Bataan Heroes Memorial College Roman Super Hi-Way Balanga City Bataan

REPUBLIC OF THE PHILIPPINES
BATAAN HEROES MEMORIAL COLLEGE

ROMAN SUPER HI-WAY BALANGA CITY BATAAN
CHAPTER I
HISTORY OF PETROLEUM REFINERY
Chinese culture was one of the first to refine oil. Chinese geographers, writers, and politicians Li
Daoyuan invented the process of refining crude oil into various lubricants in his classic work
Commentary on the Water Classic between 512 and 518, in the late Northern Wei Dynasty. Arab
chemists distilled crude oil frequently, with detailed details in Arabic handbooks such as Muhammad ibn
Zakarya Rzi's. Oil reserves were discovered in the 9th century in modern-day Baku, Azerbaijan. The Arab
geographer Abu al-Hasan 'Al al-Mas'd reported these fields in the 10th century, while Marco Polo
described the output of those wells as hundreds of shiploads in the 13th century. Chemicalists in the Arab
and Persian empires also distilled crude oil to make combustible compounds for military use.
A facility dubbed the "Fierce Oil Workshop" was created in Kaifeng during the Northern Song
Dynasty (960–1127) to produce refined oil for the Song troops as a weapon. Thousands of workers
labored in the workshop, which was one of the world's first oil refineries, producing Chinese oil-powered
weapons.Petroleum was known and used in various forms in Babylon, Egypt, China, the Philippines,
Rome, and Azerbaijan before to the nineteenth century. The modern petroleum business, on the other
hand, is considered to have begun in 1846, when Abraham Gessner of Nova Scotia, Canada, invented a
method of producing kerosene from coal.
On 1856, the world's first systematic petroleum refinery was created in Ploiești, Romania,
exploiting Romania's rich oil. In 1858, James Miller Williams of Oil Springs, Ontario, Canada, drilled the
first oil well in North America. The petroleum industry in the United States began in 1859, when Edwin
Drake discovered oil near Titusville, Pennsylvania. During the 1800s, the industry grew slowly, primarily
producing kerosene for oil lamps. The invention of the internal combustion engine and its employment in
automobiles in the early twentieth century established a market for gasoline, which fueled the petroleum
industry's fast rise. Early petroleum discoveries, such as those in Ontario and Pennsylvania, were quickly
surpassed by massive oil "booms" in Oklahoma, Texas and California. In 1853, Samuel Kier opened
America's first oil refinery on Seventh Avenue near Grant Street in Pittsburgh, and in 1854, Polish
pharmacist and inventor Ignacyukasiewicz opened an oil refinery in Jaso, then part of the Austro-
Hungarian Empire (now Poland).
The world's first large refinery opened in Ploiești, Romania, in 1856–1857. After being taken
over by Nazi Germany, the Ploiești refineries were bombed by the Allies in Operation Tidal Wave during
World War II's Oil Campaign. Salzbergen, Lower Saxony, Germany, is another close contender for the
title of hosting the world's oldest oil refinery. The Salzbergen refinery first opened its doors in
1860.Petroleum has previously only been available in small quantities in various places of the world due
to natural seepage of underground oil. Petroleum, on the other hand, was exclusively used for medicinal
and specialist purposes due to its scarcity. After the discovery of "rock oil" in northwestern Pennsylvania,
substantial quantities of crude oil were available, prompting the development of larger-scale processing
processes. The early refineries employed simple distillation units, or "stills," to separate the various
constituents of petroleum by heating the crude oil mixture in a vessel and condensing the resulting
vapours into liquid fractions. The primary product was kerosene, which proved to be a more plentiful,
cleaner-burning lamp oil of consistent quality than whale oil or pig fat.
PETROLEUM REFINERY IN THE PHILIPPINES
 Petron Corporation (26.36%)- Currently the largest oil refinery in the Philippines with its
largest Refinery in Bataan with a production capacity of 180,000 barrels per day. PCOR's
principal business involves the refining of crude oil and the marketing and distribution of refined
petroleum products including gasoline, naphtha, LPG, diesel, jet fuel, kerosene, and
petrochemicals. The Company's refinery is located in Limay, Bataan with a crude distillation
capacity of 180,000 barrels a day. PCOR also manufactures lubricants and greases through its
plants in Manila.
 Pilipinas Shell (18.53%)- Shell announced that it is permanently shutting down its oil refinery
operations in Tabangao, Batangas, on the main Philippine Island of Luzon, after suspending
refinery operations last May 24 due to reduced fuel demand from Covid-19. Pilipinas Shell said it
would be transforming the 110,000 barrel-per-day Tabangao oil refinery facility into a world-
class full import terminal “to optimize its asset portfolio and enhance its cost and supply chain
competitiveness,”. ceased refinery operations 2021 and converted into an import terminal.
 Chevron Philippines Inc. (7.93%)- The last major player in the market is Chevron who
partnered with Caltex and currently has a 7.93 percent market share. Chevron markets Caltex
fuels, lubricants and other petroleum products. The company has almost 700 service stations
nationwide and 20 major supply facilities including their main supply hub which is located at
their terminal in San Pascual, Batangas. ceased operation in 2003 to give way to a P750-million
finished product import terminal
PETROLEUM PRODUCT PROCESS FLOW
Petroleum refineries convert crude oil into petroleum products used as transportation fuels,
heating fuels, paving roads, generating power, and as chemical feedstocks.
Refining is the process of breaking down crude oil into its constituent components, which are
subsequently reconfigured into new goods. Petroleum refineries are large, complicated, and costly
industrial plants. The following are the processes that refineries do from having the crude to finished
petroleum product:
 Separation - Crude oil is piped through heated furnaces in modern separation. The liquids and
vapors that arise are pumped into distillation units. Atmospheric distillation units are used in all
refineries, while vacuum distillation units are found in more complicated refineries.
 Distilling - The liquids and vapors inside the distillation units are separated into petroleum
fractions based on their boiling points. On the bottom are heavy fractions, while on the top are
light fractions. Gasoline and liquefied refinery gases, for example, evaporate and climb to the top
of the distillation tower, where they condense back to liquids. Medium-weight liquids, such as
kerosene and distillates, remain in the distillation tower's midsection. Gas oils, which are heavier
liquids, separate towards the bottom of the distillation tower, while the heaviest fractions with the
greatest boiling points separate at the top.
 Conversion- Heavy, lower-value distillation fractions can be processed further into lighter,
higher-value products like gasoline after distillation. This is where fractions from the distillation
units are converted into streams (intermediate components) that are then processed into finished
products.
 Cracking - is used to maximize the usefulness of heavy oil heavy oil has long strings of carbon
and hydrogen molecules using a catalyst these molecules can be broken into smaller chance
transforming the heavy oil until later more valuable fluids.
 Reforming - is a process that increases the amount of gasoline produced from crude oil one of
the products separated in the distilling process is a liquid called naphtha the number of carbon
atoms in that that is about the same as the number found in gasoline but their structure is more
complex for, we range and that's a molecule turning it into a usable gasoline like molecule.
 Blending -is a process of mixing different refinery products to make finished petroleum fuel
gasoline for example is blended to achieve octane standards creating the grades of gasoline you
see it the pop regular, mid-grade and premium that are necessary to meet the needs of specific
engine type.
 Treating - is process used to produce pain or gasoline which helps protect the environment and
our health gasoline molecules contain impurities like sulfur that can be removed when the
molecules are here and come in contact with a special catalyst chemical reaction occurs at strip
sulfur compounds are used as fertilizers and in pharmaceuticals nothing goes to waste in
refinery.
 Storing- Both arriving crude oil and outgoing finished products are temporarily held in massive
tanks on a refinery's tank farm. The final products are transported from storage tanks to other
locations around the country by pipelines, railroads, and vehicles.
GENERAL PETROLEUM PLANT LAYOUT
 Isomerization is required for the conversion of n-butane to isobutane, which serves as an extra
feedstock for alkylation units, as well as the conversion of conventional pentanes and hexanes to
higher branched isomers for gasoline blending. By altering the molecular structure and increasing
the octane, the isomerization unit turns light naphtha into a higher-value gasoline blendstock.
Isomerate is the major product of isomerization. Isomerization's importance comes from its
capacity to convert light naphtha into gasoline.
 A catalytic reforming process turns paraffin, olefins, and naphthenes into aromatics, which may
be utilized as a motor fuel blending stock or as a source for particular aromatic chemicals like
benzene, toluene, and xylene for petrochemical manufacturing. A reformate is a common term for
the reformer's output stream. This technique produces reformate with a high-octane rating. As a
by-product, significant amounts of hydrogen are created. A bifunctional catalyst, capable of
rearranging and breaking long-chain hydrocarbons as well as extracting hydrogen from naphthene
to make aromatics, is typically used in catalytic reforming. This process is distinct from steam
reforming, which is likewise a catalytic process that yields hydrogen as a byproduct.
 Hydrocracking, like hydrotreating, is a refining procedure that falls under the umbrella of
hydroprocessing. The result is the conversion of a variety of feedstocks into a variety of products,
and the units required to achieve this aim can be found throughout a refinery. In comparison to
the ancient processes of thermal cracking, visbreaking, and coking, hydrocracking is a relatively
recent development. The capacity of refiners to cope with the increasing trend toward distillate
production from heavier feedstocks with low atomic hydrogen/carbon ratios has sparked fresh
interest in hydrocracking.
 Fluid catalytic cracking (FCC) is a significant oil refinery process because this process turns
heavy petroleum fractions into lighter hydrocarbon products inside a reactor. A thorough
examination of an FCC unit regenerator has been done to enhance production and improve
operational efficiency. Heavy hydrocarbons from crude oil are broken or cracked in the FCC unit,
allowing them to be converted into gasoline and other fuel products. The heavy hydrocarbons are
first mixed with a catalyst in a reactor.
- Olefins to Alkylation or Olefins Plant provides a high-quality gasoline blendstock, by mixing
two LPG-range molecules to make one gasoline-range molecule. This is accomplished by
combining isobutane with a light olefin, usually propylene or butylene from the FCC. The main
product is FCC gasoline, which is utilized in the mixing of gasoline products. The FCC, on the
other hand, provides lighter products for feeding the alkylation unit as well as heavier products
for blending into diesel and residual fuel oil.
- Hydrotreating's main goal is to improve the quality of heavy feedstocks by removing
heteroatoms and metals. Hydrotreating methods comprise multiple types of catalytic reactions
that compete for the available hydrogen due to the complicated nature of the chemical
processes involved. Using a commercial equilibrium catalyst, the coking phenomena of coker gas
oil (CGO) feedstock was examined during fluid catalytic cracking (FCC). Different forms of coke
produced by catalytic cracking of coker gas oil (CGO) were also investigated. Adsorption coke
(Cad), dehydrogenation condensation coke (Cdh), and hydrogen transfer coke were used to
make the coke (Cht). Cad, which is produced from nitrogen molecules, adsorbs on the acid
sites of the catalyst and accounts for 37 wt% of the overall coking content in typical reactions.
 N in petroleum refineries employs many important processes to transform crude oil into refined
products in a methodical manner. Atmospheric distillation, hydrocracking, hydro-treating,
reforming, and, finally, coking are examples. The atmospheric distillation column at the refinery
separates crude oil into lighter hydrocarbon streams based on their boiling temperatures. At the
top of the column, the gasoline range of petroleum distillates condenses. In the center of the
column, medium distillate fuels (kerosene, jet fuel, and diesel fuel) condense. Lower in the
column, the heavier spectrum of gas oils condenses. The boiling temperature of residuum, a thick
tar-like substance metaphorically referred to as the "bottom of the barrel," is so high that it
remains at the bottom of the column. Refineries use heat, pressure, hydrogen, and catalysts to
"crack" the heavier distillation products into the gasoline range in order to generate additional
gasoline. Through a reaction with hydrogen gas, hydro-treating eliminates elemental sulfur from
gasoline and middle-distillate fuels. Coking transforms petroleum residue into lighter
hydrocarbons, low-Btu gas that may be used as a fuel in refineries, and "green coke" at first. One
of three types of coking procedures are widely used in refineries:
- Delayed coking is a thermal cracking process that produces gasified product streams and
concentrated carbon coke from residuum. Because the cracking takes place in a coke drum
rather than a furnace or reactor, it's dubbed "delayed coking." The residue is cooked in a furnace
before being put into the coke drum's bottom. At the top of the drum, the "cracked" light products
are taken out and transferred to a fractionator, which separates gasoline, naphtha, gas oil, and lighter
products. Hydraulic or mechanical cutting methods are used to "decoke" the drums. One coking drum is
filled while the other is decoked in delayed coking (emptied). The most extensively utilized thermal
technique nowadays is delayed coking.
- Flexi-coking is a continuous fluidized bed thermal cracking and coke gasification process that
uses air and steam. The majority of the carbon coke is converted to carbon monoxide (CO),
which is then combined with light hydrocarbons to create a low-quality fuel gas.
- Fluid coking is a type of flexi-coking in which the coke is separated using a cyclone.
 Petroleum coke is a by-product of the oil industry's coker process. It's also known as "green
coke" or "green petroleum coke" in its unprocessed form. Calcined petroleum coke is a vital
industrial commodity that connects the oil and metallurgical sectors by providing carbon for a
variety of metallurgical uses, including the production of anodes for aluminum pot liners and
graphite electrodes. Rotary kilns are used to calcine petroleum coke for the most part. In this
chapter, we discuss some of the characteristics of the rotary kiln's petroleum coke calcination
process and utilize it as a design case study for sizing a rotary kiln for the application.
 Naphta Hydrotreating - The naphtha hydro treatment unit removes sulfur by converting it to
hydrogen sulfide, which is removed together with unreacted hydrogen using a cobalt-
molybdenum catalyst. The naphtha hydrotreater removes sulfur and nitrogen compounds from the
naphtha cut from the atmospheric distillation unit.
 Distillate Hydrotreating - The very first and most crucial phase in the refining process is
vacuum distillation, which is found in most crude and vacuum distillation products in refineries.
The main function of an atmospheric distillation tower is to separate crude oil into its constituents
(or distillation cuts, distillation fractions) for further processing by other processing units. sulfur
that must be removed before further processing or use. Hydrotreating, also known as
hydrodesulfurization, is a collection of procedures for removing sulfur and other pollutants from
water. Crude oil cuttings are selectively reacted with hydrogen in the presence of a catalyst at
high temperatures and moderate pressures during hydrotreating. Unwanted aromatics, olefins,
nitrogen, metals, and organosulfur compounds are converted into stable products in this process.
To meet final product standards, some hydrotreated cuts may require extra processing.
 Atmospheric distillation is the very first and most important step in the refining process. The
atmospheric distillation tower's main function is to separate crude oil into its components (or
distillation cuts, distillation fractions) for further processing by other processing units.
 VGO Hydrotreating - The VGO hydrotreater is used to eliminate sulfur in FCC (Fluid Catalytic
Cracking) feedstocks like VGO before they are fed to the FCC. This lowers the sulfur content of
FCC products while increasing yield.
 Vacuum distillation is the process of decreasing the pressure in the column above the solvent to
less than the mixture's vapor pressure, creating a vacuum, and allowing the elements with lower
vapor pressures to evaporate off
UNITS INVOLVED IN AN OIL REFINERY (LAGAY NINYO LAHAT NG MARERESEARCH)

1. Atmospheric Pipestill- Atmospheric distillation is the first and most fundamental step in the the
refining process.The primary purpose of the atmospheric distillation tower is to separate crude oil
into its components (or distillation cuts, distillation fractions) for further processing by other
processing units. In atmospheric distillation, the desalted crude is heated in a heat exchanger and
furnace to approximately 750°F then fed to a vertical distillation column under pressure. Within
each atmospheric distillation column are four or more sidestreams of low-boiling components
that are removed from the tower from different trays. The low-boiling-point mixtures are in
equilibrium with the heavier fractions, which must be removed. Each sidestream is sent to a
different small stripping column. The small stripping tower contains 4–10 trays with steam
injected under the bottom tray. Steam is used to strip light-end components from the heavier
components, and both the steam and stripped components are fed back to the atmospheric
distillation column above the corresponding sidestream draw tray. The fractions obtained from
the atmospheric column include naphtha, gasoline, kerosene, light fuel oil, diesel oils, gas oil,
lube distillate, and heavy bottoms. The majority of these can be sold as finished products or
blended with products derived from downstream processes.
2.
3. Naphtha Hydrotreating Unit- The naphtha hydrotreating / reforming unit is also called
ultrafiner / ultraformer unit, which is designed to convert naptha to high octane reformates, for
use as gasoline base stock, hydrogen and LPG. NHT receive feedstock in the form of heavy
naphtha of CDU and HCU. Heavy naphtha will be streamed to the surge drum the injected
hydrogen and dimethyl sulfate. The function of this injected is to activate the catalyst. The use of
catalysts aiming to accelerate the reaction rate, but does not affect product quality. Then the
mixture was heated in the heat exchanger to a temperature of approximately 324°C.
Here is a reaction process that occurs in the reactor:

1. Desulfurization: Aiming to reduce the sulfur content, the reaction that occurs between the
sulfur-containing compounds with hydrogen will produce hydrogen disulfide.
2. Denitrification: Aiming to reduce nitrogen content, the reaction that occurs between nitrogen
and hydrogen would result Ammonium (NH3).
3. Olefin Hydrogenation: Olefin hydrogenation is the reaction of olefins with hydrogen gas that
will produce paraffin and naphthen.
4. Decomposition of metal compounds: metals such as iron, calcium, magnesium, silica, and
others will break down and are deposited on the surface of the catalyst.
Product from the reactor is cooled through heat exchanger

(HE) and then the product is condensed in finfan, then injected the process water. Water
injection is used to dissolve the salt formed. Mixture consisting of condensate and water are
supplied to the separator so that there is a separation between gas, liquid hydrocarbon and
water. Once separated, the water will be channeled to the SWS (Sour Water Stripper), while
the gas will be supplied to the reactor through the compressor. While the liquid hydrocarbons
from the separator will be heated using a heat exchanger until it reaches a temperature of
181°C. After that flowed into the stripper column. in the stripper column, the fluid will be
heated using steam coming from the boiler. Steam is used to abolishing hydrogen sulfide,
water and light hydrocarbons contained in the feedstock.
4. Continuous Catalytic Reforming Unit (CCRU)- Catalytic Reforming is a process in which

linear paraffinic hydrocarbons contained in crude unit naphthas, which have low octane ratings,
are converted in a high-octane reformate containing aromatics and iso-paraffins. These reformates
are a premium blending stock for producing high octane gasoline.
1. The liquid feed (at the bottom left in the diagram) is pumped up to the reaction pressure (5 to
45 atm) and is joined by a stream of hydrogen-rich recycle gas.
2. The resulting liquid-gas mixture is preheated by flowing through a heat exchanger. The
preheated feed mixture is then totally vaporized and heated to the reaction temperature (495
to 520 °C) before the vaporized reactants enter the first reactor.
3. As the vaporized reactants flow through the fixed bed of catalyst in the reactor, the major
reaction is the dehydrogenation of naphthenes to aromatics) which is highly endothermic and
results in a large temperature decrease between the inlet and outlet of the reactor.
4. To maintain the required reaction temperature and the rate of reaction, the vaporized stream is
reheated in the second fired heater before it flows through the second reactor. The
temperature again decreases across the second reactor and the vaporized stream must again be
reheated in the third fired heater before it flows through the third reactor.
Usually, three reactors are all that is required to provide the desired performance of the Continuous
Catalytic Reforming Unit, but, Some installations use three separate fired heaters as shown in the above
schematic diagram and some installations use a single fired heater with three separate heating coils.
5. Fluid Catalytic Cracking Unit- Fluid catalytic cracking unit is one of the most important
conversions processes used in oil refinery process. The purpose of FCC unit is to transfer heavy
crude oil into light oil. Under the action of heat and catalyst, upgrades the heavier, higher-boiling
fractions from the crude oil distillation by converting them into lighter and lower boiling, more
valuable products like cracking gas, gasoline and diesel oil.
1. Many products includes ethylene, petrol, diesel, Heavy diesel, slurry oil… etc. could be obtained
by using FCC.
2. FCC has a high catalytic efficiency.
3. One of the main methods of secondary processing of oil, in the role of high temperature and
catalyst to make heavy oil cracking reaction, into crack gas, gasoline, and diesel.
The advantage of FCC is that the subsequent reaction is provided by hot regenerative catalyst to
reduce energy consumption and great economic benefits.
6. Isomerization Unit- converts linear molecules such as normal pentane into higher-octane
branched molecules for blending into the end-product gasoline. Also used to convert linear
normal butane into isobutane for use in the alkylation unit.
1. a key equipment in producing clean gasoline

2. an important method for oil refinery factory to increase light fraction octane number.
6. Sulfur recovery unit- A widely used to recover sulfur-containing, poisonous acidic gas in oil refinery
process. The most commonly used process in sulfur recovery practice is Claus Process, which is to burn
the incoming gas with oxygen, refrigerate the burnt gas and recover sulfur from the burnt gas.
SRU converts sulfur gas such as H2S into elemental sulfur, so as to convert waste into treasure and
protect the environment.
1. Separate sulfur from sulfur-containing oil

2. Recover the wasted material efficiently
3. This unit can reach rather high sulfur purity
The advantage of SRU is that it reduce the pollution of refineries greatly. It also turns hydrogen
sulfide (H2S) into useful material, reduce power consumption which can bring huge economic
benefits.
EQUIPMENT PRESENT IN AN OIL REFINERY
1. ROTATING EQUIPMENT -is a term commonly used in the oil and gas and process
industries to describe mechanical components that transport fluids, gases, and other process
materials using kinetic energy.
A. TURBINES
1. Gas Turbines - A gas turbine is a type of power plant that uses a combustion
engine to convert natural gas or other liquid fuels into mechanical energy. This
energy is then used to power a generator, which generates the electrical energy
that is ultimately distributed to homes and businesses via power lines.
“Gas Turbine”
Gas Turbine Parts
2. STEAM TURBINES - A steam turbine is a machine that uses steam to extract

thermal energy and converts it to mechanical work on a spinning output shaft.
B. COMPRESSORS
1. Reciprocating Air Compressor - A reciprocating air compressor is a positive
displacement air compressor that suctions air into a chamber and compresses it
with the help of a reciprocating piston. A reciprocating compressor's basic
operation is similar to that of a crankshaft piston. After going through an air filter
and a suction valve, air enters the compressing cylinder. After that, the air is
compressed by a crankshaft and a piston before exiting through a discharge valve.
After that, the compressed air is kept in a storage tank.
2. Centrifugal Compressor - Increase the kinetic energy of the gas with a high-
speed impeller and then convert this energy into increased pressure in a divergent
outlet passage called the diffuser. Centrifugal compressors are particularly suited
for compressing large volumes of gas to moderate pressures.
3. Gas Compressor - Refineries use a compressor type that is specific to the

functions and needs of the oil and gas industry: the gas compressor, for a variety
of processes. Gas compressors pressurize gases in the same way as air
compressors pressurize air by reducing its volume. Incoming gas sources are
pressured in a compression chamber and then discharged for various uses inside a
gas compressor. Hydrocracking, hydrotreating, diesel and gas desulfurization,
catalytic reforming, and other processes all use gas compressors..
Reciprocating Gas Compressor
4. Rotary Screw Compressor - For processes like hydrotreating, catalytic and

steam reforming, rotary screw compressors provide the necessary air power. In a
rotary compressor, air gets pressurized along the threads of a screw within an
airtight chamber. The air then goes on to power various industrial processes,
which could include any number of medium-powered machines at an oil or gas
refinery.
C. PUMPS - A pump moves or flows liquid, but it does not create pressure. It generates
the flow required for the creation of pressure, which is a function of fluid flow resistance in the
system.
1. Centrifugal Pumps - are used to transport fluids by the conversion of rotational

kinetic energy to the hydrodynamic energy of the fluid flow. The rotational
energy typically comes from an engine or electric motor. They are a sub-class of
dynamic axisymmetric work-absorbing turbomachinery. The fluid enters the
pump impeller along or near to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser or volute chamber (casing),
from which it exits.
2. Reciprocating Plunger Pumps - In the oil and gas business, plunger pumps are some
of the most common industrial pumps. Plunger pumps pressurize fluid in an enclosed cylinder to
a pipe system using the reciprocating motion of plungers and pistons. Plunger pumps are known
as constant flow pumps because the flow rate remains constant regardless of the system pressure
at any given speed.
3. Progressive Cavity Pumps - A progressing cavity pump excels when handling highly
viscous fluids which are required to be moved long distances (discharge pressure up to 48 bar).
They are commonly found in waste water applications for moving viscous slurry and sludge
containing softer-type solids.
4. Diaphragm pumps - A diaphragm pump is a specific type of displacement pump that

uses two flexible membranes. The membranes are connected by a central shaft, and create a
separation between the compressed air and the fluid. A centrally located air valve alternately
pushes one of the membranes to the side. As a result, one membrane expels fluid, while
membrane number two draws new fluid in. The suction is the result of a partial vacuum that is
created when the air behind the membrane is pushed into the atmosphere; when the vacuum
occurs, atmospheric pressure pushes the liquid into the empty room. In the next stroke, the
process is reversed: one membrane pushes liquid out of the filled chamber, while the empty
chamber is filled with the help of atmospheric pressure.
5. Gear Pumps - A Gear pumps are commonly used for pumping high viscosity fluids
such as oil, paints, resins or foodstuffs. They are preferred in any application where accurate
dosing or high pressure output is required. The output of a gear pump is not greatly affected by
pressure so they also tend to be preferred in any situation where the supply is irregular.
6. Metering pumps - A metering pump moves a precise volume of liquid in a

specified time period providing an accurate flow rate. Delivery of fluids in precise adjustable
flow rates is sometimes called metering. The term “metering pump” is based on the application
or use rather than the exact kind of pump used. Most metering pumps are simplex reciprocating
pumps with a packed plunger or diaphragm liquid end.
D. BLOWERS
1. Positive Displacement Blowers - A positive displacement blower is a machine

that uses rotary lobes or reciprocating pistons to move gas or air for various
applications.
2. Centrifugal Blowers - Centrifugal blowers are commonly used for dust control,
combustion air supply, cooling, drying systems, fluid bed aerators with air
conveyor systems, and other applications.
3. Multistage Centrifugal Blowers - Multistage centrifugal blowers are rotating
machines that use centrifugal force, which is generally conveyed by an electric
motor, to increase the pressure of air or gasses.
4. High-Speed Blowers - High-pressure blowers, also known as forced draft high-

pressure fans, are the preferred design for continuous duty industrial applications
with modest airflow and high static pressure. They can manage abrasive, sticky,
and heated airstreams, as well as clean air, light particles, or vapor.
5. Regenerative Blowers - It's great for moving a lot of air at low pressures or
vacuums. They pressurize air by a nonpositive displacement mechanism, unlike
positive displacement compressors and vacuum pumps. Large amounts of air can
be moved at low pressures or vacuums using regenerative blowers.
E. AGITATORS
1. Turbine Agitator - Turbine agitators are extremely adaptable; they can handle a wide
range of mixing operations due to their ability to induce turbulent fluid movement
through a combination of rotational and centrifugal action. They are widely employed in
the metal extraction industry as well as chemical reactions, and they have a high
blending efficiency. Chemical, pharmaceutical, grease, and cosmetics industries use
them the most.
2. Paddle Agitators - This agitator is particularly useful for viscous materials. These are
commonly used in the food, chemical, pharmaceutical, and sorbitol industries, among
others.
3. Anchor Agitators - The impeller's shape is similar to that of an anchor, as the name
suggests. These agitators also stretch and disseminate throughout the tank, leaving little
space between the blades and the vessel's walls. When laminar flow conditions are
desired, these agitators are also used. Because the blades are virtually in physical contact
with the vessel walls, these impellers sweep the whole batch. Ink, paint, and glue
industries use these agitators.
4. Propeller Agitators - They're generally used to stir liquids with a low viscosity. They're
used in the pharmaceutical industry, as well as other businesses that work with
suspensions, because the agitators prevent solid particles from settling.
5. Helical Agitators - It is used in polymer industries and other industries which require
the use of quite viscous materials.
F. SLIDE VALVES
1. D-SLIDE VALVE - A D-slide valve's function is to release steam from the

cylinder at the proper moment.
2. BALANCED SLIDE VALVE- The balancing rod is located on each side of the
balanced slide valve. As a result, the forces pushing on the valve are balanced by
relieving pressure on the back of the valve, resulting in less friction and wear than
in a typical slide valve.
G. SOOT BLOWERS
1. ROTARY SOOT BLOWERS rotary soot blowers (RSB) - can be used to clean
convection surfaces, heat exchangers with slight contamination. The blowing
tube/element of this sootblower remains in the boiler at all times and is supported
by element bearings that are usually attached to the boiler tubes.
2. LONG RETRACTABLE SOOT BLOWERS (LRSB) - The purpose of the

Long Retractable Soot Blower (LRSB) is to remove soot that has accumulated on
coils or tubes in a high-temperature zone (e.g. Superheater Coils). LRBS is parked
outside the Boiler to prevent the Lance Element from drooping due to the high
temperature of the Flue Gases. Cleaning efficiency is improved by using Ventury
Nozzles on the lancing element. LRSB offers an IBR-certified Poppet Valve.
A. Heat Exchangers - A heat exchanger is a piece of industrial machinery that has been specifically
developed to transfer thermal energy between two media. A barrier may or may not exist between
the two fluids in contact.
Types of Heat Exchangers

● Shell and Tube Exchangers - A shell and tube heat exchanger is made up of tubes
contained in a pressurized outer shell. To facilitate heat exchange, one fluid (usually from
the hot process) is sent through the smaller tubes, while the other is channeled through
the outer shell.
● Plate Heat Exchangers - The plate heat exchanger is a specialized design that can
transfer heat between medium and low-pressure fluids. Heat exchangers that are welded,
semi-welded, or brazed are utilized for heat transfer between high-pressure fluids or
where a more compact product is required.
● Plate-Shell Heat Exchanger - The Plate-Shell Heat Exchanger is a fully welded heat
exchanger that combines the advantages of both shell and tube and plate heat exchanger.
This involves inserting a fully welded plate pack into the shell, which distributes load and
removes the need for gaskets.
B. Distillation Towers - The atmospheric distillation tower's main function is to separate crude oil
into its elements (or distillation cuts, distillation fractions) for further processing by other
processing units. The capacity limit for an entire refinery is normally set through atmospheric
distillation.
● Tray Towers - Tray towers are used to provide liquid delay so that the distillation
process can accomplish the correct vapor-liquid mass transfer required for separation.
● Bubble Cap Towers - In petroleum refineries, Bubble Cap Tray columns are often used.
Steam escapes through the bubble cap's bottom openings. The steam bubbles through the
liquid, which is kept from leaking down to the lower floors by the bells, through the holes
in the edge of the bell.
C. Refinery Furnace - One of the most significant pieces of equipment in a refinery processing
facility is the refinery furnace. The firing of refinery heaters generates a significant portion of the
process's heat. The process requires heat, which is provided by the combustion of fuels.
● Vacuum Furnace - In every refinery, the vacuum furnace is one of the most significant
heaters. Due to the heavier crudes being processed in recent years, vacuum units have
become more critical. Refiners are also being forced to convert to heavier crudes due to
the pricing gap in crudes. As a result of this development, vacuum heaters are becoming
overheated.
D. Coke Drum - The coke drum is a vessel in the coker facility that collects pet coke as the cracking
process takes place. Cokers uses a semi-batch technique to fill numerous drums simultaneously.
When a drum is full, it is removed from service, cooled, and the coke is emptied.
E. Storage Tanks - Throughout the oil industry, storage tanks are utilized for the bulk containment
of fluids at various stages of the refinery process. Products are frequently held for a brief period
of time before being transported for further processing.
COMMON CAUSE OF UNIT SHUTDOWN IN AN OIL REFINERY
Shutdowns can occur when a refinery lacks affordable natural gas, which is required for
the refining process. Shutdowns might also occur as a result of very high crude oil prices.
Accidents and natural calamities can also cause refineries to shut down.
Here are some of the most typical reasons for oil refinery shutdowns:
1. Pump Failure - Pump failure can be caused by several issues, including but not limited
to:
a. Pressure: Pump cavitation can be caused by limits in the pump's suction.
Undersized suction lines, clogged suction strainers, and valve difficulties are the
most common culprits.
b. Cavitation: Bubbles form and collapse on impellers and interior surfaces when
liquid pressure falls below vapour pressure, damaging pump internals,
interrupting flow, and causing seal failure.
c. Temperature: A clogged discharge can cause fluid stagnation, resulting in a
temperature increase.
d. Leakage: Mechanical breakdowns can result in catastrophic leaks.
e. Vibration: There are several causes of vibration that might damage seals or
internals, leading to pump failure.
f. Installation: Improper installation might result in shaft misalignment and
excessive vibration, which can harm the pump.
2. Compressor Failure –
a. Slugging: is a short-term return of a bulk of liquid, either refrigerant or oil, or a
combination of the two.
b. Flood back/ Flooded Starts: instead of all super-heated vapor, is the continual
return of liquid refrigerant as droplets in the suction vapor.
c. Loss or Lack of Lubrication: not enough oil in the crankcase can cause engine
failure
d. Contamination: Any "dirt" that enters a system by accident or by improper
servicing practices, such as air, moisture, non-condensable, chips, oxides, scale,
brazing, or soldering flux, is a contaminant that will cause certain and rapid
failure.
e. Overheating:
f. Electrical Problems
3. Steam Engine Overheating –
a. A leak in your cooling system: One of the most common causes of coolant leaks
is corrosion within the radiator.
b. Dirty radiator: Poor coolant circulation, poor performance, overheating, and even
steam engine failure are all possible outcomes.
c. Low coolant levels: can sometimes cause a head gasket on your engine block to
blow.
d. Malfunctioning thermostat
e. Malfunctioning water pump
f. Bad hose
COMMON REPAIR OF EQUIPMENT PRESENT IN AN OIL REFINERY

1. During pump failure – show the parts needed to recondition / replace and discuss the steps on
how to repair the pump
2. During compressor failure - show the parts needed to recondition / replace (focus on
compressor valves and show the detailed parts of compressor valves) and discuss the steps on
how to repair/recondition the compressor valves
OBJECTIVE
The objective of this study is to :

1. figure out the part that causes problems or something that
needs manual repairs or cleaning.
2. Figure out a way to shorten the time required to fix it
3. Make a tool or a procedure to shorten the time it takes to
finish the task.
SCOPE AND DELIMITATION

This study will focus on how to shorten the time required to do certain manual labor tasks
and will not include mixing new chemicals or tampering with essential equipment in the refinery
unless that part is the one causing the most time fixing or maintaining
SIGNIFICANCE OF THE STUDY

1. Community- The community could benefit with a more consistent oil output in our local
refinery
2. Government- The government can benefit with lower reliance on overseas oil imports if the
product made a significant change in the amount of time a powerplant is in maintenance.
3. Future Researchers- They can further improve the product or study the problems that was
fixed by our product and the ones that it can’t fix
CHAPTER II
REFINERIES IN THE PHILIPPINES AND ITS EQUIPMENTS
PETROLEUM REFINERY IN THE PHILIPPINES

There were two petroleum refineries in the Philippines until August 2020, when Pilipinas
Shell decided to close their refinery due to low oil demand in our country, resulting in huge
monthly losses. "It is no longer economically viable for us to run the refinery due to the impact
of the COVID-19 pandemic on the global, regional, and local economies, as well as the oil
supply-demand imbalance in the region," Pilipinas Shell President and Chief Executive Officer
Cesar Romero said in a statement. Now, Philippines Shell has decided to convert its factory into
a "world-class full import terminal," where processed fuel products will be processed and stored
before being distributed to retail stations.
After Shells pullout, we are left with one local refinery in business: Petron refinery in
Limay Bataan. The Petron refinery in Limay, Bataan is the largest refinery in Bataan, it can
produce 180,000 Barrels per day which is 26.36% of the circulating oil in our local market.
Petron corporation’s business is refining crude oil and marketing refined petroleum products
which includes: gasoline,LPG, Diesel, Jet fuel, Kerosene, and Petrochemicals. Petron
Corporation also have a factory located in manila where they produce lubricants and grease.
Petron's history in the Philippines began in 1957, when Stanvac built a refinery in Limay,
Bataan, to meet the country's fuel requirements. It had a refining capacity of 25,000 barrels of
crude oil per day when it first opened in 1961. This was the most advanced refining facility in
Southeast Asia at the time. The partnership between Standard Oil and Socony Vacuums ended in
1962, and Esso Philippines was born. Even after the split, Esso extra launched the first bottled
LPG, Esso Gassul, as well as the first high-octane gasoline, Esso Gassul. At the height of the
first oil crisis in 1973, the Philippine National Oil Company (PNOC) purchased Esso Philippines
and renamed it Petrophil Corporation.and in 1988, petrophil was renamed to Petron
Corporation.In 2009, San Miguel Corporation (SMC) started managing Petron. Having been in
the beverage, food, and packaging industries for over 120 years, SMC is one of the biggest
global conglomerates in the country today. In recent years, it has diversified into industries such
as power, mining, toll ways, and airports.
Gas compressors present in an oil refinery

- Throughout the refinery, centrifugal compressors move gas from low-pressure areas
to higher-pressure areas within the various plants. Compressor selection is based on
the requirements for flow, range, pressure ratio, and specification. The specification
used for refineries is API 617, ‘Axial and Centrifugal Compressor and Expander-
Compressors’ for main chemical processes
Types of compressors in an oil refinery.
1. Hydrogen recycle compressors- Their main purpose is to move feedstock through a
reactor, then separators, then recycle the gas, which is mostly hydrogen plus any remaining
hydrocarbon vapours (usually heavy, high molecular weight vapours) through the
compressor and back to the process loop. The hydrogen consumed in the process is replaced
by a make-up gas or reciprocating compressor.
2. Wet gas compressors- The purpose of this equipment is to increase the power output of a
gas turbine by reducing compressor inlet temperatures, intercooling the air mass flow
within the compressor and hence an increasing mass flow throughout the turbine
3. Main air blower- The main air blower (MAB) in an FCCU provides air (containing
oxygen) necessary for combustion to burn coke away from catalyst in the regenerator. The
rate of supplied air must match the rate that coke is created. The blower can be a large
centrifugal compressor or an axial compressor for increased efficiency.
Types of compressor valves

Now, all compressors uses different kinds of compressor valves which controls the pressure flow
of a reciprocating compressor cylinder. There are three types of compressor valve which varies
in specifications depending on its function.
1.Plate valves- This valve is designed to withstand high pressure and dirty gas applications.
Because plate valves are used in dirty gas applications, the valve disc must be resistant to any
particles contained in these gases.
2.Radiused Disc Valves- Radiused disc valves are best for situations where temperatures are
over 390°F/ 200°C and pressure levels are over 6000 psi/400 bar. They are also useful for sour
gas applications. Radiused discs are comprised of concentric rings, and they are made out of
thermoplastics
3.High Flow Valves- High-flow valves are best for situations when liquids and other types of
debris are present in the gas that is being used. The disc rings are fashioned in a special V-shape
that improves gas flow.
Problems and repairs/reconditioning for industrial valves
How to Know It’s Time to Repair Valves

1. When there is internal leaking
2. When there is external leaking
3. When the valve becomes noisy
4. When the valve is no longer working
The Common Causes of Industrial Valve Failures

1. Improper Valve Size- The wrong valve size calculation can lead to either undersized or
oversized valves. This is important because the flow of media depends on the size of the
valve. An oversized one can decrease the pressure whereas an undersized valve can
cause bottlenecks
Solution:
Find an online valve sizing calculator. There are different formulas for liquids as
well as for gases. If manual calculation is too tedious, an online one will just do
the trick
2. Material Incompatibility- The media type, the seat material and the material of the
valve body should match. Incompatibility means that the valve is more prone to wear
and tear.
Solution
Check the product description for the type of material used for the valve seat and
3 body. These should follow the industry standards as to what media to use.
3. Elastomer Damage-Elastomers are often used as valve seats, gaskets or O-rings which
act as a seal. Because they are elastic, they are the natural choice for sealing applications
Solution
Consider the compatibility of the elastomer and the media. Check the product
description on what types of media to use with elastomers
4. Valve Stem Wear- The valve stem packing and gland bolts, for example, are smaller
components that cause wear and tear on the stem. The constant movement of the valve disc,
as well as the contact with the corrosive, all contribute to the stem's wear and tear.
Solution
For the smaller valves, the only solution is to replace them after all, they are readily
available. However, for larger valves, replacement is not cost-effective. The best solution is
to upgrade the current valve.
5 Cavitation- Cavitation often occurs in control valves with liquid media. Two factors that
contribute to cavitation are fluid velocity and pressure drop. Cavitation happens when there
is a change in the pressure levels and velocity of the fluid
Solution
Make sure that the application is using the right valve. If it is a wrong style or size, there is a
greater chance of cavitation. Use anti-cavitation valves for water and liquid applications. If
using control valves, place them in areas where the valve has a lower orientation in relation
to the pipes
6.Water Hammer- Water hammer is the condition where there are abrupt pressure spikes in
the valve. It is one of the most destructive forces that can wreak havoc to the valve body.
Three factors create water hammer: how fast the valve closes, how fast the liquid is the
moment the valve closes and what the pressure wave along the pipe is.
Solution
Use a throttling valve to minimize water hammer. Also, utilize a fast acting on/off valve such as
the butterfly valve. A slow acting one is also suitable as this reduces water hammer pressures.
Instead of manually opening and closing the valve, use a hydraulic actuator to allow faster
opening and closing.
7.Pressure and Temperature Exceeding the Required Parameters- Valves have specific
pressure and temperature requirements. Going beyond what the valve can withstand can
damage it.
Solution
Before installation, check the product requirements to ensure that no pressure and temperature
upsurge happens. Routine maintenance and repairs are important. Replace damaged parts due to
increased temperature and pressure damage.
.8. Faulty Actuator- Actuators come in three forms: manual, powered or automatic. Actuators
manage the entry and exit of media and the flow of media, pressure, and temperature. That being
said, choosing the wrong actuator shortens the life of the valve because the valve wears out
easily.
Solution
Strong input from the actuator can actually damage the valve stem and disc when the valve
positions to close or open. If the media is slow-moving, choose actuators that suit this. If to avoid
the loss of pressure, choose an actuator that can easily open or close.
To know whether the valve is damaged or it is just the actuator that is acting weird, turn on the
manual override. It the valve seems ok, the actuator is damaged.
If the valve doesn’t move, the problem is the actuator. Additionally, check the valve stem for any
damage. A worn-out valve stem affects how the actuator moves.
Installing its sensitive components should be far from the actuator when there is high pressure or
the possibility of high vibrations. This is to protect the sensitive parts from damage.
9. Incorrect Installation- Some valves are easier to install than others. Sadly, many cases of
valve failures come from incorrect valve installation. Take for example the installation of swing
check valves. Some people have been installing them in the wrong orientation. There are
symbols to follow for easier installation.
Solution
Most valves are installed in an upright position unless specified. Make sure that the person
installing the valve has enough skills and training to properly perform the task.
10. Debris- Thicker particles such as in slurries cause abrasions on the seat. These can get stuck
in the valves, making the valve remain open or closed. Additionally, debris, when it hardens in
the valve, can potentially cause the valve components to break.
Solution
Regular maintenance and valve cleaning are important. These remove debris and prevent the
debris to harden and further damage the valve
11. Incorrect Maintenance and Repair- Incorrect repair and maintenance are not only
damaging, but it is also costly and time-consuming.
Solution
Make sure that the valve orientation is correct. Use the guides in the valve body that can help in
the proper installation of the valve. Make sure that directions are followed as to the valve
orientation.
Chapter III
PROCESS
REFERENCES:
A. (n.d.). What is pump failure? What Is Pump Failure? Retrieved March 30, 2022, from
https://www.globalpumps.com.au/blog/what-is-pump-failure#:%7E:text=Pump%20failure
%20can%20be%20caused,suction%20strainer%20or%20valve%20issues. B.
Refrigeration Compressor Failure: Cause & Cure – Part 1 | Industrial Controls. (n.d.).
Compressor Failure. Retrieved March 30, 2022, from
https://www.industrialcontrolsonline.com/training/online/refrigeration-compressor-failure-
cause-cure-%E2%80%93-part-1
Midstream Oil and Gas, Production Storage & Measurement (June 25, 2019)
https://ifsolutions.com/types-of-pumps-in-oil-and-gas-industry/ (February 16, 2020 ) “How
Reciprocating Compressors Are Used in Refineries”
https://www.quincycompressor.com/how-reciprocating-compressors-are-used-in-refineries/
https://www.hydrocarbons-technology.com/projects/petron-bataan-refinery-philippines/?
fbclid=IwAR2UhSWIOXgKsXEZ51OGAhVQ0IV3GP-
KGxOMjUBxOEPwSWjHuD7WtvtAQLY
https://www.sciencephoto.com/media/339822/view/atmospheric-pipestill-at-an-oil-refinery?
fbclid=IwAR1dJ_oE0zn8jttredJK9pXq2WjqlCXvyOXC0Jzmo7ICXq2R_i4tyYBkc-k
Our History - Petron
Pilipinas Shell shuts down oil refinery in Batangas (cnnphilippines.com)
Catalytic Reforming | SIE NEFTEHIM, LLC (nefthim.com)
CONTINUOUS CATALYTIC REGENERATION (CCR) | Energy Efficiency Guidelines in
Refinery - Ebooks Terminal - Notes, Thesis, Articles, Calculation, Design, Method
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Continuous Catalytic Reforming (CCR) (chromalox.com)
Catalytic Reforming (maveng.com)
Process Work of a Naphtha Hydrotreating Unit - Proses Industri
Atmospheric Distillation - an overview | ScienceDirect Topics
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https://www.bing.com/search?q=chevron+philippines+Inc.
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Saving an oil refinery | Philstar.com
Company Information (pse.com.ph)
High And Low Temperatures. When To Use Stainless Steel? - Blog Inox mare En

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REPUBLIC OF THE PHILIPPINES

BATAAN HEROES MEMORIAL COLLEGE

HISTORY OF PETROLEUM REFINERY

PETROLEUM REFINERY IN THE PHILIPPINES

PETROLEUM PRODUCT PROCESS FLOW

GENERAL PETROLEUM PLANT LAYOUT

UNITS INVOLVED IN AN OIL REFINERY (LAGAY NINYO LAHAT NG MARERESEARCH)

Here is a reaction process that occurs in the reactor:

Product from the reactor is cooled through heat exchanger

4. Continuous Catalytic Reforming Unit (CCRU)- Catalytic Reforming is a process in which

1. a key equipment in producing clean gasoline

1. Separate sulfur from sulfur-containing oil

EQUIPMENT PRESENT IN AN OIL REFINERY

Gas Turbine Parts

2. STEAM TURBINES - A steam turbine is a machine that uses steam to extract

3. Gas Compressor - Refineries use a compressor type that is specific to the

Reciprocating Gas Compressor

4. Rotary Screw Compressor - For processes like hydrotreating, catalytic and

1. Centrifugal Pumps - are used to transport fluids by the conversion of rotational

4. Diaphragm pumps - A diaphragm pump is a specific type of displacement pump that

6. Metering pumps - A metering pump moves a precise volume of liquid in a

1. Positive Displacement Blowers - A positive displacement blower is a machine

4. High-Speed Blowers - High-pressure blowers, also known as forced draft high-

1. D-SLIDE VALVE - A D-slide valve's function is to release steam from the

2. LONG RETRACTABLE SOOT BLOWERS (LRSB) - The purpose of the

Types of Heat Exchangers

COMMON CAUSE OF UNIT SHUTDOWN IN AN OIL REFINERY

COMMON REPAIR OF EQUIPMENT PRESENT IN AN OIL REFINERY

The objective of this study is to :

SCOPE AND DELIMITATION

SIGNIFICANCE OF THE STUDY

PETROLEUM REFINERY IN THE PHILIPPINES

Gas compressors present in an oil refinery

Types of compressor valves

Problems and repairs/reconditioning for industrial valves

How to Know It’s Time to Repair Valves

The Common Causes of Industrial Valve Failures

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