the future.

Yours Sincerely,
Internee,
SYED ALI SULTAN,
B.SC – Mechanical Engineering (continue),
UET-LAHORE,
LAHORE, PAKISTAN.
Submission Date: July, 10-2019
Company Profile

Byco is Pakistan’s emerging energy companies engaged in the business of oil refining, petroleum
marketing, chemicals manufacturing and petroleum logistics. Headquartered in Karachi, they are
serving their mission to fulfill the energy demand within and beyond borders.

Byco owns the following companies:

BPPL – Byco Petroleum Pakistan Limited

BOPL – Byco Oil Pakistan Limited

BTPL – Byco Terminal Pakistan Limited

Byco's operational refinery has a capacity to refine 35,000 barrels a day of crude oil into various
saleable components including Liquefied Petroleum Gas, Light Naphtha, Heavy Naphtha, High
Octane Blending Component, Motor Gasoline, Kerosene, Jet Fuels, High Speed Diesel and Furnace
Oil. Byco expanded refining complex by setting up another refinery with the capacity of 120,000
barrels per day which is completed.
Table of Contents

 Company profile

 HSEQ facility & Fire fighting

 Laboratory

 SPM Single Point Mooring

 CFR Engine

 ORC-1 (Oil Refinery Complex)

Pre-treatment
Distillation Unit
Naphtha Splitter
HSD Treatment
LSU Extraction
Merox Treater
Hydro-Treater
Reformer &
ISOM units

 OMF – Oil Movement & Tank Farm

External Floating Roof
Internal Floating Roof
Fixed Roof
LPG Bullets
ATG Apparatus

 Glossary
HSEQ DEPARTMENT
LABORATORY
The lab is the heart of the quality and environment management department, the lab performs test
on the different products, feed and discharges all the process to look for anomalies in case of
detection of anomalies processes are analyzed to find the root cause and then steps taken to
remove them. Byco refines crude oil into various marketable components including Liquefied
Petroleum Gas, Light Naphtha, Heavy Naphtha, High Octane Blending Component, Motor Gasoline,
Kerosene, Jet Fuels, High Speed Diesel and Furnace Oil.

The lab has the following testing facilities:

Gas Testing
Environment Testing
Waste Water Testing
Fuel Testing
Utility Water Testing
Crude Testing

Flash Point
The flash point of a volatile material is the lowest temperature at which vapours of the material
Ignite, when given an ignition source. The flash point may sometimes be confused with the auto
ignition temperature, which is the temperature at which the vapour ignites spontaneously without
an ignition source.

The fire point is the lowest temperature at which the vapors of the material will keep burning after
being ignited and the ignition source removed. The fire point is higher than the Flashpoint, because
at the Flashpoint more vapors may not be produced rapidly enough to sustain combustion.
The Pensky-Martens closed-cup flash-point test is a test for the determination of the flash point of
the flammable liquids. It is standardized as ASTM-D-93, EN ISO 2719 and IP 34.

A brass test cup is filled with a test specimen and closed with a lid, through which an ignition
source can be introduced periodically. The sample is heated and stirred at specified rates
depending on the material test that is being tested. This allows the development of equilibrium
between liquid and air volume. The ignition source is directed into the cup at regular intervals with
simultaneous interruption of stirring. The test concludes upon observation of a flash that spreads
throughout the inside of the cup. The corresponding temperature is the liquid’s Flashpoint.

Pour Point
The pour point of Petroleum oil is the lowest temperature at which the oil will pour or flow under
definitely prescribed conditions when it is chilled without disturbances at a standard rate, it is an
indicator of the amount of paraffinic content found in the sample
 SPM
(Single Point Mooring)
It is an open sea anchorage with sub-sea and sub soil pipelines connecting it to the
on-shore facilities. The SPM allows Byco to import and export crude oil and refined
petroleum products directly, significantly reducing traffic at Pakistan’s ports situated
in Karachi and Port Qasim. It enables Byco to be the only vertically integrated
petroleum firm in the nation. Byco is Pakistan's largest oil refiner by design capacity,
and is the nation’s only firm having a dedicated Single Point Mooring (SPM).

Byco's SPM is the first liquid port in the country, and the company employs a round-
The clock crew dedicated for the safety and security of the buoy and vessels in and
around the SPM's anchorage area. The SPM is Pakistan's only terminal having a Tier 3
oil spill response membership.
This facility is being set up in the deep sea, at a distance of approximately of 15 km
from the Byco site located at Mouza Kund, Balochistan, Pakistan. The floating jetty
will be connected to crude oil tank farm of approximately 130,000 metric tons, via
3.3 km on-shore pipelines and 11.5 km off-shore 28" pipelines.

The SPM can currently handle vessels of 100,000 deadweight tonnage (“DWT”), and
has the expansion capacity to add two more pipelines which shall enhance facility's
throughput. It also has the Phase 2 capacity to handle Very Large Crude Carriers
(“VLCC”s) of up to 250,000 DWT.

Benefits

Key advantages of the facility are:

Handling large vessels will result in saving of freight.

Capacity to handle over 22 million MT per annum of POL products after Phase
2 expansion.
The location of the SPM will curtail the distance from the Middle Eastern Ports
by 100 nautical miles per trip thus leading to further savings of freight.
Over 150 acres of sea front land forms part of the facility which can be used to
construct additional storage of up to 1,000,000 MT of POL products.
 The SPM will be in 26 meters of water depth, with an ability to handle vessels
drawing upto 22 meters of draft.
Dedicated POL products handling, which will lead to significant time and cost
savings for users.

CFR
(Combustion Fuel Research)
The most accurate way of testing the actual octane value is to use a Combustion Fuel
Research (CFR) engine (also known as a knock engine). Currently the American
Society for Testing and Materials (ASTM) uses the CFR engine method, developed in
the 1920s to obtain official octane measurements. The CFR engine measures octane
by combusting the fuel and physically measuring the knock that occurs. These tests
have a repeatability (same operator/same lab) of 0.2 RON, and a reproducibility
(different operators in different labs) of 0.7 RON. Each sample is tested for research
octane number (RON) as prescribed by ASTM Method D2699. This is the method
used for testing at fuel refineries. This is also the method used for all our testing,
which makes them certified and independent tests that can be reproduced by
anyone wanting to confirm the results

The CFR engine is basically a carburetted, single-cylinder, variable-compression

engine. The head can be raised and lowered to change the compression ratio and
thus increase knock intensity. By reading the knock intensity at a given compression
ratio, the operator can determine the octane rating of a fuel sample. The engine has
to be warmed up to maintain a 38°C to 54°C oil temperature and a 2-3Hg manifold
vacuum. Air/fuel ratio is held at an elevation-corrected constant. Prior to every test,
both a toluene and an iso-octane mixture of known octane are run through the
engine for reference and calibration checks. The RON test is performed at 600RPM
with intake and air/fuel charge temperatures regulated at 52°C. Ignition timing is
held at 13°BTDC
 ORC - 1
Oil Refinery
Complex
OIL Movement &
Tank Farm Area
GLOSSARY
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