Professional Documents
Culture Documents
❖ I would like to express my gratitude to all those who gave me the possibility to complete
this training. I want to thank the Department of Training and Management of Gujarat
refinery for giving me permission to commence this training. I have furthermore to
thank the officers of production who giving me such knowledge of about the plant and
production process. It is really great opportunity for me by which I had learned here
many more about refinery. I am deeply indebted to Gujarat Refinery who given such
opportunity to students by which they complete their vocational training which is the
parts of our course. Without any moral support and help I was not able to visit the plant
and learn about the refinery. I would like to give my special thanks to the person who
supported me through the training at the day of starting to the end of the training.
PREFACE
❖ Industrial training plays a vital role in the progress of future engineers. Not
only does it provide insights about the future concerned, it also bridges the
gap between theory and practical knowledge. We are fortunate that we
were provided with an opportunity of undergoing an industrial training at
INDIAN OIL CORPORATION LTD. (GUJARAT REFINERY). The
experience gained during this short period was fascinating to say the least.
It was a tremendous feeling to observe the operation of different units and
processes. It was overwhelming for us to notice how such a huge refinery
is being monitored and operated with proper coordination to achieve
desired results. During our training, we realized that in order to be a
successful chemical engineer, one needs to put his/her concepts into action.
Thus, we hope that this training serves as a stepping stone for us in future
and help us carve a niche for ourselves. In this field.
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TABLE OF CONTENTS
2. Gujarat Refinery 5
5. DHDT 21
6. FCC 30
7. O.M. &S. 33
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1.
❖ Indian Oil, the largest commercial enterprise of India (by sales turnover),
is India’s sole representative in Fortune's Prestigious listing of the
world's 500 largest corporations, ranked 161 for the year 2016.
❖ Beginning in 1959 as Indian Oil Company Ltd, Indian Oil Corporation
Ltd. Was formed in 1964 with the merger of Indian Refineries Ltd. (Est.
1958).As India's flagship national oil company, Indian Oil accounts for
56% petroleum products market share,42% national refining capacity and
67% downstream pipeline throughput capacity.
❖ As India's flagship national oil company, with a 33,000-strong work-force
currently. Indian Oil has been meeting India’s energy demands for over
half a century with a corporate vision to be 'The Energy of India' and to
become “A globally admired company”.
❖ Indian oil touches every Indian’s heart by keeping the vital oil supply line
operating relentlessly in every nook and corner of India
❖ It has the backing of over 33% of the country’s refining capacity as on
1St April 2002 and 6523 km of crude/product pipelines across the length
and breadth of the country.
❖ The Corporation has a 65% share of the bulk consumer business, and
almost 6,500 dedicated pumps are in operation for the convenience of
large-volume consumers like the defense services, railways and state
transport undertakings, ensuring products and inventory at their doorstep.
They are backed for supplies by 129 bulk storage terminals and depots,
101 aviation fuel stations and 91 LPG bottling plants.
❖ The Corporation's cross-country pipelines network, for transportation of
crude oil to refineries and finished products to high-demand centers,
spans about 12,848 km.
❖ With a throughput capacity of 93.7 MMTPA for crude oil and petroleum
products and 9.5 MMSCMD for gas, this network meets the vital energy
needs of the consumers in an efficient, economical and environment-
friendly manner.
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2.
GUJARAT REFINERY
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Plant (CETP)
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3.
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4.
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B. PRODUCTS:
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EQUIPMENT LIST
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❖ OTHER EQUIPMENTS:
• Heat exchangers
• Pumps
➢ PROCESS DESCRIPTION
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➢ To heat the crude oil and bring it to the required desalting temperature.
➢ To further heat the crude oil after desalting.
➢ To recover heat from outgoing products and circulating reflux streams
by heating the crude oil, thereby improving fuel economy in operation
at unit.
❖ Crude Preheat Train–I is divided in to two parts.
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• Process System
• Fuel System
• Air Preheating System
• Steam-Air Decoking System
❖ Crude oil from Preheat Train–II is heated to desired vaporization
temperature of 375 Celsius in crude furnace before entering the
atmospheric column for fractionation.
❖ Crude enters crude charge heater at the top of the convection zone.
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❖ Bottom of the convection zone the coils come out and enter the radiation
zone from radiation zone, crude flows to atmospheric column 05-CC-
001.
❖ The heater is a box type furnace having four parallel passes of 6” size,
numbered as pass 1 to pass 4.
❖ The distribution of crude through each pass should be adjusted in such
a way that the heat duties and hence out let temperature of all the passes
is more or less same.
❖ Finally heated crude enters a common manifold of 28” size, called
transfer line before entering atmospheric column.
6. MAIN FRACTIONATING COLUMN
❖ The crude after final heating in furnace is fed to the Atmospheric
Column for separation of products by fractionation.
❖ Atmospheric column CC-001 contains 51 valve type trays for side
stream withdrawal. The column has a stripping section at the bottom.
❖ It has lower diameters at top and bottom sections than middle to cater
to higher vapour load in middle section.
❖ Local pressure gauges and DCS mounted TI are provided to indicate
pressure/temperature profile inside the column.
❖ Column consists zones:
1. FLASH ZONE
2. OVERHEAD SECTION
3. MIDDLE SECTION:
4. BOTTOM SECTION (RCO CIRCUIT)
❖ Product strippers:
1. HEAVY NAPHTHA STRIPPER
2. KERO/ATF STRIPPER
3. GO STRIPPER(Gas Oil)
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5.
➢ INTRODUCTION:
❖ The cracked feed is comprised of DHDT plant is the part of Residue Up-
gradation Project at Gujarat Refinery (South Block). The objective of the
Diesel Hydrotreater (DHDT) Unit is to produce an ultra-low-sulphur
product along with cetane improvement.
❖ The cracked feed is comprised of TCO from the FCC unit and CGO from
the Coker unit. The current design capacity is 2.86 MMTPA.
❖ There are two primary products from the DHDT unit:
o Stabilized Diesel
o Stabilized Naphtha
❖ The gas oil feed to the DHDT unit is a mixture of straight run distillates
and cracked feed stocks; the unit also stabilizes hydro treated naphtha
from an existing DHDS unit.
❖ From the FCC unit and CGO from the Coker unit. The DHDT unit
revamp was done in july-2017 for 30% enhancement in capacity. The
current design capacity is 2.86 MMTPA.
❖ There are two primary products from the DHDT unit:
• Diesel Pool
• Stabilized Naphtha, which is sent to battery limits.
➢ UNIT DETAILS
❖ PROCESS LICENSOR : ENGINEERS INDIA Ltd.
❖ PMC : TKIS INDIA
❖ CAPACITY : 2.86 MMTPA
❖ TURNDOWN : 50 %
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No Feed Stream
1 LS SRGO
2 HS SRGO
3 HS HN
4 Coker Gas Oil
5 (LCGO+HN
FCC LCO
6 FCC HN
❖ Products
❖ There are two primary products from the DHDT Unit, namely, a
desulfurized diesel product routed to HSD blending as wild stream or
OSBL storage and a stabilized naphtha stream sent to storage.
❖ In addition, there are two scrubbed off-gas streams: a medium pressure
and a low pressure off-gas. The medium pressure off-gas stream is sent
to battery limits, and the low pressure off-gas stream is routed either to
fuel gas or the FCC unit for light ends recovery. The LP off-gas also
includes the light ends that are recovered from the DHDS unit stripper
naphtha
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❖ Design Pressure
Maximum
Operating Design Pressure
<15 kg/cm²g MOP + 1.5 kg/cm² (Min. 3.5 kg/cm2g)
20 – 100 kg/cm²g MOP x 1.10
>100 kg/cm²g MOP + 10 kg/cm²g
❖ The design pressure for the lower pressure side of the heat exchangers is
normally specified at a minimum of 10/13ths of the design pressure used
for the high-pressure side to avoid specifying a PSV for tube rupture.
❖ For the column overhead systems, the design pressure of the condensers
and reflux drums are identical to the top column pressure.
❖ Design Temperature
❖ Design temperature is calculated by adding 15°C to the maximum
operating temperature with a minimum design temperature of 80°C, in
the absence of other criteria. The maximum operating temperature is
estimated based on various operating modes and possible upset situations
for the equipment considered.
❖ For the Feed/Effluent exchangers in the reaction section, 25oC was added
to the maximum operating temperature to account for the temperature
profile at lowered capacity.
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❖ EQUIPMENT LIST:
❖ HEATER:
Equipment Service
2091-F-01 Reactor Feed Heater
❖ REACTOR:
Equipment Service
2091-R-01 1st Hydrotreater Reactor
2091-R-02 2nd Hydrotreater Reactor
❖ COMPRESSORS:
Equipment Service
2091-K-01 A/B Make Up Hydrogen Compressors
2091-K-02 Recycle Gas Compressor
❖ FILTERS:
Equipment Service
2091-G-01 Feed Filter
2091-G-09 A/B Discharge air Filter
2091-G-10 A/B Filter for Coalescer
❖ COLUMNS:
Equipment Service
2091-C-01 Diesel Stripper
2091-C-02 Naphtha Stabilizer
2091-C-03 HP amine Absorber
2091-C-04 LP amine Absorber
2091-C-05 MP amine Absorber
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➢ PROCESS DESCRIPTION
Unit Description
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2. Reaction Section:
❖ The Hydrotreater Reactor (R01/02) contains two reactors in series,
with each containing three catalyst beds. Recycle hydrogen is used
as the quench gas for maintaining the desired WABT in each of the
catalytic beds.
❖ The top catalytic bed in the 1st reactor operates at a lower
temperature, and this bed saturates the feed olefins and di-olefins.
❖ The inlet temperature to the Reactor, adjusted so that the required
inlet temperature is obtained for the subsequent HDS catalytic
beds.
❖ The effluent from the first catalytic bed is quenched if required to
control the inlet temperature of the second catalytic bed. In the
remaining two catalytic beds, the targeted average WABT is about
the same to complete the remaining reactions.
❖ Quench gas is also used for controlling the 2nd reactor inlet
temperature and the temperature of the catalytic beds.
❖ Wash water is injected into the reactor effluent at the outlet of the
Reactor Effluent/MP Liquid Exchanger in order to prevent any
deposit of ammonium salts.
❖ The Recycle H2 Compressor discharge is split into recycle gas and
quench gas streams, and the recycle gas is combined with the
make-up hydrogen and gas oil feed to enter reactor circuit. The
quench gas flowing to each reactor bed is on flow control reset by
the bed temperatures.
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7. STRIPPER SECTION:
❖ The Diesel Stripper (C-01) fractionates the diesel product from the
reactor effluent liquid stream, which is supplied from the MP Cold
Separator Drum.
❖ The hot feed enters the Stripper onto the 10th tray (counting from the top)
and is stripped of H2S and light ends using superheated MP steam to
produce the wet diesel product.
❖ The Stripper overhead vapor is condensed in an air cooled condenser
(AC-02) and the trim condenser (E-08).
❖ The stripped wet diesel product is pumped to the battery limits.
8. AMINE SCRUBBING:
❖ Amine scrubbing in the unit is accomplished in three amine towers,
❖ The HP Amine Absorber (C-03) scrubs the recycle hydrogen gas from the
HP Cold Separator Drum.
❖ The MP Amine Absorber (C-05) scrubs the off-gas from the MP
Separator Drum (V-08).
❖ The LP Amine Absorber (C-04) scrubs the sour off gas mixture from the
Diesel Stripper (C-01) and the Stabilizer (C-02) as well as any dissolved
light ends from the HP and MP rich amine streams, which are let down
and fed to the LP Absorber sump.
❖ The HP Absorber employs 15 valve trays.
❖ The MP Absorber is a packed column utilizing two beds of 1” Pall Rings
(or equivalent).
❖ The LP Absorber employs 20 valve trays.
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6.
FLUID CATALYTIC CRACKING UNIT(FCCU)
➢ INTRODUCTION
❖ In 1982 FCCU was commissioned with capacity of 1 mmtpa.in the
coming years requirement of lpg and gasoline has been incresed and to
meeet that requirement this unit has been rewamped to 1.5 mmtpa.
❖ Cracking is a phenomenon by which large oil molecules are
decomposed into lower boling molecules.At this time certain of these
molecules which are reactive,combine with one onther to give more
larger molecule than those present in original stock.
❖ The more stable molecule leave the system as cracked gasoline and
reactive one polymerze forming fuel oiland coke.
❖ Primary objective of cracking processes had been to get more and more
gasoline
❖ This UOP designed Fluidized Catalytic Cracking Unit consists of
three sections: -
a. Catalyst Section
b. Fractionation Section
c. Gas Concentration Section
A. CATALYST SECTION: -
❖ The Catalyst Section consists of the Reactor and Regenerator,
which, together with the Stand Pipes and Riser, form the
“Catalyst Circulation System”.
❖ The catalyst circulates up the Riser to the Reactor, down through
the Stripper to the Regenerator across the Regenerator Standpipe,
and back to the Riser.
❖ Fresh feed and recycle streams, known as Combined Feed, are
vaporized and heated to the reactor temperature by the hot
catalyst.
❖ This mixture of oil vapour and catalyst travels up the Riser into
the Reactor. The gas oil commences to crack immediately when it
contacts the hot catalyst in the Riser and continues until the oil
vapours are disengaged from the catalyst in the Reactor.
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B. FRACTIONATION SECTION:-
❖ In the fractionation section, the Reactor vapours are fractionated
into Wet Gas, Unstabilized Gasoline, Heavy Naphtha, Light
Cycle Oil (LCO), Heavy Cycle Oil (HCO) and Clarified Oil
(CLO).
C. GAS CONCENTRATION SECTION:
❖ Compressed Wet Gas and Unstabilized Gasoline go to Gas
Concentration Unit where they are separated into
❖ Fuel Gas, LPG & Stabilized Gasoline, LPG and Gasoline
are washed with caustic in the treating section of Gas
Concentration Unit.
❖ Amine treatment of LPG is done prior to caustic wash.
For the convenience of description, process flow of the entire unit
can be divided into six sections;
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7.
OIL MOVEMENT & STORAGE(O M & S)
❖ M & S is a part of production departmant which is headed by CPF.
➢ FUNCTIONS:
❖ Receipt,storage,acccounting,samplling of crude oil
❖ Crude and LABFS tank preparation and feeding to processing units.
❖ Receipt.storage. accounting of finished products and intermediates ex
units and blending of intermediaes and blending of MS at blending
station to meet high quality.
❖ Supply of intermediates feed to processing units.
❖ Prepaation of finished products tanks for dispatch.
O M & S consists following five sections :
❖ Receipt and blending
❖ Tank wagon handling
❖ Tank truck handling
❖ LPG
❖ Bitumen
❖ Mode of Dispatch of Finished Products:
1. By Road
2. By Rail
3. By Pipelines
❖ Section under receipt are
1. GR
2. GRE
3. GRE product
4. GR product
5. Melting Pit
Gujarat Refinery receives crude oil through threee different pipelines:
1. A 98 km long pipeline brings south gujarat crude oil from fields
in ANKLESWAR.GANDHAR,NADA etc which is situated at
south gujarat.
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❖ Sensible properties
❖ Colour (sight): LPG is colourless like air.
❖ Odour (smell): LPG is distinctively odorized to give warning in
case of leakage.LPG is generally odorized by adding mercaptan.
❖ Mounted bullet concept for LPG was implemented in the year 1999 in
Gujarat refinery. First three mounded bullets were commissioned in
March, 1999. Six mounded bullet were constructed as a replacement of
Horton sphere. All the LPG Horton sphere were decommissioned in
august, 2007.
❖ As per recommendation of the condemnation committee the LPG Horton
spheres are no more required for operation & safety point of view. Hence,
condemnation & dismantling of all equipment’s, instruments and pump
motors etc connected to the said LPG Horton sphere is done.
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❖ Three new bullets numbing 2115-MB-12, 13&14 have come up under the
head of RUP project. The capacity of each bullet is 1500 M3. These
bullets were commissioned in April’2011.
➢ Rundown piping network
❖ There are six LPG rundown lines from various LPG production units,
coming into LPG manifold in LPG area as mentioned below:
1. 4” LPG Rundown line from GHC
2. 4” LPG Rundown line from AU-5
3. 4” LPG Rundown line from AU-1,2,3,4
4. 4” LPG Rundown line from MSQ
5. 4” LPG Rundown line from FCC
6. 4” LPG Rundown line from Coker
❖ 14 Mounded bullets for LPG storage are there details are:
1. MB-01,02,03(Capacity 1784 M3 each)
2. MB-04,05,06,07,08,09(Capacity 1500 M3 each)
3. MB-10,11(Capacity 900 M3 each)
4. MB-12,13,14(Capacity 1500 M3 each)
❖ There are two nomenclatures of LPG headers, one is GR/GRE header and
second is FCC header. The GR/GRE LPG from this manifold is routed to
different mounded bullets. The details are as follow
❖ LPG to MB-1,2,3,5,7,8,9,10,11,12,13,14
❖ FCC LPG is routed by only MB 04 & 05 separately or it can be routed
with GR/GRE.
❖ In addition to above two LPG lines there is one more LPG header called
PPRS. PPRS stands for polypropylene return stream. LPG which is
returned from RIL is termed as PPRS. The PPRS can be taken either MB-
05 or 06.
➢ Details of mounded bullets:
Vessel No Capacity(M3) Product
MB-01 1784 SR/CR LPG
MB-02 1784 SR/CR LPG
MB-03 1784 SR/CR LPG
MB-04 1500 FCC LPG
MB-05 1500 FCC LPG/PPRS
MB-06 1500 PPRS/SR LPG
MB-07 1500 SR/CR LPG
MB-08 1500 SR/CR LPG
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➢ Facility
❖ The facility consists of:
❖ MB-04 & 05 of 1500 Cu.M capacity for receiving PPRS return stream
from RIL.
❖ P-2304-A of 210 M3 capacity for supplying PPFS to RIL.
❖ P-2304-B of 210 M3 capacity for transferring the PPRS to the LPG
pool, as a blending material.
❖ Mass flow meter installation consists of the following :
❖ Mass flow meter installed in PPFS supply lone to RIL. This mass flow
meter was removed from bulk wagon line which was installed in
discharge line of pump.
❖ Mass flow meter, installed in PPRS line from RIL.
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