TECHNICAL REPORT ON STUDENTS

INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)
UNDERTAKEN AT:

WARRI REFINING & PETROCHEMICAL COMPANY

LIMITED

(WRPC)

FROM: AUGUST 22 th 2018 TO FEBUARY 18 th, 2019

LOCATION OF FIRM: EKPAN-WARRI, DELTA STATE

BY:

Name

Mat number
DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF ENGINEERING

UNIVERSITY OF BENIN
FEBUARY 2019.
 DEDICATION.
This work is dedicated to all mighty God for his grace and love which he showered on me during
my industrial training program and I also dedicate this work to my parents for their tireless
support, love, care, advice and prayers towards me and also I dedicate this work to my siblings
for their support.

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 ACKNOWLEDGEMENT.
I want to appreciate and give all adoration to the Almighty God for his infinite love, mercy and
protection for me throughout the duration of the training.

With great recognition to my loving parents for their care and support given to me during my
industrial training.

To my supervisors and engineers in WARRI REFINING AND PETROCHEMICAL COMPANY; Mr.

Atunu Steven who is the chief operator of my shift at fluid catalytic unit, Engr. Obi Matthew
Obina, Engr. Collins Okunbor and all who I can’t possibly mention, a big thanks to all of you for
your support, invaluable knowledge and experience shared throughout my training, Thanks and
God bless.

Finally I would not forget the amazing friend I met during my internship Mr. Israel Apoveta, who
was my co-intern in fuel plant, thanks for your push and encouragement towards a better me.
And finally to all outside my section and W.R.P.C who contributed positively towards my
training, a big thanks to you all.

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 ABSTRACT.
This report is solely and more accurately focused on the activities and knowledge received at
the course of my training with the company; it involves the explanation to the various operating
variable or condition affecting the operation of fuel plant in warri refining and petrochemical
company (with a focus on the F.C.C plant and crude distillation plant ). It also involves the basic
activities carried out on the plant during shut down, startup and emergency operation as these
operation requires experience and basic engineering knowledge before they can be successfully
carried out. The report also contains detail procedure use in equipment maintenance and
preservative maintenance during shutdown period. This report also contains detail explanation
of the organization structure of the company which includes the departments and how these
departments contribute to the overall success of the company. The report also highlights the
history of the company, the business activities or objective of the company and how these
activities affect my training. This report also highlights the activities I engage in and my
contribution to the overall success of the company during the period of my training together
with the on the job and off the job training received.

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 TABLE OF CONTENT.
DEDICATION . ---------------------------------------------------------------------------------------------------------------------------------------1
ACKNOWLEDGEMENT. --------------------------------------------------------------------------------------------------------------------------3
ABSTRACT. ------------------------------------------------------------------------------------------------------------------------------------------4
TABLE OF CONTENT. --------------------------------------------------------------------------------------------------------------------------5
ACRONYMS AND MEANING. ----------------------------------------------------------------------------------------------------------------6
CHAPTER 1 ----------------------------------------------------------------------------------------------------------------------------------------7
1.0 HISTORY OF SI WES -----------------------------------------------------------------------------------------------------------------------7
1.1 AIMS AND OBJECTIVES OF SIWES -------------------------------------------------------------------------------------------------------8
1.2 HISTORY OF THE O RGAN IZATION -------------------------------------------------------------------------------------------------------8
1.3 THE COMPANY.-----------------------------------------------------------------------------------------------------------------------------9
1.4 BUSINESS DIRECTION: ---------------------------------------------------------------------------------------------------------------- 10
1.5 OVERVIEW OF PRODUCTION DEPARTMEN T MANUFACTURING PLANT: -------------------------------------------------- 10
1.5 BRIEF DESCRIPTION OF THE PLANTS AND FUNCTIONS. ------------------------------------------------------------------------ 10
1.6 ORGAN IZATIONAL CHART OF SECTION -------------------------------------------------------------------------------------------- 12
CHAPTER 2. ------------------------------------------------------------------------------------------------------------------------------------- 13
2.1 F.C.C PLANT OVERVIEW. ----------------------------------------------------------------------------------------------------------------- 13
2.2 THE CRUDE DISTILLATION PLANT OVERVIEW.------------------------------------------------------------------------------------- 15
2.3 H.S.E INDUCTION AND TRAININ G. ---------------------------------------------------------------------------------------------------- 16
2.4 INTERN ROL ES AND RESPONSIBILITIES IN F.C.C PLANT. ------------------------------------------------------------------------ 16
2.3 INTERN ROL E AND RESPONSIBILITY IN CRUDE PLAN T. ------------------------------------------------------------------------- 16
CHAPTER 3. ------------------------------------------------------------------------------------------------------------------------------------- 18
3.1 SKILL AND EXPERIENCE ACQUIRED. -------------------------------------------------------------------------------------------------- 18
3.2 PLANT OPERATION TR AINING. --------------------------------------------------------------------------------------------------- 18
3.3 WORKS CARRIED OUT AN D PROCEDURES. ----------------------------------------------------------------------------------------- 18
3.4 PROBLEMS SOLVED AND PROCEDURES. -------------------------------------------------------------------------------------------- 21
3.5 STARTUP FOR TOPPING UNIT AFTER SHUTDOWN . ------------------------------------------------------------------------------ 22
3.6 STARTUP PROCEDURE FOR VACUUM UNIT AF TER SHUT DOWN . ----------------------------------------------------------- 24
3.7 SAFETY PROCEDURE IN THE REFINING PROCESS PLANT.----------------------------------------------------------------------- 26
3.8 MAJOR OPERATING VARIABLE OF THE CONVERTER OF THE FL UID CATALYTIC CRACKING PLANT. --------------- 27
CHAPTER 4. ------------------------------------------------------------------------------------------------------------------------------------- 29
4.1 CONCLUSION. ----------------------------------------------------------------------------------------------------------------------------- 29
4.2 APPENDIX. --------------------------------------------------------------------------------------------------------------------------------- 30
4.3 RECOMMENDATION. ------------------------------------------------------------------------------------------------------------------- 33
4.4 REFERENCES.------------------------------------------------------------------------------------------------------------------------------ 34

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 ACRONYMS AND MEANING.
N.N.P.C - Nigerian National Petroleum Commission.

W.R.P.C - Warri Refining and Petrochemical Company.

F.P – Fuel plant.

H.S.E - Health safety and Environment.

P.P.E - Personal protective Equipments.

S.V - slide valve.

W.W.T.P –Waste water treatment unit.

F.C.C.U -Fluid catalytic cracking unit.

P.P.U –Power plant and utility

P.V –Plug valve.

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 CHAPTER 1

1.0 HISTORY OF SIWES

The student’s SIWES program is a skill-acquisition program designed for 300 Level and 400 Level
students of most Nigeria universities and also N.D1 and N.D2 of Nigeria polytechnics as a
complementary program to the theoretical education and laboratory practices engaged in by
students in tertiary institutions, which by industrial standard are inadequate to serve the
practical needs of the industries. The practices are idealistic and therefore necessitate that the
student be exposed to actual industrial experience.

The official Gazette of the Federal Republic of Nigeria made it clear that, the Supreme Military
Council then headed by General Yakubu Gowon in the year 1972 promulgated decree No.47 to
indigenize the Nigeria Economic Sector. On the 31st of March 1974, the decree came into effect
with its core aim of reducing the dominance of foreigners in the Nigerian economy, and
accompanied by a systematic integration of locally oriented skilled manpower into the
economy.

The indigenization decree established many bodies which were charged with different
responsibilities to make the nations dream a reality. Among them include:

• Industrial Training Fund (ITF)

• Centre for Management Development (CMD)

• Administrative Staff College of Nigeria (ASCON).

The Industrial Training Fund (ITF) was charged with the responsibility of training low and middle
level manpower for sustainable industrialization.

However, when the Federal Government observed that the training of students who are still in
school would be easier and cheaper, and that such training would make them more competent
to assume any responsibility to their related field of study, a scheme known as Students
Industrial Work Experience Scheme was established under ITF. This body was mandated to
liaise with all the relevant agencies like National Universities Commission (NUC), National Board
for Technical Education (NBTE) to ensure proper training of undergraduate students. The
Students Industrial Work Experience Scheme (SIWES) was established in 1974, since the
inception of SIWES, it has been a partial fulfillment of the academic program. SIWES is devised
by National University Commission (NUC) as a skill training program that will bridge the long
gap that demarcates theory from practical in science and technology and other related courses
in Nigeria Universities.

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1.1 AIMS AND OBJECTIVES OF SIWES
The course is aimed at:
• Building the students ability to work with equipment they do not have access to in
school.
• Providing an opportunity for students to apply the theoretical knowledge acquired in
the classroom to a real practical work situation.
• Preparing the student against the real challenge they would encounter in their field of
specialization after graduation.
• The industries/organizations get involved in training the manpower they need; thereby
preparing the trainee for employment opportunity after graduation.

Participation in Industrial Training is a well-known educational strategy. Classroom studies are

integrated with learning through hands-on work experiences in a field related to the student’s
academic major and career goals. Successful internships foster an experiential learning process
that not only promotes career preparation but provides opportunities for learners to develop
skills necessary to become leaders in their chosen professions.

Participation in SIWES has become a necessary pre-condition for the award of Diploma and
Degree certificates in specific disciplines in most institutions of higher learning in the country, in
accordance with the education policy of government.

 Operators: The ITF; the coordinating agencies (NUC, NCCE, NBTE), employers of labor
and the institutions.
 Funding: The Federal Government of Nigeria.
 Beneficiaries: Undergraduate students of the following: Agriculture, Engineering,
Technology, environmental, science, education, medical science and pure and applied
sciences.

1.2 HISTORY OF THE ORGANIZATION

Nigerian National Petroleum Corporation (NNPC) was formed in 1977 through the merger of
some of the departments of the ministry of petroleum resources and the old Nigerian National
Oil Corporation (NNOC). In 1978, the corporation was commercialized into twelve strategic
business units, the Warri Refining and Petrochemical Company (WRPC) being one of them. The
refinery commissioned in 1978 by LT. COL. OLUSEGUN OBASANJO was built and designed by
Snamprogetti, an Italian company with an initial capacity of 100,000 barrels per stream day of
crude oil. It was de-bottle necked in 1987 to 125,000 barrels per stream day (17,000metric
tonnes per day).The fuel plants were designed to process the CHEVRON’S ESCRAVOS crude oil
(sweet crude) and SHELL’S UGHELLI QUALITY CONTROL CENTRE (UQCC) crude oil (sour
crude).The petrochemical plants (polypropylene and carbon black) which were built to optimize
the refinery were commissioned in March 1988. An HYDRO-FLOURIC alkylation unit was also
added to the refinery the same year.

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The W.R.P.C entrance board.

1.3 THE COMPANY.

In fulfillment of the SIWES program, I was attached to WARRI REFINING AND PETROCHEMICAL
COMPANY LIMITED.EKPAN- WARRI, DELTA STATE.

Warri refining and petrochemical company is a leading company in the mid stream oil and gas
sector in Nigeria. The period of my industrial attachment was from August 2018 to February
2019.

I was deployed to area 2 (fluid catalytic cracking plant), under production department of the
company. The units under this plant include vaporizer unit, condensate recovery unit, vapor
recovery unit, amine unit, MEROX unit and the converter unit. These units are integrated that is
they are connected together so that the overall performance of the plant can be increase.

I was also redeployed to crude plant of the refinery where I spent about two months learning
the basic skill require to function in the plant as a plant operator.
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1.4 BUSINESS DIRECTION:
The company on behalf of the NNPC is design to refine daily allocated crude of 125000 barrels
of local crude per day to produce fuels such as gasoline, diesel etc. and other important
petrochemical product such as carbon black and polypropylene. The refinery receive crude
from PPMC which is a subsidiary of NNPC, refines the crude at an agreed processing fee and the
yield is the taken by PPMC who is the sole processee and the off-taker of the products
produced. The refinery leases the refining and the petrochemical asset from CHQ for a fee and
also pays CHQ over head charge. The refinery uses propylene rich feed to produces
polypropylene pellet and also decant oil to produce carbon black pellet.

1.5 OVERVIEW OF PRODUCTION DEPARTMENT MANUFACTURING PLANT:

The manufacturing units can be classed into two categories namely; the primary units and the
secondary units. The primary units are the atmospheric crude distribution unit, vacuum
distillation unit, vapor recovery unit, L.P.G and fuel/amine absorption unit and the gas plant.
The secondary process units are the naphtha hydro-treating unit, the naphtha reforming unit,
the kerosene hydro-treating unit, the fluid catalytic unit, the Merox units and the HF alkylation
unit.

1.5 BRIEF DESCRIPTION OF THE PLANTS AND FUNCTIONS.

There are several processing plants in the refinery and they includes;
1. Power plant and utility:
The power plant and utility is a very important plant in the company as majority of the utilities
used by other process plant in the refinery are supplied by this plant. Most of the utility
supplied by this plant are electricity, steam (high, medium, and low pressure), cooling water,
fire water, service air and instrument air. Power plant produces electricity with the use of
steam turbine which operates with high pressure steam.
2. Crude or topping plant:
The topping plant is an important plant as it is this plant that separates the crude oil into
different product which is used as feed in other plant such as F.C.C plant or reforming plant and
its hydro treating unit. The basic equipment in this plant include pumps (electrical or turbine),
stripper column, atmospheric distillation column, vacuum distillation column, splitter column,
sour water stripper column, compressor, exchanger, fire heater, air cooler, drums, tanks and
others. These equipments are interconnected together so as to have effective separation of the
crude oil feed.
3. Carbon black plant:

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This plant uses decant oil as feed to produce different grade of carbon black. The process
involves the partial and control combustion of the feed in a horizontal plug flow reactor and
quenching and separating the product. The carbon black is then pelletized before going to

storage. The basic equipment the is presence in carbon black plant include storages tanks,
pumps plug flow partial combustion reactors, electrostatic precipitator, pneumatic valves,
manual valves, exchangers, trim cooler, air cooler, storage hopper and others. These equipment
are usually interconnected together to ensure maximum conversion of decant oil to carbon
black.
4. Fluid catalytic cracking plant:
This plant convert heavy vacuum gas oil from topping unit to lighter product such as F.C.C
gasoline, L.P.G, heavy naphtha, slurry or decant oil, and other product. This plant is very unique
because it undergoes both conversion and separator processes. The major equipment present
in this plant include surge drums, valves, pneumatic valves, main column, stripper column,
debutanizer column, depropanizer column, exchanger, trim cooler, drums, tanks, riser or
reactor, regenerator, vacuum catalyst loading drums, fire heater, C.O boilers, absorption
column and so on. The F.C.C plant is generally made up of some units which are the vapor
recovery unit, condensate recovery unit, L.P.G and gasoline merox unit, vaporizer unit and the
converter unit. All the units are interconnected together in order for the plant to work
optimally.
5. Alkylation plant:
This plant uses light olefin such as propene and butene to react with isobutane to produce
alkylate. This reaction take place in the presence of hydrofluoric acid as catalyst. In this plant
separations of contaminants from the feed first take place in a deisobutanizer column before
been feed into the reactor which contains hydrofluoric acid. After reaction another separation
take place in order to obtain the alkylate. This plant is hazardous compare to other plant in the
refinery because of the chemical (hydrofluoric acid which is very corrosive) which it is handling.
This plant contain basic refinery equipment such as pumps, compressors drums, tanks,
columns, flare, exchanger, trim cooler, water treatment facilities and so on.
6. Reforming plant:
This plant uses heavy naphtha feed from crude or topping plant which is first hydro treated to
remove element that would poison the catalyst in the reforming reactor. The hydro treating
process which uses compressed hydrogen is catalytic and uses a catalyst called cobalt-
mobylium catalyst. The reforming process converts heavy naphtha which generally has low
octane number of about 60 to reformate which have high octane number in the range of 95 to
102. The reforming process is generally fitted with three reactors and three intermediate fire
heaters and then separators which remove light ends and unreacted hydrogen. This process
requires the presences of compressed hydrogen for it to take place. The major equipment in
the plant include hydrogen compressors, hydro treating reactors, three reforming reactors,
pumps, separators, drums and others. This plant is generally made up of three unit which are

11
naphtha hydro treating unit, reforming unit and kerosene hydro treating unit, all which work
together to improve the efficiency of the process.

1.6 ORGANIZATIONAL CHART OF SECTION.

MANAGER PRODUCTION.

DEPUTY MANAGER FUEL DEPUTY MANAGER FUEL

PLANT 1. PLANT 2.

SUPERINTENDENTCRUDE SUPERINTENDENT SUPERINTENDENT FLUID

OR TOPPING PLANT. REFORMING PLANT. CATALYTIC PLANT.

The chief operator in turn communicates information they acquire in running the plant to the
superintendent. The chief operator then gives instructions to both the plant operators and the
trainee who then report directly to him.

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 CHAPTER 2

2.1 F.C.C PLANT OVERVIEW.

The refinery is a very complex integrated plant with the overall objective of process of refining
different grade of crude oil into high profitable product such as gasoline, L.P.G, automated gas
oil and dual purpose kerosene. The Warri refinery is made up of seven integrated plant which
must run together in order to optimize the profitability of the refinery. The major plants are the
crude or topping plant, fluid catalytic plant, the reforming plant, the naphtha hydro treating
plant, the kerosene hydro treating plant, power plant and utility and the nitrogen plant. The last
two plants have the responsibility of supplying the utility require for other to run or operate.
The major function of the naphtha and kerosene hydro treating plant is to remove sulfur,
nitrogen and oxygen as this element would poison the catalyst that is used in other processes
and also in turn reduces environmental pollution as the final products will usually low surphur.

During the period of my training in the refinery I was opportune to work in the fluid catalytic
plant and the topping plant. In the fluid catalytic plant which process heavy feed such as heavy
vacuum gas oil blended with heavy atmospheric gas oil into F.C.C gasoline, L.P.G, fuel gas and
other important product such as decant oil, light and heavy cycle oil and heavy naphtha using
the process of fluidize cracking and continuous regenerating process in the converter unit of
the plant. F.C.C plant is an important plant as it increases the refinery profitability as the
product (gasoline) from the plant is highly priced and in high demand. Since the reaction is
endodermic reaction, the major energy require for the reaction is supply by the heaters, heat
exchangers and combustion of the coke deposit in the used catalyst in the regenerators.

Since the energy in the column is very high as the cracked product is in vapor state, energy is
been removed from the column by continuous cooling by pump around as product such as
slurry, heavy cycle oil and heavy naphtha is continuously cooled by heating the feed and sent
back to the main Column. Some of the product is been sent to storage after cooling by loosing
heat to the feed or to vaporized boiler feed water as in the case of decant oil. The light ends
and gasoline usually leave as vapor from the main column and is been condense as unstabilized
gasoline and some is sent as reflux to the main column. The vapor recovery section of the F.C.C
plant is one of the most economic section of the plant as it ensure that large gasoline and L.P.G
is recover from the over head vapor that leave the main fractionating column with the use of
absorbers column, strippers column and the two stage compressor. There is also the gas
treating section of the F.C.C plant which helps to remove surphur from the fuel and L.P.G gas
that is produced in the F.C.C plant. The gas treating section uses monoethanolamine solution
which is not only a good absorbent of acid gas like hydrogen sulphide under fairly high pressure
and low temperature but can also be easily be regenerated under fairly low pressure and fairly
13
high temperature. This process help to reduce the sulphur content of the L.P.G and the fuel gas
to meet the sulphur specification as well as to reduce the foul smell produced by hydrogen

sulphide and mercaptan in L.P.G and fuel gas as well as gasoline. The major equipments this
unit in the F.C.C use are the absorber column, the regenerator column which strip of hydrogen
sulphide, the regenerator reboiler and the regenerator surge drum. The F.C.C plant also contain
an equipment called the converter which is the heart of the F.C.C plant as the fluidize cracking
reaction takes place in this equipment. The converter equipment is an integrated as both
cracking reaction, cyclone separation, stripping, and regenerator (combustion) processes take
place in this equipment. Without the converter or any other equipment that perform the
converter function the F.C.C can exist as it in the converter that the catalytic cracking,
separation of catalyst from the cracked hydrocarbon, stripping or the removal of hydrocarbon
from the used catalyst and regeneration of the used catalyst take place. In the F.C.C plant there
is part or column which separate the cracked vapor at about 500c into the various products.
The various side product from the main column is made to loss heat to the feed (heavy vacuum
gas oil blended with heavy atmospheric gas oil) by preheating the feed through the use of
exchangers and part of the side product is sent to the column to control the amount of heat i n
the column and also ensured that each of the side product meet the product specification.
Most of the side products in the main column include the heavy naphtha, light cycle oil, heavy
cycle oil and slurry oil. Part of slurry oil is first stripped before losing heat to boiler feed water.
The light cycle is first stripped before losing heat to the feed. The process of continually losing
heat to the feed served two purposes which include ensuring maximum energy recovery from
the side product and also maintaining the column tray temperature. The slurry oil that have
been stripped becomes decant oil and is first cooled before been sent to storage and The light
cycle oil that have been stripped is cooled by loosing heat to the feed and air cooler before
been sent to storage. The F.C.C plant also has a section that is called the condensate recovery
section. In this section all the condensate from other plant and the F.C.C plant is been recover,
that is to form boiler feed water. The major equipment in this section is the condensate trim
cooler, the separation drum, the deaeration drum, the phosphate tank, the derakor tank and
the condensate drum. In this section the low, medium and high pressure steam condensate is
been condense to form boiler feed water. The F.C.C plant also has a section that is called the
vaporizer section. This section help to process the raw natural gas that is been supplied by
Nigeria gas company to produce fuel gas that is used as the refinery major source of energy.
The major equipment in this section is a kettle type exchanger which vaporized the light end or
fuel gas from the natural gas, a demisting drum which remove the entrained liquid from the
fuel gas and a separation drum. The fuel gas produce in this section is been sent to the fuel gas
network.

The F.C.C plant usually have complex piping network, but most of this network can be
summarized into the hydrocarbon network, the high pressure steam network, the low pressure
14
steam network, the instrument air network, the service air network, the medium pressure
steam network, the condensate network, cooling water network and the fuel gas network. Of
these entire networks the hydrocarbon network is the most complex network.

2.2 THE CRUDE DISTILLATION PLANT OVERVIEW.

The crude plant is also an important plant in any refinery as the major feed required by other
plant such as the F.C.C plant, isomerisation plant and the reforming plant is been produce from
this plant. This plant processes the crude oil into various products such as L.P.G, light naphtha,
heavy naphtha, light and heavy atmospheric gas oil ( both blended to produce diesel), light
vacuum gas oil, heavy vacuum gas oil and vacuum resid. The plant is made up of principal
equipments such as compressor, exchangers, air coolers, trim coolers, drums, the stripper
column (for kerosene, light atmospheric gas oil, heavy atmospheric gas oil), the preflash
column, the splitter column, sour water stripper column, the vacuum column, the main column,
the debutanizer column, the deethanizer column and the depropanizer column, desalter tanks,
two heaters pumps and other equipments. The topping plant is made up of the atmospheric
distillation unit, the vacuum unit, the sour water treatment unit, the caustic unit and the gas
processing unit. All these unit must work together to make sure that the plant work optimally.
The crude oil to be process is first sent to the first pre heating trail which uses the heavy
vacuum gas oil, light atmospheric gas oil and the preflash column top pump around to heat the
crude to about 125c and 11 bar pressure through the use of exchangers. At this temperature
and pressure the crude is been sent to the mixing valve which mix the heated crude,
deemusifier, ammonia, corrosion inhibitor and water before it is sent to the desalter. The
desalter helps to removes salt from the crude which can cause corrosion of the downstream
equipment. There is a transformer in the desalter which helps to polarize the tiny water droplet
in the desalter so as to coagulate the droplet and cause effective water separation from the
crude oil. From the desalter the crude flows through some set of exchanger and then the
heater which raise the temperature to about 220c before entering the preflash column. At the
preflash column light naphtha is been separated from the crude, cooled, and partly sent to
stabilizer column and partly refluxed. While the bottom is been pumped the some set of
exchanger and the to the second heater which raise the temperature to about 320c before
going to the main or atmospheric distillation column which separate the bottom to naphtha,
light atmospheric gas oil, heavy atmospheric gas oil, kerosene and atmospheric resid. The resid
is been pumped to the vacuum unit where heavy vacuum gas oil, vacuum condensate, li ght
vacuum gas oil and vacuum resid is been separated. The heat require to preheat the feed at
these preheating stages is been supply by the top, bottom, intermediate pump around of the
preflash column and some of the side product of the main atmospheric column and heavy
vacuum gas oil. All the the product to be sent to storage is usually cooled in an air or trim cooler
before been sent to storage. Some of the product that is been sent to storage include kerosene,
the heavy vacuum gas oil, light atmospheric gas oil, heavy atmospheric gas oil, light naphtha or
gasoline, heavy naphtha, light vacuum gas oil and the vacuum condensate. The topping plant is
15
usually made up of complex pipping network which include the hydrocarbon network, the
medium pressure steam network, the low pressure steam network, the instrument air network,
the condensate network, the service air network, the cooling water and plant water network.
All these network is usually interconnected to ensure optimal operation of the plant.

2.3 H.S.E INDUCTION AND TRAINING.

The H.S.E induction training of the company was carried out on every new trainee deployed by
the company two weeks after resumption. The training lasted for two days and it involves both
classroom lecture and practical demonstration. During this training lecture was given on the
different type of personal protective equipment and the nature of job these equipment are
required, the different type of safety symbol or sign and what they stand for, the different type
of work permit of the company and the nature of job they are require, hazards and types, fire
hazard and basic fire safety equipment and how to use them, emergency situation and the
basic action to take when in such situation and other. Practical training was also given on the
use of fire extinguishers.

2.4 INTERN ROLES AND RESPONSIBILITIES IN F.C.C PLANT.

The roles being carried out by me during my stay can be summarized to

1. Registering daily work request for both hot and cold work.
2. Taking plant readings of different equipment in the F.C.C plant.
3. Engaged in various works such as flushing of trim coolers, drums and some hydrocarbon
line. This operation is usually done during shut down period or before hot work is to be
carried out on the equipment.
4. Taking the inventory of various materials in the plant such as lube oil drums etc. This
operation is usually done when the plant is running and when it is shutdown.
5. Barring of both wet gas compressor and air compressor for the regenerator during shut
down period.
6. Visual inspection of pumps and pipes when the plant is running in order to check for
leakages and unusual noise or sound.

2.3 INTERN ROLE AND RESPONSIBILITY IN CRUDE PLANT.

1. Checking of the desalter level in the interval of one hour and report the result to the panel
operator.
2. Visual inspection of pumps and pipes when the plant is running in order to check for
leakages and unusual sound.
3. Checking of pump lubricating oil level and topping the level when the pump is short of oil.

16
4. Assist in other activities such as opening and closing of important manual valve under the
instruction of the chief operator.
5. Taking record of daily work done by the maintenance crew during shut down period and
reporting to the chief operator.

17
 CHAPTER 3

3.1 SKILL AND EXPERIENCE ACQUIRED.

During the period of my training I have been able to acquire basic skills in plant equipments
operation which include different procedure require to start plant equipment such pumps, fire
heaters and compressors etc. Also communication skill was also acquired as the daily jobs
undertaken by the trainee and the problems encounters were constantly communicated to the
chief operator. Different methods (such as water flushing, steam purging, nitrogen blanketing,
steaming out etc.) required for preservation of equipment during shut down and also starting
up operation was learnt. The basic troubleshooting skills require for detecting the cause of
deviation in operating conditions of the plant and the action to take to nullify such deviation
was also acquired. The basic procedure and action take when starting up the plant was learnt.
Basic skill in safety was also acquired from the on the job safety practice and also from the
induction safety training organize by the company.

3.2 PLANT OPERATION TRAINING.

Training was organized Mr. Charles Okunbor who is a staff of the refinery on the whole of the
production plant of the refinery, their basic operation, their feed and the final product from the
plants, the different operation condition affecting each of the plant, the limitation of each of
the plant, the optimal condition at which maximum production of a certain product can be
acquire and the technique require to troubleshoot a plant that is having a deviation in
operating conditions.

3.3 WORKS CARRIED OUT AND PROCEDURES.

1. Water Flushing of Equipment:
This operation is usually done when hot or cold metal maintenance job is to be carried out on
the equipment like drums, pipes etc. Hot metal work include cutting, welding works etc. while
cold metal work include loosing of bolt and cleaning the internal part like filters, demister etc.
Water flushing is done when such equipment is put off. This procedure is usually carried out
when hot or cold work is to be carried out on the equipment as this is to ensure that the
hydrocarbon vapor in the equipment is below the explosive limit as during hot work, heat can
generated cause explosion. After this operation is carried out safety personnel will come and
carry out test to the level of hydrocarbon vapor in the equipment to make sure the it is below
the explosive level and give approval if the job can be continue.

18
PROSEDURES:
1. If the equipment have any hydrocarbon, the hydrocarbon should be drain out.
2. If there is presence of utility inlet point then a hose is then connected from the water utility
point of the plant (plant utility point is made up of service air utility point, water utility point
and steam utility point) into the inlet utility point of the equipment.
3. The water utility point of the plant is then open.
4. The equipment utility point is then open
5. The equipment drain valve is then open if such valve is presence.
6. If the equipment does not have a drain value, another opening is made like opening a flange
that is connected to such equipment to let the water out.

2. Steaming Out of Equipment:

This procedure is usually carried out when hot or cold work is to be carried out on the
equipment as this is to ensure that the hydrocarbon vapor in the equipment is below the
explosive limit as during hot work heat can cause explosion. After this operation is carried out
safety personnel will come and carry out test to the level of hydrocarbon vapor in the
equipment to make sure the it is below the explosive level and give approval if the job can be
continue.

PROSEDURES:
1. If the equipments originally have drain point (like some drums) then the drain point should
be open together with other possible out let point.
2. If the equipment does not originally have drain point like some columns then possible
steam outlet should be created by either opening a flange or by closing the discharge valve
of all pumps which suction from the equipment and opening of the suction valve as the
suction strainer of all pumps have a strainer valve which is then open.
3. If the equipment is originally design to use steam while in operation then the steam inlet
valve to the equipment is open.
4. But if the equipment is not originally then a hose is connected from the steam utility point
of the plant to the utility point of the equipment.
5. Then the valve of the steam utility point of the plant is open for some time.

3. Nitrogen Blackening of Equipment:

This procedure is usually carried out on equipment that is usually prone to corrosion or
equipment that have content that is easily affected by atmospheric air. Such equipment in the
F.C.C plant is the amine storage tank and in the topping or crude plant is the caustic storage
tank.
PROSEDURES:
1. Most equipment which this operation is carried on usually have nitrogen inlet line in them
2. The nitrogen inlet valve into the plant is open.
19
3. The nitrogen inlet valve into such equipment is then open until the required pressure is
attained.
4. Then the nitrogen inlet valve to the equipment is closed.

4. Steaming out of condensate out of steam lines:

This operation is usually done when the plant is about to come up, another name of this
operation is commissioning of steam. This operation is usually done to prevent hammering (a
condition experience as a result of steam condensate in the steam line as a result of long period
of shut down which is characterize by high hammering sound coming from the pipes or
equipments when steam is immediately commission into the steam piping network). This
operation is usually done to remove condensate from the steam lines in order to prevent line
hammering.
PROSEDURES:
1. After power plant and utility have communicated to the superintendent that they have built
the different grade of steam require to run the plant.
2. The steam low point valves in the plant are then open.
3. Then the different grades of steam inlet valve into the plant are then open gradually for
about thirty minutes (usually the small bypass valve is usually open for sometime first
before opening the larger steam valve so as to gradually push condensate out of the line).
4. This operation is then left for some time until dry steam is seen from the steam low point
valves.
5. Then some of the low point’s valve is then closed.

5. Steaming out of Exchanger or trim cooler.

This is one of the procedures carried out by the plant operator whenever hot maintenance
work is to be carried out on an exchanger. This is to guaranty the safety of the maintenance
work.
PROSEDURES:
1. If the exchanger is a trim cooler then the inlet and outlet valve should be isolated.
2. Then the drain valve of the shell and tube side line should be open.
3. A hose should be connected from the steam utility point of the plant to the steam utility
point of the shell side or the tube side of the exchanger then the plant steam point should
be open.
4. After some time stop the operation.

6. Commissioning of heater:
This operation is usually done during critical period or during the start up of the plant when
circulation activities is been carrying on as the energy requires for the circulation is been supply
by the heaters.
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PROSEDURES:
1. Before any heater is commission during start up operation there must be an instruction
from the chief operator.
2. The safety personnel must be call to perform explosivity test on the heater.
3. If the heater does not pass the explosivity test then the heater must be purge with steam.
4. Then the purging operation is left for some time like three hours then call the safety
personnel to carry out another explosivity test if the heater pass the test then the heater
can be commission.
5. For heaters that have pilot burners the pilot burners must first be lighted before the main or
auxiliary burner can be lighted.
6. The heater operator then checks if the flame is burning properly by looking at the flame
through the sight hole.

3.4 PROBLEMS SOLVED AND PROCEDURES.

Below are some of the operational problems solved and the troubleshooting procedures
required. These operational problems were solved by the collective effort of the operator
together with the interns.

1. LOSS OF VACUUM.

Loss of vacuum is one of the problems that occur when vacuum column is to be put into
service. This problem results in rapid loss of vacuum condition in the column. The cause of this
problem is as a result of opening in the column or leak of air into the column when vacuum
condition have been established and left for one hour during vacuum loss test. The vacuum loss
test is used to test the extent at which vacuum is lost in one hour and to determine if the
column is air tight or if the column have any opening.

TROUBLESHOOTING PROCEDURES.

1. The low point valves attached to all the line to the column should be check if they are
tightly close and if not they should be closed.
2. Leakage should be check for the entire manhole into the column especially the ones open
during maintenance work and if a leakage is found the boiler maker should be informed to
tighten the bolt use to close the manhole.
3. The pump around pumps strainer valves should be checked if they are tightly close if not
they should be tightly closed.
4. The drain valves attached to the over head drum should be checked if they are tightly
closed and if not they should be closed.
5. Vacuum should be established again in the column by putting the ejectors at the top of the
column into service. When vacuum is about -740mmHg then the ejector should be put off

21
 and the time at which the ejector is put off should be recorded after one hour the guage
attached to the top of the column should be read an if the pressure increase by less than
25mmHg the good vacuum have been established, but if the pressure increase by more
than 25mmHg then the vacuum is not a good vacuum.
6. If good vacuum is not establish then procedure 1, 2, 3 and 4 should be carry out again
properly.

3.5 STARTUP FOR TOPPING UNIT AFTER SHUTDOWN.

Prolong shutdown is usually cause as a result of fault in major equipment or when turnaround
maintenance is to be carried out. During this period many activities is usually carried out which
include the maintenance of the faulty equipment, the preservation of the non faulty equipment
and so on. When the topping plant is to start up there are some major activities or procedure
that is to be carried out. These procedures are as follows.
1. All maintenance fixture used during the shutdown period should be removed as well
making sure that scaffold is available for hot bolting.
2. All blind that is installed during the shutdown maintenance job should be removed. The
radio and the intercom should be in good condition. The chemicals should be prepared and
ready for use as well as all injection should be tested.
3. Utility such as low pressure steam, medium pressure steam, cooling water, instrument air,
service air, steam tracing line, fuel gas, fuel oil and atomizing steam should be commission
into the plant. Stroking of pneumatic valve should also be carried out.
4. The charge circuit should be steam out. Before this is done the unit should be isolated at
the all the battery unit. This is done by commissioning steam through a pneumatic valve up
to the desalter drum inlet. The steam line that is attached to the desalter pump discharge is
open and the steam flow through the first preheating exchanger and the preflashed fire
heater inlet. This is done to pressurize the lines and exchangers so as to check for leakages.
5. The preflash heater combustion chamber should be purge with steam, gas explosivity test
carried out by safety personnel and the pilot burner should be put on. The temperature
should be brought to about 120-180c. Steam should be commission to the heater passes as
this is done by opening the feed inlet valve to the heater after the desalter discharge line is
open. The outlet valve of the heater should be open so as to purge the heater to the
preflash column. The pressure of about 1-2 bars should be maintained Leakages should be
checked and eliminated.
6. The steam line to the discharge line of the bottom pump of the preflash column should be
commission so as to pressurized the second exchanger train to the main column heater pass
pneumatic valve. During this operation leakages should be checked for and eliminated.
7. Steam should be commission to the stabilizer. Leakages should be check for and eliminated.
8. The main column heater passes should be purge with steam which passes up to the main
column and its connecting circuits. Leakages should be checked for. Gas explosivity test
should be carried out on the main column combustion chamber, the pilot burner of the
22
 main column should be put into service together with its longstrong air blower and the
temperature is then raised to about 120-180c

9. Stream is the commission to through the steam line attached to the main distillation
column bottom pump discharge line. The steam then pass through some exchanger to the
vacuum heater flow recording controller valve 1,2,5,6. Each attached to the four passes.
Leakages should be check for and eliminated.
10. Steam should be commission to the stabilizer column and pressure to about 1-2 bars.
Leakages should be check for and eliminated.
11. Steam should be commission through the low pressure steam line provision into the splitter
column and back pressure the column up to the bottom pump and the reflux/storage
pump. Leakages should be checked for and eliminated. The column should be pressure up
to 1-2 bars.
12. All steaming out process should be stop and fuel gas is then introduced into the various
columns and lines so as to avoid the creation of vacuum. All the drain and vent should be
closed. The bypass should be closed also.
13. All the air coolers should be put on. The gland oil level should be increased to the require
amount and the pump 10-p-23 should be put on. The tempered water system should be
commission after the tempered water tank is at the required level (15-d-05).
14. After all these activities the refinery superintendent, power plant and utility
superintendent, and oil movement superintendent should be inform of the intension to
start up. The oil movement is then asked to start the feed inlet pump to the plant.
15. The external circulation procedure should begin. This is done by putting the feed inlet pump
in the plant into service and opening the feed inlet isolation valve until the pressure gauge
located at the feed inlet downstream isolation valve read about 25 bars and opening the
necessary isolation and bypass valve to ensure that the crude flow to the first preheating
train exchangers, the desalter is bypassed, the feed flow to the second preheating train
exchangers, the preflash heater, the preflash bottom pump to the third preheating train
exchanger, the main distillation column, the main column bottom pump through some
exchanger to the main slop line. The temperature of the system should be closely monitor
and together with the main and preflash column bottom level and when the level increases
more than the required then corrective action should be taken by reducing the flow of
circulation feed into the unit. At this point only the pilot burner and the fuel gas burners of
the main, vacuum and the preflash heater should be put on. The splitter and the stabilizer
are not put into service during circulation. The skin temperature, together with the transfer
temperature of both heaters should be monitored. The preflash and the main column
bottom pump should be put on.
16. When flue gas of the heaters is about 200c, low pressure should be commission to the
superheaters coil and then vented to atmosphere. The superheaters help to produce
medium pressure steam into the medium steam network and also to provide steam require

23
 in the main column. Hot bolting of the exchanger should then begin when the temperature
of the exchanger is about 200c (this is usually done to prevent leaking from the bolted joint
of the exchanger which is cause as a result of difference of thermal expansion of the bolt
and the material which the exchanger casing is made up of). This operation is carried out by
boiler makers (mechanical maintenance crews).
17. Then circulation activity is then cut off after some time, this is done by isolating the main
slop line and removing the desalter from bypass. The desalter transformer is then
commission when the crude oil temperature is about 90c. The mixing valve located before

the desalter is the commission and water, corrosion inhibitor, ammonia solution and the de-
emulsifier injection will begin. The temperature of the preflash and the main heater is then
increased by putting on more burners including more fuel oil burner. The skin temperature
together with the transfer temperature of the heater passes are monitored by panel operators.
The steam vent of the superheaters is the closed after the required temperature and pressure
of the medium pressure steam is achieve and the steam outlet temperature of the
superheaters is monitor by panel operator so as to prevent the temperature from rising above
350c design temperature.
18. The preflash and the main column heater temperature is then increase gradually to about
240c and 350c at the rate of 40c/hr. the level of the
19. Stripping steam into the stripper columns is then sent gradually to the columns until their
required flow rate and column pressure is attained. This activity is done in communication
with the panel operator. The bottom level of the strippers column (kerosene, light gas oil
and heavy gas oil) should increase to sufficient amount before starting the product pumps
(so as to prevent cavitation) which sent the products to slop or storage (slop is used to store
product that is off specification especially during start up operation).
20. The panel operators together with the topping operators (panel operators) then try to
stabilize the plant system. The plant operator together with the trainee carries out visual
inspection of the plant to check for leakages from pump seals, pipes and other equipments.
During most of these activities there must be communication between the panel operator
and the plant operator through the use of radio

3.6 STARTUP PROCEDURE FOR VACUUM UNIT AFTER SHUT DOWN.

1. The vacuum distillation unit is a unit in the crude distillation plant responsible for produce
heavy and light vacuum gas oil. The feed to this unit is the atmospheric distillation residue
or bottom from the main distillation column in the topping unit. This residue is pump from
the bottom of the main column through some exchangers and heater which raises the
temperature to about 380c into the already commission vacuum column.
2. After all maintenance works have already been carried out on the unit, the plant operators
must ensured that all the blinds that have been installed on the lines during the
24
 maintenance work by boiler makers have been removed. Pneumatic valves in the unit must
be stroke to ensure that they are in good condition.
3. The tempered water circulation pump must be commission or put on. Then the tempered
water air cooler is put on.

4. The vacuum heater pilot burners are put on and the manual inlet valve into the heater and
the manual out let valve to the heater is also open.
5. A bottom circulation activity then begins. This activity is carried out by bypassing the
atmospheric bottom to storage and reroute the atmospheric bottom through some
exchangers, vacuum heater and into the column until the required level is achieved, also
AGO can also be used to topped the level (to reduce the viscosity since AGO have less

Viscosity than atmospheric residue) When these activities is achieve the AGO line is isolated
and the atmospheric bottom line is the bypass to storage.
6. Pump 1 (vacuum bottom pump around is put on). And after some time the pump is shut off
and the condensate in the line is drain off from the low point valve and the strainer valve of
the vacuum bottom pump.
7. Tray 2 circulation activity then begin (tray 2 is the tray that is immediately above the
bottom of the column). This is achieve by opening the AGO line that join the AGO line
leading to storage. This line lead to tray two and the pump 4 suction (pump 4 is the tray 2
pump around and storage pump). When the level is achieved then the tray pump around is
put on and the line leading to storage is isolated. After some time the pump is put off and
then the water condensate in the line is then drain off from the strainer valve and the line
low point valve.
8. After there is no water condensate on the tray 2 and its lines, then tray 9 circulation
activities then begin. This is done by opening the AGO line to tray 9 and pump 5 suction
(light gas oil tray suction). When level is achieved on the tray then the line is isolated. Then
pump 5 (tray 9 pump around and storage pump) is put on. Pump 5 pump the fluid on the
level through some coolers which uses tempered water back to the column while the line to
storage is isolated. After some time the pump is put off and the water in the line is drain off.
9. After these activities is carried out successfully then vacuum is pull in the column. This is
done by gradually opening the medium steam line to the third stage injector and constantly
monitoring of the gauge on the line leading to the vacuum column and constant
communication with the panel operators. When vacuum have been pull to about -
740mmhg the vacuum is then tested for leakages or opening, this is done by leaving the
achieved vacuum for about one hour and if the pressure increase by more than 25mmhg
then the vacuum is not a good vacuum, but if the pressure increase by less than 25mmhg
then the vacuum is good vacuum. If good vacuum is achieved then proper production
begins

25
10. Proper production begin by putting on the fuel burners of the vacuum heater and opening
the inlet and valve of the heater and checking if the tempered water system have been
commission together with the air coolers.
11. After some time when quality control test have been carried out and the products meet
specification then the pump around line leading to storage is then open.
12. The panel operator then tries to stabilize the system.

These startup procedures have to be followed and each operation have a precise time at
which they are to be carried out. During the period of startup all hand must be on deck to
ensure the success of the operation.

3.7 SAFETY PROCEDURE IN THE REFINING PROCESS PLANT.

 Protective clothing (PPE) and helmet should always be worn.
 An un-authorized flame should never be lit.
 All mobile phones are not allowed in the plant areas.
 Work permit should be given before any maintenance work is carried
out.
 Ensure that all oil and fuel hills are washed off.
 Horse play is not allowed especially in the process plant.
 Fire arms are not allowed in the process plant area to avoid accidental
discharge.
 Only speed limit of 25km/hr is allowed in plant areas.

26
3.8 MAJOR OPERATING VARIABLE OF THE CONVERTER OF THE FLUID
CATALYTIC CRACKING PLANT.
In order to get maximum yield of gasoline the conversion of the plant must be kept as high as
possible bearing in mind the need to get more gasoline. Conversion of the plant is express as
the percentage of the feed (heavy vacuum gasoil) that is crack to product that is lighter than
cycle oil (product with end boiling point less than 221c). The major operating variables which
will increase conversion are increase riser temperature of the converter, increase in recycle,
increase in catalytic activities, increase in the catalyst oil ratio, increased in the catalyst oil
contact time and finally increased in the disengage pressure.
The operators of the plant have the capacity to control any of the variables by actuating of
some special valves either opening or closing as the case may be.
1. Catalyst oil contact time:
It is the measure of the time which the catalyst oil mixture spends in the riser. It is a function of
the vapor load in the riser. The contact time can be control by the plug valve which release
regenerated catalyst to the riser and the vertical and the dispersion steam pot to the riser.
2. Catalyst activity:
The catalyst activity is the ability of the catalyst to support the cracking reaction to produce
different products. The catalyst activity can be restored by continually adding fresh catalyst to
the regenerator from the fresh catalyst drum and also by carrying out regeneration properly.
3. Catalyst oil ratio:
This is defined as the weight rate of catalyst circulation divided by the gasoil feed rate. The
catalyst oil feed rate is usually control by both the feed manual and pneumatic valve to the
riser. A high catalyst to oil ratio will lead to high conversion but care must be taken when
controlling this variable as too high catalyst to oil ratio will cause light gas to be produce which
is difficult to recover.
4. Recycle to the riser:

During operation some of the slurry or heavy cycle oil that has been cooled is usually sent back
as feed to the riser of the converter. This variable is usually one of the major determination of
gasoline and coke yield and also an important contribution of the density of the feed to the
riser. Usually an increase in the recycle will cause an increase in the gasoline yield. The value of
the recycle is usually 2-3% of the fresh feed.
5. Disengage stripping steam rate:
This is also an important operating variable to consider when operating the converter. The
stripping steam rate is the rate at which steam is feed into the H/D stripper in the converter. An
increased in stripping steam rate help to further reduce the partial pressure of the hydrocarbon
that stick the catalyst thus inducing vaporization of the hydrocarbon. Stripping steam should be
increase under any of the conditions, increase in fresh feed rate, increase in the recycle rate,

27
increase in fresh feed density, when the riser temperature decrease, when the feed
temperature increase and when the disengager pressure increases.
6. Disengager catalyst level:
This is also an important operating variable as this variable determines the safety of the
operation and also the smooth circulation of the catalyst because with its own weight the
catalyst provides the hydrostatic pressure required to send the catalyst to the regenerator
through the plug valve. This variable is usually control by a level controller which actuate on the
plug valve which open to the regenerator.
The disengager level is also control by other transducers and controller loop such as the
differtial pressure controller, and the temperature controller which override the level controller
signal when the differtial pressure is too low or the temperature is too high to close the plug
valve to the regenerator from the stripper part of the converter.
Other important variable include the main fractionating over head temperature, product
extraction rate from the side of the main column, vapor recovery unit pressure. And the
temperature and pressure of all the column (the botanizer column, depropanizer column, the
absorber column, the gasoline stripper column, LPG amine absorber and the fuel gas amine
absorber).

28
 CHAPTER 4

4.1 CONCLUSION.
Without a doubt, the importance of the industrial training program cannot be overemphasized.
The basic aims of which are;

 Bridging the gap existing between theory and practice of engineering.

 Exposing students to machines and equipment together with its working principle.
 Professional work methods and ways of safe guarding the work areas and workers in the
industries.
 Bridging the gap existing between theory and practice of engineering. From practical
knowledge gained in the Warri Refining and Petrochemical Company, I fully appreciate the
theory behind many chemical processes and equipments such as reactors, exchangers,
turbines, pumps and distillation, reboiler and reflux system, etc.

Also from my stay in the warri refining I have been able to understand the basic safety skill
require when dealing with hydrocarbon and other corrosive liquid. And the basic equipment
preservation carried out during shut down period and also the basic emergency situation that
arise when operating the fluid catalytic unit and the basic approach that is require the combat
such situation.

29
4.2 APPENDIX.
Below are the list of most equipment used in refinery operation and brief working principles.
PUMPS:
Pumps are device which is used in the refinery to move liquids from one point to another.
Most pumps used in the refinery are either electrical pumps or turbine pumps. The electrical
pumps uses electrical power to drive the shaft which rotate the impeller while turbine pump
uses the pressure energy of the steam inlet to the turbine casing to drive the shaft which rotate
the impeller. Majority of the pumps in the refinery are centrifugal pumps . The major
component of the pumps use in the refinery are the impeller, the bearing, the hub, seal ,
motors, turbine casing and blade and the impeller casing.

COMPRESSOR:

Compressor are device which is use to increase the pressure of gases by reducing the volume.
They work with the principle of compressor is to transfer the mechanical energy from any
energy source into pressure energy of the gas. Compressor can also be use to increase the flow
rate of gases and to transport gases. The refinery uses steam to drive large capacity
compressors while smaller compressors are driven by motors. Most of the compressors used in
the refinery are centrifugal compressor. The major component of the centrifugal compressor
include the housing or casing, the diffuser, the impeller, the bearing, seals, flow control device,
speed control device and so on. Larger compressors also have more sophisticated control
system and also cooling system which uses cooling water.

DRUMS:

Drums are one of the most used equipment in the refinery. Most drum are made from material
which depend on the type of fluid such drum is to handle. A drum serves any of the following
function which is to carry out simple phase separation, to demist a gas stream before been sent
to a compressor, to receive fluid from condensers and to transfer fluid to other processing
equipment. Drums in the refinery are usually cylindrical in shape with both ends been
hemispherical. Almost all drum have level controller attached to them which controls the level
in the drum. For drums which is expected to deal with high pressure will usually have pressure
relief valve install in them.

30
COLUMN.

Columns are one of the most common equipment that is found in the refinery. The column can
serve different function such as distillation, adsorption, absorption, extraction and so on. Most
columns are cylindrical in shape with both end been semispherical and are mostly installs in the
vertical position. The internal of most columns are usually divided by trays which serve as an
equilibrium stage in the process. The type of tray depends on its application. The top of some
column usually have a pressure relief valve install which act as a safety device while the bottom
and some trays usually have a level recording controller installed. The level recording controller
is used to control the level of fluid in the tray or bottom.

DESALTER:

The desalter is a special type of drum which is been used in the crude distillation plant. The
desalter serves multiple functions which include removing salt from the crude oil to be process,
to separate the desalted crude oil from water and to send the waste water to water treatment.
The desalter is made up of the desalter drum, the transformer which carries out eletrolytical
separation of tiny water particle from the desalted crude oil, tanks from which the de-
emulsifier, alkaline and corrosion inhibitors are injected and a level controller which control the
level in the desalter drum. The mode of separation which the desalter uses includes the
electrolytic and gravitational separation of non soluble liquid phases.

CONVERTER:

The converter is one of the most important devices used in F.C.C plant. This device is
sometimes refers to the heart of the F.C.C plant cause without this device the F.C.C plant will
not exist. The converter is made up of different component or parts which include the riser,
stripper, disengager, cyclones and the de-generator together with their control devices.

The riser is the part where the cracking reaction take place (in vapor phase), having enough
volume to provide the necessary space time require for reaction. The disengager is the part
where the separation of catalyst from the cracked product takes place. The disengager is equip
with cyclones which help to separate the solid catalyst particle from the cracked hydrocarbon
(in vapor phase). The stripper is also an important part of the converter. It is in the stripper that
the hydrocarbon the stick in the used catalyst is been removed as this is to prevent over heating
of the regenerator. The stripper uses medium pressure steam to operate. Finally the

31
regenerator is the part of the converter the carbon together with the sulphur deposit on the
Used catalyst is burn off, this is necessary as these deposit reduces the activity of the catalyst.
The regenerator also has some control devices which prevent the regenerator from
overheating. Device such as pump, compressor, tank, drum and blower are common to all the
plant in the refinery. But some plant has some equipment that is unique to them.

32
4.3 RECOMMENDATION.
I strongly suggest that the program be introduced right from the second year of study in all
science disciplines and third year in all Engineering disciplines. This will enable students to be
exposed to more than one industry and also increase the duration and frequency of the
program. Students will be equipped with the skills required for working in more than one firm,
thereby, increasing the level of employment opportunities for the students in the near future.
It is necessary to sensitize staff of the various companies on how to relate to students by
helping them to get the needed knowledge.
It would be very important if the organizers of the SIWES program could sit with the various
companies and discuss the relevance of the program and to create more industrial training
spaces.
Financial aids should be given to students in order to help them with feeding, transportation
etc.
All supervisors should visit every student in their various places of attachment.

33
4.4 REFERENCES.
1. Engr. Bender oluayo; reforming operational manual.
2. Engr. Ani okafor; compressor operational manual.
3. Engr. James okoro; chemical engineering process.
4. John daintith; a dictionary of chemistry, sixth edition, oxford university press.
5. Hunter, Loius .C ., Bryant Lynwood, The transmission of power, oxford university press.

34