ETP Manual

Document No: PDR/PN/ETP/OM
Operating Manual for Issue Date Rev. No. Rev. Date
Indian Oil ETP August, 2012 7 Jan, 2022

Paradip Refinery
2022
Operating Manual
Effluent
Treatment
Plant
INDIAN OIL CORPORATION LTD.

PARADIP REFINERY

Paradip Refinery
ARADEEP REFINERY
IndianOil
Paradip Refinery
Effluent Treatment Plant
Operating Manual
 January, 2022 


Paradip Refinery
The Energy Gateway to Eastern India...


Paradip Refinery
Indian Oil
Paradip Refinery
ETP Unit
Document No
PDR/PN/ETP/OM -01
Copy No.
4/5
Department: PRODUCTION Type Controlled/Uncontrolled
Disaster Control
Section : ETP ( U-0230 ) Issued To.
Room
Information available inside this Manual may be used by all authorized personnel.
Responsibility for the documents, however, shall remain with the copy holder to
whom it is issued.
Prepared By Checked By Approved By
BHARAT BHUSHAN
T BHATTACHARJEE SANDEEP MAHAJAN
CPNM
SPNM
DGM-PN
Paradip Refinery
The Energy Gateway to Eastern India…

Paradip Refinery
Revision History
Revision
Date Description Approved By
No.
0 August, 2012 First Issue DGM-PN
1 August, 2015 First Revision DGM-PN
2 July, 2017 Second Revision DGM-PN
3 August, 2018 Third Revision DGM-PN
4 January, 2020 Fourth Revision DGM-PN
5 April, 2020 Fifth Revision DGM-PN
6 January, 2021 Sixth Revision DGM-PN
7 January, 2022 Seventh Revision DGM-PN

Paradip Refinery
Operating Manual Distribution List
Copy No. Distributed To Department

Production
1/5 HOD - DGM
2/5 Unit In-Charge ETP

Production
3/5 Shift Officer ETP

Production
4/5 Disaster Control Room
5/5 PDR Intranet PN Website
Prepared by Reviewed By Approved By
T Bhattacharjee, SPNM Bharat Bhushan, CPNM Sandeep Mahajan, DGM-PN

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AMENDMENT LIST
Amendment Revision Brief Description Of

Date Document No Approved by
No. No. Amendment
Emergency SOP and

PDR/PRODN/ETP/O
01 10.04.2020 05 Updated Work DGM-PN (HOD)
PERATING MANUAL
Permit System
VOC operating
PDR/PRODN/VOC/O
02 24.12.2021 07 manual DGM-PN (HOD)
PERATING MANUAL
incorporated
PDR/PRODN/SCTP/ SCTP operating
03 24.12.2021 OPERATING 07 manual DGM-PN (HOD)
MANUAL incorporated
PDR/PRODN/WRP/ WRP operating
04 24.12.2021 OPERATING 07 manual DGM-PN (HOD)
MANUAL incorporated

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TABLE OF CONTENTS
CHAPTER 1: GENERAL Page No.
1.1 Introduction 08
1.2 Plant Capacity 11
1.3 Battery Limit Conditions 21
CHAPTER 2: PROCESS DESCRIPTION

2.0 Effluent treatment section 24
2.1 OWS Water Treatment 24
2.2 Biological Treatment section 30
2.3 Sludge Treatment section 36
2.4 Landfill leachate Treatment plant 40
2.5 Hard COD Treatment plant 40
CHAPTER 3: OPERATING VARIABLES

3.1 Plant Inlet / Outlet Normal Operating parameters 43
Chapter 4: UTILITIES, CHEMICALS & EFFLUENTS

4.1 Chemical 50
4.2 Utilities 50
Chapter 5: PREPARATIONS FOR START UP

5.1 Start- up procedures 55
CHAPTER 6: COMMISSIONING AND START UP PROCEDURES

6.1 Commissioning 58
6.2 Start up 58
CHAPTER 7: NORMAL SHUTDOWN
7.1 Normal shutdown 87

7.2 Partial shutdown 88
7.3 Complete shutdown
88

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CHAPTER 8: EMERGENCY SHUTDOWN AND HANDLING

8.1 Feed Failure 91
8.2 Instrument Air Failure 92
8.3 Power Failure 92
8.4 Steam Failure 92
8.5 Critical Pump Failure 92
8.6 Air Compressor Failure 92
8.7 PLC Failure 93
Chapter 9: PROCESS INTERLOCKS

9.1 Oily water Treatment sub-package 95
9.2 Bio treatment sub-package 95
9.3 Slop oil sub-package 111
9.4 Oily sludge treatment subsystem 127
9.5 Bio sludge treatment subsystem 131
9.6 Landfill leachate treatment package 140
9.7 Hard COD Management package 154
9.8 Chemical dosing section 161
Chapter 10: HAZARDS & SAFETY

10.1 Safety and Hazards 182
Chapter 11: EQUIPMENT LIST 185
Chapter 12: MAJOR EQUIPMENTS AND THEIR OPERATION 194
Chapter 13: MATERIAL SAFETY DATA SHEETS 198
Chapter 14: FIRE FIGHTING AND COMMUNICATION FACILITIES 199
Chapter 15: Consequences due to UPSETS IN OUTGOING B/L STREAMS 202
CHAPTER 16: EQUIPMENT DATA SHEETS 214
CHAPTER 17: EQUIPMENT HANDOVER PROCEDURES 216
CHAPTER 18: SAMPLING, LABORATORY ANALYSIS AND QUALITY CONTROL

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18.1 Sampling schedule 220

18.2 Analytical Procedures for Laboratory 224
18.2.1 Biochemical oxygen demand 224
18.2.2 Dissolved oxygen 227
18.2.3 Total suspended solids 229
18.2.4 Volatile solids 230
18.2.5 Sludge volume Index 232
18.2.6 Chemical oxygen demand 233
18.2.7 pH 235
18.2.8 Oil and Grease 236
18.2.9 Ammonia 238
CHAPTER 19: PLANT PERFORMANCE MONITORING

19.1 Oily water Treatment section 243
19.2 Biological Treatment section 247
19.3 Oily sludge Treatment section 252
19.4 Bio Treatment section 253
19.5 Landfill leachate Treatment section 254

19.6 Hard COD Management section 256
CHAPTER 20: INSPECTION REQUIREMENTS

20.0 Inspection Requirements 258
CHAPTER 21: DCS, PLC AND ONLINE ANALYZERS

20.0 DCS, PLC and Online Analysers 261
20.1 List of Online Analysers 262
CHAPTER 22: UTILITY AND AUXILIARY NETWORKS

12.1 Utility Networks 265
CHAPTER 23: STANDING INSTRUCTIONS FOR SAFER OPERATION

23.1 Introduction 270
23.2 Potential Hazards 271
23.3 Employee Training 277
23.4 Protection Devices 278
23.5 First Aid 278

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CHAPTER 24: WORK PERMIT SYSTEMS

24.0 Work Permit systems 283
24.1 Accident Reporting Procedures 284
CHAPTER 25: STANDING INSTRUCTIONS 286
CHAPTER 26: ATTACHMENTS 296
A. PROCESS FLOW DIAGRAMS

B. PIPING AND INSTRUMENTATION DIAGRAMS

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PURPOSE OF THE MANUAL
The operating instructions laid down in this manual assist the operating staff for smooth and
trouble-free operation of ETP. The various sections enclosed in this manual give sufficient and
required information about the ETP facilities for understanding the operation of the plant.
The characteristics of raw and treated effluent, treatment methodology, treatment facilities,
process description etc. are given in the first few sections of this manual.
The detailed operation and maintenance procedure for each individual equipment / unit
along with the routine start-up, normal operation and shut down procedures trouble shooting
and safety are described in the subsequent sections of this manual. The manual also includes
the analytical procedures required to assess the quality of raw and treated effluent in the
laboratory and safety aspects required in plant operation.
This manual help the operating staff to operate and sustain the performance of the ETP
efficiently, meeting the statutory limits for further use. This manual is to be read, in
conjunction with the documents referred in the respective chapters.
The manual is addressed to technicians with previous experience in plant operating and
provides a general idea about the process and specific information about the operation and
maintenance. The manual contains certain specific information and is to be treated
confidentially.
It must be noted that improper operation of the ETP unit and handling of the equipment and
related components will deem invalidation of the guarantees.
The manual does not cover the operation and maintenance instructions of WRP, Spent caustic
and VOC abatement Packages.

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CHAPTER-1
GENERAL

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1.1 INTRODUCTION
The Project ‘Paradip Refinery Project’ is to install an integrated grassroots 15 MMTPA (300,000
BPSD) refinery and petrochemical complex, as ‘Phase 1’ of the development at a site located 5
km south of the Port of Paradip in the state of Orissa, on the northern part of the east coast of
India. The Paradip Refinery Project facilities process imported crude oil and produces refined
products and polymers for domestic use and export.
The Refinery is comprised of the following Units ;Atmospheric Vacuum Distillation, Naphtha
Hydrotreaters, CCR Reformer, LPG Treating, ATF Treater, Diesel Hydrotreater, VGO Hydrotreater,
Fluid Catalytic Cracker, Propylene Recovery, Delayed Coker, Alkylation, Hydrogen Generation,
Amine, Sour Water Stripper, Sulphur Recovery, Spent Acid Regeneration, Flue Gas
Desulphurisation, FCC Light Naphtha Treatment, FCC LPG Treatment, Straight Run LPG
Treatment, Utilities, Offsites.
The primary function of the Effluent Treatment Plant hereafter referred as ETP is to render
refinery effluent safe for onward processing within the Water Recovery Plant hereafter referred
as WRP to maximize the reuse of water within the processes, and to ensure that any effluents
discharged to the environment are compliant with regulatory requirements.
The following refinery site effluents will be delivered to the Effluent Treatment Plant (ETP) &
Water Recovery Plant (WRP) via segregated headers as follows:
 Oily water and contaminated rain water;

 Desalter water, brine from crude tank farm and FGD effluent;
 Stripped sour water;
 Cooling tower blow down and side-stream filter backwash;
 Coke Pile surface water run-off;
 Sulphidic and naphthenic spent caustic;
 Landfill site leachate, incinerator quench and caustic;
 Sanitary wastewater
 De-mineralized Unit rejects.
 Steam system blow down
Scope of the Project
The Paradip Refinery Project will be executed in 3 stages, namely:
 Phase I Stage I

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 Phase I Stage II
 Phase II (Future Plan)
The ETP & WRP will be constructed in phases to match the expansion of the refinery as follows
Phase I Stage I:
Design - Phase I Stage I + Phase I Stage II

Construction - Only Phase I Stage I
ETP is constructed for the case without deferred units;
- During wet weather, CRWS will be routed to OWTP and BTP and thus to Check Basin.
- During wet weather, a flow equivalent to the CRWS flow will be pumped from the
Check Basin to the storm water Reservoir.
- WRP will be constructed with membrane units to treat the “dry weather flows” +
design margins.
Phase I Stage II:
Design - Included in Phase I Stage I

Construction - Only piling for structures
ETP will be expanded to accommodate flow from the deferred units;
Additional Case with CRWS Routed to WRP – (Included in the design for this contract but not
part of the construction for this contract):
Note: The ETP & WRP shall not be designed to accommodate any flows or pollution loads from
the Phase II (Future Plan) scope.
Sub Packages
The Effluent Treatment package comprises of the following sub packages.
1. Oily Water Treatment Plant sub package.

2. Bio treatment plant sub package.
3. Water recovery plant sub package.

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4. Sludge Thickening & dewatering sub package.

5. Chemical Dosing package.
6. Spent caustic, landfill leachate & COD management sub package.
The general process design margin will be 20% above the sustained maximum process flow.
The overall requirements for the ETP & WRP is summarised as follows:
The ETP shall in general
 receive and equalise spent caustic from the refinery and subject it to treatment in a wet
air oxidation process in order to render it suitable for bio-treatment;
 receive and equalise leachate from the nearby landfill site and quench water from
incinerator and subject it to suitable pre-treatment in order to render it suitable for bio-
treatment;
 receive and equalise quench water from the incinerator and subject it to suitable pre-
treatment in order to render it suitable for bio-treatment;
 receive, equalise and treat the aqueous effluents from the Project such that they are
suitable for transfer to the WRP for recovery and upgrading of treated water;
 produce and equalise bio-treated water;
 deliver bio-treated water into a header for distribution to users in the Paradip Refinery
Project;
 collect and manage internal recycles within the ETP;
 contain slop oil, oily floats and oily sludge;
 return slop oil to the refinery;
 Collect and dewater oily sludge and bio-sludge which are produced within the ETP.
The WRP shall in general
 receive and filter bio-treated water;

 recover and upgrade sufficient bio-treated water for re-use within the Paradip Refinery
Project in order to ensure compliance with the flow limit for the discharge to sea;
 produce and distribute water of a suitable grade which is required within the ETP & WRP
for the make-up of chemicals and Clean In Place (CIP) systems;
 balance recovered and upgraded water flows against demands from the users of
upgraded water and deliver the upgraded water into a header for distribution to users
(primarily the Demineralisation Plant) in the Paradip Refinery Project;
 collect and manage internal recycles within the WRP;
 upgrade the saline reject (RO reject) from the water recovery stage to the quality which
is required for discharge to sea;

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 Deliver the upgraded saline reject into a header which connects into the sea outfall
pipeline.
This manual covers only the Effluent Treatment Plant, Hard COD Management Plant, Landfill
Leachate Treatment Plant and its associated facilities.
1.2 PLANT CAPACITY
The ETP is been primarily designed for the Phase I Stage I flow conditions. ETP configurations for
Phase I Stage II flow conditions have been mentioned. The general process design margin shall
be 20% above the sustained maximum process flow.
1.2.1 OWS WATER TREATMENT
Design Flow for Primary Oil treatment section - API : 1034.0 m3/h
Turndown for Primary Oil treatment section - API : 132.0 m3/hr (1 No API Channel)
Design Flow for Sec. Oil treatment section – DAF : 1275.0 m3/h
Turndown for Sec. Oil treatment section – DAF : 160.0 m3/hr (1 No DAF Unit)
On-stream factor :1
EFFLUENT PARAMETERS UOM VALUES
Total Phase I Stage I Design Flow rate m3/h 1034.0
pH 6.0 - 10.0
Total Oil & Grease mg/l 5006
Total Suspended solids mg/l 1187.4
COD mg/l 696.3
Note: Turndown capacities indicated above are the recommended min. flow rates for the individual
unit up to which it may be operated upon. Operation of the unit shall presume after holding
up of the effluent in the respective equalization tanks, if any lesser than recommended flow
rates are encountered.

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API Separator (Phase I Stage I)
 No. of units : 3 nos

 No. of Channels : 3 nos
 Design flow per unit : 345.0m3/h
 Design Lowest Temperature : 30 OC
 Density of Oil considered : 940 kg/m3
 Total inlet Free Oil : 4172 mg/l
 Design free oil removal efficiency : 95 % of Oil globules > 150 micron
 Design Suspended solids removal efficiency : 60 %
 Globule Rising Velocity : 3.07 m/h
 Vh/Vt Ratio : 15.0
Designed to handle 120 m3 of Total oil in 12 hour’s time in addition to normal/max flow
conditions & 2 tonnes/h of suspended solids.
One No. of API of same capacity shall be added for the Phase I Stage II flow and provision for
the same is specified in the layout.
Tilted Plate Interceptor (Phase I Stage I)

 No. of bays working : 3 Nos.
 Design Lowest Temperature : 30 oC
 Design flow per Bay : 344.64m3/h
 Total inlet Free Oil : 1397.5 mg/l (max load)
 Size of Free Oil considered for removal : 100 micron
 Percentage free oil > 100 micron : 90 %
 Free oil removal efficiency > 100 micron : 98 % (Max Oil)
 Rising rate : 1.36 m/h
 No of Packs/Bay/Channel : 4 nos.
One No. of TPI shall be added for the Phase I Stage II flow and provision for the same is
specified in the layout.
Dissolved Air Floatation (Phase I Stage I)
 Quantity : 4 nos
 Total flow to the DAF system : 1275.0 m3/h

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Paradip Refinery
 Temperature of effluent : 40 oC
 Type of tank : Rectangular
 Design flow per unit : (318.8 + 124) m3/h
 Inlet Emulsified Oil : 680.14 mg/l (max load)
 Design Emulsified oil removal efficiency : > 98.0%
 Air to solid ratio : 0.02
 DAF recycle ratio : 38.90 %
One No. of DAF of same capacity shall be added for the Phase I Stage II flow and provision
for the same is specified in the layout.
Design flow during pumping will be 1280 m3/h.
1.2.2 BIOLOGICAL TREATMENT SECTION
Design Flow of Pretreated Leachate : 49.1 m3/h
Design Flow of Treated Spent caustic : 10.3 m3/h
Design Flow of bio-sludge supernatant : 37.25 m3/h
Total Design Flow rate to Biotower m3/h 1341.4
pH 6.0 - 8.0
Oil & Grease mg/l 14.3
BOD3 mg/l 252.68
COD mg/l 662.0
Total Sulfides mg/l 21.6
Turndown for biological treatment section : NA.
On-stream factor :1
Note: Detailed Operation of biological section during any compromised influent conditions is
described in subsequent sections.

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Biotower (phase I stage I)
 No. of Tanks : 3 nos.

 Flow to each Bio-tower : 896 m3/h
 Recirculation Flow : 100%
 Type of Media : Random Media
 Media Surface area : 100 m2/m3
 Diameter of Bio-tower provided : 25.5 m
 Height of media provided for Phase I Stage I : 5.4 m
 Organic Loading rate : < 1.5 Kg/m3/d
 Volumetric Loading rate : > 25 m3/m2/d
 COD removal Efficiency : 65%
For Phase I Stage II flow only the quantity of media has to be added and hence total height
of the tank is designed for Phase I Stage II flow.
To treated effluent from Bio-tower, the following effluent streams will be added
Design Flow of sanitary effluent : 43.5 m3/h
Design Flow of UF & RGSF backwash : 196 m3/h
Aeration System (phase I stage I)
 Total Design Flow for aeration tank : 1580.6 m3/h

 No. of Aeration tanks : 2 nos.
 Flow to the each tank : 790.3 m3/h
 Inlet BOD : 96.0 ppm.
 Inlet COD : 254.4 ppm
 F/M ratio : 0.101 kg BOD/kg MLSS.d
 Detention period in each aeration tank : ~ 12.0 H
 MLSS : 2000 ppm
 Total volume provided : 18240 m3
 RAS Recirculation ratio : 100%
The provision for expanding the aeration tank during Phase I Stage II flow is provided.

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Secondary Clarifier (Designed to accommodate Phase I Stage II flow)
 No. of Secondary clarifier : 2 nos.

 Flow to the each Clarifier : 790.3 + 792 m3/h
 Overflow rate : 0.9 m3/m2/h
 Solids Loading rate : < 5 kg/m2/h
 Diameter of the clarifier : 37.0 m
No addition of clarifier is required for Phase I Stage II flow as Sec. Clarifier is designed for
Phase I Stage II flows.
Bio -Dissolved Air Floatation
 Type of tank : Circular
 Design flow per unit : (396 + 150) m3/h
 Solids Loading rate : 6.3 Kg/m2/h
 Volumetric Loading rate : 6 m3/m2/h
 Air to solid ratio : >0.015
 Diameter of Bio-DAF : 12.0 m
One No. of Bio-DAF of same capacity shall be added for the Phase I Stage II flow and provision
1.2.3 SLUDGE TREATMENT SECTION:
All Sludge treatment equipment’s & units are designed for Phase I Stage II flow and hence no
addition of units are required for the Phase I Stage II expansion.
Data mentioned below is for Phase I Stage I flow conditions.
Turndown capacity : NA
On-stream factor :1
SLUDGE TREATMENT SECTION – OILY SLUDGE
Oily Sludge Thickener:


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 Design flow rate : 1548.6 m3/d

 Hydraulic Loading rate : 20 m3/m2/d
 Solids Loading rate : 80 Kg/m2/d
 Diameter of the thickener : 23.5 m
 Solids removal efficiency in Thickener : 90%
 Thickened sludge consistency : 4-5 %
Oily Sludge Centrifuge:

 Design flow rate per unit : 30 m3/h
 Quantity of dry solids to be dewatered : 25504.5 Kg/d
 Desired cake consistency : 20 %
 No. of operation hours – Max. Flow : 12 hours.
Oily Sludge Re-slurry System:
 Volume of Re-Slurry Liquid tank : 8 m3

 Consistency of Sludge to be pumped to DCU : Solids < 15%, Oil < 10%
 Viscosity of sludge at which it is pumped : 100 cSt
Wet Slop oil tank:
 No. of tanks : 2 nos

 Nominal Capacity of each Tank : 2189 m3
 Design Basis of capacity : 7 days flow of slop oil on normal
case basis + oil spill cases
SLUDGE TREATMENT SECTION – BIO SLUDGE
Bio Sludge Thickener:

 Design flow rate : 529 m3/d + 275 m3/d (Sludge
dilution)
 Solids Loading rate : 40-50 kg/m2/d

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Bio Sludge Centrifuge:

 Quantity of dry solids to be dewatered : 5254.5 kg/d
 Desired cake consistency : < 18 %
 No. of operation hours – Max. Flow : 12 hours
Sludge Weathering Package:

 Cycle of Operation : 6 Months
 Desired inlet cake consistency : < 18 %
 Desired cake consistency : 50-70 %
One No. of weathering bed of same size shall be added for the Phase I Stage II flow and
provision for the same is specified in the layout.
1.2.4 LANDFILL LEACHATE TREATMENT PLANT

Total design flow to the treatment : 50 m3/h
Designed for Phase I Stage II flow
Turndown capacity : 35 m3/hr
On-stream factor :1
Plate Type Clarifier
 Capacity of Equalisation tank : 1920 m3

 Inlet TSS : 342 ppm
 Outlet TSS : < 10 ppm
 Retention time in Flash Mixer : 60 Sec
 Retention time in Flocculator : 20 Min
 No. of Clarifier units : 1 nos
 Clarifier Mechanism : nil
 Settling rate : 1.25 m3/m2/h
 Sludge Produced : 28.6 m3/d

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 Filter Press Capacity : 4.0 m3/h

 Aeration pot and with inhibition system : 1 no.
 LLPP Weathering Beds : 2 nos.
No addition of equipment is required for Phase I Stage II flow as LLPP is designed for Phase I
Stage II flows condition.
1.2.5 HARD COD TREATMENT PLANT

Total design flow to the treatment : 420 m3/h
Design & Supply for Phase I Stage II flow
Turndown capacity : NA
On-stream factor :1
Lamella Plate Clarifier with PAC Dosing
 Inlet Design COD : 269.9 ppm

 Outlet Design COD : 125 ppm
 Retention time in Carbon Contact tank : 20 Min
 No. of Clarifier units with mechanism : 2 nos of 66%
 Settling rate : 0.931 m3/m2/h for phase I
stage I/1.19 33/m2/h for Phase I
stage II
 Clarifier Mechanism : Provided
 PAC dosing rate : 3.33 Kg/Kg COD
 PAC sludge Sump : 40 m3
 Guard Filter - Disk Type : < 20 microns, Auto Backwash
 Clean effluent tank retention : 10 min
Guard filter is provided at the inlet of clean effluent collection sump for retaining the escaping
powdered carbon particles.
Note: For detailed flow rates of individual and consolidated streams, refer to Process Flow
Diagrams for Effluent Treatment Plant (PDRP-0451-8110-20-230-0001).

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1.2.6 PIPING DESIGN CRITERIA

Pipe class & Service
Service Class
All Oily Effluent (Up to Biological System Inlet) - A2AP
Effluent and Oily Effluent (in and after Biological System) - A1AA / A2AW
Sanitary waste - A1AA
Spent Caustic - A4AN
Gravity Filter Area - A2AW
CRWS - A2AP
Water main line upto UF system Inlet - A2AP
UF Outlet to RO Outlet - HDPE / CSRL
RO Outlet to Permeate Tank Inlet - CSRL
DM Neutralization Waste line from B/L to UF Feed Tank - CSRL
Slop Oil - A2AP
Oily Sludge - A2AP
Chemical Sludge - A2AP
Biological Sludge - A1AA
Conc. Sulfuric Acid - A1LJ
Caustic Solution - A2AN
Di-Ammonium Phosphate Solution - A0LG
Urea Solution - A0LG
De-oiling Polyelectrolyte - A0JG
Dewatering Polyelectrolyte - A0JG
Coagulant Solution - HDPE

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Paradip Refinery
Service Water - A1AA
Plant Air - A1AA
Instrument Air - A1AA
LP Steam - A1AG
Leachate (Up-to Mixing Tank) - HDPE
Leachate (after Mixing Tank) - A2AW
COD Treatment (Up-to Mixing Tank) - GRP
COD Treatment (after Mixing Tank) - A2AW

Note
1. Effluent and Oily Effluent lines we have considered combination of both A1AA and
A2AW i.e.,
a) For sizes up to DN 600:- A1AA for Pipes, Fittings, Flanges, Gate Valve, Globe and NRV
and A2AW for Butterfly Valves.
b) For sizes DN 700 and above size:- A2AW for Pipes, Fittings, Flanges and Valves.
2. HDPE pipe lines shall have Polypropylene Valves in-case of Dosing Lines and Lined
Butterfly Valves / Check Valves (Wafer type) in case of Leachate.
3. GRP pipe lines shall have Polypropylene Lined Butterfly Valves / Check Valves (Wafer
type) in case of Leachate.
4. Ball Valve shall be used for Chemical Dosing Lines and the MOC shall be in line with
Piping Class.
Velocity Criteria in Pipes
Description Velocity (max)

Gravity Lines 1.2 m/s
Pump Suction 1.5 m/s
Pump Discharge 2.4 m/s
Pump Discharge Header 2.4 m/s
Blower Air Lines 25.0 m/s
Gravity Filter Inlet 1.2 m/s
Gravity Filter Outlet 1.5 m/s
Gravity Filter B/W inlet 3.0 m/s
Gravity Filter B/W outlet 2.0 m/s

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Paradip Refinery
Note:
1. The pipe line headers (wherever required), inside the ETP, has been designed for
Phase I Stage II.
2. All excess / OFF-SPEC line headers are designed for Phase I Stage II with CRWS
condition.
3.
1.3 BATTERY LIMIT CONDITIONS (B/L)
PROCESS LINES ENTERING B/L Normal Op. Pressure (kg/cm2 g)
1. Brine from crude tank farm 2.0

2. FGD effluent 2.0
3. Desalter effluent line 2.0
4. Oil water sewer 0.5
5. Settled coke pile runoff 3.0
6. CRWS 0.5
7. Cooling Tower Blow down – 4 Separate Headers 2.5
8. Stripped Sour water 5.5
9. Steam Systems Blow down 1.5
10. Landfill Leachate 2.5
11. Demin Regeneration. Effluent 2.5
12. Sulphidic Spent Caustic 2.5
13. Naphthenic Spent Caustic 2.5
14. Sanitary line from Township 1.0
15. Sanitary line from Refinery 3.0
16. Off-Spec from Storm water reservoir 3.05
UTILITY LINES ENTERING B/L AT GATE-055
1. Instrument Air 7.0

2. Plant Air 7.0
3. Service Water 6.0
4. Potable Water 6.0
5. LP Steam 4.0
6. Nitrogen 8.0

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7. Caustic Solution 4.0
UTILITY LINES LEAVING B/L AT GATE-056
1. Instrument Air 7.0

2. Plant Air 7.0
3. Service Water 6.0
4. Potable Water 6.0
5. Nitrogen 8.0
6. LP Steam 4.0
PROCESS LINES LEAVING B/L
1. Off-spec to Strom Water Reservoir 3.05

2. Dry Slop oil to Refinery 12.0
3. Oily Sludge to DCU 18.6
4. CRWS at DCU 4.3
5. Sea (Long Outfall Package) 7.0
6. RO Permeate to DM 8.5
7. RO reject for Dust Suppression 10.4
Note: For Design Pressures and other operating pressures inside Battery Limits, refer to Design
Pressure and Temperature diagram for Effluent Treatment Plant (PDRP-0451-8110-22-230-0001
to 0004), Hard COD Management (PDRP-0451-8110-22-231-0001), Land fill leachate treatment
(PDRP-0451-8110-22-231-0002).

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CHAPTER -2
PROCESS DESCRIPTION

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2.1 EFFLUENT TREATMENT PLANT (ETP – SECTION 230)
The Refinery Effluents contains pollutants like oil (Free and Emulsified) BOD, COD and
suspended solids, which are to be removed before discharging the effluent for further reuse.
Primary treatment is provided for the part removal of free oil in the influent in the units like
API separator followed by TPI separator. Emulsified oil will be removed in the secondary Oil
Separation units like DAF System.
After Secondary Oil removal the influent is fed to biological treatment for removal of BOD,
after which the effluent will be routed to the sand filters for Tertiary Treatment, Filtration
units like Sand Filters, UF units and RO systems are provided to meet the Outlet water
Characteristics.
The Sludge generated from the process units is categorized as Oily Sludge and Bio-Sludge and
will be treated separately. The Bio Sludge will be thickened and dewatered separately and
then sent for Final Sludge Disposal. The Oily Sludge will be thickened and pumped to the
battery limit.
The below described overview is to be read in Conjunction with Process Flow and Piping &
Instrumentation Diagrams (P&ID’s).
2.1.1 OILY WATER TREATMENT SUB PACKAGE (OWTP) – Process Description
The purpose of the Oily Water Treatment Plant Sub-package is to remove free oil and
settleable solids from contaminated aqueous effluent streams and to render these streams
suitable for biotreatment.
The Oily Water Treatment Plant Sub-package consists of the following units:
1. Parshall Flume
2. API Separator
3. TPI Separators
4. Flash mixing tank
5. Flocculator
6. Dissolved Air Floatation system.
The Oily water treatment package is designed to handle major flow streams like Salty oily
water, oily water sewer, drained effluents from slop oil tank and other tank bottoms, and to
handle the maximum of CRWS/CWBD (Cooling tower blowdown).

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Saline Effluents
Saline effluents from crude tank drainage will be intermittent and impose a salt load with an
unacceptably high peaking factor for reliable biotreatment. Saline effluents from crude tank
drainage, FGD Effluents and the desalter effluent will be routed to the Desalter Water / Brine
Equalisation Tank, combined and equalised in this tank.
The Desalter Water / Brine Equalisation Tank provides a minimum of 24 hours working
capacity for the total of the following flows in the Phase 1 normal case:
- normal averaged crude tank separated water drainage;
- normal averaged desalter effluent.
The tank will be located inside the dyke wall. Saline effluents shall be pumped at a constant
rate to the downstream OWTP facilities for further treatment. There shall be no requirement
of additional pumps for Phase I Stage II as there will be no flow difference between Phase I
Stage I and Phase I Stage II.
API Separator
The above mentioned effluent streams from the battery limit will be pumped/discharged at
the Splitter Box 1 upstream of parshall flume. The parshall flume enables the measure of flow
to the treatment system.
The wastewater is routed to API Separator for removal of free oil and suspended solids. The
basic principle governing separation of oil from the wastewater by specific gravity differential
at design temperature is governed by Stoke’s Law which is applicable to the rate of rise of oil
globules. The design of API Separator for removal of free oil is based on the rate of rise of oil
globules of greater than 150 micron size. Steam heating will be provided in the API Separator
to facilitate easy skimming of floating free oil, by the slotted pipe oil skimmer. API is designed
for lowest effluent temperature of 30 OC.
API Oil Separator of RCCEL construction is provided with three channels for Phase I Stage I
and one more channel shall be constructed during Phase I Stage II. The API Oil Separator is
covered with removable MS chequered plates, with venting arrangement leading to Volatile
Organic Contaminant (VOC) abatement package. Each Channel is provided with a gate at the
inlet to facilitate the isolation and maintenance of any Channel of the API Oil Separator.
Rotatable slotted pipe oil skimmers are provided in each Channel both at the inlet and
towards the outlet end, to collect and convey the oil to the Wet Slop Oil Sump. The flight oil
skimmers move the free oil floating at the top liquid surface towards the slotted pipe oil

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Paradip Refinery
skimmer and the scraper blades scrape the settled solids towards the sludge pit at the inlet
end of Main Separator. Separate sludge hoppers are provided for each channel for ease of
operation and maintenance.
TPI Separator
The treated effluent from the API separator is further treated in the TPI separator. The TPI
Separator is of RCCEL construction with three channels matching the width of the API
separator removes free oil of greater than 100 micron cut-off size, in the Effluent. The TPI
Separator will be covered with removable MS chequered plates, with venting arrangement
leading to VOC abatement package.
The TPI consists of a number of inclined corrugated plates of FRP Construction placed at 45°
to the horizontal and mounted parallel to each other at equal spacing. The wastewater
containing the oil and suspended solids passes between the plates. Laminar flow conditions
persist for effective gravity separation of water, oil and suspended particles. In the course of
passing from pack inlet to pack outlet, the oil droplets coalesce into larger droplets and the
oil floats upward into the top of corrugation and rises up the inclined plate to the surface of
the system where it is skimmed by rotatable slotted pipe oil skimmer.
The sludge moves towards the bottom of the corrugation and slides down the inclined plate
into the bottom hopper, to be discharged intermittently. LP Steam sparging is provided both
in API and TPI Separator for heating up of floating free oil, because of its high pour point, to
facilitate easy skimming and conveying. The treated effluent shall flow via overflow weir for
further treatment by Oily DAF system.
Isolation shutter gates provided at the inlet of API separator shall be operated to isolate the
bays, for maintenance. The free oil rising to the surface is skimmed through slotted pipe oil
skimmer and routed to Wet Slop Oil Sump.
The sludge formed due to settling of suspended solids at the bottom of both the API and TPI
will be removed intermittently by gravity and will be collected in nearby common Oily Sludge
sump for further treatment.
The treated effluent from the TPI separator is collected in covered API Sump. From the API
sump the effluent shall be pumped by means of 2 nos. of Equalization feed pumps to two nos
of Equalisation Tanks. The Equalisation Tanks shall provide a minimum of 20 hours working
capacity in total for the total flows in the Phase I Stage II maximum averaged flow case
including the API effluent, stripped sour water (in case of oil contamination) and other minor

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Paradip Refinery
flows except that the effluent recycle from the Check Basin shall not be considered to be
coincidental with the stripped sour water.
The equalization tanks are provided with oil skimmer for facilitating the removal of oil and
shall mixing facility to prevent stratification and ensure complete mixing. The equalized
effluent from the equalization tank is further pumped by means of DAF feed pumps to Oily
DAF units for further treatment. API & TPI are designed for lowest effluent temperature of 30
OC.
Oily DAF System
Flash Mixing Tank
The oily effluent from the equalization tank are let into Splitter box-2 for dividing the streams
to equal flows and hence to have identical secondary oil removal units like Flash Mixer,
Flocculation tank, DAF tank and Saturation Vessel. The splitter box will have 5 splitting
divisions (Weirs) with 4 operating during the Phase I Stage I conditions and the fifth one will
be left with blind flange for operation during Phase I Stage II flows.
Four nos of flash mixing tanks of equal size are provided for Phase I Stage I conditions. Ferric
chloride will be dosed by means of dosing pumps in the splitter box for aiding the coagulation
of suspended solids. Provision of adding acid at the inlet of flash mixer is provided.
A typical reaction of Ferric chloride as a coagulant may be expressed as given below
2FeCl3 + 3Ca(HCO3)2  2Fe(OH)3 + 3CaCl2 + 6CO2
The desired dispersion and mixing of chemicals with the Effluent is achieved by the high-speed
agitator provided in the flash mixing tank. After the thorough mixing of the chemicals, the
effluent from the Flash Mixing Tank exits at the bottom and enters the inlet chamber of
Flocculators.
Flocculators
Deoiling polymer will be dosed in each Flocculation tanks by means of dedicated dosing
pumps. The chemical dosing shall be made flow proportional. The DOPE will be prepared at
0.5% concentration max. and will be pumped to the dosing point. Inline dilution water from
overhead tank will be added in the discharge of the dosing pump to make it 0.1%
concentration. The desired dispersion and mixing of 0.1% DOPE solution with the Effluent will
be achieved by means of gentle agitator provided in the flocculator. After the de-
emulsification of oil-in-water emulsion and the flocculation of micro flocs into agglomerated

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Paradip Refinery
bigger flocs, aided by the DOPE solution, the effluent from the flocculator will led through
pipe to the Dissolved Air Floatation Tanks.
Oily DAF
The flocculated effluent enters the inlet chamber within the floatation tank, operated on
dissolved air flotation type where the de-emulsified oil and light suspended solids rise to the
top of flotation tanks due to the action of micro fine air bubbles getting released from the
depressurised recycle effluent. Four nos. of Oily DAF units are provided for Phase I Stage I
flow conditions. A part of the treated wastewater ex-floatation tank is recycled back to the
Saturation Vessel, using the DAF recycle pumps.
2 nos. DAF Air Compressors, supply air at required rate and pressure. The compressed air
from the either of the source is connected to the Saturation Vessel, which is a vertical
pressure vessel, containing spray plates or bars and will not be provided with packing to
reduce the potential of bio fouling. The recycle effluent gets saturated with air in the vessel
and the air water mixture under pressure in the pressure pipe is released through hosepipe
connections to atmospheric pressure in the floatation tank.
The de-emulsified oil and the solid precipitates gets attached to micro fine air bubbles and
rise to the top surface of flotation tank, forming a scum which is skimmed to the oily scum
outlet and then conveyed to the DAF Sludge Sump, by gravity. The DAF Unit is also provided
with a number of inclined corrugated plates placed at 60° to the horizontal, at equal spacing.
The wastewater containing heavier suspended solids and left out de-emulsified oil passes
between the plates. Laminar flow conditions between the plates ensure the effective gravity
separation of water, oil and suspended particles.
In the course of passing from pack inlet to pack outlet, the remaining de-emulsified oil
droplets coalesce into larger droplets and the oil floats upward into the top of corrugation
and rises up the inclined plate to the surface of the system where it is removed by the moving
surface skimmer of non-adsorbent material, along with the already floating demulsified oil.
The sludge moves towards the bottom of the corrugation and slides down the inclined plate
into the bottom hopper and discharged to the DAF Sludge Sump, by gravity.
The oil removed effluent from DAF units will flow by gravity to Biotower/Aeration tank feed
sump for biological treatment. Oily DAF is designed for possible highest temperature of
effluent, 40 oC, as solubility of air in water decreases at the temperature increases.

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VOC Abatement Package:
The Volatile Organic Contaminant (VOC) Abatement System is a system of relief vents,
ducting, balancing valves, ID fans, flame arrestors, carbon filters, valving and safety
Instruments to treat the odorous and VOC laden air from the vents of closed process units.
The System is fairly compact, minimizes the cost, localizes the carbon near the sources or in
the designated VOC control system area. The carbon to accommodate the estimated flow
rates and concentrations of the system, meet the emission requirement (Min. 90% capture
rate), and minimize pressure drop.
All contaminated and odorous wastewater streams should be handled in closed systems from
the source to the primary treatment stages like oil-water separator and equalization tanks
etc. All tanks, separators and sumps in which floating oil is intended or likely to accumulate
shall be covered and be vented via a vent header to the VOC Emissions Abatement Package.
The vent header shall be operated at a slight negative pressure to prevent hydrocarbons from
leaking into the atmosphere. All items of equipment which are connected into the vent
header shall be provided with sealed covers, water seals or other appropriate systems to
prevent gross in-leaking of air.
The exhaust gas is introduced into the VOC system through a flanged connection. Sufficient
primary air for operation below 25% LEL is introduced prior to the duct / chamber. The excess
air rate shall be field adjusted for best operating cost conservation. The additional air rate is
modulated based upon the percent of LEL that is measured in an upstream location. This
measurement may be a one time test at startup by which the air is fixed and the point that it
is needed the most or the %LEL may be monitored continuously to modulate the air in order
to reduce operating cost of blower and conserve carbon bed.
As the VOC gas flow rate fluctuates, the controls continue to modulate to maintain the
operating condition for improved safety. Pressure transmitters are used to control the
pressure by controlling the ID fans.
Another concern of the carbon system is that a high concentration level of some VOCs may
cause the carbon to generate heat on the bed since adsorption is a exothermic reaction. This
heat may eventually build into a fire. Thus, the quantities of VOC’s need to remain below the
Lower Explosive Limit for the VOC compounds. Hence we have provided LEL monitor to meter
the level of VOC’s and add dilution air as necessary. High concentrations that may be present
will shorten the life of the carbon beds. Carbon needs replenishment when the adsorption
level drops below 90%. The threat of fires with the fixed beds could mean that additional
items are best used for safety. Thermocouple connections upstream and downstream of the
carbon bed are provided in duct. The duct length is also optimized for best plant layout,

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Paradip Refinery
balanced flow and equipment cost. The diameter is sized to maintain a good design velocity
at full flow.
A More detailed description and manual will be submitted as a separate document.
2.1.2 BIOLOGICAL TREATMENT SUB PACKAGE (BTP):
Biotower
Treated leachate from Landfill Leachate Pretreatment Plant (LLPP) (described further in the
section) and Treated Spent Caustic effluent from Spent Caustic Treatment plant (SCTP)
(described further in the section) shall be pumped separately and mixed with the treated
effluent from DAF system for further biological treatment. Supernatant and Centrate of bio-
sludge shall also be pumped to the inlet of Biotower.
Biotreatment will be carried out in multiple parallel streams in 2 stages in series with an
attached growth “roughing” trickling filter stage, “the Biotowers”, followed by a dispersed
growth activated sludge process “the Activated Sludge Unit”. The Biological treatment helps
in the biodegradation of organic matters for reduction of BOD5 & COD. The Biotowers are
designed for the possible min. temperature of effluent of about 30 oC.
The effluent from the Biotower feed sump compartment will be pumped to 3 nos. of
biotowers by means of Biotower feed pumps with 1 working for each Biotower and 1 no of
common standby pump. The discharge header feeding to the biotower will be designed to
handle Phase I Stage II flows and the provision of adding pumps for Phase I Stage II will be
provided. Each Biotower will be designed for 100% recirculation flow. The treated effluent
from Biotower will flow by gravity to the central compartment of the Biotower feed sump.
The excess treated will overflow to the aeration tank feed compartment.
Nutrients like DAP & urea is dosed in Bio-tower feed sump. The bio-tower is essentially a
plastic media trickling filter having random packing with above 90% voidage and operates on
forced draft conditions. At the bottom of the bio-tower, there are peripheral openings for air
circulation through the packed bed. The effluent under hydrostatic pressure rotates its
distributor arms and the flow is uniformly distributed all over the packing media through the
spreaders.

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Paradip Refinery
As the wastewater trickles through the filter media, the metabolic conversion processes are
carried out by microorganisms colonizing the surface of the reactor media and forming a
biofilm or slime layer. Influent wastewater, which is simultaneously exposed to ambient air,
flows over the surface of the attached biofilm and transport of substrate and oxygen to the
biofilm occurs. Organic removal will be by substrate diffusion and microbial assimilation, i.e.
biodegradation.
The trickled flow from the bio-tower is collected through under drains and flows back to the
bio-tower feed sump compartment. Nearly 50-60% of the total BOD is removed in the Bio
tower and more than 60% of COD is removed. The effluent from the aeration tank feed
compartment will be pumped by means of 3 nos of aeration tank feed pumps. The effluent
will be pumped to the splitter box-3, which equally splits the flow into two equal streams.
Activated Sludge Process
The biological treatment is of activated sludge process with extended aeration mode and is
mainly for the removal of pollutants viz., BOD5, COD and sulphides. The aeration tank is
provided with Diffused aeration system for maintaining a constant Dissolved Oxygen (DO)
level in the Tank. Suitable No of blowers are provided for supply of air into the Diffusers.
The Activated Sludge system shall receive effluents from,

 pre-treated effluent from the biotowers
 Screened sewage from Township and Refinery.
 Filtrate from weathered drying beds.
 UF waste/reject and Sand filter waste backwash
 Used Powdered Activated Carbon (PAC) from the Hard COD Management
Package (HCMP).
The Biotower treated effluent pumped to the splitter box-3 will be get split into two parallel
streams and get treated in 2 nos. of Aeration tanks and 2 nos. of Secondary clarifier in series.
While Bio-Towers work on the attached growth, the activated-sludge process works on the
suspended growth treatment process for the removal of BOD and COD.
The activated sludge process (ASP) is an aerobic suspended growth type biological process
that encompasses diverse group of microorganisms kept in suspension in the reactor to
decompose and stabilize the soluble and particulate (colloidal and suspended) organic matter
present in wastewater to more stable inorganic forms or to cellular mass. Activated sludge
comprises a mixed microbial culture wherein the bacteria are responsible for oxidizing the
organic matter.
The organic matter (represented as COHNS) will be utilized by the bacteria resulting in cell

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synthesis and energy for maintenance. The following reactions best describe the organic
utilization by the aerobic bacteria:
Oxidation:
COHNS + O2 + Bacteria  CO2 + NH3 + other end Products + Energy
Synthesis:
COHNS + O2 + Bacteria  C5H7O2N (New Bacterial Cell)
Endogenous Respiration:
C5H7O2N + 5 O2  5CO2 + NH3 + 2H2O + Energy
Nutrients available in the wastewater cater to the nutrient requirements of the aerobic
microorganisms and to enhance the activity of the aerobic microbes. Furthermore, additional
requirements of nutrients shall be added to the aeration system by means of dosing pumps.
Nutrient sources such as urea and di-ammonium phosphate shall be added by means of
common dosing pumps for both chemicals. In addition to the nutrient requirements, the
aerobic microbes require oxygen to sustain their microbial activity.
Hence air will be supplied by means of diffused aeration system. The aeration systems shall
be provided with adequate installed blowers and diffuser capacity to ensure adequate
suspension and aeration to maintain fully mixed and suitably aerobic conditions with a
minimum dissolved oxygen concentration of 2 mg/l throughout the Aeration Basins in all likely
operating conditions which can reasonably be expected due to the potential variations in
flow, pollution load, temperature, atmospheric conditions, and the like. In actual aeration
system is designed with additional margin of 25% than it required for maintaining 2 ppm DO
in the aeration tank. This 25% margin will augment Pollution load design margin of 10%.
Fine bubble aeration system of silicon base rubber material will be provided with easily
retrievable system, i.e diffuser system can be taken out for maintenance without draining the
tank. And aeration will be provided by means of 3 nos. (2W+1S) of blowers for each aeration
tank.
The required MLSS of around 2000 mg/l will be maintained by recirculating settled activated
sludge from the Secondary Clarifiers to the Aeration Tank. RAS shall be routed by gravity to a
common RAS and WAS sump, which shall be provided with separate sections, which shall act
as the suction wells for the RAS and WAS pumps. The clarified effluent from the secondary
clarifier is routed to BioDAF where the particulate fines and scum if any is removed. The
BioDAF floats and sludge shall be routed to the WAS side of the RAS and WAS Sump.
The used PAC sludge from the Hard COD Management Package (described further in the

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section) is fed to the aeration tank and will be mixed with the effluent from Biotower via the
RAS. It will be introduced and mixed with effluent at splitter box-3. As powdered activated
carbon is introduced here the unused portion of carbon will cater to reduce the COD in the
effluent. The used PAC routing to RAS & SAS Sump is considered with a simple flow splitter
with manually adjustable weir penstocks to allow PAC to be distributed between the RAS
(goes to aeration) and SAS (goes to disposal) sections of the RAS & SAS Sump.
The mixed liquor effluent with PAC sludge from each aeration tank will overflow via weir to
its secondary clarifier. 2 nos. of Secondary Clarifier have been provided to handle the effluent
from its respective aeration tank. A splitting device is provided at the common outlet of both
aeration tanks to facilitate the use of either of the secondary clarifier from either of the
aeration tanks. The clarifiers provided are of peripheral driven type. The clarifiers are
provided with a sludge scraper, which revolves slowly to scrape the bio-solids settled at the
bottom. The collected sludge in the Secondary clarifier is recycled back by RAS pumps to the
aeration tank. This sludge recirculation facility is provided to maintain a Constant Mixed
Liquor Suspended Solids (MLSS) level in the aeration tank.
The excess Bio-sludge collected in the WAS sump will be pumped by means of SAS pumps to
Bio-Sludge Thickener for sludge treatment. The aeration systems, clarifier internals, RAS and
SAS pumps, sludge handling and thickening systems, centrifuges and liquor return pumps are
all rated for duty with the abrasive PAC.
Bio DAF – Circular Type
As the BTP will receive saline effluents and spent caustic flows with high TDS and these flows
will be variable and occasionally intermittent, there will be the risk of upsets in the activated
sludge clarifiers leading to substantial loss of biomass. Hence, the treatment scheme is
provided with dissolved air flotation unit, “the BioDAF”, to reduce excessive solids loads to
the downstream sand filters in the Water Recovery Plant (WRP) (described further in this
section) and protect them in case of upsets in biotreatment.
The overflow from the secondary clarifiers will flow into Splitter Box-5, for splitting the
streams in equal parallel streams for treatment in Bio-DAF system. The bio treated effluent
is dosed with a coagulant FeCl3 by means of Dosing pumps and well mixed in high intensity
flash mixer of 4 nos. for Phase I Stage I flows. And followed by a polymer dosing separately
in each of 4 nos. of Flocculation tanks and gently agitated prior to being treated in the
Dissolved Air Flotation (DAF) unit.

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The flocculated effluent enters the inlet chamber within the floatation tank circular in type,
operated on dissolved air flotation mode where the light suspended solids rise to the top of
flotation tanks due to the action of micro fine air bubbles getting released from the
pressurised recycle effluent. Four nos. of Bio DAF units are provided for Phase I Stage I flow
conditions. A part of the treated wastewater ex-floatation tank is recycled back to a
Saturation Vessel, using the DAF recycle pumps.
Bio-DAF Air Compressors, supply air at required rate and pressure. The compressed air from
the either of the source is injected into Saturation Vessel, which is a vertical pressure vessel,
containing spray plates or bars and is not provided with packing to reduce the potential of bio
fouling. The recycle effluent gets saturated with air in the vessel and the air water mixture
under pressure in the pressure pipe is released through hosepipe connections to atmospheric
pressure in the floatation tank.
The solid precipitates get attached to micro fine air bubbles and rise to the top surface of
flotation tank, forming a scum which is skimmed to the scum outlet and then conveyed to the
DAF Sludge Sump, by gravity. A separate Sludge shall be provided for collecting the sludge
and scum for bio-DAF or can be sent to RAS sump based on hydraulics. The bio treated
effluent from the Bio-DAF will flow to the Effluent check basin by gravity.
Effluent Check Basin
The effluent check basin shall receive treated effluent from BioDAF and the steam system
blowdown stream from the battery limit will be pumped directly to it. The facility to collect
the non-contaminated CWBD has been provided. The effluent check basin shall be provided
with 2 No. compressed air driven portable floating oil skimmers of disc-type complete with
onboard oil pump for the removal of any floating oil in the effluent. The effluent Check Basin
shall be provided with a minimum of 3 hours working capacity in total for the total flows in
the Phase I Stage II maximum sustained flow case.
Submersible pumps will be provided in the effluent check basin for further treatment and
conveyance. 3 pumps shall be provided for transferring the excess/offspec effluent to the
storm water reservoir and to the required destination if it is an offspec. The provision of
transferring the offspec effluent to equalization tank or the Biotower feed sump is provided.
The same pipeline header transferring the effluent to reservoir can also be used to pump back
(scope by others) the effluent to equalization tank/Biotower feed sump, to be decided during
operation.
2 nos. pumps shall be provided for transferring the effluent for gardening. The treated water
will be salty. The header from the pump set which discharges water to gardening shall be
provided with a facility to blend in RO permeate in order to reduce the Sodium Absorption

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Paradip Refinery
Ratio (SAR) to the required quality. The same header will be used and led to the Truck loading
point/facility.
3 nos. (2W+1S) submersible pumps will be provided that will feed the treated biological
effluent for further treatment to the Rapid Gravity sand filters (WRP package).
2.1.3 SLOP OIL HANDLING SECTION
Wet slop i.e. oil skimmed / removed from API Oil separator, TPI Separators, Equalization
tanks, Spent Caustic Storage Tank and from various subsequent oil handling units, through
appropriate oil skimmers, shall be routed to a Wet Slop Oil Sump and then to Wet Slop Oil
Tank. The oil separated from the latter i.e. dry slop shall be pumped back to the refinery slop
oil tanks. The decanted water from the Wet Slop Oil Tank shall be routed under gravity to the
OWS sump for treatment in the WWTP.
The Slop Handling Section consists of following units:
 Wet Slop Oil Sump and wet slop oil pump.
 Wet Slop Oil Tank.
 Dry slop oil transfer pump.
Wet slop oil sump
The slop oil will be received in the Wet Slop Oil Sump, after recovering from the oil skimmers
of following treatment units.
 API Oil Separator
 TPI Separators
 Equalisation tanks
 Desalter Equalisation tanks
 Check basin
 Spent Caustic storage tanks
The Wet Slop Oil Sump is an above ground RCCEL tank. The Sump is covered with
removable MS chequered plates, with venting arrangement to VOC abatement system.
Horizontal centrifugal, Wet Slop Oil Transfer Pumps will be used for transferring the wet slop
oil to Wet Slop Oil Tank.
Wet slop oil tank
PID Ref : DWG NO: PDRP0451-8110-25-230-0009

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Paradip Refinery
Two nos. Wet Slop Oil Tanks will be provided for receiving the wet slop oil from the Wet Slop
Oil Sump as well as through decantation of off-spec tanker from outside refineries,
transferred by the Wet Slop Oil Transfer Pumps. The each Wet slop oil tank has been designed
to handle 7 days normal case flows of the effluent and the maximum spill cases. The two
tanks will be located inside the dyke wall.
The tank is a closed, circular, fixed conical roof, vertical CSEP tank and is provided with steam
heating coil facility to ensure the separation of oil from the water. Steam will be introduced
into the coil and the heating process will be continued for at least 6 hours so that efficient
demarcation between oil and water are formed. The separated water will be drained down
and routed to the intermediate drain collection sump. The condensate from the steam used
shall be taken to common sludge sump, even though the quantity is very small.
Intermediate Drain Transfer pumps will be provided for transferring the effluent from the
drain sump to the API inlet. The dry slop oil will be pumped by horizontal centrifugal type Dry
Slop Oil Transfer Pumps, to the Battery Limit for further processing in the refinery.
2.1.4 SLUDGE THICKENING & DEWATERING SUB PACKAGE
Oily sludge Handling
Oily Sludge generated in various Oil handling units and chemical treatment units shall be
collected in the Local Sludge Sump and then pumped to Oily Sludge Thickener. Thickened
Sludge shall be dewatered in Centrifuge.
The Oily Sludge Handling Section consists of following units:

 Common Oily Sludge Sump and pump.
 DAF Sludge Sump and pump
 Oily Sludge Thickener
 Thickened Oily Sludge Sump and pump.
 Oily Sludge Centrifuge
 Supernatant Sump
 Oily Sludge Reslurrying System
Oily sludge sumps
The oily sludge from API and TPI will be received in the Common Oily Sludge Sump, and the
Oily scum from DAF units will be collected in the nearby local DAF sludge sump. Both sumps
will be of RCC construction. The sludge sump will be provided with oil skimmer for the removal
of oil and wax floating in the sludge sump.

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Paradip Refinery
Positive displacement screw type Oily Sludge Pumps & DAF Oily Sludge Pumps will be
provided for transferring the Oily Sludge from common oily sludge Sump and DAF sludge
sump respectively. And it will be pumped to the Oily Sludge Thickener. Common oily sludge
pumps are designed to handle the max flow of 2 tonne/dry solids.
Oily sludge thickener
The oily sludge from the local Sludge Sump will pumped into the Oily Sludge Thickener for
further thickening. The thickener will be of RCCEL construction.
The Thickener is provided with centrally driven and picket & fence type sludge scraping
mechanism and a scum skimmer. The scum and the bottom sludge will be drained into the
Thickened Oily Sludge Sump. A bypass line shall be provided which shall delivery the sludge
into thickened sludge sump instead of thickener. The supernatant from the Thickener will
overflow and get collected in Oily Supernatant Sump. Both the Thickener and the supernatant
sump are designed to handle Phase I Stage II Flows. The thickener underflow line will be
steam traced to prevent the sludge from solidifying and to ensure free flow of oily sludge.
Thickened oily sludge sump
The 1 nos. of Thickened Oily Sludge Sump will be of RCCEL construction. The sump will be
provided with an agitator to keep the solids in suspension. The Sump will be provided with a
LP Steam hose connection. Positive displacement screw type, Thickened Oily Sludge Pumps,
will be provided for feeding the Oily Sludge to Centrifuge for dewatering. The sump will be
designed to store the sludge during non-operating hours of Oily Centrifuge considering the
storage capacity of sludge in the hopper bottom of the sludge thickener.
Oily sludge centrifuge
2 nos. Solid Bowl type Oily Sludge Centrifuge will be provided and designed to handle the
Phase I Stage II1 flows. The thickened sludge having a consistency of approx. 5% is pumped
to the Centrifuge by the Thickened Oily Sludge Pumps for dewatering. The operation of the
Centrifuge will be intermittent and may be operated for a maximum of 12 hours including the
timing required for starting and cleaning. The Centrifuge will be kept elevated in the
Centrifuge Building.

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The dewatering of solids will be brought about by the centrifugal action. A dry sludge cake
with solid content of 20% by weight will be achieved at the outlet of Centrifuge. 0.1%
Dewatering polyelectrolyte (oily) will be dosed at the inlet to Centrifuge to aid in the
dewatering of solids. The dewatered sludge will be discharged through a chute either into a
tipper trolley, for suitable disposal by the Client or to the reslurrying facility. The centrate
from the Centrifuge will be recycled back to the supernatant sump. The collected effluent
from the oily supernatant sump will be pumped back to the API inlet by means of vertical
sump pumps, oily supernatant transfer pumps.
The space around the oily sludge bin beneath the centrifuge will be carefully arranged to allow
for forced ventilated to prevent the development of a flammable atmosphere. The hood
around the bins will be provided with a suitable blow-off panel to prevent serious damage in
case of an accidental ignition of a flammable atmosphere. The oily sludge bin area ventilation
system vent will be provided with LEL monitor which will be set to indicate the risk of a
flammable atmosphere developing in the bin.
Oily sludge reslurrying system
A facility shall be provided to re-slurry dewatered oily sludges as they exit the Oily Sludge
Centrifuge and to pump the re-slurried oily sludge to the DCU, at a solids content not
exceeding 15 wt% and at an oil content not exceeding 10 wt% and at a viscosity not exceeding
50 cSt (50 times that of water). The viscosity limit will be required to ensure turbulent flow in
the pipeline and pumpability at the DCU. The dosage of viscosity thinning chemical will not
be provided and hence will be pumped @ 100 cSt in which case a larger pipeline will be
required and higher flows and higher discharge pressures will be required.
A facility shall be provided to route dewatered sludge from the centrifuge into the Re-slurry
Tank / Sump, e.g. by reversing the conveyor which discharges to skips. A sparge-type facility
shall be provided to wash sludge from the centrifuge conveyor discharge chute into the Re-
slurry Tank / Sump.
Re-slurry liquid shall normally be centrate from the oily sludge centrifuge. Re-slurry liquid
shall be provided with a recovered water connection and automatic valve from the discharge
head of oily supernatant transfer pumps into the Re-slurry sump. The sump shall be covered
and vented to atmosphere. The working capacity shall be a minimum of 8 m 3. The Re-slurry
sump shall be provided with an overflow to the ETP Oily Centrate Sump. A facility will be
provided by others to deliver back flush water into the pipeline from the DCU to the ETP. A
facility shall be provided in the ETP to allow back flushing water to be routed into a connection
to the Oily Centrate Sump. Two nos. of Oily Sludge Pump will be provided to pump the

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slurried sludge to the battery limit.
Biosludge Handling
The Bio Sludge Handling Section consists of following units:
 Bio Sludge Thickener

 Thickened Bio Sludge Sump and pump.
 Bio Sludge Centrifuge
 Supernatant Sump
 Sludge Weathering beds and pumps
Bio sludge thickener
The bio sludge of activated sludge system and Sludge from the Bio-DAF from the SAS
compartment Sludge Sump will pump into the Bio Sludge Thickener for further thickening.
The thickener will be of RCCEL construction.
The Thickener will provided with centrally driven and picket & fence type sludge scraping
mechanism and a scum skimmer. The scum and the bottom sludge will be drained into the
Thickened Bio Sludge Sump. The Sludge Dilution line from check basin will be provided to
maintain the minimum required hydraulic loading rate. The supernatant from the Thickener
will overflow and get collected in Bio Supernatant Sump. Both the Thickener and the
supernatant sump are designed to handle Phase I Stage II Flows.
Thickened bio sludge sump
The 1 nos. of Thickened Bio Sludge Sump will be of RCCEL construction. The sump will be
provided with an agitator to keep the solids in suspension. Positive displacement screw type,
Thickened Bio Sludge Pumps, will be provided for feeding the Bio Sludge to Centrifuge for
dewatering. The sump will be designed to store the sludge during non-operating hours of Bio
Centrifuge considering the storage capacity of sludge in the hopper bottom of the sludge
thickener.
Bio sludge centrifuge
2 nos. Solid Bowl type Bio Sludge Centrifuge will be provided and designed to handle the
Phase I Stage II flows. The thickened sludge having a consistency of approx. 3-5% will be
pumped to the Centrifuge by the Thickened Bio Sludge Pumps for dewatering. The operation
of the Centrifuge will be intermittent and may be operated for a maximum of 12 hours
including the timing required for starting and cleaning. The Centrifuge will be housed at the
first floor of the Centrifuge Building. The dewatering of solids will be brought about by the

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Paradip Refinery
centrifugal action.
A dry sludge cake with solid content of 18-20% by weight will be achieved at the outlet of
Centrifuge. 0.1% Dewatering polyelectrolyte (bio) will be dosed at the inlet to Centrifuge to
aid in the dewatering of solids. The dewatered sludge will be discharged by common
converyor & through a chute into tipper trolley, for suitable disposal by the Client. The
centrate from the Centrifuge will be recycled back to the Bio supernatant sump. The collected
effluent from the bio supernatant sump will be pumped back to the inlet of aeration tank by
means submersible, bio supernatant transfer pumps.
Sludge weathering beds
The dewatering cake of approx 18% will be carried by tipper trolleys of 3 nos. (common for
oily and will evenly be distributed into 3 nos. of Weathering beds, by means of 1 no. of four
wheel drive with hydraulic operated scraper and digging bucket. The weathering beds will be
provided for adequately handling & storing dried sludge for 6 months. The filtrate from the
beds will be collected in sludge Liquor sump and will be pumped back to the inlet of aeration
tank by means of weathered sludge liquor transfer pumps.
2.1.5 CHEMICAL DOSING SUB PACKAGE
The purpose of the Chemical Dosing Package will be to dose chemicals into the process
streams in order to enable and / or enhance the performance of the process units and / or
protect the process equipment within the ETP & WRP. ALL DOSING PREPARATION AND DAY
TANKS ARE DESIGNED FOR PHASE I STAGE II FLOWS.
The ETP is provided with chemical dosing facilities for the following duties:
Oily Water Treatment:
1. Oily DAF – Acid, Ferric chloride and De-oliing Polyelectrolyte (DOPE)

2. Oily sludge – Dewatering polyelectrolyte
Biotreatment:
1. screenings disinfectant / odor abatement (sodium hypochlorite)

2. soluble bio-available nitrogen (Urea dosing to Biotowers and Aeration tank)
3. soluble bio-available phosphorus (DAP to Biotowers and Aeration tank)
4. chlorination of gardening water - Hypo

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5. Bio-DAF - FeCl3 and Polyelectrolyte.

6. Biosludge – Dewatering polyelectrolyte
Hard COD Treatment Plant:
1. Acid (H2SO4)
2. Powdered activated carbon
Landfill Leachate Treatment plant:
1. Acid/Caustic for neutralisation;

2. Ferric chloride for Coagulation;
3. Polymer – Flocculation tank.
4. Sludge dewatering aid.
The preparation tank and dosing tank of all chemicals shall be kept in the chemical house and
are sized to provide 150% of the maximum capacity required to allow operations over any 24
h period. Water for the dilution of raw chemicals shall be derived from the site utility water
system (treated river water), which is considered as a back up provision. The day tanks will be
located in tank bund and shed will be provided and hence the dosing pumps shall be located
there. Polymer solid feeder shall be provided for easy handling of polymer chemicals. All types
of polymer shall be made up to a suitable concentration for pumping and subsequently be
provided with in-line dilution to optimize dispersion.
Water for in-line dilution of chemicals prior to mixing with process streams in the ETP shall
preferably be derived from bio-treated recovered water from the overhead tank used for
backwashing of filters. Urea and DAP available as powder, will be stored in the ground floor
of Chemical House. Urea, FeCl3 & DAP will handled by Hydraulic Lift scissor and Bag slitter
machine for feeding the same into preparation tank.
A bulk storage tank for concentrated Sulphuric acid along with transfer pumps both for
loading from the outside tankers are provided adjacent to the chemical dosing area. Sodium
hydroxide will be available from a site-wide ring main as 20% w/w NaOH.
The purpose of dosing the various chemicals is mentioned below.
1. DAP and urea will be dosed at inlet of bio-tower to meet the necessary nutrient
requirement (Nitrogen & Phosphorus) of microorganisms involved in biological
treatment.

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Paradip Refinery
2. Ferric chloride (FeCl3) used as a coagulant agent and dosed in the Flash Mixer of Oily &
Bio DAF.
3. Polyelectrolyte used as a flocculation agent and dosed in the Flocculator of Oily & Bio DAF.
4. Dewatering Polyelectrolyte (DWPE) dosing in upstream of Oily & Bio Centrifuges for better
sludge consistency.
5. Sulphuric acid dosing for pH correction when the incoming water is highly alkaline.
6. Caustic solution dosing for increasing the alkalinity when the incoming water is acidic.

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CHAPTER 3
OPERATING VARIABLES

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3.1 PLANT INLET / OUTLET NORMAL OPERATING PARAMETERS
API Separator (Phase I Stage I)

 No. of Channels : 3 nos
 Design flow per unit : 345.0m3/h
 Design Lowest Temperature : 30 OC
 Density of Oil considered : 940 kg/m3
 Total inlet Free Oil : 4172 mg/l
 Design free oil removal efficiency : 95 % of Oil globules > 150 micron
 Globule Rising Velocity : 3.07 m/h
 Vh/Vt Ratio : 15.0
Tilted Plate Interceptor (Phase I Stage I)

 No. of bays working : 3 Nos.
 Design flow per Bay : 344.64m3/h
 Total inlet Free Oil : 1397.5 mg/l (max load)
 Size of Free Oil considered for removal : 100 micron
 Percentage free oil > 100 micron : 90 %
 Free oil removal efficiency > 100 micron : 98 % (Max Oil)
 Rising rate : 1.36 m/h
 No of Packs/Bay/Channel : 4 nos.
Dissolved Air Floatation (Phase I Stage I)
 Total flow to the DAF system : 1275.0 m3/h
 Temperature of effluent : 40 oC
 Type of tank : Rectangular
 Design flow per unit : (318.8 + 124) m3/h
 Inlet Emulsified Oil : 680.14 mg/l (max load)
 Design Emulsified oil removal efficiency : > 98.0%

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 Air to solid ratio : 0.02

BIOLOGICAL TREATMENT SECTION
Design Flow of Pre-treated Leachate : 49.1 m3/h
Design Flow of Treated Spent caustic : 10.3 m3/h
Design Flow of bio-sludge supernatant : 37.25 m3/h
Total Design Flow rate to Biotower m3/h 1341.4
pH 6.0 - 8.0
Oil & Grease mg/l 14.3
BOD3 mg/l 252.68
COD mg/l 662.0
Total Sulfides mg/l 21.6
Biotower (phase I stage I)
 No. of Tanks : 3 nos.

 Flow to each Biotower : 896 m3/h
 Recirculation Flow : 100%
 Type of Media : Random Media
 Media Surface area : 100 m2/m3
 Diameter of Biotower provided : 25.5 m
 Height of media provided for Phase I Stage I : 5.4 m
 Organic Loading rate : < 1.5 Kg/m3/d
 Volumetric Loading rate : > 25 m3/m2/d
 COD removal Efficiency : 65%

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Paradip Refinery
To treated effluent from Biotower, the following effluent streams will be added
Design Flow of sanitary effluent : 43.5 m3/h
Design Flow of UF & RGSF backwash : 196 m3/h
Aeration System (phase I stage I)
 Total Design Flow for aeration tank : 1580.6 m3/h

 No. of Aeration tanks : 2 nos.
 Flow to the each tank : 790.3 m3/h
 Inlet BOD : 96.0 ppm.
 Inlet COD : 254.4 ppm
 F/M ratio : 0.101 kg BOD/kg MLSS.d
 Detention period in each aeration tank : ~ 12.0 H
 MLSS : 2000 ppm
 Total volume provided : 18240 m3
 RAS Recirculation ratio : 100%
The provision for expanding the aeration tank during Phase I Stage II flow is provided.
Secondary Clarifier (Designed to accommodate Phase I Stage II flow)
 No. of Secondary clarifier : 2 nos.

 Flow to the each Clarifier : 790.3 + 792 m3/h
 Overflow rate : 0.9 m3/m2/h
 Solids Loading rate : < 5 kg/m2/h
 Diameter of the clarifier : 37.0 m
No addition of clarifier is required for Phase I Stage II flow as Sec. Clarifier is designed for
Phase I Stage II flows.
Bio -Dissolved Air Floatation
 Type of tank : Circular
 Design flow per unit : (396 + 150) m3/h
 Solids Loading rate : 6.3 Kg/m2/h

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Paradip Refinery
 Volumetric Loading rate : 6 m3/m2/h

 Air to solid ratio : >0.015
 Diameter of Bio-DAF : 12.0 m
One No. of Bio-DAF of same capacity shall be added for the Phase I Stage II flow and provision
SLUDGE TREATMENT SECTION:
SLUDGE TREATMENT SECTION – OILY SLUDGE
Oily Sludge Thickener:

 Design flow rate : 1548.6 m3/d
 Solids Loading rate : 80 Kg/m2/d
Oily Sludge Centrifuge:

 Quantity of dry solids to be dewatered : 25504.5 Kg/d
 Desired cake consistency : 20 %
 No. of operation hours – Max. Flow : 12 hours.
Oily Sludge Reslurrying System:
 Volume of Re-Slurry Liquid tank : 8 m3

 Consistency of Sludge to be pumped to DCU : Solids < 15%, Oil < 10%
 Viscosity of sludge at which it is pumped : 100 cSt
Wet Slop oil tank:
 No. of tanks : 2 nos

 Nominal Capacity of each Tank : 2189 m3

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Paradip Refinery
 Design Basis of capacity : 7 days flow of slop oil on normal

case basis + oil spill cases
SLUDGE TREATMENT SECTION – BIO SLUDGE
Bio Sludge Thickener:

 Design flow rate : 529 m3/d + 275 m3/d (Sludge
dilution)
 Solids Loading rate : 40-50 kg/m2/d
Bio Sludge Centrifuge:

 Quantity of dry solids to be dewatered : 5254.5 kg/d
 Desired cake consistency : < 18 %
 No. of operation hours – Max. Flow : 12 hours
Sludge Weathering Package:

 Cycle of Operation : 6 Months
 Desired inlet cake consistency : < 18 %
 Desired cake consistency : 50-70 %
One No. of weathering bed of same size shall be added for the Phase I Stage II flow and
provision for the same is specified in the layout.

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Paradip Refinery
GUARANTEED PARAMETERS OF TREATED STREAM FROM OUTLET OF

EFFLUENT CHECK BASIN/INLET OF WATER RECOVERY PLANT
Effluent concentration
EFFLUENT
S No kg/1000 tonne of crude
PARAMETERS mg/l, except pH
processed, except for pH
1. pH 6.0 - 8.5 -
2. Oil & Grease <5 2
3. TSS <20 8
4. BOD3 15 6
5. COD 125 50
6. Phenols < 0.35 0.14
7. Total Sulphides < 0.5 0.2
8. Cyanides 0.2 0.08
9. Phosphorus < 3.0 1.2
10. Ammonia as N 15 6
11. TKN 40 16
12. Cr(IV) 0.1 0.04
13. Total Cr 2.0 0.8
14. Pb 0.1 0.04
15. Hg 0.01 0.004
16. Zn 5.0 2.0
17. Ni 1.0 0.4
18. Cu 1.0 0.4
19. V 0.2 0.8
20. Benzene 0.1 0.04
21. Benzo(a) pyrene 0.2 0.08

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Paradip Refinery
CHAPTER – 4
UTILITIES, CHEMICALS AND EFFLUENTS

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4.1 CHEMICALS
Description Chemical Form/Concentration/Supply

Flash Mixer - Neutralizing agent Sulphuric Acid Liquid / 98% w/w / Tanker
Oily DAF Flash Mixer - Coagulant Ferric Chloride Powder / Bags
Oily DAF Flocculator - Flocculant De-Oiling Polyelectrolyte Powder / Bags
Nutrient 1 Di Ammonium Phosphate Powder / Bags
Nutrient 2 Urea Powder / Bags
Bio DAF Flash Mixer - Coagulant Ferric Chloride Powder / Bags
Bio DAF Flocculator - Flocculant Polyelectrolyte Powder / Bags
Disinfectant - Gardening Sodium Hypo Chlorite Liquid / 10% w/w / Drum
Disinfectant - Sanitary Sodium Hypo Chlorite Liquid / 10% w/w / Drum
Dewatering Agent Dewatering Polyelectrolyte Powder / Bags
pH Neutralizing Agent - LLPP Caustic Liquid / 20%w/w / Plant utility
pH Neutralizing Agent - LLPP Sulphuric Acid Liquid / 98%w/w / Tanker
Flash Mixer – Coagulant -LLPP Ferric Chloride Powder / Bags
Flocculating Agent -LLPP Polyelectrolyte Powder / Bags
Dewatering Agent - Filter Press Dewatering Polyelectrolyte Powder / Bags
pH Neutralizing Agent - HCMP Caustic Liquid / 20%w/w / Plant utility
pH Neutralizing Agent - HCMP Sulphuric Acid Liquid / 98%w/w / Tanker
Carbon Contact Tank PAC + H2SO4 + DAP solution Slurry/10% w/w/tank
UTILITY CONSUMPTION
ITEM NO DESCRIPTION CHEMICAL FORM/ INITIAL AVERAGE ANNUAL

CONCENTRATION/ FILL FLOW CONSUMPTION
SUPPLY CONTAINER
TYPE
230-TK- Flash Mixer - Sulphuric Acid Liquid / 98%w/w / N/A 10-20 N/A
108...508 Neutralizing Tanker kg/h
agent
230-TK- Oily DAF Ferric Chloride Powder / Bags N/A 25.5 kg/h 223.4 Tonnes
108...508 Flash Mixer -
Coagulant

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Paradip Refinery
230-TK- Oily DAF De-Oiling Powder / Bags N/A 3.8 kg/h 33.3 Tonnes
109...509 Flocculator - Polyelectrolyte
Flocculant
Unit 230 Nutrient 1 DAP Powder / Bags N/A 14.5 kg/h 127.0 Tonnes
Unit 230 Nutrient 2 Urea (Bio Powder / Bags N/A 0 -5 kg/h N/A
nutrient)
230-TK- Bio DAF Flash Ferric Chloride Powder / Bags N/A 23.75 208.1 Tonnes
115...515 Mixer - kg/h
Coagulant
230-TK- Bio DAF Polyelectrolyte Powder / Bags N/A 1.58 kg/h 13.8 Tonnes
116...516 Flocculator -
Flocculant
Unit 230 Disinfectant - Sodium Hypo Liquid / 10% w/w / N/A 1.80 kg/h N/A
Gardening Chlorite Drum
Unit 230 Disinfectant - Sodium Hypo Liquid / 10% w/w / N/A 0.10 kg/h N/A
Sanitary Chlorite Drum
Unit 230 Dewatering Dewatering Powder / Bags N/A 5.90 kg/h 23.7 Tonnes
Agent Polyelectrolyte
231-TK-004A pH Caustic Liquid / 20%w/w / N/A 2.50 kg/h N/A
Neutralizing Pipelines
Agent
231-TK-004B Flash Mixer - Ferric Chloride Powder / Bags N/A 1.25 kg/h 11.0 Tonnes
Coagulant
231-TK-004C Flocculating Polyelectrolyte Powder / Bags N/A 0.05 kg/h 0.44 Tonnes
Agent
231-TK-013 pH Sulphuric Acid Liquid / 98%w/w / N/A 1.00 kg/h N/A

Neutralizing Tanker
Agent
Unit 231 Dewatering Dewatering Powder / Bags N/A 0.20 kg/h 0.44 Tonnes
Agent -Filter Polyelectrolyte
Press
231-TK-002 pH Caustic Liquid / 20%w/w / N/A 0-5 kg/h N/A
Neutralizing Pipelines
Agent
-HCMP
231-TK-002 pH Sulphuric Acid Liquid / 98%w/w / N/A 3.30 kg/h 28.9 Tonnes
Neutralizing Tanker
Agent -HCMP
231-TK-002 Carbon Powdered Powder / Bags N/A 60.00 525.6 Tonnes
Contact Tank Activated Carbon kg/h

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Paradip Refinery
4.2 UTILITY CONSUMPTION FOR ETP
EQUIPMENT DESCRIPTION STEAM CONDENSATE PLANT AIR SERVICE

NO. te/h te/h Nm3/h WATER
LP SATURATED LP M3/h
230-TK- API & TPI -0.6 150
105/…./405 seperation tank
230-TK-010/011 Slop Oil Tank -4.7 4.7
230-P-135 A Drained effluent -4.7
Transfer pump
230-TK- Oily DAF Tank -0.1
110…510
230-K-001A Air Compressor 40
DAF
230-K-001B Air Compressor [40]
DAF
230-V-101 DAF Saturation vessel 16
230-TK-111 Aeration Tank 4900.0
230-TK-211 Aeration Tank 4900.0
230-K-102A Aeration Tank air 2450.0

blower
230-K-102B Aeration Tank air 2450.0
blower
230-K-102C Aeration Tank air [2450]
blower
230-K-202A Aeration Tank air 2450.0
blower
230-K-202B Aeration Tank air 2450.0
blower
230-K-202C Aeration Tank air 2450.0
blower
Aeration Tank air [2450]
blower
230-V-102 BioDAF Saturation 16.0
Vessel

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Paradip Refinery

Vessel
Vessel
230-K-104A BioDAF Air 40.0
Compressor
230-K-104B BioDAF Air [40.0]
Compressor
230-OS-005 A Floating Oil 24.0
Skimmer Check
basin
230-TK-112 Secondary Clarifier 140)
230-TK-212 Secondary Clarifier (140)
230-TK-120 Bio Sludge (100)
Thickener
230-TK-121 Oily sludge Thickener (100)
230-TK-125 Ferric Chloride 20
Make up tank
230-TK-125 Ferric Chloride [20]
Make up tank
230-TK-127 Urea/DAP make up (6.0)
tank
230-TK-127 Urea/DAP make up [6.0]
tank
230-TK-126 DOPE Make-up cum 4.8
Ageing tank
230-TK-130 Polymer makeup 2.0
cum ageing tank
230-TK-131 DWPE makeup 5.1
cumageing tank -
Oily
230-TK-132 DWPE makeup 1.5
cumageing tank -
Bio
Note: For detailed consumption figures refer to Catalysts and chemical summary (PDRP-0451-
8110-PD-230-0002)

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Paradip Refinery
CHAPTER -5
PREPARATIONS FOR START UP

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Paradip Refinery
5.1 START UP PROCEDURES
PRE COMMISSIONING:
Pre-Commissioning activities will be started during the later stages of construction. The focus
will be on checking for installation completeness in accordance with the project specifications
and reviewing any aspects that may impact on operational safety and reliability in the
commissioning, startup and operation phases. On the completion of the Pre-Commissioning
work pre-start up, the status of a process System will typically be as follows;
General Inspection:
A general inspection of all equipment, piing, instruments, valves and insulation must be
carried out to verify the complete accordance with the mechanical drawings. The following
points should be checked in particular:
 Consistency check with respect to latest revision of P&ID’s.

 Vessel internals installed correctly and internally clean/inspected
 Sizes of lines (piping type and material)
 Gaskets: Type, material, rating, assembling.
 Piping fully reinstated, aligned and supports properly set
 Sample points and operability
 Safety valves: Type, set pressure, tag number, position and support.
 Insulation/Painting.
 Readiness of utilities
Flushing
All process and utilities piping lines have to be thoroughly flushed to remove any foreign
material due to fabrication and assembly.
Electrical and Instrumentation check
 Instruments and control connections installed

 Instruments fully installed and loop checked
 DCS Systems SAT
 Control valve actions confirmed
 All Electrical cables and equipment inspected and tested
 Uncoupled electric motor runs complete

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 Safety Devices (Relief valves, Interlocks etc).
Equipment inspection and cleaning
 Rotating equipment initial (static) alignment complete

 Lube oil flushing complete and lubricant first fill installed
 Isolation blinds installed, as directed and recorded in Blind Control Register
 All punch list items resolved at the appropriate category level. The timing for the
completion of any outstanding punch items will be agreed with IOCL.
 Installation of Seals and Packing
 Temporary spools, Strainers, Screens and Blinds
 Safety and Firefighting equipment readiness.
 House Keeping
 Equipment Protection and Spare Parts
 Test run of Pumps and compressors.
Water test run
Before first start up, the complete unit has to be tested with water to ensure the proper
operation of all piping, electrical, instrument and other facilities.

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Paradip Refinery
CHAPTER- 6
COMMISSIONING & START UP

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6.1 COMMISSIONING
Commissioning of the process starts after the plant hydraulics is checked with water and all
problems are rectified. Raw effluents are introduced into the system and treat as per the
requirements specified under treatment scheme in earlier sections of this manual. Prior to this,
the systems will be subsequently filled with water and cold testing will be done, without using
effluent, and without addition of any chemicals. Where there is biological treatment is envisaged,
seeding with activated sludge is to be done from a nearby sewage treatment plant or with cow
dung for the development of bacteria and subsequent growth of Mixed Liquor Suspended Solids.
Jar testing of the effluent is to be established first to optimize the chemical requirement. The
Chemical dosing and process stabilization phase will be undergoing until the required design
outlet treated effluent characteristics is achieved.
During the above phase, samples at designated and accepted locations may be collected to
access and improve the process stabilization. The analysis report is to be circulated to the
concerned people and official record to be maintained in the laboratory.
For more details on the procedures, REFER to Pre-commissioning and Commissioning

Procedures for ETP: Doc No PDRP0451-8130-PR-231-0001 Rev 3.
6.2 NORMAL START UP PROCEDURE
Normal start up and subsequent plant operation is a vital activity to sustain consistency in the
performance of the treatment systems. The plant operation requires close supervision to
make sure that all the units are operating well and delivering the effluent to the design
parameters and the final effluent being discharged or reused within or meeting the design
specification as per contract.
The plant supervisor should practice and implement the operation activities for smooth and
continuous operation of the plant. This section of the manual will delineate the unit wise
normal start-up operation activities to be followed with a due consideration for the common
instructions highlighted at the end of this section.

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FROM BOTTLED UP CONDITION - EFFLUENT TREATMENT PLANT (ETP –

SECTION 230)
PRETREATMENT SECTION
DESALTER WATER/BRINE EQUALIZATION TANK AND PUMPS
1. Check all safety valves, level transmitters, and gauges are in operation.
2. Ensure all the drain valves in the equalization tanks are closed.
3. Close the influent Desalter water bypass valve to Splitter box 1.
4. Open the valve in the desalter water influent line to desalter water/brine equalization
tank (230-TK-001).
5. The equalization tank is filled with desalter water.
6. While in the filling condition, ensure the level transmitter indicator (LI 1001) is
indicating the increase in level.
7. Open the suction valves of the Desalter water/Brine pumps (230-P-001A/B). Switch
the mode of the pumps to REMOTE.
8. The Brine pumps are started/stopped automatically after start permissive condition
in Desalter water/Brine equalization tank.
9. Open the respective working pump’s discharge valve and set the desired pressure of
pump discharge by throttling the discharge valve very gently by observing the pressure
gauge.
10. Now, Set the desired flowrate to be pumped in the VFD/PID controller available in DCS
HMI.
11. The pumps are to be checked for its vibration, seal leakages, noise and other
parameters locally.
12. Open the outlet valve of floating oil skimmer (230-OS-001), or any of the oil outlet
valves periodically to discharge any floating oil in the tank. This operation is manual
and the frequency is decided based on the actual site conditions, and influent
characteristics.
13. Operate the desalter water/brine recirculation pump (230-P-002A/B) intermittently
or when the effluent in the desalter water/brine equalization tank is stagnant for
significantly longer periods of time. The operation is similar to that as described for
the Brine/Desalter water pumps.
14. Changeover working/standby pumps every 24 hours.
API OIL SEPARATOR
1. Open the inlet gate of API channel. (230-TK-105/205/305).

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2. Check all level transmitters, flow transmitters and gauges are in operation.
3. Ensure the level in the API Sump (230-TK-004) is low, and the level transmitters and
the API OWS pumps (230-P-106A/B/C) are ready.
4. Ensure the sludge drain valves in the TPI separator tank are ready for operation and
are closed.
5. Start the Desalter water/Brine pumps (230-P-001A/B).
6. The effluent from the desalter water/brine equalization pump is received in the
splitter box along with other effluents from the battery limit.
7. Observe the level in the API feed channel (LT 1003) and the flow rate in Flow
transmitter indicator (FT 1002).
8. Bring on line sufficient no.s of API’s according to the desired flow rate.
9. After gradual filling of the API tank, start the mechanism manually (230-A-002A/B/C).
No AUTO operation is envisaged for API.
10. Observe for smoothness of the API chain scrapper mechanism, noise etc.
11. Deoiling operations through slotted skimmer pipes to be carried out 2-3 times
manually in a shift of 8 hours.
12. In case of high oil inlet and deoiling operation is made continuous, ensure a min. oil
layer of 5-10 mm in the API and skim oil accordingly. This is must to avoid effluent
entry to slop oil system (keep water / effluent content in slop oil to minimum for steam
optimization in wet slop oil tank).
13. Before commencing the deoiling operations, ensure the levels in the Wet slop oil sump
(230-SU-007) is low and the Wet slop oil transfer pumps (230-P-012A/B) are ready for
operation.
14. Drain sludge by opening the drain mushroom valve minimum once a shift for a few
minutes. Adjust drain depending on incoming solids load to plant. Ensure the sludge
level in common oily sludge sump (230-SU-010) is minimum to avoid any overflow.
15. Before commencing the desludging operation ensure the readiness of the Common
oily sludge sump (230-SU-010) and the common oily sludge sump agitator (230-M-10),
oil skimmer in Common oily sludge sump (230-OS-002) and common sludge transfer
pumps(230-P-033A/B/C).
16. Start steam sparging if oil solidification is seen. Optimize steam consumption for good
operation. This will be essential during winter conditions.
TPI Separator
1. The effluent after filling up the API tank will start to overflow into the TPI tank (230-
TK-105/205/305).
2. Ensure the flow to the each bay of the TPI Separator is uniform for its effectiveness.
3. The floating oil to be skimmed and the sludge is drained at regular intervals. (Minimum
once per shift). The timing and frequency of sludge drain valve shall be set as desired.

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Ensure the sludge level in common oily sludge sump is minimum to avoid any
overflow.
4. Start steam sparging if oil solidification is seen. Optimize steam consumption for good
operation. This will be essential during winter conditions.
5. Follow points 11 to 15 as indicated for API.
Common oily sludge sump
1. Once the API and TPI separator units are kept in operation, the drained sludge from
these units will be collected in the common oily sludge sump (230-SU-010).
2. Ensure while draining the API/TPI units, the level in the common oily sludge sump is
at a low level to avoid any overflow.
3. Observe the level in the tank (LI – 1005) while receiving the sludge from API/TPI units
(230-TK-105/205/305).
4. Once the sludge submerges the impeller, start the agitator mechanism(230-M-010)
and keep in continuous operation.
5. Operate the Oil skimmer (230-OS-002) intermittently to skim off any excess floating
oil.
6. During winter conditions or when the sludge in tank is highly viscous, open the valves
in the steam sparging line to facilitate heating with LP steam. The desired temperature
is set in the Temperature Indicator Controller (TIC 1001) at the DCS HMI, which
controls the LP steam inlet to the sludge tank via the Flow control valve.
7. After reaching the maximum level in the tank, the sludge shall be pumped to the Oily
sludge Thickener (230-TK-121).
8. Ensure the readiness of the common sludge transfer pump (230-P-033A/B/C) and Oily
API SUMP AND PUMPS
Feed to Equalization tank

1. Check all level transmitters, gauges are in operation and the API OWS pumps (230-TK-
106A/B/C) are ready.
2. Close the influent Desalter water bypass valve to Splitter box 1.
3. The API sump is filled with Effluent from API/TPI tanks.
4. While in the filling condition, ensure the level transmitter indicator (LI 1008) is
5. Before pumping the Effluent to the Equalization tank (230-TK-006A/B), open the Inlet
valve of either of the Equalization tank A/B and close the other.
6. Close all the drain valves in the Respective Equalization tank.

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Note: The Feeding of the API OWS effluent from the API OWS sump can be done either
to the Equalization tank (230-TK-006A/B), or directly to the Oily DA system. The
primary requirement of the Equalization tank is to equalize the effluents over a period
of time for reducing the impact or minimizing any shock load to the downstream units.
7. Close the valve leading the API OWS effluent directly to the Oily DAF system i.e to
Splitter box II.
8. Open the suction valves of the API OWS pumps (230-TK-106A/B/C). Switch the mode
of the pumps to REMOTE.
9. The API OWS pumps are started/stopped automatically after start permissive
condition in API Sump.
10. Open the respective working pump’s discharge valve and set the desired pressure of
pump discharge by throttling the discharge valve very gently by observing the pressure
gauge.
Feed to Oily DAF system (Splitter Box II/Equalization Tank Bypass)

12. Observe until point 4 as indicated above. Close the valve leading the API OWS effluent
directly to the Equalization tanks A/B and open the bypass valve to Oily DAF system
i.e to Splitter box II.
15. Set the desired flow rate to be pumped to oily DAF system, in the Flow control valve
based flow controller available in DCS HMI.
SECONDARY OIL REMOVAL SECTION
EQUALIZATION TANK AND DAF FEED PUMPS
1. Open the valve in the influent line (API sump to Equalization tank).
2. Check all safety valves, level transmitters, and gauges are in operation.
3. Close the bypass valve to Splitter box II.
4. Open the stripper sour water influent line to the Equalization tank and record the
Incoming flowrate in the Flow indicator (FT1009).
5. Ensure all the drain valves in the equalization tanks are closed.
6. While in the filling condition, ensure the respective level transmitter indicator (LI
1010/LI1012) is indicating the increase in level.
7. In case stripped sour water from battery limit is to collected in the equalization tank,
open the valve in the influent line.
8. The respective equalization tank (either 230-TK-006A or 230-TK-006B) is selected in
the DCS HMI as FILL or DRAW mode.

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9. The DAF Feed pumps are stopped / started automatically after start permissive
condition as per the respective equalization tank. Ensure all the suction and delivery
valve are in open condition.
10. Set the desired flow rate to be pumped in the PID controller of the flow control valve
available in DCS HMI.
parameters locally.
12. Set the desired pressure of pump discharge by throttling the discharge valve very
gently by observing the pressure gauge.
13. Open the outlet valve of floating oil skimmer (230-OS-004A/B) periodically to
discharge any floating oil in the tank.
15. Operate the equalization tank recirculation pump intermittently or when the effluent
in the equalization tank is stagnant for significantly longer periods of time.
Flash Mixing tank
1. Before start-up of the Oily DAF system, ensure the readiness of the Chemical dosing
system as described in the later part of this section.
2. Depending on the flow rate desired the required no.s of flash mixing tanks are to be
taken online and the others isolated by means of the isolation stop logs provided.
3. As the flash mixing tanks and flocculation tanks are filled in gradually, start the Flash
mixer (230-M-201) and Flocculator (230-M-203).
4. Observe for any abnormal noise or vibration in the agitators.
5. Open the valve in the FeCl3 dosing line.
6. Observe the pH in the pH analysers (AE1001A and AE1001B) and dose H2SO4 as per
requirement.
7. Start dosing DOPE in the flocculation tanks.
Note:
1. Refer to start-up of the chemical dosing pumps in the subsequent sub sections below
and are to be started up during the start-up of the flash mixing tanks.
2. FeCl3 and DOPE dosage shall be set in AUTO according to the desired flow rate to be
treated. The initial Dosage and concentration shall be decided manually based on jar
test observations done on the effluents.
Flocculation tanks
As described above
Dissolved air flotation

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In the floatation system, two parallel systems are provided for handling the effluents. In each
system, the effluent is mixed with a recycled stream of the same effluent. Two sets each with
Three nos. (2W+1S) DAF recycle pumps (230-P-113 A/B/C & 230-P-213 A/B/C ) each of 124
m3/h is used to recirculate the water from outlet chamber of the DAF tank. The stream is
transferred through a Saturation vessel (230-V-101 & 230-V-201) saturated with compressed
air delivered by DAF Air Compressors (230-K-001 A/B) in order to achieve very fine air bubble
dispersion in the water, which adheres to the impurities. The air/particles-agglomerates float
to the surface of the system will be removed by the floating oil skimmer (230-A-003 A/B/C)
and it is collected in DAF sludge sump (230-SU-119). Settled sludge is removed from the tank
based on timer operated valves provided in the sludge line.
Prior to start-up close the following valves must be in the respective positions
CLOSE:
1. Close all drain valves.

2. Isolation valve for pressurised distribution header. (Line from Saturation vessel to DAF
Tank)
3. Airflow regulating valve.
4. Airflow meter bypass valve.
5. DAF pressurisation vessel drain valve.
OPEN:
1. Level transmitter & Level gauge isolation valves in the saturation vessel.
2. Shut off valve for air bleed line.
3. Upstream & downstream valves of flow meter.
4. Discharge valve in compressor outlet line.
Sequence of Operation
1. Allow the Influent flow in to the DAF system.

2. Start the drive motor for the oil skimmer.
3. Start the compressor and ensure the pressure in the compressor tank is 4.5 – 6 kg/cm2.
4. The pneumatic ON/OFF valve XV 1011/XV1013 will be opened to allow compressed air
to pass to into saturation vessel based on the Pressure set point set in the saturation
vessel (PT1001 & PT1002).
5. Gradually adjust the air Flow meter inlet and outlet valves to set the reading to about
5 Nm3/hr for each operating DAF unit.

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6. The oily DAF Recirculation pumps are stopped / started automatically after start
permissive condition as per conditions in the Saturation vessel. Ensure all the suction
and delivery valve are in open condition.
7. Open the Valve in the Discharge pressure header of the DAF Unit gradually.
8. Simultaneously, set the desired pressure of pump discharge by throttling the
discharge valve very gently by observing the pressure gauge.
ADJUSTMENTS DURING OPERATION
Saturation of the effluent with the compressed air will require a few minutes, and requires
fine adjustment of Air flow reading and the Oily DAF Recirculation pump discharge until the
desired set point of 4.5-5 kg/cm2 in the Saturation vessel is achieved. This adjustment
NECESSIATES continuous FIELD monitoring of the DAF system until the set point is achieved.
9. Withdraw the settled sludge from the bottom sludge cone of the unit by operating the
screw auger. Decide frequency and duration of operation of sludge valve during this
stage, ensuring that excess effluent is not drained out. However, drain must be done
minimum once in 8 hours (even if sludge / SS inlet is very less)
10. Ensure the sludge level in DAF sludge sump (230-SU-119) is minimum to avoid any
overflow.
12. Check the moving surface skimmer and the mechanism of the skimmer checked for its
noise vibration etc.
DAF sludge sump
1. Ensure the readiness of the DAF sludge transfer pump (230-P-036A/B) and Oily sludge
Thickener (230-TK-121).
2. Once the oily DAF units are kept in operation, the drained sludge from these units will
be collected in the DAF sludge sump (230-SU-119).
3. Ensure while draining the DAF units, the level in the common oily sludge sump (LI
4001) is at a low level to avoid any overflow.
4. Once after the submergence of the impeller, start the agitator (230-M-119).
5. After reaching the maximum level in the tank, the sludge shall be pumped to the Oily

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BIOLOGICAL TREATMENT
BIOTOWER/AERATION FEED SUMP
1. The Effluent from the DAF tank will be collected in the Biotower/Aeration tank feed
sump (230-TK-003).
2. Depending on the Process planning and operational requirements, receive the
Stripped sour water effluents, Treated spent caustic from WAO, Treated leachate, Off
Spec/Excess effluent from Effluent check basin and any Supernatants from Bio sludge
supernatant sump.
3. Start dosing Urea/DAP solution in the Biotower/Aeration feed tanks, as per Process
requirements and as described in other sections.
4. Observe and record the Oil level and pH readings in the analyser and start dosing the
H2SO4 as per the Process requirements. The requirements and necessities of the
process control is indicated in other sections.
5. There are two sets of pumps in the Biotower/Aeration feed sumps. One, the Biotower
feed pumps(230-P-126A/B/C/D) feeds to the Biotower and the Aeration feed pumps
(230-P-127 A/B/C/D/E) feeds to the Aeration tank.
Note:
 The Biotower arm rotates through the hydrostatic pressure available as provided by
the Biotower feed pumps, and the effluent is recycled back into the
Biotower/Aeration feed sump.
 When there is incoming effluent to the Biotower/Aeration feed sump, the effluent
overflows into an adjacent feed chamber in the sump, from where the effluent can
be pumped into Aeration tank. This is designed in such a way that during no inflow
into the Biotower/Aeration feed sump, the Biotower feed pumps can be operated
continuously thereby maintaining the media in the Biotower in a wet condition.
FEED to Biotower
6. Decide on the number of biotowers to be kept in operation. Each unit of biotower is

fed by a dedicated feed pump.
7. The Biotower feed pumps (230-P-126A/B/C/D) are stopped / started automatically
after start permissive level in Biotower/Aeration tank feed sump (230-TK-003). Ensure
all the suction and delivery valve are in open condition.

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parameters locally.
10. After a few minutes, ensure the effluent fed to the Biotower is recycled back to the
Biotower/Aeration feed sump through the recycle channel.
11. Check the function of rotary distributor and the smoothness of rotation.
FEED to Aeration tank
13. While the adjacent compartment (feed sump to aeration tank) is in the filling
condition, ensure the level transmitter indicator (LI 2005) is indicating the increase in
level.
14. The Aeration feed pumps are started/stopped automatically after start permissive
condition in Biotower/Aeration tank feed sump. Ensure all the suction and delivery
valve of the Aeration feed pumps are in open condition.
parameters locally.
Note: 1. Refer to start-up of the chemical dosing pumps in the subsequent sub sections
below and are to be started up during the start-up of the Biotower/Aeration feed pumps.
2. Daily or at least weekly once visual inspection of bio-film for any changes in colour. The
lighter the color the better the performance of the bio-tower.
AERATION TANK/SECONDARY CLARIFIER
The Splitter box III (230-SU-115) for aeration tank (230-TK-111/211) receives the flows
from Biotower/Aeration feed sump, recycle flows from RAS pump (230-P-115A/B/C),
Weathered sludge liquor, Screened sewage from Refinery and Waste backwash UF Reject.
Isolation gates are provided in the aeration tank inlet for isolation. The recycle of activated
sludge from the secondary clarifier ensures the desired MLSS (biomass) to be maintained, in
the aeration tank. Nutrients like DAP and Urea are dosed in the Aeration/Biotower feed sump
depending upon the requirement.
1. Open the gates feeding the Aeration tanks and ensure there is no obstruction.

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2. Ensure that all the diffusers are checked prior to start up and that the air distribution
is uniform.
3. Start the Aeration tank feed pumps (230-P-127A/B/C) and gradually fill the Aeration
tank. The number of pumps shall be decided according to the flow rate that is to be
treated.
4. Start 2 nos. (4W+2S) aeration tank air blowers (230-K-102 A/B/C, 230-K-202 A/B/C)
(total of two no.s working for each compartment) each of 2050 Nm3/h when the liquid
level in the aeration tank is around 0.5 M above Fine bubble fixed type Membrane
Tube Diffusers.
5. Once the tank level is around 3.0 m deep start the other two air blowers as well.
6. Add measured quantity of biomass/bio sludge from existing nearby ETP/or Secondary
sludge sourced from a nearby Municipal sewage treatment plant into aeration tank.
7. Ensure Air Blowers are running, without any unusual noise.
8. Check for dissolved oxygen by continuous monitoring of D.O. analyzers. Calibrate the
DO analysers periodically once every 15 days.
9. Maintain a Dissolved oxygen level of 1.5 – 2.0 mg/l in the Aeration tank and operate
the Blowers accordingly.
VFD based Blower:
There are two no.s of working blowers provided for each Aeration tank (2050 Nm 3/hr).
One no. of blower is provided with a VFD Drive for controlling the RPM, thereby controlling
the delivery of Blower. The signal from the DO sensor in the aeration tank provides the
input signal to the PID controller configured in the DCS to control the speed of the VFD
blower. The required D.O to be maintained in the aeration tank is to be entered in the DCS
HMI by the operator, which thereby controls (i.e reduces or increases the RPM of the
blower) the blower capacity vis-a-vis the amount of D.O that is to be maintained in the
aeration tank.
10. Once the Aeration is tank is filled, collect sample and analyze for MLSS, MLVSS and SVI
as per the sampling schedule.
11. Open the outlet sluice gate in the Aeration tank to allow the Mixed liquor (i.e Aeration
tank effluent) to flow to the secondary clarifier.
12. Record the pH in the aeration tanks.
Refinery sewage feed to Aeration tank:
The sewage from the Refinery and Township is received in the Screen chambers (230-SU-
117A/B) and is added in the Splitter box III. The screen chambers are provided with one no.
of mechanized screen and one no of manual screen.

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1. The sewage is received in the screen chamber and is screened for any debris or floating
materials by the mechanized screen. The mechanized screen works automatically
after detecting any upstream and downstream level difference that arise as a result of
obstruction in the screens.
2. The manual screen is provided as a mode of standby.
3. After receiving the sewage in the chambers, switch on the Centrifugal fan (230-K-
103A/B) that is provided for clearing of the odours in the chamber.
SECONDARY CLARIFIER
Two no.s of Secondary clarifier are provided with a peripheral driven type mechanism. The
solids in the Mixed liquor (i.e effluent from the Aeration tank) settles down in the clarifier and
is scrapped to the central hopper. Overflow weir is provided at the overflow launder of the
secondary clarifier to ensure smooth overflow of the clarified treated effluent. The sludge
withdrawal is done from secondary clarifier underflow to recycle part of the sludge back into
the aeration tank and the remaining for disposal.
4. Once the Mixed liquor from the aeration tank is received in the Secondary clarifier,
start the mechanism.
5. Check the scrapper of secondary clarifier for proper functioning and ensure
smoothness of running. Observe for any abnormal noise in the gear box.
6. Once the clarifier is filled up, the clarified effluent starts overflowing in the outer
launder of the clarifier and is conveyed to the Splitter box IV.
7. After allowing sufficient time for plant stabilization (i.e D.O level stabilization, desired
MLSS levels in aeration tank), bleed the settled sludge from the secondary clarifiers by
opening the sludge bleed valve in the underflow line of the clarifier.
8. The consistency of the sludge bleed from the clarifier can be visualized through the
telescopic chamber provided.
9. Ensure the levels in the RAS sump (230-SU-104) are low to avoid any overflows.
Note: The amount of sludge bleed and the parameters for biological plant stabilization
are described in detail in Section 4.0 Operating variables and Section 9.0 Plant
performance monitoring.
10. Periodically flush the sludge lines for clearing any sludge blockages.

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RAS Sumps and Pump
1. The RAS pumps/SAS feed pumps are stopped / started automatically w.r.t. activated
sludge level in RAS sump. Ensure all the suction and delivery valve are in open
condition.
2. The pumps are to be checked for its vibration and other parameters for the smooth
operation of the pump.
3. The amount of sludge to be recycled shall be decided as described in Section 9.0 Plant
performance monitoring. Accordingly the no. of pumps for recycling RAS shall be
operated, by monitoring the flow in the Flow meter (FT2013).
5. Similarly, the excess sludge bleed from the RAS sump to Bio sludge thickener is
recorded with the Magnetic flow meter (FT 2003).
Bio-DAF system.
In the floatation system, two parallel systems are provided for handling the secondary
clarified biological effluent. In each system, the effluent is mixed with a recycled stream of
the same effluent. Two sets each with Three nos. (2W+1S) Bio DAF recycle pumps (230-P-120
A/B/C & 230-P-220 A/B/C ) each of 150 m3/h is used to recirculate the water from outlet
chamber of the DAF tank. The stream is transferred through a Saturation vessel (230-V-102 &
230-V-202) saturated with compressed air delivered by DAF Air Compressors (230-K-104 A/B)
in order to achieve very fine air bubble dispersion in the water, which adheres to the
impurities. The air/particles-agglomerates float to the surface of the system will be removed
by the floating skimmer (230-A-005 A/B/C/D) and it is collected in RAS sump (230-SU-104).
Settled sludge is removed from the tank based on timer operated valves provided in the
sludge line.
Refer oily DAF system for normal start-up operation.
EFFLUENT CHECK BASIN/TREATED TRANSFER PUMPS
1. The biologically treated effluent from the BioDAF system is collected in the Effluent
Check basin (230-SU-101).
2. The OFF SPEC/EXCESS EFFLUENT Transfer pumps/Treated effluent transfer pumps are
started automatically w.r.t. effluent level in Effluent check basin. Ensure all the
delivery valves are in open condition.
4. For further filtration, the biologically treated effluent is pumped to Water Recovery
plant via the Treated effluent transfer pumps (230-P-022A/B/C), and the flow rate is

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recorded in the flow meter (FT-2010).

5. In case of any off spec effluent is received, the same shall be pumped to Off spec storm
water Reservoir/Biotower feed sump/Clean Effluent sump/Equalization tank
depending on the effluents quality and as per process requirements.
6. In the case of treated water requirements for any Dust suppression/Gardening
Purpose in the refinery, the treated water shall be pumped to the water tankers via
the Treated effluent transfer pumps (gardening)(230-P-025A/B).
7. The Biologically treated effluent is pumped to Water Recovery Plant for further
filtration and is recorded with the flow transmitter (FT-2010).
8. The floating oil skimmers are operated periodically, to ensure no oil film is present.
SLOP OIL AND SLUDGE HANDLING FACILITIES
Wet Slop oil Sump/ Pump
1. All the slop oil (skimmed oil) from Desalter water/Brine equalization tank (230-TK-
001), API separator (230-TK-105/205/305/405), TPI Separator (230-TK-
105/205/305/405), common oily sludge sump(230-SU-010), Equalization tank (230-
TK-008A/B), API sump (230-TK-008A/B), Naphthenic oil transfer pumps (231-P-108A),
Slop oil transfer pumps (231-P-109A/B) is received in the Wet slop oil sump (230-SU-
007).
2. The collected oil is to be further pumped into the Slop oil tanks (230-TK-010/011),
where the water is separated from the wet slop oil by phase separation. Two no.s of
tank are provided for this purpose and the tanks operate in FILL and DRAW mode.
3. The operator has to select either of the tank for Filling operation from the DCS HMI
screen. This opens the respective inlet pneumatic valve of the tank.
4. The Wet slop oil transfer pumps (230-P-012 A/B) are started/stopped automatically
after start permissive condition in Wet slop oil sump. Ensure all the suction and
delivery valve of the wet slop oil transfer pumps are in open condition.
Slop oil Tank/ Dry slop oil transfer Pumps
1. Once the tank is selected for FILL mode, the Wet slop oil transfer pumps transfer the
wet slop oil from the wet slop oil sump to the Slop oil tanks.
2. Once the tank is gradually being filled, Open the Steam Inlet valves for heating of the
slop oil tank contents. Open the Steam trap inlet and outlet valves in the steam coil

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outlet line to facilitate condensate drain. The steam coil heating facilitates the phase
separation of the water and slop oil. The steam can be regulated via the Flow control
valve by setting the desired temperature in the DCS HMI, to be maintained in the
tank.(TIC – 3001)
3. Ensure the steam heating is continuous. This ensures efficient oil water interface in
the tank.
4. Once the tank is filled to more than a half & as a result of phase separation in the tank,
the excess water will tend to accumulate in the bottom of the tank with the oil floating
over the water layer.
5. The excess effluent/water in the slop oil tank is to be periodically drained by opening
the intermediate drain valve in the tank based on the oil-water interface level
recorded in the oil water interface level transmitter, or by visually observing the
quality of the effluent. The excess effluent is drained off in the Intermediate drain
sump (230-SU-118).
6. Before draining the excess effluent from the slop oil tanks, ensure the level in the
Intermediate drain sump is low.
7. The draining activity is stopped once after the drain effluent is observed with oil or
when the interface level is reached.
8. The drained effluent transfer pumps (230-P-135A/B) are stopped / started
automatically w.r.t. drained effluent level in sump. Ensure all the delivery valve is in
open condition.
Note: During the draining over activity, the inlet wet slop oil transfer must be stopped to
ensure good phase separation.
9. Resume the Wet slop oil transfer as indicated in Section 7.4.1

10. Carry out the draining of the excess effluent as indicated in steps 1 to 7 above
gradually consolidating the consistency of slop oil i.e. reducing the water content in
the slop oil.
11. Once the level reaches the maximum in the Slop oil tank, start feeding the wet slop oil
to the alternate tank as indicated in Section 7.4.1. The selection can be made by the
operator in the DCS HMI.
Dry Slop oil transfer pumps
12. Select the Slop oil tank for the DRAW mode. This can be done by the operator from
the DCS HMI. Open the pneumatic valve in the outlet line of the slop oil tank.
13. The dry slop oil pumps (230-P-011A/B) are stopped / started automatically w.r.t. dry
slop level in slop oil tanks (230-TK-010/011). Ensure all the suction and delivery valve
are in open condition.

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14. The dry slop oil is to be transferred to battery limit for further slop oil processing by
client.
17. The temperature of the slop tank is to be monitored regularly.
Sludge Dewatering (Oily chemical Sludge)
1. The oily sludge collected in the common oily sludge sump and DAF sludge sump, is to
be thickened in the Oily sludge Thickener (230-TK-121).
2. The common sludge transfer pumps (230-P-033 A/B/C) are started/stopped
automatically after start permissive condition in Common oily sludge sump. Ensure all
the suction and delivery valve of the common oily sludge transfer pumps are in open
condition.
4. The DAF sludge transfer pumps (230-P-036 A/B) are started/stopped automatically
after start permissive condition in DAF sludge sump. Ensure all the suction and delivery
valve of the common oily sludge transfer pumps are in open condition.
7. Once the oily sludge from the common oily sludge sump and DAF sludge sump is
received in the Oily sludge thickener, start the mechanism.
8. Check the scrapper of oily sludge thickener for proper functioning and ensure
9. Once the thickener is filled up, the supernatant starts overflowing in the outer launder
of the thickener and is conveyed to the Oily supernatant sump (230-SU-011) by
gravity.
10. After sufficient operation time (8 hr), de-sludge the thickener by opening the
thickened sludge underflow drain valve, to collect the thickened sludge in the
Thickened oily sludge sump (230-SU-110).
11. There is also a provision of bypassing the thickener and collecting the sludge directly
in the Thickened oily sludge sump (230-SU-110).
13. After reaching the maximum level in the tank, the sludge shall be pumped to Oily
sludge centrifuges (230-DEW-301/401)

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Note: The amount of sludge generated is described in Section 9: Plant Performance

monitoring. Accordingly, the time and frequency of opening of the valve is decided.
14. Ensure the readiness of oily centrifuge feed Pumps and DWPE dosing system and the
0.5% DWPE solution is prepared and kept ready for dosing, before preparing for the
dewatering operation.
15. Start the Belt Conveyor (230-CR-001A/B) for carrying the Dewatering cake into Tipper
trolley.
16. Start the Centrifuge (230-DEW-401/301) prior to start of the centrifuge feed pumps
for the centrifuge to reach the desired speed.
17. Start the Oily centrifuge feed pump (230-P-132A/B/C).
18. The centrifuge and feed pumps are to be checked for any vibration and other
parameters for the smooth operation of the pump.
19. After the desired time of operation of the centrifuges, the oily centrifuge feed pumps
are stopped first followed by centrifuge.
20. Always run the centrifuges for a short while with water before shut down.
21. Arrange to cart away the dewatered cake from the area, so that the next batch of
operation can be started.
Re-slurry sump and pumps
22. In the case of oily sludge processing requirement at the Clients DCU facility (outside
B/L), Collect the dewatered sludge in the Re slurry sump (230-SU-121).
24. After reaching the maximum level in the tank, the sludge shall be pumped to the
Clients DCU facility.
Sludge Dewatering (Bio Sludge)
1. The bio sludge collected in the RAS sump, is to be thickened in the Bio sludge Thickener
(230-TK-120).
2. The SAS pumps (230-P-128 A/B) are started/stopped automatically after start
permissive condition in RAS sump. Ensure all the suction and delivery valve of the SAS
pumps are in open condition.
6. Once the bio sludge from the common RAS sump is received in the Bio sludge

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thickener, start the mechanism.

7. Check the scrapper of Bio sludge thickener for proper functioning and ensure
8. Once the thickener is filled up, the supernatant starts overflowing in the outer launder
of the thickener and is conveyed to the Bio supernatant sump (230-SU-002) by gravity.
9. After sufficient operation time (8 hr), de-sludge the thickener by opening the
thickened sludge underflow drain valve, to collect the thickened sludge in the
Thickened bio sludge sump (230-TK-118).
11. After reaching the maximum level in the tank, the sludge shall be pumped to Bio
sludge centrifuges (230-DEW-101/201)

monitoring. Accordingly, the time and frequency of opening of the valve is decided.
12. Ensure the readiness of bio centrifuge feed Pumps (230-P-124A/B/C) and DWPE
dosing system and the 0.5% DWPE solution is prepared and kept ready for dosing,
before preparing for the dewatering operation.
13. Start the Belt Conveyor (230-CR-002A/B) for carrying the Dewatering cake into Tipper
trolley.
14. Start the Centrifuge (230-DEW-101/201) prior to start of the centrifuge feed pumps
for the centrifuge to reach the desired speed.
15. Start the Bio centrifuge feed pump (230-P-124A/B/C).
16. The centrifuge and feed pumps are to be checked for any vibration and other
parameters for the smooth operation of the pump.
17. After the desired time of operation of the centrifuges, the bio centrifuge feed pumps
are stopped first followed by centrifuge.
18. Always run the centrifuges for a short while with water before shut down.
19. Arrange to cart away the dewatered cake from the area, so that the next batch of
operation can be started.
Weathered sludge and Liquor transfer pumps
25. The dewatered sludge is to be transported bio tipper trolleys to Sludge weathering
beds (230-TK-122A/B/C/D) for further drying.
26. The dewatered sludge is manually loaded into the sludge weathering beds from the
tipper trolley.
27. Gradually, over a period of days the liquor in the dewatered cake starts to trickle from
the weathering beds and is collected in the weathered sludge Liquor transfer sump

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(230-SU-122).
28. After reaching the maximum level in the tank, the liquor shall be recycled back to
Splitter box III for treatment.
29. The Weathered sludge Liquor transfer pumps (230-P137A/B) are started/stopped
automatically after start permissive condition in the weathered sludge Liquor transfer
sump (230-SU-122). Ensure the delivery valve of the pumps is in open condition.
30. After sufficient consolidation of the sludge in the weathering beds, the sludge cake
shall be disposed by client.
LANDFILL LEACHATE TREATMENT PLANT (ETP – SECTION 231)

Leachate Equalization Tank/ Leachate Transfer Pumps
1. Open the valve in the Leachate Equalization tank (231-TK-001) influent line to receive
the Leachate effluent
2. Ensure the drain line is closed.
3. While in the filling condition, ensure the level transmitter indicator (LI 1001B) is
4. The Leachate transfer pumps (231-P-007A/B) are started/stopped automatically after
start permissive condition in Leachate equalization tank. Ensure all the suction and
delivery valve of the leachate transfer pumps are in open condition.
5. Set the desired flowrate to be pumped in the VFD/PID controller available in DCS HMI.
parameters locally.
8. Open the outlet valve of floating oil skimmer (231-OS-001), or any of the oil outlet
valves periodically to discharge any floating oil in the tank.
9. Operate the Leachate recirculation pump (231-P-005A/B) intermittently or when the
effluent in the leachate equalization tank is stagnant for significantly longer periods of
time.
pH Adjustment/Flash Mixing/Flocculation tank
1. Ensure the readiness of Caustic dosing system, Ferric chloride and polymer dosign and
kept ready for dosing, before pumping the leachate effluent to pH adjustment tank I.
2. The Leachate effluent is received in the pH Adjustment tank I (231-TK-004A).

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3. After the Submergence of the agitator (231-M-001) in the effluent, start the agitator.
4. Start Caustic dosing pump as per the process requirement. The desired pH that is
required to be maintained in the pH adjustment Tank I is to be set in the DCS HMI.
Accordingly, the caustic chemical will be dosed automatically.
5. Once the effluent overflows from the pH Adjustment tank I to Flash mixing tank (231-
TK-004B), start the agitator (231-M-002) followed by Ferric chloride dosing pump.
6. The effluent from the flash mixing tank will subsequently enter the Flocculation tank
(231-TK-004C). Once after submergence of the agitator (231-M-003) in the effluent,
start the Flocculator (231-M-003) followed by the Polymer dosing pump.
7. Observe the mixer drives for any abnormal noise, vibration and heating up.
8. Check chemicals are dosed for proper coagulation the Flash Mixer.
9. Observe the flocculation tank for proper floc development and the flocs should be
fluffy.
Plate type Clarifier/Treated Leachate transfer pumps
1. The flocculated effluent will be conveyed to the Plate type clarifier(231-TK-005),

where the settling of the flocculated particles takes place and the clarified overflow is
collected in the pH adjustment tank II.
2. There is no mechanical equipment associated with the Plate type clarifier.
3. After sufficient operation time (8 hr), desludge the plate type clarifier by opening the
thickened sludge underflow drain valve, to collect the settled sludge in the Leachate
sludge sump (231-SU-002).
4. Start Acid dosing pump to pH Adjustment tank II as per the process requirement. The
desired pH that is required to be maintained in the pH adjustment Tank II is to be set
in the DCS HMI. Accordingly, the Acid chemical will be dosed automatically.
6. Subsequently, the pH adjusted effluent will be received in the Leachate Effluent
collection sump (231-TK-013).
7. The treated leachate is to be further pumped to Biotower/Aeration feed sump (230-
TK-003) for Biological treatment.
8. The Treated Leachate transfer pumps (231-P-009A/B) are started/stopped
automatically after start permissive condition in Leachate effluent collection sump
(231-TK-013). Ensure all the suction and delivery valve of the treated leachate transfer
pumps are in open condition.
parameters locally.

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11. In order to ensure the pumped leachate to biological treatment is not toxic nor cause
a shock load, certain part of the treated leachate shall be collected in a Aeration pot
(231-TK-006), where its Dissolved oxygen is monitored. The aeration is facilitated by
plant air. The dissolved oxygen shall be in the range of 1.5 to 2.0 mg/l to ensure
minimal shock loading.
12. Some part of the RAS is also added in the aeration pot. The timer operated valves
shall be operated accordingly.

monitoring. Accordingly, the time and frequency of opening of the valve is
decided.
Leachate sludge sump/ Filter press
1. The settled sludge from the Plate type clarifier is collected in the Leachate sludge sump
(231-SU-002).
2. Once the agitator in the tank is submerged, start the agitator (231-M-005).
3. The sludge is further dewatered with the filter press (231-GN-002A/B). Open the inlet
valve of the filter press. The operation of the filter press is entirely manual and a batch
operation.
4. The filter press feed pumps (231-P-008A/B) are stopped / started automatically w.r.t.
sludge level in leachate sludge sump. Ensure all the suction and delivery valve are in
open condition.
6. The suction lines are to be periodically flushed.
7. The sludge generated in the filter press is collected in the tipper trolley and is carted
away to LLPP sludge weathering beds (231-TK-014A/B) for further dewatering.
8. The sludge liquor from the dewatering beds is collected in the LLPP drainage sump
(231-SU-001) from where it is recycled back to pH adjustment tank I (231-P-006A/B)
of the Landfill leachate treatment system.
9. The LLPP drainage pumps (231-P-006A/B) are stopped / started automatically w.r.t.
effluent level in LLPP drainage sump. Ensure the delivery valve is in open condition.
HARD COD MANAGEMENT PACKAGE (ETP – SECTION 231)

Carbon Contact Tank/ Plate type clarifier
1. The HARD COD Management plant treats the RO Reject, and renders it more suitable
for disposal to Sea.
2. The RO Reject is collected in the Carbon contact tank (231-TK-002).

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3. Ensure the PAC dosing system and Acid dosing system is ready before start up of the
Hard COD management plant.
4. Once the Effluent starts collecting in the Carbon contact tank and when the agitator is
submerged, start the agitator (231-M-006).
5. Start the PAC dosing and Acid dosing.
6. Bring in line the Plate type clarifier (231-TK-003A/B) by opening the isolation inlet gate
valve and the effluent overflows into the Overflow chamber and is conveyed to the
respective plate type clarifier by gravity.
7. Monitor the pH and set the desired pH that is to maintained in the Carbon contact
tank in the DCS HMI. Accordingly the acid quantity shall be dosed automatically.
8. Once the effluent enters the plate type clarifier, start the mechanism (231-CLR-
007A/B).
9. Check the scrapper of plate type clarifier for proper functioning and ensure
10. Once the plate type clarifier is filled up, the supernatant starts overflowing in the outer
launder of the clarifier and is conveyed to the Clean effluent sump (231-TK-008) by
gravity.
11. After sufficient operation time (8 hr), desludge the clarifier by opening the thickened
sludge underflow drain valve, to collect the settled sludge in the PAC sludge sump
(231-SU-004).
13. After reaching the maximum level in the tank, the sludge shall be pumped to RAS sump
(230-SU-104) in the Effluent Treatment plant section.
14. After sufficient level in the clean effluent sump (231-TK-008), start the Clean Effluent
Transfer pumps (231-P-011A/B).
15. The clean effluent transfer pumps (231-P-011A/B) are stopped / started automatically
w.r.t. effluent level in clean effluent sump. Ensure all the suction and delivery valve
17. The clean effluent is discharged into sea after filtering through the Guard filters (231-
GN-001A/B)
18. The guard filters are fully automatic in functioning.
19. There is also a provision of bypassing the Guard filters.
Coke pile dust suppression
20. The untreated RO Reject shall be used for Coke pile dust suppression in the Refinery
complex and a dedicated set of pumps are provided for the purpose.

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21. The coke suppression pumps (235-P-127A/B) are stopped / started automatically
w.r.t. effluent level in carbon contact tank. Ensure all the suction and delivery valve
Note:
1. The amount of sludge generated and the chemical dosing rates is described in Section
9: Plant Performance monitoring. Accordingly, the time and frequency of opening of
the valve is decided.
2. Refer to start-up of the chemical dosing pumps in the subsequent sub sections below
and are to be started up during the start-up of the HCOD management system.
CHEMICAL DOSING SYSTEM

When handling various chemicals rubber or PVC gauntlet gloves, protective clothing and
close fitting chemical goggles must be worn. A face shield should be worn in addition to the
goggles if there is a risk of liquid splashes. Rubber boots should be worn when operating in
the dyke/spill up areas. If accidentally splashed on skin, wash off immediately under safety
shower.
General Operating Procedure: (For all Chemical dosing)
1. Select one of the Dosing Tanks for preparing solution with appropriate strength.
2. Fill up the selected Dosing Tank with service water up to the required level to prepare
solution.
3. Start the agitator, when the water is above the impeller.
4. Add manually the required quantity of chemical into the selected Dosing Tank.
Note: DWPE, Polymer and DOPE are added via pneumatic and powder feeder systems, and
the respective operation is covered in the respective vendor manual.
5. Keep the agitator in running condition.

6. Ensure all the chemical is dispersed and dissolved.
7. Open the suction side and discharge side of the valves of the selected pump and start
the appropriate pump for dosing to respective areas.
8. Keep the agitator (in running condition).
9. Prepare the same solution in the other tank, similarly, when the tank, which is full

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with the prepared solution, is under dosing mode.

10. When the level in Dosing Tanks, which is in feeding mode, drops to set low level, the
level transmitter trips the running Dosing Pump and the agitator.
11. Change over to the other tank preferably, just in time before the tripping of the
running Dosing Pump, because of low level in the tank in service.
12. Dose the solution as per plant requirement. Ensure the discharge valve is kept fully
open, when the dosing pump is started. Adjust the dosing rates, as required, by stroke
adjustment.
13. Periodically change over to the standby pump and flush up the suction line/Cleaning
up of the strainers for smooth running of dosing pumps.
Note:
1. The respective chemical dosing and consumption rates are described in Section 9:
Plant Performance monitoring. Accordingly, the solution is prepared.
Acid Dosing System:
1. Ensure 98% H2SO4 is carefully received into the respective H2SO4 day tanks, (230-TK-
133), (231-TK-012), (230-TK-010), from the header line. Collect the sample of acid
and send to lab to determine strength of acid.
2. Before filling the tank ensure the Breather vent is filled in with Silica gel, and the drain
valve is closed.
3. Dose the 98% H2SO4 as such without any dilution, with the help of acid Dosing Pumps
to the respective areas.
4. Ensure the discharge valve is kept fully open, when the dosing pump is started.
5. Adjust the dosing rates as required, by stroke adjustment.
6. In the case of HCOD treatment plant and LLTP package, the dosing is automated with
respect to the desired pH to be maintained in the respective process unit.
7. Periodically change over to the standby pump.
Note:
1. Do not flush the Acid dosing lines with water after taking into service.
Caustic Dosing System:
1. Ensure 20 % Caustic is carefully received into the respective Caustic day tanks, (231-
TK-011), (231-TK-009) from the header line.
2. Collect the sample of alkali and send to lab to determine strength of alkali.
3. Before filling the tank ensure the Breather vent is ready.
4. Dose the 20% Caustic as such without any dilution, with the help of caustic Dosing

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Pumps to the respective areas.

5. Ensure the discharge valve is kept fully open, when the dosing pump is started.
6. Adjust the dosing rates as required, by stroke adjustment.
7. In the case of HCOD treatment plant and LLTP package, the dosing is automated with
respect to the desired pH to be maintained in the respective process unit.
8. Periodically change over to the standby pump.
Note: The chemical dosing rates and consumption is described in Section 9: Plant
Performance monitoring.
Other Routine Checks and Operations
a. Daily basis:
 Test annunciation system at the PLC for proper functioning.

 Check MCC for any abnormal noise and correct position of isolator switches.
 Check MCC for any O/L trip indication; Reset if any one existing.
 Check the rotary equipment in operation for normal flow, pressure, load current,
abnormal noise, vibration, excess gland leak, over heating etc.
 Check lubricating oil levels wherever oil lubrication is provided. Ensure lubrication
schedule for equipment is also implemented and its records are maintained.
 Follow the instructions given in the equipment supplier’s manual.
 Check for any mechanical loose parts or any undue noise or vibration.
 Analyze the cause of trip of any rotating equipment before its re-start.
 Check the functioning of level instruments provided in sumps for its low level trip
operations.
 Collect samples for analysis.
 Prepare fresh batch of polyelectrolyte solution & DWPE solution and keep it ready for
dosing to meet daily requirement.
 Prepare for the dewatering operation during the day.
 Check treated effluent quality to be within the permissible limits.
 Arrange for carting away the screenings, Grit and cake.
 Ensure all the instruments are working properly.
 Change over the duty of the standby equipment wherever available.
 Check stock status of chemicals and make up depleted stock.
b. Weekly
 Close/open manual valves/gates (which was idle for long time) to ensure freeness and
lubricate, if necessary.

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 Make up the lubricating oil level with recommended grade of lubricating oil.
JOB RESPONSIBILITY
RESPONSIBILITY OF SHIFT ENGINEER/SHIFT IN CHARGE
1. Responsibility of smooth plant operation ensuring plant safety lies on shift in charge.
2. Guiding the panel engineers and field operators for production stability and achieving
the required specification of treated effluents.
3. Close monitoring of the quality norms, environmental regulations by means of smooth

plant operation.
4. Guiding and supervising field operations and PLC operations.
5. Ensuring routine sampling as per schedule.
6. Ensuring work permit system with risk analysis in place.
7. Issuing and approving closed work permits and continuous follow ups, if necessary.
8. Ensuring safe work conditions for the maintenance crew/operating personnel to work
in the plant and regular round to the site to check the safety measures.
9. Coordinating with all upstream and downstream process units/plants for smooth
plant operation to avoid upsets.
10. Coordinating with all service departments for required maintenance, inspection etc.
11. Handling emergency scenario like power failure, utility failure, fire, leak etc & to guide
the panel and field staff to take safe shut down, if required.
12. Shall act as a single point communication during emergency in the plant with
concerned personnel/upstream and downstream process units/plants.
13. Monitoring and identifying the upsets/deviations and take necessary actions to avoid
further breakdown/shutdowns.
14. Ensuring adherence to SOP’s and check lists for various activities to ensure the safety
while working.
15. Ensure regular field visits so as to identify field abnormalities (equipment vibrations,
leakages & emissions, unsafe practices) & taking remedial actions.

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16. Proper logging of all shift activities for proper follow ups and future records.
17. Preparation of field change orders (FCO)/modifications for operation flexibilities when
required.
18. Close monitoring of hot jobs, vessel entry and excavation etc. where high risk is
involved.
19. Ensuring close coordination between inter departments, field & PLC operations to
ensure the timely completion of the work ensuring minimum loss of the production.
20. Shall provide necessary plant data/information for Technical services group/special
task forces for trouble shooting, debottlenecking/revamp works.
RESPONSIBILITY OF PANEL ENGINEER
1. Guiding and coordinating with field operators under the supervision of shift in charge.
2. Shall maintain the process stable by adjusting various process parameters to avoid plant
upset, quality degradation, production loss, unforeseen breakdowns and shutdown.
3. Shall log the identified critical plant parameters on defined intervals.
4. Shall closely watch the critical process parameters for smooth operation.
5. Monitoring the quality norms, environmental regulations by means of smooth plant

operation.
6. Follow up for work permits, informing the status to shift in charge.
7. Shall have sufficient knowledge of PLC system logic functions.
8. Shall be responsible for operation of Auxiliary console switches/buttons as and when

required.
9. Shall enable/disable auto/remote start/stop facility of rotating equipment from PLC during
maintenance.
10. Shall be in close coordination with field operators during emergency with Annunciations,
public address systems, Walkie talkie and pagers under the guidance of shift in charge.

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11. Proper logging of all shift activities and follow ups for future records.
12. Monitoring and identifying the upsets/deviations and inform shift in charge for necessary
actions to avoid further breakdowns/shutdowns.
13. Coordinating with all upstream and downstream process units/plants for smooth operation
to avoid upsets, under the guidance of shift in charge.
14. Shall extend support to shift in charge and field personnel during emergency in the plant by
means of plane operation to take safe shutdown.
RESPONSIBILITY OF FIELD OPERATOR
1. Shall be well versed with process plant as well as with safe operating practices and permit
system.
2. Adherence/commitment to follow safety rules.

3. Responsible for routine plant activities through the instructions received from control room
and shift in charge.
4. Shall guard the plant for any mischief actions by others, and reporting to shift in charge for
any observation.
5. Shall immediately take necessary action as and when required to avoid breakdowns and
shutdown of the running plant.
6. Responsible for continuous field visits so as to identify any field abnormalities (equipment
vibrations, leakages and emission, unsafe practices) and informing the control room for taking
remedial actions.
7. Follow routine sampling schedule as well as sampling required for smooth plant operation.
8. Shall be responsible for systematic line and isolations of the equipment as per SOP and check
lists provided.
9. Shall log the critical parameters and inventory levels identified on regular interval basis in the
field.
10. Close monitoring of hot jobs vessel entry, vehicle entry and excavation etc. where high risk is
involved.
11. Maintaining inventory levels of required specialty chemical dosing systems in the field.

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12. Shall report to control room for equipment vibrations, leakages and emissions for further
action by maintenance crew.
13. Shall facilitate safe working conditions for the maintenance crew while working in the plant.
14. Shall initiate emergency alarm provided at manual call point (MCP) if fire is observed and try
to mitigate the same and inform the same to control room/Fire and safety for onward
mitigation action.

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CHAPTER – 7
NORMAL PLANT SHUTDOWN

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7.1 NORMAL SHUT DOWN
Effluent treatment plants are generally not shut down completely in view of their
essentiality from the environmental angle as under no circumstances effluent can be
discharged without treatment. However, at times, shutdown may be required due
to non-availability/ breakdown of equipment for which the following operations are
suggested:
1. In case of breakdown of TPI Oil Separators or downstream equipment, by-

pass the equipment. Store excessive influent in guard ponds for processing
after the equipment is restored.
2. In case of shutdown of Bio Tower, keep recirculation pump running for
survival of the microbes.
3. In case of shutdown of Aeration Tank, keep air blowers running. Biological
sludge recirculation pump should also be kept running for survival of the
microbes.
4. In case of shutdown of Clarifier, keep sludge scrapping mechanism running.
5. In case of shutdown of Sludge Thickeners, keep sludge scrapping mechanism
running.
6. Before shutdown of Centrifuges & Centrifuge Feed Pumps, flushing is must.
Shut down of the plant is decided and taken for repair and maintenance purposes of the
identified equipments and structures during operation of the plant and also in the events of
effluent unavailability. Before planning any shutdown activity, ensure the readiness and
availability of sufficient manpower and spares.
Sufficient provisions are provided in the plant to carry out shutdown activities for individual
process units enabling bypasses so as to minimize all necessary downtime of the activities
required.
 In general, ensure no high level exists in any sump, before shutting down.
 Stop the rotating equipments right from inlet to the final effluent storage tank at local
or at MCC.
 Isolate the equipment mechanically and the power supply for the equipment is to be
isolated at MCC, before taking the equipment for maintenance.
 In case of short shut down of API, close inlet gate, drain the accumulated sludge,
remove oily layer through slotted pipe skimmer and bring down to as low as possible.

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 Stop scraper mechanism

 In case of maintenance, ensure that power is switched off positively from MCC.
 In case unit is to be emptied, drain the unit through drain valve.
 Laminar plates in the TPI are to be cleaned up during the shut down operations.
 Sludge lines in the plant to be flushed during the plant shut down period.
 Continue aeration to the aeration tank to keep the microorganism alive by running the
Air Blowers, supplying air to both the aeration tanks.
 In case of complete shut down for long duration and on restarting the entire system,
only in such cases the aeration tank contents are allowed to settle down and the high
MLSS is drained into the Bio sludge sump to the maximum extent possible with
dewatering pumps from the dewatering pit.
 Stop the scrapper bridge and take up the maintenance work, after emptying the
thickeners of bio and oily.
 On shut down of equipment, the corresponding inlet/outlet valves/gates are to be
closed.
 All the level switches in the plant are to be cleaned during the shutdown period.
 All the probes of online analysers are to be cleaned and instruments are to be
calibrated during the shutdown period.
7.2 PARTIAL SHUT DOWN

 In case of partial shutdown of the Effluent Treatment Plant with 50% or 33% turn down
capacity, isolate some of the units.
 Reduce the dosing rates of chemicals, proportionate to the requirement of turn down
in capacity.
 Before isolating the units, it is ensured that the accumulated sludge in the clarifier
units is desludged and then the respective clarifiers in proportion turndown
requirement, is also tripped and isolated.
 Ensure all the sludge lines are properly flushed clean and then the units and the
equipment are stopped / isolated.
 For short term shut down (no more than several minutes) of DAF unit, the DAF recycle
pump can be turned off while compressed air is left on.
7.3 COMPLETE SHUT DOWN
 Ensure all the effluents in the Equalization tanks/sumps is pumped up for treatment
and the remaining effluent is drained.

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 In general, ensure no high level exists in any sump, before shutting down.
 Stop all moving equipment at local or at MCC or at PLC.
 Isolate the equipment and the power supply for the equipment at MCC, if it is to be
taken up for maintenance.
 In case of complete shutdown of the Effluent Treatment Plant, it is ensured that the
accumulated sludge in the clarifier units and the sludge sump is dewatered. Shut down
the dewatering units is as per the standard procedure, outlined earlier.
 Ensure all the sludge lines are properly flushed clean and then the units and the
equipment is stopped / isolated.
 Isolate all the dosing system.
 The tanks are drained and flushed clean. However, schedule the shutdown
programme such that unnecessarily no chemical requires wasting, except for the dead
volumes.
 For longer period shut down or for maintenance of DAF system, the pump and
compressed air should both be turned off. The water remaining in the Saturation
vessel should be drained off. All connecting pipes should also be drained.

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CHAPTER – 8
EMERGENCY SHUTDOWN AND

HANDLING

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Emergency could arise from equipment failure, interruption of utilities, power failure or due
to feed supply failure. Obviously, any written procedure cannot cover all the details of
problem, which might arise in an emergency as degree of emergency varies from time to time.
However, general guidelines are described here.
8.1 FEED FAILURE
In the case of feed failures, planned action or planned shutdown of the whole or part of the
plane can be undertaken depending on the possible consequence of such a feed failure.
Feed to Planned Action to be Undertaken

Oily waste 1. Depending on the total flow rate received, the required no of API/TPI
Treatment plant and the corresponding downstream units can be taken offline. The
Effluent stored in the Desalter water/Brine Equalization tank (230-TK-
001) can be used up to keep the plant in operation.
2. In the case of DAF units, the DAF recirculation pumps (230-P-113A/B/C,
230-P-213A/B/C) shall not be stopped even in the absence of the any
incoming flow. This is to ensure the air/water saturation is readily
available if suddenly any incoming flow is received.
Biological 1. Under no condition, the biological treatment plant be stopped unless if
Treatment plant it is for a longer scheduled period of time.
2. In the case of absence of any feed to the Biological treatment plant, The
bio tower feed pumps should continue to run to keep the bio tower
media moist and wet.
3. The blowers in the aeration tank should be kept in continuous running
condition to maintain the required Dissolved oxygen levels of 1.5 to 2.0
mg/l, and the secondary clarifier mechanism to continue running.
4. The Activated sludge Recycle (RAS Pumps – 230-P-115A/B/C) and
Surplus Activated sludge Pumps (230-P-128A/B) can be shutdown.
Effluent Check 1. In the case of absence of any feed to Effluent check basin, the existing
basin effluent in the check basin can be pumped to Water recovery plant for
treatment. Depending on the availability of effluent, activity of the
water treatment plant shall be planned accordingly.
Landfill Leachate 1. Depending on the total flow rate received, The Effluent stored in the
Treatment Leachate Equalization tank (231-TK-001) can be used up to keep the
package plant in operation, after which the units can be taken for a planned
shutdown.

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8.2 INSTRUMENT AIR FAILURE
Loss of Instrument air will cause the various control valves in the plant to go to their respective
fail safe position. Although the plant can be kept running partially during short interruption
of instrument air by taking all control valves on bypass, it is not advisable to do for long
periods as controlling of various parameters becomes difficult and unsafe.
8.3 POWER FAILURE
Power failure causes tripping of all running pumps, Air compressors and under such
conditions:
1. All the pumps will stop. Isolate all pumps by closing all the pump discharge isolation
valves.
2. In case that is only for a short shut down, it is not necessary to undertake any draining
activity of any tanks.
3. If power failure persists for any scheduled longer duration, shutdown the unit
completely as per normal shutdown procedures.
Note: The process could be continued as soon as the problems are solved/power restored.
8.4 STEAM FAILURE
Steam is used in the Effluent Treatment plant in the following areas;
1. Steam sparging of the top liquid levels in the API/TPI Tanks.

2. Steam sparging in Common oily sludge sump (230-SU-010).
3. Steam heating of the slop oil tanks.
There is no significant Process consequence that will arise as a result of Steam failure in the
plant. In the case of slop oil handling, any excess water draining off the slop oil tanks is to be
temporarily suspended until steam supply is restored.
8.5 CRITICAL PUMP FAILURE
All the pumps are in continuous operation. All these pumps are provided with stand by
pumps. In the case on any of these pumps fail, this will be intimated in the DCS HMI with a
visual status alarm. Under such conditions, the Panel Engineer must ensure the start of the
Standby pump or direct the field operator to start the standby pump immediately.

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8.6 AIR COMPRESSOR FAILURE
The compressors are provided in the Effluent Treatment Plant for Oily DAF and BIO DAF
systems and are in continuous operation. All these compressors are provided with stand by
unit. In the case on any of these compressor fail, this will be intimated in the DCS HMI with a
visual status alarm. Under such conditions, the Panel Engineer must ensure the start of the
Standby unit or direct the field operator to start the standby unit immediately.
8.7 PLC FAILURE
In the case of PLC failure, it is assumed that PLC failure will lead to the display interruption
and thereby panel engineer doesn’t know what is happening in the plant from the Control
Room/Panel LCD Screen. After such a screen blackout, the Shift In Charge must immediately
alert all the field operators to watch closely all the critical process parameters (like levels,
pressures, process values and variables, equipment run status, Temperatures etc.) by
observing the Field Instruments and Local Displays and the same has be conveyed instantly
to the Shift In Charge/ Panel Engineer using the applicable communication systems in case of
any abnormalities or directives for manual action.
The Field operators shall log all the respective critical parameters/data in regular intervals
until the PLC display is restored.

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CHAPTER -9
PROCESS INTERLOCKS

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OILY WATER TREATMENT SUB PACKAGE (OWTP)
The purpose of the Oily Water Treatment Plant Sub-package is to remove free oil and
settleable solids from contaminated aqueous effluent streams and to render these streams
suitable for biotreatment.
9.1.1 DESALTER / BRINE EQUALISATION TANK:
P&ID Ref: PDRP0451-8110-25-230-0001
Saline effluents from crude tank drainage will be intermittent and imposes a salt load with an
unacceptably high peaking factor for reliable biotreatment. Hence saline effluents from crude
tank drainage and the desalter effluent are routed to the Desalter Water / Brine Equalisation
Tank, combined and equalized.
A) Equipment and Function:
1) The desalter water/brine equalization tank 230-TK-001 is provided to equalize the brine
from crude tank farm and the desalter effluent.
2) Radar type level transmitter 230-LT-1001 is provided in the tank for monitoring the tank
levels and to generate various operational and high and low alarm set points as defined in
This transmitter is connected to the DCS.
3) Another radar type level transmitter 230-LZT-1002 is provided to generate the low low level
alarm setpoint and is directly connected to the ESD system. From the ESD system,
hardwired interlocks are provided in the MCC for tripping the pumps at low low level.
4) Two numbers of desalter water/brine pumps 230-P-001 A/B are provided for pumping the
effluent from the equalization tank to the splitter box – 1. These pumps are VFD driven
and work on the duty / standby philosophy. The speed of the pump is varied with respect
to the required discharge flow.
5) A electro magnetic type flow transmitter FT 1001 is provided in the common discharge line
of the desalter water/brine pumps to measure the flow. This instrument provides the input
flow signal to the PID flow controller whose output is connected to the VFD controller to
vary the speed of the pump to achieve the desired flow set by the operator in DCS HMI.
6) A diaphragm type pressure gauge 230-PG-1001A/B is provided in the individual discharge
of the desalter water/brine pumps to monitor the pump discharge pressure locally.
7) Two numbers of desalter water/brine recirculation pump 230-P-002A/B are provided for
recirculation and mixing.These pumps work on the duty standby philosophy.
of the desalter water / brine recirculation pumps to monitor the pump discharge pressure
locally.

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9) A pressure vaccum relief valve 230-PVRV-1001 is provided at the Desalter water/Brine

equalization tank for safety purpose.
B) Interlock Alarm and Control descriptions
1) 230-I-1000:
High level (Set point 1) - Generate alarm in DCS HMI and operator shall ensure the feed to the
desalter water /brine equalization tank to be stopped. However operator to ensure that the
duty pump is in operation..
Start level (Set point 2)– Start desalter water / brine pumps
Stop level (Set point 3) – Stop desalter water / brine pumps
Low level (Set point 4)– Generate alarm in DCS and stop desalter/brine recirculation pump.
Also start permissive to desalter water/brine pumps and desalter/brine recirculation pumps
to be disabled.
2) 230-IZ-0100:
Low low level(Set point 1) – Trip desalter water / brine pumps and desalter water / brine
recirculation pump through ESD.
3) 230-FIC-1001:
The speed of the desalter water/brine pump is modulated through the VFD based on the flow
transmitter to achieve the flow set by the operator in DCS HMI.
C) Operation
1) When the level in the desalter water / brine equalization tank reaches the start level, the
duty pump starts running and the speed of the pump is varied with respect to the discharge
flow set by the operator in DCS HMI.
2) When the level in the desalter water / brine equalization tank reaches the stop level, the
duty pump stops.
3) The desalter/brine pump is alternated as duty and standby manually based on the preset
run time set by the operator from the DCS HMI.
4) The desalter/brine recirculation pump is started and stopped manually by the operator
from the DCS HMI provided the start permissive for this pump is enabled. The start
permissive is enabled only when the level in the equalization tank is above the low level.
5)The desalter/brine recirculation pump is alternated as duty and standby in every operation
cycle.

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6) When the level in the equalization tank reaches high level, the operator shall ensure that
the inlet feed to the brine equalization tank is stopped.
9.1.2 SPLITTER BOX
P&ID Ref: PDRP0451-8110-25-230-0002
The effluents from the various streams at the battery limit are connected to the splitter box-
1 in addition to the discharge from drained effluent transfer pump, oily supernatant pump
and desalter water/brine pumps.
There are no automatic controls envisaged for this piece of equipment.
A) Equipment and Function
1) The splitter box 230-TK-114 is provided to collect the feeds to the API units and distribute
it evenly to each of the units.
2) At the outlet of the splitter box a parshall flume is provided to measure the total flow to
the API system. The flow is measured with an ultrasonic type flow transmitter 230-FT-1002.
This flow transmitter is also used to generate high flow alarm in the DCS HMI.
3) A radar type level transmitter 230-LT-1003 is provided in the common inlet channel of the
API to monitor the channel levels and generating high and high high level alarm setpoints
as defined in 5.1.2.B(1).
4) A manual screen 230-SCR-004 is provided in the outlet of the splitter box to remove large
floating particles.
B) Interlock Alarm and Control descriptions
1) 230-I-1020:
High high level(Set point 1) – Alarm to be generated in the DCS HMI and stop the desalter
water/brine pumps.
High level (Set point 2)– Alarm to be generated in the DCS HMI for the necessary action by
the operator.
2) 230-I-1010:
High flow - Alarm to be generated in the DCS HMI and stop the desalter water/brine pumps.
C) Operation:
1) There is no automatic operation envisaged for this piece of equipment.
9.1.3 API SEPARATOR:

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P&ID Ref:- PDRP0451-8110-25-230-0002
The API Separator is provided for the removal of free oil and suspended solids from the
effluent. Three numbers of API separators is provided as part of phase I stage I. As part of
phase I stage II, one more API separator will be provided.
1) Three no of combined tanks 230-TK-105/205/305 for API separator and TPI separator are
provided as part of phase I stage I.
2) Each of the API oil Separator will be covered with removable chequered plates, with venting
arrangement. The vent is connected to the Volatile Organic Compound(VOC) abatement
package.
3) Each Channel will be provided with a manual gate at the inlet to facilitate the isolation and
maintenance of any Channel of the API Oil Separator.
4) Rotatable slotted pipe oil skimmers (manually adjusted by operator) will be provided in
each separator both at the inlet and outlet to collect the oil at the surface and sent to the
Wet Slop Oil Sump.
5) Each API separator is provided with a flight chain oil skimmer to move the free oil floating
at the top liquid surface towards the slotted pipe oil skimmer and scrape the settled solids
towards the sludge pit of the separator. This flight oil skimmer is driven by a motor 230-
A(M)-002 A/B/C/D
6) Two sludge hoppers are provided in the sludge pit to remove the sludge from the API
separator to the common oily sludge sump.
7) LP Steam sparging facility is provided to facilitate easy skimming of floating free oil, by the
slotted pipe oil skimmer
B) Interlock Alarm and Control descriptions:
Not applicable for this section.
C) Operation:
1) There is no automatic operation envisaged for the API system. Whenever the system is
selected online by the operator from the DCS OWS, the flight oil skimmers start
automatically and stop whenever the separator is taken offline for maintenance.
2) The slotted pipe oil skimmers are to be operated by the operator manually from the field.
3) The sludge valves are operated manually from the field twice to thrice in a shift depending
on the sludge volume.

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9.1.4 TPI SEPARATOR
P&ID Ref:- PDRP0451-8110-25-230-0002
The TPI separator is provided for the further treatment of the effluent from the API separator.
In the TPI separator, free oil of particle size greater than 100 micron size, is removed. Three
numbers of TPI separator are provided, each dedicated to an individual API separator as part
of phase I stage I. As part of phase I stage II, one more TPI separator will be constructed.
A) Equipment and Function
1) The TPI Separator shall also be covered with removable chequered plates, with venting
arrangement. The vent is connected to the Volatile Organic Compound(VOC) abatement
package.
2) A rotatable slotted pipe oil skimmer (manually adjusted by operator) is provided at the
surface of the separator for removing the floating oil. The free oil is sent to the wet slop oil
sump.
3) The sludge moves towards the bottom of the corrugation and slides down the inclined plate
into the bottom hopper, to be discharged intermittently into the common oily sludge
sump.
4) Sludge is automatically withdrawn via actuated valves 230-XV-1001/1002/1003 to the
Common Oily Sludge Sump 230-SU-010. The operator has two timer controls. The first
timer controls the frequency of valve opening and the second timer controls the duration
of valve opening in each cycle.
5) LP Steam sparger shall be provided in TPI Separator for heating up of floating free oil,
because of its high pour point, to facilitate its easy skimming and conveying.
5) The treated effluent shall flow via overflow weir into the concrete channel for further
treatment by Oily DAF system. The overflow weir provides the necessary isolation during
maintenance.
6) Manual gates provided at the inlet of API separator shall be operated to isolate the bays,
for maintenance.
1) 230-X-1001/1002/1003:
- Each of the automatic valves is provided with two timers.

- The first timer controls the frequency of the valve opening.
-The second timer controls the duration of the valve opening in each cycle.
Automated valve will not open incase of high level at API separator.

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C) Operation:
1) Once the TPI system is put online and the sludge valve is put in auto, the valve operates
based on the timer settings of the operator provided on the DCS HMI. The operator shall
set the timers based on the incoming sludge load.
2) There is no other automatic operation envisaged for the TPI system. Whenever the system
is taken online, and API inlet gates are opened, the TPI system is brought under operation.
3) The slotted pipe oil skimmers are operated manually by the operator from the field.
9.1.5 COMMON OILY SLUDGE SUMP
P&ID Ref:- PDRP0451-8110-25-230-0002
The Common Oily Sludge Sump receives oily sludge from the API and TPI system and transfers
to the oily sludge thickener by the common sludge transfer pumps.
1) A common oily sludge sump 230-SU-010 is provided to collect the oily sludge from the API
system and TPI system.
2) A radar type level transmitter 230-LT-1005 is provided in the sump for monitoring the tank
levels and to generate various operational and high and low alarm setpoints as defined in
5.1.5.B.(1)
3) Another radar type level transmitter 230-LZT-1004 is provided for generating the low low
level alarm setpoint which is directly connected to the ESD system. From the ESD system,
hardwired interlock are provided in the MCC for tripping the common sludge transfer
pumps at low low level.
4) A temperature transmitter 230-TT-1001 is provided in the tank for monitoring the
temperature in the tank. This instrument also provides the inlet temperature signal for the
PID temperature controller configured in the DCS, whose output is connected to the
temperature control valve TV 1001 in the LP steam line for controlling the steam inlet to
the tank.
5) A motorized oil skimmer 230-OS-002 is provided to skim the floating oil which is transferred
to the wet slop oil sump. Continuous operation of this skimmer is not envisaged and is
operated only when floating oil/wax is observed in this sump.
6) An agitator 230-M-010 is provided to maintain the oily sludge in suspension.
7) Three numbers of common sludge transfer pumps 230-P-033 A/B/C are provided to
transfer the oily sludge to the oily sludge thickener system. These pumps work on two duty
and one standby philosophy.

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8) A diaphragm type pressure gauge 230-PG-1003A/B/C is provided in the individual discharge

of the common sludge transfer pumps to monitor the pump discharge pressure locally.
9) A pressure transmitter 230-PT-1004A/B/C is provided in the individual discharge of the
common sludge transfer pumps to generate the high pressure alarm in the DCS HMI and
to stop the running pump.
10) A temperature transmitter 230-TT-1002 A/B/C is provided in the individual stator of the
common sludge transfer pumps to generate the high temperature alarm in the DCS HMI
and to stop the running pump.
11) Bursting Disc Tell-Tale strips(230-PSE-1001A/B/C) are provided to stop the motor incase
of Bursting Disc Rupture
1) 230-I-1030:
High level (Set point 1) – Generate alarm in DCS HMI and inhibits opening of sludge valves
of TPI.
Start level 1 (Set point 2)– Start both the duty pumps with a time delay of 2 min between
the pump starts
Start level 2 (Set point 3) – Start the agitator and open the sludge valves at TPI.
Stop level 4 (Set point 5) – Stop the duty pumps.
Stop level 3 (Set point 4) – Stop the agitator.
Low level (Set point 6)– Generate alarm in the DCS HMI and further action to be taken by
the operator
2) 230-IZ-0110:
Low low level – Trip common sludge transfer pumps and agitator through ESD.
3)230-I-1050/1080/1110:
High pressure – Generate alarm in DCS HMI and stop the pump. Operator has to check field
conditions and restart the pump.
4) 230-I-1040/1070/1100:
High stator temperature – Generate alarm in DCS HMI and stop the pump. Operator has to
check field conditions and restart the pump.
5) 230-I-1060/1090/1120:
Bursting disc ruptured – Generate alarm in DCS and Stop pump. Requires operator
intervention to re-start the pump by resetting Soft button in DCS HMI
6) 230-TIC-1001:

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The steam inlet to the common oily sludge sump is controlled via the temperature control
valve to maintain the temperature in the common oily sludge sump.
C) Operation:
1) When the level in the common oily sludge sump reaches start level 1, the duty common
sludge transfer pumps start running and stops at the stop level 2.
2) The common sludge transfer pumps are alternated as duty and standby in every operation
cycle.
3) When the level in the common oily sludge sump reaches start level 2, the common oily
sludge sump agitator starts running and stops at stop level 1.
4) The oil skimmer is operated only when floating oil is observed in the sump. This skimmer
can be started and stopped manually by the operator from the DCS HMI.
9.1.6 CRWS SUMP:
P&ID Ref:- PDRP0451-8110-25-230-0002
The CRWS sump is provided to collect the overflow and surface run off of the entire plant and
pump the same to outside the battery limit.
1) The CRWS sump 230-SU-123 is provided to collect the overflow and surface runoff of the
entire plant.
levels and to generate various operational and high and low alarm setpoints connected to
the DCS.
4) Three numbers of CRWS transfer pumps 230-P-136 A/B/C are provided for pumping the
effluent from the CRWS sump to outside the battery limit. These pumps work on two duty
of the CRWS transfer pumps to monitor the pump discharge pressure locally.

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1) 230-I-1130:
High level(Set point 1) – Generate alarm in DCS and further action to be taken by the operator.
Start level(Set point 2) – Start both the duty pumps with a time delay of 2 min between the
pump starts
Stop level(Set point 3) – Stop the duty pumps
Low level(Set point 4) - Generate alarm in DCS and further action to be taken by the operator.
2) 230-IZ-0120:
Low low level – Trip CRWS transfer pumps through ESD.
C) Operation:
1) When the level in the CRWS sump reaches the start level, the duty pump starts running
and stops at the stop level.
2) The CRWS transfer pump is alternated as duty and standby in every operation cycle.
9.1.7 API SUMP AND API OWS PUMP SYSTEM:

P&ID Ref:- PDRP0451-8110-25-230-0003
The API sump is provided to store the treated effluent from the TPI. The API OWS pumps
transfer the effluent from the API sump to the Equalization Tanks. Three numbers of API
pumps are provided for Phase I Stage I and two more pumps will be added for Phase I Stage
II.
A) Equipment and Functions:
1) The API sump 230-TK-004 is provided to collect the effluent from the TPI separator and
feed it further to the equalization tanks 230-TK-006A/B.
2) Three numbers of API OWS pumps 230-P-106A/B/C are provided to transfer the effluent
from the API sump to the equalization tanks. These pumps work on 2 working 1 standby
philosophy with duty / duty assist /standby modes of operation.
3) A radar type level transmitter 230-LT-1008 is provided in the API sump for monitoring the
level in the DCS and also to generate the various operation set points and high and low
alarm set points.

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5) A diaphragm type pressure gauge 230-PG-1005 A/B/C is provided in the individual

discharge of the API OWS pumps for monitoring the individual pump discharge pressure
locally.
1) 230-I-1140:
High level (Set point 1) - Generate alarm in DCS HMI and inhibit desalter water/brine pumps.
Start level 2(Set point 2) – Start duty assist pumps
Start level 1(Set point 3) – Start duty pumps
Stop level(Set point 4) – Stop duty and duty assist pumps
Low level(Set point 5) – Generate alarm in DCS HMI and further action to be taken by the
operator.
2) 230-IZ-0130:
Low low level – Trip API OWS pumps through ESD.
C) Operation:
1) When the level in the API sump reaches the start level 1, the duty pump starts running and
stops at the stop level.
2) When the level in the API sump reaches the start level 2, the duty assist pump starts running
3) The API OWS pumps are alternated as duty / duty assist and standby manually based on
the preset runtime set by the operator form the DCS HMI.
9.1.8 EQUALISATION TANKS AND DAF FEED PUMPS:
P&ID Ref:- PDRP0451-8110-25-230-0003
The equalization tanks are provided to equalize the effluent from the API sump, Stripped sour
water and effluent recycle from effluent check basin. The DAF feed pumps 230-P-003A/B/C is
provided for transferring the equalized effluent from the equalization tanks to the splitter box
– II. Three pumps are provided for phase I stage I and two more pumps will be added for
phase I stage II.

1) Two numbers of equalization tanks 230-TK-006A/B are provided to equalize the effluent
from API, Stripped sour water and effluent recycle from effluent check basin. Both the
tanks are operated in parallel.

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2) A radar type level transmitter 230-LT-1010 / 1012 is provided in each of the equalization
tanks to monitor the level and to generate the various operating and high and low alarm
setpoints in the DCS.
3) Another radar type level transmitter 230-LZT-1011/ 1013 is provided in each of the
equalization tanks to generate the low low level alarm setpoint and is directly connected
to the ESD system. From the ESD system, hardwired interlocks are provided in the MCC for
tripping the pumps at low low level.
4) The equalization tanks are also provided with oil skimmer for facilitating the removal of oil
and shall be provided with mixing facility to prevent stratification and ensure complete
mixing.
5) Three numbers of DAF feed pumps 230-P-003A/B/C are provided to pump the effluent from
the equalization tanks to the splitter box-2. These pumps work on 2 working and 1 standby
philosophy with duty/assist modes of operation.
of the DAF feed pumps for monitoring the individual pump discharge pressure locally.
7) Two pH analysers 230-AT-1001A and 230-AT-1001B with pH sensors are provided on the
common discharge of the DAF feed pumps to measure pH. This analyzer generates high
and low pH alarms in the DCS HMI.
8) An electro magnetic flow transmitter 230-FT-1003 is provided in the common discharge of
the DAF feed pumps to measure the flow into the DAF system. This instrument provides
the input flow signal to the PID flow controller configured in the DCS whose output is
connected to the control valve FV 1003 to control the desired flow to the DAF.
9) Two numbers of equalization tank recirculation pumps 230-P-004 A/C is provided to the
equalization tank 230-TK-006A and another two numbers of equalization tank recirculation
pumps 230-P-004B/D is provided to the equalisation tank 230-TK-006B for recirculation
and mixing.
10) A diaphragm type pressure gauge 230-PG-1007A/B/C/D is provided at the individual
discharge of the equalization tank recirculation pumps to monitor the pump discharge
pressure locally.
11) A clamp on type Flow transmitter 230-FT-1009 is provided at the inlet of the equalization
tank 230-TK- 006 to monitor the inlet flow to the equalization tank.
12) A Pressure vaccum relief valve 230-PVRV-1002 is provided for safety purpose.
1) 230-I-1150/1160:
High level(Set point 1) – Generate alarm in DCS HMI and operator to take further action.
Start level(Set point 2) – Start both the duty pumps with a time delay of 2 min between the
pump starts.

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Stop level(Set point 3) – Stop duty pumps

Low level(Set point 4) - Stop the equalization tank recirculation pump and disable start
permissive for DAF feed pumps.
2) 230-IZ-0140/0150:
Low low level – Trip DAF feed pumps through ESD.
3) 230-FIC-1003:
The control valve 230-FV-1003 is throttled to control the flow to the DAF system based on the
flow measured by the magnetic level transmitter 230-FT-1003. The PID controller is
configured in the DCS. Also based on this flow, auto stroke controller of FeCl3 and DOPE
dosing pump is controlled to adjust the dosing rate.
4) 230-FQR-1003:
The flow to the oily DAF system is recorded and totalized in the DCS from the flow measured
by the magnetic flow transmitter 230-FT-1003
5) 230-A-1001A & 1001B:
High pH(Set point 1) – Generate alarm in DCS and operator to take further action
Low pH(Set point 2) - Generate alarm in DCS and operator to take further action
6)230-FQI-1009:
The flow to the equalisation tank is totalized in the DCS.
C) Operation:
1) Both the equalisation tanks are operated in parallel and the tanks are in continuous fill and
draw modes.
2) When the level in the equalization tank reaches the start level, the duty pump starts
running and stops at the stop level.
3) The DAF feed pumps are alternated as duty and standby manually based on the preset run
time set by the operator from the DCS HMI.

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4) The equalization tank recirculation pump is started and stopped manually by the operator
from the DCS HMI provided the start permissive for this pump is enabled. The start
permissive is enabled only when the level in the equalization tank is above the low level.
5) The equalisation tank recirculation pump is alternated as duty and standby in every
operation cycle.
6) The flow to the DAF system is controlled automatically to the flow set by the operator in
the DCS HMI through the control valve.
9.1.9 FLASH MIXER:
P&ID Ref:- PDRP0451-8110-25-230-0004
Effluent from equalization tank will be pumped by the DAF feed pumps into splitter Box – 2,
where FeCl3 will be dosed proportionately by means of dosing pump with auto stroke control
and Sulphuric acid will be dosed if required. The outlet from the box splitter is divided into
four equal parts into the four flash mixer channels. The Flash mixer is provided to thoroughly
mix the chemical with the effluent which is achieved by the agitator. The effluent after mixing
exits at the bottom and enter the flocculators. Four unit is provided for phase I stage I and
one unit is considered for phase I stage II.
1) Splitter box -II is provided to divide the DAF feed pump discharge to the four flash mixers
equally.
2) Four numbers. of flash mixer tank 230-TK-108/208/308/408 is provided to mix the effluent
with ferric chloride and acid thoroughly. The acid dosing in the effluent is decided by the
operator based on the pH value in the DAF feed pump discharge and this operation is
envisaged to be occasional.
3) Each of the flash mixer tanks is provided with a agitator 230-M-101/201/301/401 for
mixing the effluent and the chemical.
4) Splitter Box-2 will be provided with Adjustable weir with stop log at the inlet to flash mixer
to facilitate the isolation and maintenance of any train of Flash mixer, Flocculator and Oily
DAF unit.
Not applicable for this piece of equipment.

C) Operation:
1) The starting and stopping of the flash mixer is to be carried out by the operator manually
from the DCS HMI.

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9.1.10 FLOCCULATORS
P&ID Ref:- PDRP0451-8110-25-230-0004
The flocculators are provided for dosing deoiling polymer (DOPE) to the flash mixer outlet and
for the formation of flocs and de-emulsification of dissolved oil from the effluent. DOPE will
be dosed proportionately based on the feed to DAF system, by means of dosing pump with
auto stroke control. The effluent after flocs formation and de-emulsification flows to the DAF
unit. Four units are provided for phase I stage I and one unit is considered for phase I stage II.
1) Four flocculation tanks 230-TK-109/209/309/409 are provided for the above stated
purpose. Each of the flocculator is connected to an individual flash mixer.
2) Each flocculator consists of a paddle agitator 230-M-103/203/303/403 for mixing the 0.5%
DOPE to the effluent to enable the formation of flocs and de-emulsification of the dissolved
oil.

C) Operation:
1) The starting and stopping of the flocculator is to be carried out by the operator manually
from the DCS HMI.
9.1.11 OILY DAF:
P&ID Ref:- PDRP0451-8110-25-230-0004
The Oily DAF unit is provided to remove the remaining oil from the effluent. Four numbers of
Oily DAF unitsbare provided which are connected to the individual flocculators as part of
Phase I stage I. One more oily DAFunits will be provided as part of Phase I stage II.
1) Four numbers of oily DAF units 230-TK-110/210/310/410 are provided for the above stated
purpose.

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2) The flocculated effluent enters the inlet chamber of the oily DAF unit and de-emulsified oil
rises to the top of floatation tanks due to the action of the micro fine bubbles getting
released from the depressurized recycle effluent.
3) The part of the outlet from the oily DAF is used for recirculation and this is achieved by two
sets of recirculation pumps.
4) Three no recirculation pumps 230-P-113A/B/C is connected to the oily DAF unit A/B and
they work on two working and 1 standby philosophy in duty/standby modes of operation.
The pump A is dedicated for oily DAF unit A and pump C is dedicated for oily DAF unit B.
The pump B is a common standby.
5) Another three no recirculation pumps 230-P-213A/B/C is connected to the oily DAF unit
C/D and they work on two working and 1 standby philosophy in duty/standby modes of
operation. The pump A is dedicated for oily DAF unit C and pump C is dedicated for oilly
DAF unit D. The pump B is a common standby.
6) A diaphragm type pressure gauge 230-PG-1008A/B/C and 230-PG-1009A/B/C are provided
at the individual discharge of the recirculation pumps for monitoring the pressure locally.
7) Two saturation vessels 230-V-101/201 are provided in the system. Saturation vessel 230-
V-101 is dedicated for oily DAF A/B and saturation vessel 230-V-201 is dedicated for oily
DAF C/D.
8) The saturation vessels are provided with pressure transmitters 230-PT-1001/1002 for
monitoring the pressure in the saturation vessel and also for generating high and low
pressure alarm set points.
9) Each of the saturation vessel is provided with a radar type level transmitter 230-LT-
1014/1015 for monitoring the saturation tank level and also to generate various
operational and high and low alarm set points.
10) Each of the saturation vessels is provided with an online flow indicator FI 1001/1002 to
monitor the air flow into the saturation vessel locally.
11) Each of the saturation vessel air inlet line is provided with a pneumatic on/off valve 230-
XV-1011/1013 for controlling the air flow inlet to the saturation vessel based on
operational requirements.
12) Each of the saturation vessel is also provided with a pneumatic on/off valve 230-XV-
1010/1012 for venting purpose.
13) Each of the saturation vessel is provided a reflex type level gauge 230-LG-1001/1002 to
monitor the level locally.
14) The recycle effluent gets saturated with air in the vessel and the air water mixture under
pressure in the pressure pipe is suddenly released through hosepipe connections to
atmospheric pressure in the oily DAF tank. The de-emulsified oil get attached to micro fine
air bubbles and rise to the top surface of flotation tank, forming a scum which is skimmed
to the oily scum outlet and then conveyed to the oily DAF Sludge Sump, by gravity.
15) A DP type flow transmitter 230-FT-1004/1005/1006/1007 is provided in the inlet of each
oily DAF unit to monitor the recycle flow to the oily DAF unit.

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16) Each of the oily DAF unit is provided with a surface oil skimmer 230-A-003A/B/C/D for
skimming the floating scum.
17) The OILY DAF Unit is also provided with a number of inclined corrugated plates placed at
60° to the horizontal, at equal spacing. The wastewater containing heavier suspended
solids and left out demulsified oil passes between the plates. Laminar flow conditions
between the plates ensure the effective gravity separation of water, oil and suspended
particles. In the course of passing from pack inlet to pack outlet, the remaining de-
emulsified oil droplets coalesce into larger droplets and the oil floats upward into the top
of corrugation and rises up the inclined plate to the surface of the system where it is
removed by the moving surface skimmer of non-absorbent material, along with the
already floating demulsified oil.
18) Each of the OILY DAF unit is provided with a motorized auger for intermittent removal of
sludge. A pneumatic on/off valve XV1005/1006/1007/1008 in the sludge line is operated
based on two timers. All these operations are carried out automatically from the DCS HMI.
19) Two numbers of air compressor 230-K-001A/B is provided for supplying air to the
saturation vessel.These compressors start and stop automatically based on the set receiver
pressure.
20) A diaphragm type pressure gauge PG-1011A/B is provided at the individual discharge of
the DAF air compressor to monitor the compressor discharge pressure locally.
21) Saturation vessels are provided with pressure safety valves 230-PSV-1001/1002 for safety
purpose
1) 230-I-1180/1200:
High Pressure(Set point 1) – Open air vent valve and close air inlet valve
Low pressure(Set point 2) – Close air vent valve and open air inlet valve
2) 230-I-1170/1190:
High level – Generate alarm in DCS and operator to take further action.
Open level(Set point 1) – Open air vent valve and close air inlet valve
Close level(Set point 2) - Close air vent valve
Low level(Set point 3) – Generate alarm in DCS and operator to take further action.
3) 230-XV-1005/1006/1007/1008:
- Each automated valve is provided with two timers
- The first timer controls the frequency of operation of the automated sludge removal
system.
- The second timer controls the duration of operation.

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- When the timer is set for operation, the on/off valve opens. After opening of the valve
the motorized auger starts.
- When the timer is elapsed, the motorized auger stops following which the on/off valve
closes.
4) 230-FQR-1004/1005/1006/1007:
The recycle flow to the individual oily DAF is recorded and totalized in the DCS.
C) Operation:
1) The OILY DAF unit is selected / deselected for operation by pressing the OILY DAF train
selector provided on the DCS HMI, after isolating the deselected Oily DAF train by
adjustable weir with stop log at the inlet of flash mixer.
2) Once the OILY DAF unit is selected, the oil skimmer is started, the recirculation pump starts
and the unit is taken for operation. The oil skimmer and the recirculation pump is stopped
when the unit is deselected.
3) There is no alternation of duty/standby in this pump system since the duty pumps are
dedicated for the individual OILY DAF and the third pump is a common standby.
4) The compressors start and stop automatically based on the set receiver pressure and there
is no control of the same by the operator.
5) The upstream pressure self regulating valve regulates the upstream pressure at 5 Kg/cm2.
9.2 BIO TREATMENT SUBPACKAGE
9.2.1 AERATION FEED SUMP AND BIO TOWER FEED PUMP
P&ID Ref:- PDRP0451-8110-25-230-0005
This sump is provided to collect the oily DAF treated effluent and mix it with other effluents
such as treated spent caustic from WAO, treated landfill leachate, excess treated effluent and
stripped sour water. Chemical such as DAP/urea and sulphuric acid is also dosed to the
effluent and sent to the bio tower for further treatment.
The bio tower treated water is also stored in this sump for further pumping into the aeration
tanks. Four numbers of bio tower feed pumps are provided for pumping the effluent from the
sump to the bio towers for phase I stage I and four more will be considered for phase I stage
II.

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1) The sump 230-TK-003 is provided for the above mentioned purpose. This tank consists of
three sections. In the first section, the effluent from oily DAF is mixed with the other
effluents and chemical and pumped to the bio tower. In the second section, the effluent
after bio tower treatment is stored. In the third section, the bio tower treated effluent
from section 2 overflows and further pumped to aeration tank from this section.
2) Two pH analysers 230-AT-2001A/B with sensors is provided in the first section for pH
measurement.
3) A radar type level transmitter 230-LT-2001 is provided in the second section (Bio tower
feed section) of the tank for monitoring the tank level and to generate the various
operating and high and low alarm setpoints.
4) Another radar level transmitter 230-LT-2005 is provided in the third section (aeration tank
feed section) of the sump for monitoring the tank level and to generate the various
operating and alarm setpoints.
5) An oil in water analyser 230-AT-2011 is provided in the first section of the tank to measure
the level of oil and to generate high oil alarm in the DCS HMI.
5) Four bio tower feed pumps 230-P-126A/B/C/D are provided for transferring the effluent
from the sump to the bio tower. The first three pumps are dedicated to the individual bio
tower and the fourth pump acts as the standby pump which can be used for any of the bio
tower in case of failure of it’s dedicated pump.
4) Diaphragm type pressure gauge 230-PG-2001A/B/C/D is provided in the individual
discharge of the bio tower feed pump to monitor the discharge pressure locally.
1) 230-I-1230:
High level(Set point 1) - Generate alarm in DCS HMI and further action to be taken by the
operator.
Start level(Set point 2) – Start bio tower feed pumps
Stop level(Set point 3) – Stop bio tower feed pumps
operator.
2) 230-A-2001A/2001B:
High pH – Generate alarm in DCS and operator to take further action
Low pH - Generate alarm in DCS and operator to take further action
3) 230-A-2011

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High Oil - Generate alarm in DCS and operator to take further action
C) Operation:
1) When the level in the sump reaches the start level all three duty bio tower feed pumps
shall start operating and stop at the stop level. The duty pumps will start one by one after
a certain time delay.
2) Since the duty pumps are dedicated to individual bio towers, there shall not be any rotation
of duty and standby operation for this pump system.
3) In case of failure of any of the duty pump, the standby pump shall start after a permissive
from the operator. The operator shall provide the permissive after opening or closing the
necessary manual valves so that the discharge of the standby pump is routed to the stream
of the failed duty pump.
3.2.2 BIOTOWERS
P&ID Ref:- PDRP0451-8110-25-230-0005
The bio tower is provided to bio degrade the organic matter present in the effluent and to
reduce the BOD and COD.

1) Three numbers of bio towers 230-R-101/201/301 are provided for the above mentioned
purpose.

C) Operation:
No automatic operation is envisaged for this equipment.
3.2.3 AERATION FEED PUMPS:
P&ID Ref:- PDRP0451-8110-25-230-0005
The aeration feed pumps pumps the water from the overflow compartment of the bio tower
sump to the splitter box-3 from where it is further routed to the aeration tank. As part of
phase I stage I, three pumps are provided and 2 pumps are considered for phase I stage II.

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1) A radar type level transmitter 230-LT-2005 is provided in the third section of the tank for
monitoring the tank level and to generate the various operating and high and low alarm
setpoints.
2) Three numbers of aeration feed pumps 230-P-127A/B/C are provided for pumping the bio
treated effluent to the splitter box-III from where it is further routed to the aeration tank.
These pumps work on 2 working 1 standby philosophy with duty / standby modes of
operation.
3) A diaphragm type pressure gauge 230-PG-2002A/B/C are provided in the individual
discharge of the aeration feed pumps for monitoring the discharge pressure locally.
230-I-1240:
operator.
Start level(Set point 2) – Start both aeration feed duty pumps with a time delay of 2 min
between the starts.
Stop level(Set point 3) – Stop aeration feed pumps
Low level(Set point 4) – Generate alarm in DCS and further action to be taken by the operator.
C) Operation:
1) When the level in the third compartment of the biotower/aeration feed sump reaches the
start level, the duty pumps starts running after receiving signal that any of the biotower
feed pump is running and stops at the stop level.
2) The aeration feed pumps are alternated as duty and standby manually based on the preset
run time set by the operator form the DCS HMI.
9.2.4 SPLITTER BOX-3:
P&ID Ref:- PDRP0451-8110-25-230-0005
Effluent after treated by the bio tower is pumped by the aeration feed pump into the splitter
box – 3 where it is mixed with the screened sewage from Township and Factory, Filtrate from
weathered drying beds, UF waste/reject and Sand filter waste backwash, and RAS. After this
the effluent is equally distributed to the two aeration tanks.
A) Equipments and Functions:
1) The splitter box 230-SU-115 is provided for the above stated purpose.

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2) The splitter box consists of three sections. In the first section the effluent is mixed with the
other effluents and then overflows into the other two equal sections.
3) From these section, the effluent flows into the aeration tank 1 and 2 through manual gates
230-SG-0501 and 230-SG-0502 respectively. These gates are used to isolate the aeration
tanks.

C) Operation:
1) The manual gates are the inlet to the aeration and has to be opened or closed manually.
2) No automatic operation is envisaged for this equipment.
9.2.5 SCREEN CHAMBER:
P&ID Ref:- PDRP0451-8110-25-230-0005
The screen chamber is provided to remove the large floating particles from the sewage
coming from township before getting added to the effluent in splitter box-3.
1) Two numbers of screening sumps 230-SU-117A/B is provided for the above said purpose.
2) The sump 230-SU-117A is provided with an automated screen 230-SCR-002 which operates
on time and level differential. A manual gate 230-SG-0503 is provided for isolation of the
screen chamber. The screenings from the screen is conveyed by the rake arrangement into
the opening chute of the screw conveyor.
3) The sump 230-SU-117B is provided with a manual screen 230-SCR-003 which is to be
cleaned manually and isolated with an inlet weir. This screen is operated only in case of
failure of the automated screen and to handle excess flow than peak hydraulic flow.
4) Two radar type level transmitters 230-LT-2002A/B are provided across the automated
screen for sensing the differential level and to generate the various operating and alarm
setpoint.
5) A screw conveyor with compactor 230-CR-003 is provided for conveying the screenings
from the bar screen to the trolley. The screenings filtered by the bar screen is moved by
the rake arrangement into the opening chute of the screw conveyor.

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6) Two fans 230-K-103A/B are provided to suck the air from the screen chamber and routed
to the aeration tank. This acts as the odour abatement system.
7) A pneumatic On/Off valve 230-XV-2014 is provided in the service water inlet line of the
screw conveyor with compactor to control the service water inlet into the conveyor, where
hypo will be dosed by means of dosing pump.
1) 230-I-1250:
High level(Set point 1) – Generate alarm in the DCS for the operator to take necessary action.
Start level(Set point 2) – Start the screen operation, start hypo dosing pumps, open service
water inlet valve and start conveyor
Stop level(Set point 3) – Stop the screen. The conveyor stops , hypo dosing will stop after a
preset time following which service water inlet valve opens.
2) 230-XS-2001:
High torque – Generate alarm in the DCS HMI and stop the conveyor.
C) Operation:
1) The screen operates on two modes of time and level or level only. When selected in time
mode and level mode, the screen operates after a preset time set in the DCS HMI by the
operator. However within the set time if the differential level across the screen reaches
high level then the screen operation will have the following start sequence. When selected
in level mode, the screen will operate when the differential level across the screen reaches
the start level and stop when the level reaches the stop level. Once the barn screen gets a
demand to start, the screw conveyor and the hypo chlorite dosing pump will also start. The
sequence of starting is as shown below,
a) Start screw conveyor

b) Start Bar screen
c) Start hypo dosing pump
2) The screen shall stop and an alarm shall be raised if the screw conveyor fails to start or
stops due to high torque. This shall also stops when differential level reaches stop level.
The screw conveyor stops after a preset time of stopping of the screen mechanism. The
sequence of stopping is as shown below,
a) Stop Bar screen

b) Stop screw conveyor

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c) Stop hypo dosing pump

d) Open service inlet valve and close after a preset time.
3) The odour control centrifugal fan is started and stopped manually by the operator form the
DCS HMI.
9.2.6 AERATION TANK AND AERATION BLOWERS:
P&ID Ref:- PDRP0451-8110-25-230-0006
The aeration tank is provided for the removal of pollutants viz., BOD5, COD and sulphides.
The aeration tank is provided with Diffused aeration system for maintaining a constant
Dissolved Oxygen (DO) level in the tank. Fine bubble aeration system of silicon base rubber
material will be provided with easily retrievable system and aeration will be provided by
means of 3 numbers. (2W+1S) of blowers for each aeration tank.
1) Two numbers of aeration tanks 230-TK-111/211 are provided for aeration.

2) Each aeration tank is provided with a DO analyzer 230-AIT-2002/2004 for measuring the
dissolved oxygen level in the aeration tank. The signal from this DO sensor provides the
input signal to the PID controller configured in the DCS to control the speed of the VFD
blower. High and low DO alarms are also generated from this analyser.
3) Two pH transmitters with sensor 230-AIT-2003A/B are provided in aeration tank 230-TK-
111 and another two pH transmitters with sensor 230-AIT-2005A/B are provided in
aeration tank 230-TK-211 to measure the pH and to generate high and low pH alarms.
4) Each aeration tank is provided with 3 blowers (230-K-102A/B/C for aeration tank 1 and 230-
K-202 A/B/C for aeration tank 2) which work on 2 working and 1 standby philosophy with
duty/duty assist/standby modes of operation. The blower 230-K-102B and 230-K-202B are
VFD based and are always kept in service. The blower speed is modulated based on the DO
in the aeration tank. Provision is also provided to interchange the blower groups between
the aeration tanks.
5) A DP type flow transmitter 230-FT-2001/2002 is provided to measure the air flow into the
aeration tank and to generate high and low flow alarms in the DCS HMI.
6) A temperature transmitter 230-TT-2001/2002 is provided in the air inlet line to monitor the
air temperature and to generate high temperature alarm in the DCS HMI as defined in
5.2.6.B.(5).
7) An air cooler 230-AC-101/201 is also provided in the air inlet to reduce air temperature into
the aeration tank.

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1) 230-I-1270 & 230-I-1280:

- The air blower is modulated through the VFD based on the DO analyzer to achieve the
required DO in the aeration tank.
2) 230-A-2002/2004:
High DO(Set point 1) – Generate alarm in the DCS and the operator to take further action.
Low DO(Set point 2) - Generate alarm in DCS and the operator to take further action.
3) 230-A-2003A/2003B/2005A/2005B:
High pH(Set point 1) - Generate alarm in the DCS and the operator to take further action.
Low pH(Set point 2) - Generate alarm in DCS and the operator to take further action.
4) 230-T-2001/2002:
High temperature - Generate alarm in the DCS HMI and the operator to take further action.
5) 230-F-2001/2002:
High Flow (Set point 1)- Generate alarm in the DCS HMI and the operator to take further
action.
Low Flow (Set point 2)- Generate alarm in the DCS HMI and the operator to take further
action.
C) Operation:
1) An Online/Offline button will be provided in the DCS HMI to take the aeration tank online
and offline. Once the tank is taken online the VFD blower will start operation. The VFD
based blower is always selected as the duty blower.
2) The speed of the VFD blower is varied with respect to the dissolved oxygen level in the
aeration tank.
3) The non VFD blowers is alternated as duty and standby manually based on the preset run
time set by the operator from the DCS HMI.
4) When the VFD based blower is running in full speed and still the desired DO levels are not
reached in the aeration tank for a pre defined time, then the non VFD duty assist blower
will start operating.
5) The air cooler is started and stopped manually by the operator from the DCS HMI.
9.2.7 SECONDARY CLARIFIER, RAS SUMP AND RAS PUMP
P&ID Ref:- PDRP0451-8110-25-230-0006

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Two numbers of Secondary Clarifier has been provided to handle the effluent from its
respective aeration tank. The clarifiers provided are of peripheral driven type. The clarifiers
are provided with a sludge scrapper, which revolves slowly to scrap the bio-solids settled at
the bottom. From the bottom of the secondary clarifier the sludge flows to the RAS sump
through gravity. The collected sludge in the Secondary clarifier is recycled back by 3
numbers.(2W+1S) of RAS pumps to the aeration tank. This sludge recirculation facility is
provided to maintain a Constant Mixed Liquor Suspended Solids (MLSS) level in the aeration
tank. The PAC sludge from the landfill and leachate system also flows into the small chamber
and then overflows in the RAS sump.
A) Equipment and Functions
1) Two clarifiers 230-TK-112/212 are provided for the above mentioned purpose.
2) Each of the clarifier mechanism is provided with a peripheral motor 230-CLR-112/212 for
scraping the sludge from the bottom.
3) A RAS sump 230-SU-104 is provided for collecting the sludge from both the secondary
clarifiers and the PAC sludge from the landfill and leachate system. This sump is divided
into four compartments. Two compartments are for collecting the sludge from the
individual secondary clarifier. Two other compartments are for the Surplus Activated
sludge (SAS), which also receive .BIO-DAF sludge.
4) Three numbers of RAS pumps 230-P-115A/B/C is provided to recirculate the RAS to the
aeration tank. These pumps work on 2 working and 1 standby philosophy with
duty/standby mode of operation. The pump C acts as a common standby for pump A & B
and it is selected for operation when any one of the working pumps stops running.
5) A diaphragm type pressure gauge 230-PG-2005A/B/C is provided at the discharge of the
individual RAS pump for monitoring the discharge pressure locally.
6) A magnetic flow transmitter 230-FT-2013 is provided in the common discharge of the RAS
pumps to measure the total RAS flow to the aeration system.
1) 230-XS-2002/2003:
High Torque – Generate alarm in DCS

High high torque - Stop secondary clarifier for operator intervention.
C) Operation:
1) The secondary clarifier drive starts operating when the secondary clarifier is taken online
from DCS HMI and stops when taken offline.
2) The RAS pumps are started and stopped manually from the DCS HMI.

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3) Selection will be provided in the DCS HMI for selecting the pump B as either a standby for
pump A or pump C.
9.2.8 SAS PUMP:
P&ID Ref:- PDRP0451-8110-25-230-0006
The SAS pump is provided to pump the activated sludge to the bio sludge thickener for further
treatment. A common suction header with manual isolation facility is provided from the two
compartments for SAS sump to the SAS pump, which in turn pump the surplus sludge to the
thickener.
1) Two numbers of SAS pumps 230-P-128A/B is provided to pump the activated sludge to the
sludge thickener. These pumps work on 1 working and 1 standby philosophy with
duty/standby mode of operation.
2) A diaphragm type pressure gauge 230-PG-2006A/B is provided at the discharge of the
individual SAS pump for monitoring the discharge pressure locally.
3) A radar type level transmitter 230-LT-2003 is provided in the first SAS compartment for
monitoring the level in the DCS and to generate various operational and high and low alarm
set points.
4) Another radar type level transmitter 230-LT-2010 is provided in the second SAS
compartment for monitoring the level in the DCS and to generate the various operational
and high and low alarm setpoints.
5) A magnetic flow transmitter 230-FT-2003 is provided in the common discharge of the SAS
pumps to measure the total SAS flow to the dewatering system.
1) 230-L-2003:
operator.
Low level (Set point 2)– Generate alarm in DCS and stop SAS pump 230-P-128A/B.
2) 230-L-2010:
operator. Low level(Set point 2) – Generate alarm in DCS and stop SAS pump 230-P-128A/B.
2) 230-FQR-2003:
The total SAS flow to the SAS system is recorded and totalized in the DCS.

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C) Operation:
1) The SAS pumps are started and stopped automatically based on the setpoints of level
transmitters .
9.2.9 SPLITTER BOX-IV, FLASH MIXER AND FLOCCULATOR:
P&ID Ref:- PDRP0451-8110-25-230-0007
The Splitter Box-IV is provided for collecting the clarified effluent from the secondary clarifier
and splitting the effluent equally in four parallel streams of Bio-DAF system. The bio treated
effluent shall be dosed with a coagulant(FeCl3) in the upstream of splitter box-4 and well
mixed in high intensity flash mixer. From the flash mixer the effluent flows into the
flocculators where it is mixed with a polymer and gently agitated prior to being treated in a
Dissolved Air Flotation (DAF) unit. Ferric Chloride and Polymer will be dosed proportionately
based on the feed to BIO-DAF system, by means of dosing pump with auto stroke control.
Four numbers of flash mixer and flocculators is provided for phase I stage I and one more will
be provided for phase I stage II.
A) Equipment and Functions :
1) A splitter box 230-SU-116 is provided to distribute the secondary clarified water equally
into 4 streams of flash mixer, flocculator and bio DAF Train and have a manual isolation
facility by means of adjustable weir with stop log for each Bio-DAF trains.
2) Four no of flash mixer tanks 230-TK-115/215/315/415 are provided mixing the clarified
effluent with polymer
3) Each of the flash mixer is provided with a agitator 230-M-104/204/304/404 for mixing.
4) Four numbers of flocculation tanks 230-TK-116/216/316/416 are provided for the purpose
of flocculation.
5) Each of the flocculation tank is provided with a gentle mixer 230-M-116/216/316/416 for
the purpose of flocculation.
Not applicable for this piece of equipments
C) Operation:
1) Provision is provided in the DCS HMI to select the individual stream of flash mixer,
flocculator and bio DAF in online mode of operation. Once the stream is selected online,
the flash mixer, flocculator and bio DAF is started automatically.

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2) The flash mixer, flocculator and bio DAF can be stopped by selecting the stream in offline
mode.
9.2.10 BIO DAF:
P&ID Ref:- PDRP0451-8110-25-230-0007
The bio DAF unit is provided to remove the suspended solids in the effluent. Four no of bio
DAF units are provided for Phase I stage I and one more is considered for phase I stage II.

1) Four numbers of BIO DAF units 230-TK-117/217/317/417 are provided for the above stated
purpose.
2) Each of the BIO DAF unit is provided with a movable scraper connected to a motor 230-A-
005A/B/C/D.
3) The BIO DAF unit A and B is connected to a set of three pumps 230-P-120A/B/C operating
on 2 working and 1 standby modes of operation for recirculating the effluent to the BIO
DAF. The pump A is dedicated for BIO DAF unit A and pump C is dedicated for BIO DAF unit
B. The pump B is a common standby.
4) The BIO DAF unit C and D is connected to a set of three pumps 230-P-220A/B/C operating
on 2 working and 1 standby modes of operation for recirculating the effluent to the BIO
DAF. The pump A is dedicated for BIO DAF unit C and pump C is dedicated for BIO DAF unit
D. The pump B is a common standby.
5) Each of the recirculation pumps is provided with a diaphragm type pressure gauge 230-PG-
2007 A/B/C and 230-PG-2008 A/B/C for monitoring the discharge pressure locally.
6) Two saturation vessels 230-V-102/202 are provided in the system. Saturation vessel 230-
V-102 is dedicated for BIO DAF A/B and saturation vessel 230-V-202 is dedicated for BIO
DAF C/D.
8) The saturation vessels are provided with pressure transmitters 230-PT-2001/2002 for
monitoring the pressure in the saturation vessel and also for generating various
operational and high and low pressure alarm setpoints.
9) Each of the saturation vessel is provided with a radar type level transmitter 230-LT-
2004/2006 for monitoring the saturation tank level and also to generate various
operational and high and low alarm setpoints.
10) Each of the saturation vessels is provided with an online flow indicator 230-FI-2001/2002
to monitor the air flow into the saturation vessel locally.
11) Each of the saturation vessel air inlet line is provided with a pneumatic on/off valve 230-
XV-2009/2011 for controlling the air flow inlet to the saturation vessel based on
operational requirements.

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12) Each of the saturation vessel is also provided with a pneumatic on/off valve 230-XV-
2008/2010 for venting purpose.
13) The recycled effluent gets saturated with air in the vessel and the air water mixture under
pressure in the pressure pipe is suddenly released through hosepipe connections to
atmospheric pressure in the floatation tank.
14) A DP type flow transmitter 230-FT-2004/2005/2006/2007 is provided in the inlet of each
BIO DAF unit to monitor the inlet flow to the BIO DAF unit. The flow transmitter is also
used to record and totalize the flow to the individual DAF units.
15) In the downstream of the flow transmitter an upstream self regulating valve is provided
to control the upstream pressure.
16) Each of the BIO DAF unit is provided with a pneumatic ON/OFF valve 230-XV-
2001/2002/2003/2004 in the sludge line for intermittent removal of sludge. This valve is
operated based on two timers and all these operations are carried out automatically from
the DCS HMI.
18) Two numbers of air compressor 230-K-104 A/B is provided for supplying air to the
saturation vessel. These compressors start and stop automatically based on the set
receiver pressure and there is no control of the same by the operator.
19) Saturation vessels are provided with pressure safety valves 230-PSV-2001/2002 for safety
purpose.
1) 230-I-1340/1360:
High Pressure(Set point 1) – Generate alarm in DCS, close air inlet valve and open air vent
valve.
Low pressure(Set point 2)– Generate alarm in DCS, open air inlet valve and close air outlet
valve.
2) 230-I-1330/1350:
High level(Set point 1) – Generate alarm in DCS, and operator to take further action
Set level 1(Set point 2) – Open air vent valve and close air inlet valve.
Set level 2(Set point 3) - Close air vent valve and open air inlet valve
Low level (Set point 4)– Generate alarm in DCS and operator to take further action
3) 230-XV-2001/2002/2003/2004:
- The first timer controls the frequency of operation of the automated sludge removal system.

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4) 230-FQR-2004/2005/2006/2007:
The flow to the individual bio DAF is recorded and totalized in the DCS.
C) Operation:
1) The BIO DAF unit is selected / deselected for operation by pressing the BIO DAF train
selector provided on the DCS HMI, after isolating the deselected Bio-DAF train by
adjustable weir with stop log at the inlet of respective flash mixer.
2) Once the BIO DAF unit is selected, the BIO DAF unit is started, the recirculation pump starts
and the unit is taken for operation. The BIO DAF unit and the recirculation pump is stopped
when the unit is deselected.
3) There is no alternation of duty/standby in this pump system since the duty pumps are
dedicated for the individual BIO DAF and the third pump is a common standby.
4) The compressors start and stop automatically based on the set receiver pressure and there
is no control of the same by the operator.
5) The upstream self regulating valve regulates the upstream pressure at the 5 Kg/cm2.
9.2.11 EFFLUENT CHECK BASIN:
P&ID Ref:- PDRP0451-8110-25-230-0008
The effluent check basin is provided to receive treated effluent from BioDAF, the steam
system blowdown stream from the battery limit and non-contaminated CWBD. The effluent
check basin shall have separate compartment to receive CWBD stream and shall be provided
with 2 No. of air driven floating Disc skimmers for the removal of any oil in the effluent.
Different sets of submersible pumps are provided in the effluent check basin for transferring
the treated effluent to various other sections as explained below.
1) The effluent check basin tank 230-SU-001 is provided to collect the bio DAF treated
effluent, steam systems blowdown and uncontaminated cooling tower blowdown. The
effluent check basin consists of two sections. In the main section, the treated effluent after
bio DAF and the steam systems blowdown is collected. The submersible pumps are also
located in this section. In the other section the uncontaminated cooling tower blowdown
is collected which overflows into the main section. This section also consists of a baffle wall
to retain any floating oil in the cooling tower blowdown.

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2) An oil analyzer 230-AT-2010 is provided in the cooling tower blowdown discharge chamber
to monitor the oil presence and to generate high alarm setpoint. In case of high alarm in
this analyzer the operator shall divert the flow to splitter box-1 manually.
3) Two numbers of oil skimmers 230-OS-005A/B are provided in the cooling tower blowdown
section to remove the floating oil. 4) 3 numbers of offspec/excess effluent transfer pumps
230-P-021 A/B/C are provided for transferring the excess/offspec effluent from the
effluent check basin to the storm water reservoir. These pumps work on 2 working and 1
standby philosophy. Provision is also available to divert the pumped flow either to
equalization tank or to the bio tower feed sump. Treated effluent from hard COD is
connected to the pump discharge line to transfer the fluid to the storm water reservoir.
of the off spec/excess effluent transfer pumps to monitor the pump discharge pressure
locally.
6) Three numbers of treated effluent transfer pumps 230-P-022 A/B/C are provided to
transfer the treatedmeffluent from the effluent check basin to the Rapid Gravity sand filter
in the WRP package. These pumps work on 2 working and 1 standby philosophy in duty
and standby modes of operation.
of the off treated effluent transfer pumps to monitor the pump discharge pressure locally.
8) At the common discharge of the treated effluent transfer pumps a TDS analyzer 230-AT-
2006, two pH analyzers 230-AT-2007A/B, a COD analyzer 230-AT-2008 and a turbidity
analyzer AT 2009 is provided to monitor the parameters of the treated effluent and to
generate various alarm setpoints in the DCS.
9) A DP type flow transmitter 230-FT-2009 is provided in the common discharge of the treated
effluent pump to measure the total flow to GSF and to monitor the same in the DCS.
10) Two numbers of treated effluent transfer pumps 230-P-025A/B are provided which will
pump the treated effluent for gardening purpose into tankers. Before discharging into the
tanker, the effluent is dosed with hypo chlorite for disinfection and blended with treated
RO water to maintain the Sodium Absorption Ratio (SAR) to the required level. This pump
will normally pump the effluent to the biosludge thickener to maintain the required surface
loading rate thereby preventing the septic condition in the thickener.
of the treated effluent transfer pumps (Gardening) to monitor the pump discharge
pressure locally.
12) A DP type flow transmitter 230-FT-2010 is provided in discharge of the treated effluent
pump for gardening to measure the total flow and to monitor the same in the DCS.
13) A DP type flow transmitter 230-FT-2011 is provided in the treated RO line for blending to
monitor the flow in the DCS.
14) A radar type level transmitter 230-LT-2008 is provided in the effluent check basin to
measure the level and to generate the various high and low alarm and operation setpoints.

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15) Another radar type level transmitter 230-LZT-2009 is provided to generate the low low
level alarm setpoint and is directly connected to the ESD system. From the ESD system,
16)A diaphragm type pressure gauge 230-PG-2017 is provided at the inlet to truck loading for
dust supression/gardening to monitor the pressure at the common discharge header of
treated effluent transfer pump(Gardening).
1) 230-I-1390:
High level(Set point 1) – Generate alarm in DCS and further action to be taken by operator.
Start level 2(Set point 2) – Start both treated effluent transfer duty pumps with a time delay
of 2 min between the pump starts..
Start level 1(Set point 3) – Enable treated effluent transfer pump (gardening).
Stop level 1(Set point 4) – Stop treated effluent transfer pump.
Stop level 2 (Set point 5)– Stop off spec/excess effluent transfer pump.
Stop level 3 (Set point 6)– Stop treated effluent transfer pump (gardening).
Low level(Set point 7) – Generate alarm in the DCS HMI for operator action.
2) 230-IZ-0160:
Low low level – Trip off spec/excess transfer pumps, treated effluent transfer pumps and
Start treated effluent transfer pump (gardening).pumps through ESD.
3) 230-A-2010:
High oil content - Generate alarm in DCS and operator to take further action
4) 230-A-2006:
High TDS(Set point 1) - Generate alarm in DCS and operator to take further action
5) 230-A-2007A/B:
High pH(Set point 1) - Generate alarm in DCS and operator to take further action
Low pH (Set point 2) - Generate alarm in DCS and operator to take further action
6) 230-A-2008:
High COD(Set point 1) - Generate alarm in DCS and operator to take further action
7) 230-A-2009:
High turbidity(Set point 1) - Generate alarm in DCS and operator to take further action

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8) 230-FQI-2009:
The flow to the RGF system is totalized in the DCS.
9)230-FQI-2010:
The flow to the biosludge thickener is totalized in the DCS.
10)230-FQI-2011:
The flow to the truck loading is totalized in the DCS.
C) Operation:
1) When the level of the effluent check basin reaches high level, an alarm is raised in the DCS
HMI. The off spec/excess effluent pumps are operated for two conditions, one to pump
the excess effluent and other during the condition of offspec.
2) During excess flow condition the effluent will be pumped to the storm water reservoir and
during offspec condition, based on the nature of offspec the destination of effluent to be
pumped will be decided by the operator. However this has to be done manually by the
operator from the DCS HMI after setting the valves in the field. The pump shall stop at stop
level 2.
3) The off spec/excess effluent pumps are alternated as duty and standby in every operation
cycle.
4) When the level in the effluent check basin reaches a start level 2, the treated effluent pump
shall start operating. These pumps work on 2 working and 1 standby philosophy in
duty/standby modes of operation.
5) The treated effluent transfer pumps are alternated as duty and standby manually based on
the preset run time set by the operator form the DCS HMI.
6) When the level in the effluent check basin reaches a start level1 the gardening pumps are
enabled for operation and the operator can start and stop the pump manually. The pump
will also stop automatically at stop level 3. These pumps work on 1 working and 1 standby
philosophy. Before starting these pumps the operator shall manually set the valves in the
field such that the discharge reaches the intended area.
7) The treated effluent pump(gardening) is alternated as duty and standby in every operation
cycle .
9.3 SLOP OIL SUBPACKAGE
This sub package deals with the collection of slop oil from various parts of the plant as well
as from decantation of mobile tankers from other outside third parties, storage (230-TK-

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010/011) and transfer the same outside battery limit through dry slop oil transfer pump
(230-P-011A/B).
9.3.1 WET SLOP OIL SUMP & TRANSFER PUMPS

P&ID Ref: PDRP0451-8110-25-230-0009
The wet slop oil from slop oil transfer pump, Naphthenic oil transfer pump, Desalter
water/Brine equalization tanks, API Separator, TPI separator, common oily sludge sump and
equalization tanks is collected in wet slop oil sump. The slop oil is then transferred to the wet
slop oil storage tanks by the wet slop oil transfer pumps.
1) The wet slop oil sump 230-SU-007 is provided for collection of the slop oil within ETP B/L.
2) One Radar type level transmitter 230-LT-3001 is provided in the tank for monitoring the
tank levels and to generate various operational and high and low alarm set points. This
transmitter is connected to the DCS.
4) Wet slop oil transfer pumps (230-P-012A/B) 2 numbers are provided for pumping the oil to
the slop oil storage tanks. These pumps work on 1 working 1 standby philosophy with duty
/standby modes of operation. (230-P-012A) is provided with an extended suction arm with
mounted female knob that can be connected to decanter tanker unloading fitting for
unloading purpose of off-specs material & transfer it into slop oil storage tanks.
of the wet slop oil transfer pumps to monitor the pump discharge pressure locally.
1) 230-L-3001:
High level(Set point 1) - Generate alarm in DCS HMI and operator to manually start the
standby pump to transfer more wet slop oil to the slop oil tank.
Start level(Set point 2) – Start wet slop oil transfer pumps
Stop level(Set point 3) – Stop wet slop oil transfer pumps
operator.
Low low level – Trip wet slop oil transfer pumps through ESD.

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C) Operation:
1) When the level in the wet slop oil sump reaches the start level, the duty pump starts
2) The wet slop oil transfer pump is alternated as duty and standby in every operation cycle.
9.3.2 SLOP OIL STORAGE TANKS & DRY SLOP OIL TRANSFER PUMPS
P&ID Ref: PDRP0451-8110-25-230-0009
Two numbers of Slop Oil Storage Tanks have been provided with steam heating coil facility to
store the slop oil for a period of time, and to separate water from oil and to pump the
separated oil outside the battery limit using the dry slop oil transfer pumps.
1) Two numbers of slop oil storage tanks 230-TK-010/011 are provided for storing the slop oil
and separating the water from oil. One tank is operated in the fill mode and the other tank
is operated in the transfer mode.
2) Each tank has been provided with Radar type level transmitter 230-LT-3003 & 230-LT-3005
for monitoring the level and to generate various operational and high and low alarm
setpoints.
3) Each tank has been provided with another radar type level transmitter 230-LZT-3004 &
230-LZT-3006 provided to generate the low low level alarm setpoint and is directly
connected to the ESD system. From the ESD system, hardwired interlocks are provided in
the MCC for tripping the pumps at low low level.
4) Each tank is provided with a temperature transmitter 230-TT-3001 & 230-TT-3002 to
monitor the tank temperature and to generate the control signal for the LP steam inlet
control valve 230-TV-3001 at the common header to control the temperature in the tank.
The steam heating is done to facilitate the phase separation of oil and water before starting
the transfer pump. The tank isolation for the steam has to be done manually from the field.
5) Two numbers of dry slop oil transfer pumps 230-P-011 A/B is provided to transfer the slop
oil from the transfer tank to outside the battery limit.
6) A diaphragm type pressure gauge PG 3003A/B is provided in the individual discharge of the
dry slop oil transfer pumps to monitor the pump discharge pressure locally.
7) A pressure transmitter 230-PT-3001 is provided in the common discharge of the dry slop
oil transfer pumps to monitor the discharge pressure and also to stop the pumps in case
of high pressure.

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8) A pneumatic on/off valve XV-3001/3002 is provided in the inlet of each of the slop oil tank.
This valves are remote operated shut off valves(ROSOV) which can be operated from the
DCS HMI and as well as from the field.
9) Two nos.of manual Dyke valves, one routed to CRWS and other routed to storm water
drain. Both valves are provided with open position indications in the control room.
10) A Pressure vaccum relief valve 230-PVRV-3001/3002 are provided for safety purpose.
11) A pneumatic on/off valve 230-XZV-3003/3004 is provided at the discharge of slop oil tank
230-TK- 010/011 to pump the oil into wet slop oil storage tank.
1) 230-I-1410/1420:
High level (Set point 1) - Generate alarm in DCS HMI and operator to switch over the tank or
stop the wet slop oil transfer pump.
Low level(Set point 2) – Generate alarm in DCS and stop dry slop oil transfer pump
2) 230-IZ-0180/0190:
Low low level – Trip dry slop oil transfer pumps through ESD.
3) 230-TIC-3001/3002:
The temperature control valve is modulated to control the steam inlet to the transfer tank to
maintain the temperature.
4) 230-IZ-0260:
High pressure – Generate alarm in DCS and stop dry slop oil transfer pumps.
C) Operation:
1) Soft buttons are provided in the DCS HMI to select the tanks in fill mode or transfer mode.
The transfer mode tank temperature transmitter is used to control the steam inlet valve.
The steam inlet isolation valve provided for two slop oil tanks has to be carried out
manually from the field.
2) With phase separation happened in the slop oil tank due to the steam heating, the operator
shall manually drain the oil separated effluent by manual valves provided in the tank.. The
manual drain valves shall be closed as soon the operator visually identifies oil presence in
the drained effluent.
3) Then the dry slop oil transfer pump is started and stopped manually to ensure only oil is
pumped from the tank.

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4) When the level in the transfer tank reaches low level, the dry slop oil transfer pump shall
stop.
5) The ROSOV's at the inlet and outlet can be operated both from the DCS HMI and the field.
A operating station is provided outside the dyke wall for operating these valves.
9.3.3 OWS SUMP- I & DRAINED EFFLUENT TRANSFER PUMPS
P&ID Ref: PDRP0451-8110-25-230-0009
The OWS sump-I collects the oil free drained water from the slop oil storage tanks and transfer
the collected effluent to splitter box-I through the drained effluent transfer pumps.
1) The OWS sump-I 230-SU-118 is provided to collect the oil free drained water from the slop
oil tank.
2) One RADAR level transmitter (LT-3007) is provided in the tank for monitoring the tank levels
and to generate various operational and high and low alarm setpoints. This transmitter is
connected to the DCS.
3) Another Radar type level transmitter 230-LZT-3008 is provided to generate the low low
level alarm setpoint and is directly connected to the ESD system. From the ESD system,
4) Two drained effluent transfer pumps (230-P-135A/B) are provided to pump the collected
effluent to the API splitter box-I
5) A diaphragm type pressure gauge PG 3001A/B is provided in the individual discharge of the
drained effluent transfer pumps to monitor the pump discharge pressure locally.
1) 230-I-1440:
operator.
Start level(Set point 2) – Start drained effluent transfer pumps
Stop level(Set point 3) – Stop drained effluent transfer pumps
Low level(Set point 4)– Generate alarm in DCS HMI and further action to be taken by the
operator.
2) 230-IZ-0200:

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Low Low level-Trip the effluent transfer pump through ESD.
C) Operation:
1) When the level in the OWS sump-I reaches the start level, the duty pump starts running
2) The dry effluent transfer pump is alternated as duty and standby in every operation cycle.
3.4 OILY SLUDGE TREATMENT SUBSYSTEM:
This subsystem is provided for the collection of the oily sludge from various areas of the plant
and to treat them.
9.4.1 DAF SLUDGE SUMP & DAF SLUDGE TRANSFER PUMP

P&ID Ref: PDRP0451-8110-25-230-0010
The DAF sludge sump is provided to collect the oily sludge from the oily DAF tank and pumped
to the oily sludge thickener using the DAF sludge transfer pump.
1) DAF sludge sump (230-SU-119) is provided for collecting the oily sludge from the oily DAF
tank.
levels and to generate various operational and high and low alarm setpoints. This
setpoint and is directly connected to the ESD system. From the ESD system, hardwired
interlocks are provided in the MCC for tripping the pumps and mixers at low low level.
4) Two numbers of DAF sludge transfer pumps 230-P-036 A/B is provided to transfer the oily
sludge from the DAF sludge sump to the oily sludge thickener. These pumps work on 1
working 1 standby philosophy with duty /standby modes of operation. A manual bypass
facility is provided to transfer the sludge directly to the thickened oily sludge sump.
5) A diaphragm type pressure Gauge 230-PG-4001A/B is provided in the individual discharge
of the DAF sludge transfer pumps to monitor the pump discharge pressure locally.
6) A pressure transmitter 230-PT-4001 A/B is provided to generate the high pressure alarm in
the individual discharge of the DAF sludge transfer pumps and to stop the pump.
7) A stator temperature transmitter 230-TT-4001 A/B is provided to generate the high
temperature alarm in the stator and to stop the pump.
8) A mixer 230-M-119 is provided in the DAF sump to keep the sludge in suspension.

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9) The mixer is provided with a torque switch 230-XS-4001 to stop the mixer in case of high
torque.
10)Bursting Disc Tell-Tale strips(230-PSE-4001A/B) are provided to stop the motor incase of
Bursting Disc Rupture
1) 230-I-1450:
operator.
Start level 2(Set point 2) – Start DAF sludge transfer pumps
Start level 1(Set point 3) – Start DAF sludge sump mixer
Stop level 2(Set point 5) – Stop DAF sludge transfer pumps
Stop level 1(Set point 4) – Stop DAF sludge sump mixer
2) 230-IZ-0210:
Low low level - Trip the pumps and mixers through ESD.
3) 230- XS-4001:
High Torque – Generate alarm in DCS and stop mixer.
4) 230-I-1470/1500:
High pressure – Generate alarm in DCS and stop the pump.
5) 230-I-1460/1490:
High temperature – Generate alarm in DCS and stop the pump.
6) 230-I-1480/1510:
intervention to re-start the pump by resetting Soft button in DCS HMI.
C) Operation:
1) When the level in the DAF sludge sump reaches the start level 2, the duty pump starts
running and stops at the stop level 2.
2) The DAF sludge transfer pumps is alternated as duty and standby in every operation cycle.
3) When the level in the DAF sludge sump reaches the start level 1, the mixer starts running
and stops at the stop level 1.

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9.4.2 OILY SLUDGE THICKENER:

P&ID Ref: PDRP0451-8110-25-230-0010
The oily sludge thickener is provided to thicken the oily sludge from the DAF sludge sump and
common oily sludge sump. The thickened sludge is sent to the thickened oil sludge sump and
the supernatant is sent to the OWS sump-II.
1) The oily sludge thickener tank 230-TK-121 is provided for thickening the oily sludge.
2) A centrally driven thickener mechanism 230-THK-121 is provided for thickening the sludge.
3) A torque switch XS-4002 is provided in the scraper mechanism to generate high torque
alarm and high high torque alarm in the DCS.
4) A pneumatic ON/OFF valve 230-XV-4001 is provided in the sludge discharge line of the
sludge thickener to enable automatic discharge of the thickened sludge. Two timer
controls are provided for this valve. The first timer controls the frequency of operation and
the second timer controls the duration of valve opening in every cycle. In addition to the
timer, the valve will also be opened in case of high torque in the sludge thickener.
1) 230-I-1520:
High Torque(Set point 1) – Generate alarm in DCS and open sludge discharge valve 230-XV-
4001.
High high Torque(Set point 2) - Generate alarm in the DCS and trip the oily sludge thickener.
2) 230-XV-4001
- The first timer controls the frequency of operation of the automatic valve
- The second timer controls the duration of opening.
Automated valve will not open in case of high level of thickened oily sludge sump.
C) Operation:
1) The operator can start and stop the sludge thickener manually from the DCS HMI.
9.4.3 THICKENED OILY SLUDGE SUMP AND OILY CENTRIFUDGE FEED PUMP:
P&ID Ref: PDRP0451-8110-25-230-0010

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The thickened oily sludge sump is provided to collect the thickened sludge from the Oily
sludge thickener and to transfer the same to the centrifuge using the oily centrifuge feed
pump.
1) The thickened oily sludge sump 230-SU-110 is provided to collect the thickened sludge from
the oily sludge thickener and also can receive sludge directly both from common oily
sludge sump and DAF sludge sump with the help of manual bypass facility provided.
interlocks are provided in the MCC for tripping the pumps at low low level.
4) A thickened oily sludge sump agitator 230-M-110 is provided in the thickened oily sludge
sump to keep the thickened sludge in suspension.
5) Three numbers of oily centrifuge feed pumps 230-P-132A/B/C are provided to transfer the
thickened sludge from the thickened oily sludge sump to the oily sludge centrifuge. The
pump A and B are dedicated to individual centrifuge and pump C acts as a common
standby.
6) A diaphragm type pressure gauge 230-PG-4003A/B/C B is provided in the individual
discharge of the oily centrifuge feed pumps to monitor the pump discharge pressure
locally.
7) A pressure transmitter 230-PT-4002 A/B/C is provided to generate the high pressure alarm
in the individual discharge of the oily centrifuge feed pumps and to trip the pump.
8) A stator temperature transmitter 230-TT-4002 A/B /C is provided to generate the high
temperature alarm in the stator and to trip the pump.
9) The agitator is provided with a torque switch 230-XS-4003 to stop the mixer in case of high
torque.
10) Bursting Disc Tell-Tale strips(230-PSE-4002A/B/C) are provided to stop the motor in case
of Bursting Disc Rupture
1) 230-I-1540:
High level (Set point 1) - Generate alarm in DCS HMIand inhibits opening of on/off valve of
oily sludge thickener
Start level 1(Set point 2) – Start thickened oily sludge sump agitator
Stop level 1(Set point 3) – Stop thickened oily sludge sump agitator

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Stop level 2(Set point 4)– Disable starting of oily centrifuge feed pump
2) 230-IZ-0230:
Low low level - Trip the pumps and agitators through ESD.
2) 230- I-1530:
High Torque – Generate alarm in DCS and trip agitator.
3) 230-I-1560/1590/1620:
High pressure – Generate alarm in DCS and trip pump.
4) 230-I-1550/1580/1610:
High temperature – Generate alarm in DCS and stop pump.
5) 230-I-1570/1600/1630:
C) Operation:
1) The thickened oily sludge sump agitator will start and stop based on the levels in the
thickened oily sludge sump.
2) The oily centrifuge feed pump is enabled for operation above the stop level 2 and the pump
will start. when the dedicated centrifuge is put in service and stop when the centrifuge is
taken out of service.
9.4.4 CENTRIFUGE:
The centrifuge is provided to dewater the oily sludge. The supernatant is sent to the OWS
sump-II and the dewatered cake is collected in trolleys for further disposal.
1) Two oily centrifuges 230-DEW-301/401 is provided for dewatering the oily sludge.
2) Each of the centrifuge is provided with a dedicated reversible belt conveyor 230-CR-001A/B
for conveying the oily sludge cakes into the trolley or the reslurry sump.
3) Each centrifuge is provided with a torque switch XS 4004/4005 for generating the high
torque alarm and high high torque alarm in the DCS and to stop the centrifuge.
4) An LEL detector is provided in the centrifuge vicinity to sense the presence ot LEL and raise
alarm for operator safety.

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5) Two DWPE dosing pumps are provided to dose the chemical at the inlet of each centrifuge.
1) 230-I-1710/1720:
High Torque – Generate alarm in DCS.
High high torque - Genrate alarm in the DCS HMI and stop centrifuge.
C) Operation:
1) Soft push buttons are provided in the DCS HMI to put the centrifuge online and offline.
Once the centrifuge is selected online the dedicated conveyor and the feed pump is
started. The sequence of starting is as below provided oily sludge sump level and DWPE
dosing tank level not low.
a) Start conveyor
b) Start Centrifuge
c) Start DWPE dosing pump
d) Start centrifuge feed pump
2) The centrifuge is taken offline by pressing the offline push button provided on the HMI.
The dedicated conveyor and the feed pump is stopped when the centrifuge is taken offline.
The centrifuge will also stop when the level in the oily supernatant sump reaches high level.
The sequence of stopping is as below:
a) Stop centrifuge feed pump
b) Stop DWPE dosing pump
c) Stop centrifuge
d) Stop conveyor
3) Provision is also provided in the DCS HMI to select the direction of rotation of the conveyor.
9.4.5 RESLURRY SUMP AND OILY SLUDGE TRANSFER PUMP:
The reslurry sump is provided to collect the oily sludge cakes and mix it with the centrifuge
supernatant tapped from the discharge outlet of oily supernatant transfer pumps and pump
the mixed slurry to outside the battery limit using the oily sludge transfer pump. This facility
is an alternate facility and not in continuous operation.
1) The reslurry sump 230-SU-121 is provided to collect the centrifuge cakes and to prepare
the slurry and also a manual bypass facility is provided to receive the sludge directly from
the discharge centrifuge feed pump.

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4) An agitator 230-M-121 is provided in the reslurry sump to mix the cakes with the
supernatant.
5) Two numbers of oily sludge transfer pumps 230-P-134 A/B are provided to transfer the
reslurry from the reslurry sump to outside the battery limit. These pumps work on 1
working 1 standby philosophy with duty /standby modes of operation.
6) A diaphragm type pressure gauge 230-PG-4004A/B is provided in the discharge of the oily
sludge transfer pump to monitor the pump discharge pressure locally.
7) A pressure transmitter 230-PT-4003 A/B is provided to generate the high pressure alarm in
the individual discharge of the oily sludge transfer pumps and to stop the pump.
9) The agitator is provided with a torque switch to generate the high torque alarm and high
high torque alarm in the DCS and to stop the agitator.
10) A magnetic flow transmitter 230-FT-4001 is provided in the discharge of the Oily
supernatant transfer pumps to measure the flow to the reslurry sump.
11)A pneumatic ON/OFF valve 230-XV-4002 is provided in the oily supernatant transfer
pumps discharge line to divert the flow to the reslurry sump.
12)Bursting Disc Tell-Tale strips(230-PSE-4003A/B) are provided to stop the motor incase of
1) 230-I-1640:
operator.
Start level 2(Set point 2) – Start oily sludge transfer pumps
Start level 1(Set point 3) – Start reslurry sump agitator
Stop level 2(Set point 5) – Stop oily sludge transfer pumps
Stop level 1(Set point 4) – Stop reslurry sump agitator
2) 230-I-0240:
Low low level - Trip the pumps through ESD system.

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3) 230- XS-4006:
High Torque – Generate alarm in DCS.
High High torque - Generate alarm in the DCS and stop agtitator.
4) 230-I-1660/1690:
5) 230-I-1650/1680:
6) 230-I-1670/1700:
C) Operation:
1) When the level in the reslurry sump reaches the start level 2, the duty pump starts running
2) The reslurry pumps is alternated as duty and standby in every operation cycle .
3) When the level in the reslurry sump reaches the start level 1, the agitator starts running
9.4.6 OILY SUPERNATANT TRANSFER PUMP (OWS SUMP-II):
The OWS sump-II is provided to collect the supernatant from the oily sludge centrifuge and
the supernatant from the oily sludge thickener and transfer the same to the splitter box-I
using oily supernatant transfer pumps.
1) The OWS sump - II 230-SU-011 is provided to collect the supernatant from the oily
centrifuge and the oily sludge thickener.

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4) Two numbers of oily supernatant transfer pumps 230-P-133 A/B are provided to transfer
the supernatant from the oily supernatant sump to splitter box-I. These pumps work on 1
working 1 standby philosophy with duty / standby modes of operation.
supernatant transfer pump to monitor the pump discharge pressure locally.
1) 230-I-1530:
High level(Set point 1) - Generate alarm in DCS HMI and stop centrifuge.
Start level(Set point 2) – Start oily supernatant transfer pumps
Stop level(Set point 3) – Stop oily supernatant transfer pumps
2) 230-IZ-0220:
Low low level - Trip the pumps through the ESD system.
C) Operation:
1) When the level in the oily supernatant sump reaches the start level, the duty pump starts
2) The oily supernatant pumps is alternated as duty and standby in every operation cycle.
9.5 BIO SLUDGE TREATMENT SUBSYSTEM:
This subsystem is provided for the collection of the bio sludge from various areas of the plant
and to treat them.
3.5.1 BIO SLUDGE THICKENER:
P&ID Ref: PDRP0451-8110-25-230-0011
The bio sludge thickener is provided to thicken the bio sludge and PAC sludge from the SAS
sump and send the thickened sludge to the thickened bio sludge sump. The supernatant from
the thickener is collected in the bio supernatant sump.
1) The bio sludge thickener tank 230-TK-120 is provided for thickening the bio sludge.

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2) A centrally driven thickener mechanism 230-THK-120 is provided for thickening the sludge.
3) A torque switch 230-XS-5001 is provided in the scraper mechanism to generate high torque
alarm and high high torque alarm in the DCS.
4) An pneumatic ON/OFF valve 230-XV-5001 is provided in the sludge discharge line of the
sludge thickener to enable automatic discharge of the thickened sludge. Two timer
controls are provided for this valve. The first timer controls the frequency of operation and
the second timer controls the duration of valve opening in every cycle. In addition to this,
the sludge valve will also open in case of high torque alarm in thickener.
1) 230-I-1730:
High Torque – Generate alarm in DCS and open sludge discharge valve 230-XV-5001.
High high torque - Generate alarm in DCS and stop the thickener.
2) ) 230-XV-5001
- Each automated valve is provided with two timers.
- The first timer controls the frequency of operation of the automatic valve.
- The second timer controls the duration of opening.
Automated valve will not open incase of high level of thickened bio sludge sump
C) Operation:
1) The operator can start and stop the sludge thickener manually from the DCS HMI.
9.5.2 THICKENED BIO SLUDGE SUMP AND BIO CENTRIFUDGE FEEDPUMP:
P&ID Ref: PDRP0451-8110-25-230-0011
The thickened bio sludge sump is provided to collect the thickened sludge from the sludge
thickener and to transfer the same to the centrifuge using the bio centrifuge feed pump.
1) The thickened bio sludge sump 230-TK-118 is provided to collect the thickened sludge from
the bio sludge thickener.
2) A radar type level transmitter 230-LT-5002 is provided in the tank for monitoring the tank

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3) A thickened bio sludge sump agitator 230-M-118 is provided in the thickened bio sludge
sump to keep the thickened sludge in suspension.
4) Three numbers of bio centrifuge feed pumps 230-P-124A/B/C are provided to transfer the
thickened sludge from the thickened bio sludge sump to the bio sludge centrifuge. The
pump A and B are dedicated to individual centrifuge and pump C acts as a common
standby.
of the bio centrifuge feed pumps to monitor the pump discharge pressure locally.
6) A pressure transmitter 230-PT-5001 A/B/C is provided to generate the high pressure alarm
in the individual discharge of the bio centrifuge feed pumps and to stop the pump.
8) The agitator is provided with a torque switch 230-XS-5003 to stop the mixer in case of high
torque.
9) Bursting Disc Tell-Tale strips(230-PSE-5001A/B/C) are provided to stop the motor incase of
1) 230-I-1750:
High level(Set point 1) - Generate alarm in DCS HMI and inhibits opening of on/off valve of
oily sludge thickener
Start level 1(Set point 2) – Start thickened bio sludge sump agitator
Stop level 1(Set point 3) – Stop thickened bio sludge sump agitator
Stop level 2(Set point 4) – Stop of bio centrifuge feed pump
Low level (Set point 5) – Generate alarm in DCS and further action to be taken by the operator.
2) 230- XS-5003:
High Torque – Generate alarm in DCS and stop agitator.
3) 230-I-1770/1800/1830:
4) 230-I-1760/1790/1820:
5) 230-I-1780/1810/1840:

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C) Operation:
1) The thickened bio sludge sump agitator will start and stop based on the levels in the
thickened bio sludge sump.
2) The bio centrifuge feed pump is enabled for operation above the stop level 2 and the pump
will start. When the dedicated centrifuge is put in service and stop when the centrifuge is
taken out of service.
9.5.3 CENTRIFUGE:
The centrifuge is provided to dewater the bio sludge. The supernatant is sent to the bio
supernatant sump and the dewatered cake is collected in tipper trolleys for further drying in
sludge weathering beds.
1) Two bio centrifuges 230-DEW-101/201 is provided for dewatering the bio sludge.
2) The centrifuges are provided with a two common belt conveyor 230-CR-002A/B for
conveying the bio sludge cakes into the trolley.
3) Each centrifuge is provided with a torque switch XS 5002/5004 for generating the high
torque alarm in the DCS and to stop the centrifuge.
4) Two DWPE dosing pumps are provided to dose the chemical at the inlet of each centrifuge.
1) 230-XS-5002/5004:
High Torque – Generate alarm in DCS and stop centrifuge.
C) Operation:
1) Soft push buttons are provided in the DCS HMI to put the centrifuge online and offline.
Once the centrifuge is selected online the conveyor and the feed pump is started. The
sequence of starting is as below:
a) Start conveyor
b) Start Centrifuge
c) Start DWPE dosing pump

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d) Start centrifuge feed pump

2) The centrifuge is taken offline by pressing the offline push button provided on the HMI.
The conveyor and the feed pump is stopped when the centrifuge is taken offline. The
centrifuge will also stop when the level in the bio supernatant sump reaches high level.
The sequence of stopping is as below:
a) Stop centrifuge feed pump
b) Stop DWPE dosing pump
c) Stop centrifuge
d) Stop conveyor
9.5.4 BIO SUPERNATANT SUMP AND BIO SUPERNATANT TRANSFER PUMP:
The Bio supernatant sump is provided to collect the supernatant from the bio sludge
centrifuge and the supernatant from the bio sludge thickener and transfer the same to the
splitter box-III using bio supernatant transfer pumps.
1) The bio supernatant sump 230-SU-002 is provided to collect the supernatant from the bio
centrifuge and the bio sludge thickener.
2) Radar type level transmitter LT 5001 is provided in the tank for monitoring the tank levels
and to generate various operational and high and low alarm setpoints. This transmitter is
3) Two numbers of bio supernatant transfer pumps 230-P-023 A/B are provided to transfer
the supernatant from the bio supernatant sump to splitter box-III. These pumps work on 1
working 1 standby philosophy with duty / standby modes of operation.
4) A diaphragm type pressure gauge PG-5001A/B is provided in the discharge of the oily
1) 230-I-1740:
High level(Set point 1) - Generate alarm in DCS HMI and stop centrifuge.
Start level(Set point 2) – Start bio supernatant transfer pumps
Stop level(Set point 3) – Stop bio supernatant transfer pumps
C) Operation:

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1) When the level in the bio supernatant sump reaches the start level, the duty pump starts
2) The bio supernatant pumps is alternated as duty and standby in every operation cycle.
9.5.5 SLUDGE WEATHERING BEDS, WEATHERED SLUDGE LIQUOR SUMP AND WEATHERED
SLUDGE LIQUOR TRANSFER PUMP:
The sludge weathering beds is provided to store the bio sludge cakes collected from the bio
centrifuge for further weathering. The sludge liquor from the weathering beds is collected in
the weathered sludge liquor sump and the weathered sludge liquor transfer pump is provided
to transfer the liquor to splitter box-III. Three numbers of sludge weathering beds are
provided for phase I stage I and one more will be considered for phase I stage II.
1) The sludge weathering beds 230-TK-122 A/B/C is provided to weather the bio sludge
produced from the bio centrifuge and it has to be transported by tipper trolley provided
with tipping mechanism. Then the dewatered sludge will be spread in the bed by means of
industrial four wheel drive tractor.
2) The weathered sludge liquor sump 230-SU-122 is provided to collect the slurry from the
sludge weathering beds.
3) Two numbers of weathered sludge liquor transfer pumps 230-P-137 A/B are provided to
transfer the slurry from the weathered sludge liquor sump to splitter box-III. These pumps
work on 1 working 1 standby philosophy with duty / standby modes of operation.
1) 230-I-1870:
High level(Set point 1) - Generate alarm in DCS HMI and operator to take further action.
Start level(Set point 2) – Start weathered sludge liquor transfer pumps
Stop level(Set point 3) – Stop weathered sludge liquor transfer pumps
C) Operation:

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1) When the level in the weathered sludge liquor sump reaches the start level, the duty pump
starts running and stops at the stop level.
2) The weathered sludge liquor pumps is alternated as duty and standby in every operation
cycle manually.
9.6 LANDFILL LEACHATE TREATMENT PACKAGE (LLTP) – SECTION 231
The LLPP will receive leachate from the nearby solid waste landfill site which will serve the
refinery and will also receive the incinerator scrubber effluent and the spent caustic effluent
from U-25 and U-24.The purpose of the Landfill Leachate pretreatment package (LLPP) is to
pre-treat the landfill leachate prior to bio-treatment such that the overall requirements for
the ETP & WRP can be met.
9.6.1LEACHATE EQUALISATION TANK & LEACHATE TRANSFER PUMPS

P&ID REF: PDRP0451-8110-25-231-0001
The leachate from the solid waste landfill, incinerator quench water and spent caustic from
unit U-25 and U-24 is collected in the leachate equalization tank (231-TK-001) and the
equalized effluent will be pumped into the pH adjustment tank -1 by means of Leachate
Transfer Pumps (231-P-007 A/B).
1) The leachate equalization tank (231-TK-001) is provided to collect the leachate from the
solid waste landfill, incinerator quench water and spent caustic from unit U-25 and U-24
and equalize the same.
2) Radar type level transmitter 231-LT -1001 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm set-points. This transmitter is
3) Another radar type level transmitter 231-LZT- 1002 is provided to generate the low low
level alarm and is directly connected to the ESD system. From the ESD system, hardwired
4) Two numbers of leachate transfer pumps 231-P-007 A/B are provided for pumping the
effluent from the equalization tank to the pH adjustment tank-1. These work on one
working and one standby philosophy.
5) Diaphragm type pressure gauge 231-PG 1002A/B is provided in the individual discharge of
the leachate transfer pumps to monitor the pump discharge pressure locally.

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6) Two numbers of leachate equalization tank recirculation pump 231-P-005A/B are provided
to mix the effluents in the equalization tank.
7) Diaphragm type pressure gauge 231-PG 1005A/B is provided in the discharge of the
leachate recirculation pumps to monitor the pump discharge pressure locally.
8) A magnetic flow transmitter231- FT- 1001 is provided in the common discharge of the
leachate transfer pump to measure the flow. This instrument provides the input flow signal
to the PID flow controller whose output is connected to the flow control valve 231-FV -
1001 provided in the common discharge to maintain a desired flow to the pH adjustment
tank-1.
B) Interlock, Alarm and Control descriptions:
1) 231-I-1000:
High level(Set point 1) - Generate alarm in DCS HMI and operator shall ensure the feed to the
leachate equalization tank to be stopped.
Start level(Set point 2) – Start leachate transfer pumps
Stop level(Set point 3) – Stop leachate transfer pumps
Low level(Set point 4) – Generate alarm in DCS and stop recirculation pump.
2) 231-IZ-0100:
Low low level – Trip leachate transfer pumps and recirculation pumps through ESD.
3) 231-FIC-1001:
Desired flow to the pH adjustment tank-1 is controlled via the flow control valve.
3) 231-I-1280:
Low Flow – Generate alarm in the DCS HMI and stop the leachate transfer pump
4) 231-I-1290:
231-FV-1001 close feedback – Generate alarm in the DCS HMI and stop the leachate transfer
pump.
C) Operation:
1) When the level in the leachate equalization tank reaches the start level, the duty pump
starts running and stops at the stop level.
2) The leachate equalization tank recirculation pump is started and stopped manually by the
operator from the DCS HMI provided the start permissive for this pump is enabled. The
start permissive is enabled only when the level in the equalization tank is above the low
level.

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9.6.2 pH ADJUSTMENT TANK-1, FLASH MIXER & FLOCCULATION TANK:
P&ID REF: PDRP0451-8110-25-231-0001
The pH adjustment tank-1 is provided to mix the equalized leachate to LLPP drainages and to
increase the pH level to 8-9 by dosing caustic. The effluent after pH adjustment overflows into
the flash mixer where it is dosed with FeCl3 and further flows into the flocculator where it is
dosed with polymer which helps in the formation of flocs.
1) The pH adjustment tank -1(231-TK-004A) is provided to mix the equalized leachate to LLPP
drainages and dosed with caustic to increase the pH to 8-9.
2) An agitator 231-M-001 is provided in the pH adjustment tank-1 to ensure proper mixing of
the chemical to the effluent.
3) Two pH analyzers 231-AT 1001-A/1001B is provided in the flocculation tank to measure the
pH level based on which the dosing rate of caustic is controlled by the control system..
4) The flash mixer 231-TK-004B is provided to mix FeCl3 to the effluent. The flash mixer is
provided with an agitator 231-M-002 to ensure the proper mixing of the chemical.
5) The flocculators 231-TK-004C is provided to mix polymer to the effluent and thereby
forming flocs before flowing into the plate type clarifier. The flocculators is provided with
an agitator 231-M-003 to ensure proper mixing of chemical .and for formation of flocs.
1) 231-AIC-1001
High pH – Generate Alarm in DCS HMI and operator to check Caustic dosing pump status.
Low pH – Generate Alarm in DCS HMI and operator to check Caustic dosing pump status.
pH measurement error(high differential)-Generate alarm in DCS HMI and operator to resume
pH sensor performance by cleaning and re-calibration if necessary.
C) Operation:
1) The starting and stopping of the agitators of pH adjustment tank-1, flash mixer and
flocculators is carried out by the operator manually from the DCS HMI.
2) Based on the pH value in the flocculation tank, the control system (auto stroke control) will
adjust the dosing rate of the caustic to obtain a pH between 8-9 as per operator setpoint.
The pH control system will compare the pH signals from the two probes and raise an alarm

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in case the difference between the signals exceeds a preset maximum value i.e to indicate
a potential error in pH measurement.
9.6.3 PLATE TYPE CLARIFIER :
P&ID REF: PDRP0451-8110-25-231-0001 SH 1 OF 2
The effluent after formation of flocs flows into the plate type clarifier where more surface
area is provided for formation of bigger flocs and the heavier solids settle down and the
clarified water flows into the pH adjustment tank-2.
1) The plate type clarifier 231-TK-005 is provided for the above stated purpose.
2) The plate type clarifier is provided with two numbers of on/off valves 231-XV 1001/1002 in
the bottom sludge line for automatic withdrawal of sludge.
1) 231-XV-1001/1002:
Each automated valve is provided with two timers
The valve timers will be inhibited to start when the level in the Leachate sludge sump is at the
high level.
C) Operation:
1) The plate type clarifier is selected online / offline from the DCS HMI using the soft
pushbuttons provided.
2) The sludge valves operate whenever the clarifier is taken online based on the two timers
provided in the DCS HMI.
9.6.4 pH ADJUSTMENT TANK-2 AND LEACHATE EFFLUENT COLLECTION SUMP AND

TRANSFER PUMP:
P&ID REF: PDRP0451-8110-25-231-0001 SH 1 OF 2

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The pH adjustment tank-2 is provided to neutralize the effluent by dosing acid. The
neutralized effluent overflows into the leachate effluent collection sump from where it is
pumped to the splitter box-III by the treated leachate transfer pump.

1) The pH adjustment tank 231-TK-013 is provided for the above stated purpose.
2) Two pH analyzers 231-AT -1002A/1002B is provided in the leachate effluent collection
sump to measure the pH level based on which the control system (auto stroke control) will
dose acid based upon operator setpoint. The pH control system will compare the pH signals
from the two probes and raise an alarm in case the difference between the signals exceeds
a preset maximum value i.e to indicate a potential error in pH measurement.
3) The leachate effluent collection sump 231-TK-007 is provided for collecting the treated
leachate effluent and two numbers of treated effluent transfer pumps 231-P-009A/B is
provided for pumping the treated leachate effluent to splitter box-III of the main ETP.
4) A diaphragm type pressure gauge 231-PG-1001 A/B is provided at the discharge of the
individual treated leachate effluent transfer pump for monitoring the discharge pressure
locally.
5) A radar type level transmitter 231-LT- 1003 is provided in the leachate effluent collection
sump for monitoring the level in the DCS and to generate various operational and alarm
set points.
1) 231-I-1010:
High level(Set point 1) - Generate alarm in DCS HMI and operator to stop Leachate Transfer
Pumps(231-P-007A/B).
Start level(Set point 2) – Start treated leachate transfer pumps
Stop level(set point 3) – Stop treated leachate transfer pumps
Low level(Set point 4) – Generate alarm in DCS and operator to check the status of Leachate
Transfer Pumps(231-P-007A/B).
2) 231-AIC-1002:
High pH – Generate alarm in DCS HMI and operator to check the performance of Acid Dosing
pump
Low pH – Generate alarm in DCS HMI and operator to check the performance of Acid Dosing
pump.
pH measurement error(high differential)-Generate alarm in DCS HMI and operator to resume
pH sensor performance by cleaning and re-calibration if necessary.

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3) 230-I-2070:
The treated leachate transfer pumps will start after receiving permissive feedback signal of
Bio-tower feed pumps running and stop when Bio tower feed pumps are not running.
C) Operation:
1) Based on the pH value in the leachate effluent collection sump, the control system shall
vary the dosing rate of acid based on operator setpoint.
2) The treated leachate transfer pumps starts operation when the level in the treated leachate
collection sump reaches start level and stops when the level reaches stop level.
3) The treated leachate transfer pumps are alternated as duty and standby in every operation
cycle by the opeartor.
9.6.5 AERATION POT:

P&ID REF: PDRP0451-8110-25-231-0001
The purpose of the aeration pot facility at the leachate treatment plant is to pre check the
effect of adding the treated leachate effluent to the activated sludge system of the aeration
tank. This acts as an early warning system to inhibit the leachate transfer to the aeration
tanks. This testing will be done in batch and the approximate frequency will be one batch per
hour.

The complete aeration pot facility consists of;
1. Circular aeration pot made in HDPE tank (Sintex make) capacity of about 400 liters
2. A feed of return activated sludge with on/off valve 231-XV-1006 from RAS pumps discharge
header.
3. A feed of plant air line with on/off valve 231-XV-1007. The tank bottom is provided with
header and lateral arrangement for diffusion of air uniformly inside the tank.
4. Overflow and drain arrangement facility. The same are routed back to leachate drainage
system.
5. A treated leachate line from the discharge of the leachate transfer pumps into the aeration
pot. Same is provided with on/off valve 231- XV-1005.
6. Dissolved oxygen measurement unit 231-AT-1003 (DO analyzer) that can transmit signal
and also generate alarm in case of low DO levels.
B) Interlock, Alarm and Control Description :
1. 231-AT-1003:

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High DO: Generate Alarm in DCS HMI as "Leachate Good for Aeration Tank" and no operator
action is required.
Low DO: Generate Alarm in DCS HMI as " Leachate Bad for Aeration Tank" and operator to
inhibit treated effluent entry to aeration Tank by stopping the Treated leachate transfer duty
pump
C) Operation:
Each operation of the aeration pot is in the following sequence of operation:

1) A small quantity of mixed liquor shall be tapped from the RAS pump discharge into the
aeration pot.
2) The air inlet valve is opened for a pre-set interval.
3) Then the air inlet valve is closed and the DO shall be measured.
4) The air inlet valve shall be again opened and a small quantity of neutralized pre-treated
leachate shall be discharged into the aeration pot and then aerated for a pre-set time.
5) The aeration shall be turned off and the DO is measured again.
6) In-case the difference in DO measured in step 3 and step 5 is within acceptable limits, then
the leachate transfer pumps are allowed to run and the procedure is repeated for fresh
samples after the specific interval.
7) In case the difference in DO measured in step 3 and step 5 is outside the acceptable limits,
the system shall raise an alarm and the operator shall inhibit the leachate flow to bio
treatment.
8) The sample collected in the aeration pot shall be drained off using 231-XV-1008 on/off
valve just before the start of the new sequence.
9) The sample testing frequency shall be once in an hour.
9.6.6 LEACHATE SLUDGE SUMP, FILTER PRESS FEED PUMPS AND FILTER PRESS
P&ID REF: PDRP0451-8110-25-231-0001 SH 2 OF 2
The sludge generated from the clarifier will be collected in the sludge sump, which will be
then fed to the filter press for dewatering by means of filter press feed pumps.
1) The leachate sludge sump 231-SU-002 is provided for the above stated purpose.
2) An agitator 231-M-005 is provided in the leachate sludge sump to keep the sludge is
suspension. The agitator is provided with a torque switch 231-XS-1001 to stop the agitator
in case of high torque.

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3) Radar type level transmitter231- LT- 1004 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm setpoints. This transmitter is
4) Two numbers of filter press feed pumps 231-P- 008A/B are provided to pump the sludge
to the filter press.
5) Diaphragm type pressure gauge 231-PG-1003A/B is provided in the individual discharge of
the filter press feed pumps to monitor the pump discharge pressure locally.
6) Pressure transmitter 231-PT -1001 A/B is provided to generate the high pressure alarm in
the individual discharge of the filter press feed pumps and to stop the pump.
7) A stator temperature transmitter 231- TT- 1001 A/B is provided to generate the high
8) Bursting Disc Tell-Tale strips(231-PSE-1001A/B) are provided to stop the motor in case of
Bursting Disc Rupture. The rupture happens in case of high high pressure.
9) DWPE Dosing Pump(230-P-154A/B) are provided for dosing DWPE in Leachate Sludge
Sump.
10) Two numbers of filter press 231-GN-002A/B is provided to dewater the sludge. The
dewatered sludge from the filter press is collected in tipper trolley and stored in LLPP
sludge weathering beds. The filtrate from the filter press is collected in the LLPP drainage
sump.
1) 231-I-1020:
High level(Set point 1) - Generate alarm in DCS HMI and operator to check the operation of
Filter Press Feed Pumps(231-P-008 A/B)
Start level 1(Set point 2) – Start leachate sludge sump agitator
Stop level 1(Set point 3) – Stop leachate sludge sump agitator
Stop level 2(Set point 4) – Stop filter press feed pump
Low level(Set point 5) – Generate alarm in DCS and Operator to check the operation of
Leachate Transfer
Pump(231-P-007 A/B) and Treated Leachate Transfer Pump(231-P-009A/B).
2) 231-I-1070:
High Torque – Generate alarm in DCS and operator to check consistancy of Sludge and the
agitator.
High High Torque – Generate alarm in DCS and stop agitator.
3) 231-I-1050/231-I-1060:
High pressure – Generate alarm in DCS and stop pump. Requires operator intervention to re-
start the pump by resetting Soft button in DCS HMI.

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4) 231-I-1030/231-I-1040:
High stator temperature – Generate alarm in DCS and stop pump. Requires opeartor
5) 231-I-1090/231-I-1100:
Bursting Disk-Ruptured- Generate alarm in DCS and Stop pump. Requires operator
6) 230-I-1270
DWPE Dosing Pump(230-P-154A/B run feed back is required to start the Filter press feed
Pump. Filter Press Feed pump is stopped when the DWPE dosing pump is Stopped.
C) Operation:
1) The leachate sludge sump agitator will start and stop based on the levels in the leachate
sludge sump.
2) The filter press feed pump is enabled for operation above the stop level 2 and the pump
will start when the filter press is put in service and stop when the delivery pressure reaches
the preset maximum which will indicate that the filter press is full.
9.6.7 LLPP DRAINAGE SUMP AND PUMP:

P&ID REF: PDRP0451-8110-25-231-0001 Sht: 2 of 2
The LLPP drainage sump is provided to collect the filtrate from the filter press and the LLPP
drainage pumps are provided to transfer the filtrate to the pH adjustment tank-1.
1) The LLPP drainage sump 231-SU-001 is provided for the above stated purpose.
2) Radar type level transmitter 231-LT- 1005 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm setpoint. This transmitter is
3) Two numbers of LLPP drainage pumps 231-P-006A/B are provided to transfer the filtrate
from the LLPP drainage sump to the pH adjustment tank-1.
of the LLPP drainage pumps to monitor the pump discharge pressure locally.
1) 231-I-1080:

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High level(Set point 1) - Generate alarm in DCS HMI and operator to check the performance
of LLPP drainage pumps (231-P-006A/B).
Start level(Set point 2) – Start LLPP drainage pumps
Stop level(Set point 3) – Stop LLPP drainage pumps
Low level(Set point 4) – Generate alarm in DCS HMI and Operator to check the performance
of Filter Press.
C) Operation:
1) When the level in the LLPP drainage sump reaches the start level, the duty pump starts
2) The LLPP drainage pump is alternated as duty and standby in every operation cycle.
9.7 HARD COD MANAGEMENT PACKAGE– SECTION 231
The purpose of the Hard COD Treatment element of the package (HCTP) is to treat the reject
from the Water Recovery Plant (WRP), particularly the reject from the RO plant, and to make
suitable for discharge to sea. There also be the flow limitation that can be discharged to sea
during dry weather season. The reject from the RO plant will be taken directly to Carbon Tank
as it will be always with pressure. The RO Reject before neutralization process will be pumped
from the carbon tank to Dust Suppression by means of RO Dust Suppression pumps, which
will operate intermittently. The reject effluent will further be neutralized by addition of both
acid and alkali.
The provision of adding either of the chemical will be provided depending upon the effluent
pH. The chemicals will be dosed by means of dosing pumps located in tank bunds. The
neutralized effluent will further be treated in the carbon contact tank, where powdered
activated carbon will dosed for reduction of the COD. The PAC will be dosed by means of
pneumatic transfer system with silos. The flocculated effluent will then flow into 2 nos. of
plate type clarifier, provided with scraper mechanism, for the separation of the activated
carbon sludge.
The Lamella Clarifiers shall be with distinct plate separation zone, sludge thickener zone, and
clear water zone. Within each of the Lamella Clarifiers 3 rows of plates will be arranged so
that the incoming solids can be distributed in between the plate rows whereby the flocs can
enter the lamella packs in the lower portion through special inlet feed ports. The clarified
water overflow takes place over adjustable overflow weirs on the upper edge of the plate
pack. Each of the plate row (the water layer in between two plates) has an individual overflow,

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which ensures an equal distribution of solids and water over the whole of the projected
sedimentation area.
The overflow weirs will be attached to both the upper corners of the plate rows. Heavy solids
can settle even whilst they are travelling between the plate rows and are directly entering the
thickener zone underneath the sedimentation area. This way, the plate type clarifier system
has a polishing function for the residual smaller solids and projected settling area is not fully
loaded with the total solids to be treated.
The sludge which shall be settling on the floor of the Plate Type Clarifiers shall be scrapped by
mechanical scraper (2 nos. in each Clarifier), to the central pit. The PAC sludge will be collected
in separate PAC sludge sump. 3 Nos. of Sludge pumps with 2 working will be provided to
transfer the PAC sludge to the inlet of aeration tank. Guard filter of disc type is provided at
the discharge side of clean effluent transfer pumps for retaining the escaping powdered
carbon particles. The online guard filter waste backwash will also be collected in the PAC
sludge sump and pumped along with the sludge. The treated RO reject water from the clarifier
will be then collected in Clean Effluent Tank, from there it will be pumped to battery limit by
means of Clean Effluent Transfer pumps for disposal to the sea.
NOTE : For Detailed Process Parameters, refer Process Flow Diagrams.
9.7.1 CARBON CONTACT TANK:
P&ID REF: PDRP0451-8110-25-231-0002
The carbon contact tank is provided to collect the RO reject and to reduce the COD by dosing
PAC and send it to the plate type clarifier.
1) The carbon contact tank 231-TK-002 is provided for the above stated purpose. The tank
consists of two sections. In the first section acid is dosed to the alkaline RO reject to reduce
the pH around 5-6 suitable for carbon adsorption and flocculation and the effluent
overflows to the second section where Powdered activated carbon (PAC) is dosed for the
COD removal.
2) An agitator 231-M-006 is provided in the second section to mix the chemical properly to
the effluent.

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3) Two pH analyzers 231-AT-2001A/B is provided in the second section to measure the pH

level in the effluent. Based on the pH measurement the operator varies the dosing rate of
the acid to reduce the pH of the effluent. The pH control system will compare the pH signals
from the two probes and raise an alarm in case the difference between the signals exceeds
a preset maximum value i.e to indicate a potential error in pH measurement.
4) Coke Dust Suppression pumps 235-P-127A/B is provided for transferring the RO reject for
handling Coke Pile Dust suppression which will be occasional.
5) Diaphragm Type Pressure Gauges (231-PG-2003A/B) on individual discharge line of Coke
dust suppression pump(231-P-127A/B)
1) 231-AIC-2001:
The stroke length of the acid dosing pump is varied to maintain the pH in the carbon contact
tank to the value set by the operator.
High pH – Generate alarm in DCS HMI and operator to start acid dosing pumps.
Low pH – Generate alarm in the DCS HMI and the operator to stop the acid dosing pumps.
2)231-I-1110:
Low level(Set point 4) – Generate alarm in DCS HMI and stop coke dust suppression pumps.
Operator to check the reject flow from RO
C) Operation:
1) The agitator is started and stopped manually by the operator from the DCS HMI.
2) The PAC is also dosed by a VFD controlled motor to reduce the COD of the effluent.
3) The neutralized effluent overflows from the launder into two individual channels for the
plate type clarifier.
4) pH measurement error(high differential)-Generate alarm in DCS HMI and operator to
resume pH sensor performance by cleaning and re-calibration if necessary.
5) The coke dust suppression pumps are started and stopped manually by the operator based
on the requirement in the coke pile area.
3.7.2 PLATE TYPE CLARIFIER:
P&ID REF: PDRP0451-8110-25-231-0002

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The effluent from the carbon contact tank will flow into the Plate Type clarifier provided with
scraper mechanism for separation of the activated carbon sludge. The sludge from the
clarifier shall be collected in PAC sludge sump and from where it shall be pumped to the RAS
sump by means of PAC sludge transfer pumps. The clarified water from the clarifier flows into
Clean effluent sump by gravity and from Clean effluent Tank water is disposed to sea.
1) Two plate type clarifiers 231-TK-003A/B is provided for the above stated purpose.
2) Each of the clarifier is provided with centrally driven scrapping mechanism 231-CLR-007A/B
for scraping the sludge from the bottom.
3) A pneumatic on/off valve 231-XV-2001/2002 is provided in the individual sludge line of
each of the clarifier for automatic sludge removal.
1) 231-XV-2001/2002:
2) 231-I-1130:
The Frequency of operation Timer for Valve(231-XV-2001/2002) will be inhibited from
opening when the level is high high and will start at high level in PAC Sludge Sump.
C) Operation:
1) The clarifier drive starts operating when the clarifier is taken online from DCS HMI and
stops when taken offline.
2) The automatic sludge removal system works only when the clarifier is taken online.
9.7.3 CLEAN EFFLUENT SUMP AND TRANSFER PUMPS:
P&ID REF: PDRP0451-8110-25-231-0002
The clean effluent transfer sump is provided to collect the clarified water from the plate type
clarifier, neutralize the same by dosing caustic and pump the same through the gravity filter
to sea either via the sea outfall or storm water outfall.

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1) The clean effluent sump 231-TK-008 is provided for the above stated purpose.
3) Two numbers of clean effluent transfer pumps 231-P-011 A/B are provided for pumping
the effluent from the clean effluent sump to the sea. These pumps work on duty/standby
philosophy.
4) A diaphragm type pressure gauge 231-PG -2001A/B is provided in the individual discharge
of the clean effluent transfer pumps to monitor the pump discharge pressure locally.
5) A flow transmitter 231-FT -2001 is provided in the common discharge of the clean effluent
transfer pumps to measure the total flow to the sea.
6) Caustic dosing is done in the clean effluent sump to neutralize the effluent.
7) Two pH analyzers 231-AT-2002A/B is provided in the tank to measure the pH level in the
effluent. Based on the pH measurement the dosing rate of the caustic is varied manually
in the caustic dosing pumps (231-P-015 A/B). The setting is to be done initially during
commissioning. The control system will also compare the pH signals from the two probes
and raise an alarm in case the difference between the signals exceeds a preset maximum
value i.e to indicate a potential error in pH measurement.
1) 231-I-1120:
High level(Set point 1) – Generate alarm in DCS and Operator to check the operation of clean
effluent Transfer pump(231-P-011A/B)
Start level(Set point 2) – Start clean effluent transfer pump
Stop level(Set point 3) – Stop clean effluent transfer pump
Low level(Set point 4) - Generate alarm in DCS and Operator to check the operation of Carbon
Contact Tank and Plate Type clarifier.
C) Operation:
1) When the level in the clean effluent sump reaches the start level, the duty pump starts
2) The clean effluent transfer pump is alternated as duty and standby in every operation cycle.
9.7.4 GUARD FILTER:
P&ID REF: PDRP0451-8110-25-231-0002

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The clean effluent from the clean effluent sump (231-TK-008) is pumped into guard filter and
then the discharge of the guard filter goes to sea. Guard filter is used to remove the unusual
particles of Powder activated carbon (PAC).
1) Guard Filter (231-GN-001) is provided for the above stated purpose.

2) Suction Scanner: Cleaning of the filter element is carried out by the suction scanner having
spring loaded suction nozzles which rotates in a spiral movement while removing the
filtration cake from the screen and expels it out through the exhaust valve
3) 3 -Way Solenoid Exhaust Valve: During Cleaning Cycle the soleniod valve will open to
transfer the filtration cake out of the filter.
4) Motor: The scanner rotation is operated by a 2-way (fwd/rev) drive unit which is attached
to the scanner by a threaded shaft, providing the linear movement.
5) Limit Switches: It is provided for detecting the movement of scanner .
6) Pressure Differential Switch: It is provided to initiate the Self-Cleaning cycle when there is
more pressure differential between inlet and outlet.
B) Interlock, Alarm and Control Description:

Control of Guard Filter is achieved by a local control Panel having the following functions
During the self-cleaning cycle the exhaust valve opens. The self-cleaning cycle begins under
any one of the following conditions:
1. Receiving a signal from the Pressure Differential Switch
2. Time interval parameter set at the control board
3. Manual Start at Control Board.
C) Operation:
1) The water enters through the inlet pipe into the fine screen from inside out. The "filtration
cake" accumulates on the fine screen surface and causes head loss to develop.
2) The Guard Filter will start the self-cleaning process when the pressure differential across
the screen reaches a pre-set value or a predetermined lapse of time.
3) Cleaning of the filter element is carried out by the suction scanner having spring loaded
suction nozzles which rotates in a spiral movement while removing the filtration cake from
the screen and expels it out through the exhaust valve.
4) The scanner rotation is operated by a 2-way (fwd/rev) drive unit which is attached to the
scanner by a threaded shaft, providing the linear movement.
5) The exhaust valve is activated for the duration of the cleaning cycle by a 3-way solenoid.
6) During the self-cleaning process, which takes approximately 35 seconds, filtered water
continues to flow downstream of the filter.

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9.7.5 PAC SLUDGE SUMP:
P&ID REF: PDRP0451-8110-25-231-0002
The PAC sludge sump is provided to collect the sludge from the Plate Type clarifier and pump
the same to the RAS sump through the PAC sludge transfer pumps. The Waste backwash from
the guard filter is also collected in the PAC sludge sump and disposed to RAS sump along with
PAC sludge.
1) The PAC sludge sump 231-SU-004 is provided for the above stated purpose.
3) Three numbers of PAC sludge transfer pumps 231-P-010 A/B/C are provided for pumping
the sludge from the PAC sludge sump to the RAS sump. These pumps work on two working
4) A diaphragm type pressure gauge 231-PG- 2002A/B/C is provided in the individual
discharge of the PAC sludge transfer pumps to monitor the pump discharge pressure
locally.
1) 231-I-1130:
High level(Set point 1) – Generate alarm in DCS and operator to check the operation of PAC
Sludge Transfer pump(231-P-010 A/B/C)
Start level(Set point 2) – Start PAC sludge transfer pump
Stop level(Set point 3) – Stop PAC sludge transfer pump
Low level(Set point 4) - Generate alarm in DCS and operator to check the operation of plate
type clarifier.
C) Operation:
1) When the level in the PAC sludge sump reaches the start level, the duty pump starts running
2) The PAC sludge transfer pump is alternated as duty and standby in every operation cycle.

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9.7.6 CHEMICAL DOSING PAC :
The PAC Bags received from trolley are stacked inside the chemical house and then charged
into bag dump station viz: chain pulley, as per the demand of PAC slurry dosing concentration
required inside the CARBON CONTACT TANK (231-TK-002). A service water line (viz: XV-5001
& XV-5002) is connected to the PAC slurry preparation tanks (231-TK-015 A/B) respectively. A
provision for H2SO4 line (from 231-P-014 A/B discharge) and manual DAP dosing has also
been provided into the PAC slurry preparation tank (after modification) in order to reduce
the alkalinity content for the RO rejects and to maintain the COD for the treated HCOD outlet
from CLEAN EFFLUENT TANKS (231-TK-008). THE PAC slurry preparation tanks is equipped
with respective agitators (231-M-007 A/B) and slurry transfer VFD pumps (231-P-018 A/B).
9.8 CHEMICAL DOSING SECTION
The purpose of the Chemical Dosing Package will be to dose chemicals into the process
streams in order to enable and / or enhance the performance of the process units and / or
protect the process equipment within the ETP & WRP. ALL DOSING PREPARATION AND DAY
TANKS ARE DESIGNED FOR PHASE I STAGE II FLOWS.
The ETP are provided with chemical dosing facilities for the following duties:
Oily Water Treatment:
3. Oily DAF – Acid, FeCl3 and De-oiling Polyelectrolyte (DOPE)

4. Oily sludge – Dewatering polyelectrolyte
Bio treatment:
7. screenings disinfectant / odor abatement (sodium hypochlorite)

8. soluble bio-available nitrogen (Urea dosing to Biotower and Aeration tank)
9. soluble bio-available phosphorus (DAP to Biotower and Aeration tank)
10. chlorination for gardening water - Hypo
11. Bio-DAF - FeCl3 and Polyelectrolyte.
12. Bio sludge – Dewatering polyelectrolyte
Water Recovery Plant:
1. Chemical cleaning systems for UF, e.g. NaOH, NaOCl, Citric Acid;
2. Chemical cleaning systems for RO, e.g. HCl, Na-DSS, Na2S2O4, NaOH, Na4EDTA;

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3. Anti-scalants for RO.
Hard COD Treatment Plant:
3. Acid
4. Powdered activated carbon
Landfill Leachate Treatment plant:
5. Acid/Caustic for neutralization;

6. FeCl3 for Coagulation;
7. Polymer – Flocculation tank.
The preparation tank and dosing tank of all chemicals shall be kept in the chemical house and
be sized to provide 150% of the maximum capacity required to allow operations over any 24
h period. Water for the dilution of raw chemicals shall be derived from the site utility water
system (treated river water), which is considered as a backup provision. The day tanks will be
located in tank bund and shed will be provided and hence the dosing pumps shall be located
there. Polymer solid feeder shall be provided for easy handling of polymer chemicals. All types
of polymer shall be made up to a suitable concentration for pumping and subsequently be
provided with in-line dilution to optimize dispersion.
Water for in-line dilution of chemicals prior to mixing with process streams in the ETP shall
preferably be derived from bio-treated recovered water from the overhead tank used for
backwashing of filters. Urea and DAP available as powder, will be stored in the ground floor
of Chemical House. Urea, FeCl3 & DAP will handled by Hydraulic Lift scissor and Bag slitter
machine for feeding the same into preparation tank.
A bulk storage tank for concentrated Sulphuric acid along with transfer pumps both for
loading from the outside tankers are provided adjacent to the chemical dosing area.
The purpose of dosing the various chemicals is mentioned below.
DAP and urea will be dosed at inlet of bio-tower to meet the necessary nutrient requirement
(Nitrogen & Phosphorus) of microorganisms involved in cell synthesis.
FeCl3 used as a coagulant agent and dosed in the Flash Mixer of Oily & Bio DAF.
Polyelectrolyte used as a flocculation agent and dosed in the Flocculator of Oily & Bio DAF.

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Dewatering Polyelectrolyte (DWPE) dosing in upstream of Oily & Bio Centrifuges for better
sludge consistency.
Sulphuric acid dosing for pH correction when the incoming water is highly alkaline.
Caustic solution dosing for increasing the alkalinity when the incoming water is acidic.
CHEMICAL DOSING SUB SYSTEM: ETP (SECTION 230)
The chemical dosing system is provided to prepare the various chemicals required for the
plant operation and to transfer them to the required locations.
9.8.1 FERRIC CHLORIDE DOSING SYSTEM:
P&ID Ref:- PDRP0451-8110-25-230-0013
The ferric chloride system is provided to prepare the ferric chloride solution in the ferric
chloride make up tank and transfer the same to oily DAF, bio DAF and landfill leachate
package.
1) Two numbers of ferric chloride make up tank 230-TK-125A/B is provided to prepare the
ferric chloride solution. Ferric chloride is added in powder form to the tank where it is
mixed with service water to prepare the solution.
2) An electrical hoist 230-CR-201 is provided to lift the chemical bag and bring it near to the
makeup tank.
3) A radar type level transmitter 230-LT-7001/7002 is provided in each of tank for monitoring
the tank levels and to generate various operational and high and low alarm setpoints. This
4) An agitator 230-M-124A/B is provided in the ferric chloride tank to mix the ferric chloride
powder to the water.
5) Reflex type level indicators LG7003A/LG7003B and LG7004A/LG7004B are provided in each
of the tank to monitor the level locally.
6) Two numbers of ferric chloride dosing pumps 230-P-141A/B is provided to dose the ferric
chloride solution to the oily DAF system. These pumps work on duty/standby mode of
operation.
7) A Pressure safety valve 230-PSV-7001A/B is provided across the suction and discharge line
of ferric chloride dosing pumps-Oily DAF for safety purpose.
8) A Pressure transmitter 230-PT-7001A/B is provided at the Ferric chloride dosing pump-oily
DAF to generate low pressure alarm.

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9) A diaphragm type pressure gauge 230-PG-7001 A/B is provided in the individual discharge
of the ferric chloride dosing pumps to monitor the pump discharge pressure locally.
chloride solution to the bio DAF system. These pumps work on duty/standby mode of
operation.
of ferric chloride dosing pumps-Bio DAF for safety purpose.
12) A Pressure transmitter 230-PT-7002A/B is provided at the Ferric chloride dosing pump-
Bio DAF to generate low pressure alarm.
chloride solution to the landfill and leachate system. These pumps work on duty/standby
mode of operation.
of ferric chloride dosing pumps-LLPP for safety purpose.
17) A Pressure transmitter 230-PT-7003A/B is provided at the Ferric chloride dosing pump-
LLPP to generate low pressure alarm.
18) An ultrasonic clamp on type flow transmitter 230-FT-2012 is provided in the common
discharge of the DAF feed pumps to measure the flow into the DAF system. This instrument
provides the input flow signal to the PID flow controller configured in the DCS whose
output is connected to the control valve FV 2012 to control the desired flow to the DAF.
1) 230-L-1880/1890:
operator.
Low level(Set point 2) - Generate alarm in DCS HMI and stop the agitator
Low Low Level(Set point 3)-Stop all the running pumps.
2) 230-FIC-2012:
The control valve 230-FV-2012 is throttled to control the flow to the Bio DAF flocculation
system based on the flow measured by the clamp on type flow transmitter 230-FT-2012. The
PID controller is configured in the DCS. Also based on this flow, auto stroke controller of FeCl3
dosing pump is controlled to adjust the dosing rate.

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3) 230-FQR-2012:
The flow to the Bio DAF system is recorded and totalized in the DCS from the flow measured
by the ultrasonic clamp on type flow transmitter 230-FT-2012.
C) Operation:
1) Soft push buttons are provided in the DCS HMI to select the makeup tanks in fill mode or
draw mode. The stop protection for the dosing pumps is enabled from the level transmitter
of the tank selected in draw mode.
2) The preparation of the ferric chloride solution is to be carried out manually from the field.
3) The ferric chloride dosing pumps and agitators for oily DAF, bio DAF and landfill leachate
are to be started and stopped manually by the operator from the DCS HMI.
9.8.2 SULPHURIC ACID DOSING SYSTEM:
P&ID Ref:- PDRP0451-8110-25-230-0013
The sulphuric acid system is provided to store the chemical in the H2SO4 make up tank and
transfer the same to oily DAF.
1) One sulphuric acid make up tank 230-TK-133 is provided to store the sulphuric acid from
bulk storage tank for dosing into oily DAF.
2) A radar type level transmitter 230-LT-7003 is provided for monitoring the tank levels and
to generate various operational and high and low alarm setpoints. This transmitter is
3) A reflex type level indicator 230-LG-7001 is provided in the tank to monitor the level locally.
4) A pneumatic On/Off valve XV 7001 is provided in the chemical inlet to the tank for
controlling the inlet from the bulk storage tank.
5) Two numbers of sulphuric acid dosing pumps 230-P-144A/B is provided to dose the
sulphuric acid to the oily DAF system. These pumps work on duty/standby mode of
operation.
of the sulphuric acid dosing pumps to monitor the pump discharge pressure locally.
of sulphuric acid dosing pump for safety purpose.
8) A pressure transmitter 230-PT-7004A/B is provided at the common sludge transfer pumps
to generate the low pressure alarm in the DCS HMI.

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1) 230-I-1960:
High level (Set point 1)- Generate alarm in DCS HMI and further action to be taken by the
operator.
Close level (Set point 2)– Close chemical inlet valve.
Open level (Set point 3)– Open chemical inlet valve.
Low level(Set point 4) - Generate alarm in DCS HMI and stop dosing pumps.
C) Operation:
1) The chemical inlet valve to the tank operates automatically based on the level in the tank.
2) The sulphuric acid dosing pumps for oily DAF is to be started and stopped manually by the
operator from the DCS HMI.
9.8.3 UREA/DAP DOSING SYSTEM:

P&ID Ref:- PDRP0451-8110-25-230-0014
The UREA/DAP system is provided to prepare the UREA/DAP solution in the UREA/DAP make
up tank and transfer the same to bio tower/aeration feed sump and splitter box-III.
1) Two numbers of UREA/DAP make up tank 230-TK-127A/B is provided to prepare the

UREA/DAP solution. UREA/DAP is added in powder form to the tank where it is mixed with
service water to prepare the solution.
2) A radar type level transmitter 230-LT-7004/7005 is provided in each of tank for monitoring
the tank levels and to generate various operational and high and low alarm setpoints. This
3) An agitator 230-M-126A/B is provided in the UREA/DAP tank to mix the UREA/DAP powder
to the water.
4) Reflex type level indicator 230-LG-7005A/7005B and 230-LG-7006A/7006B are provided in
each of the tank to monitor the level locally.
5) The service water inlet of each tank is provided with manual isolation valve to control the
service water taken for dilution.
6) Two numbers of UREA/DAP dosing pumps 230-P-145A/B is provided to dose the UREA/DAP
solution to the bio tower/aeration tank feed sump. These pumps work on duty/standby
mode of operation.

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7) A diaphragm type pressure gauge PG 7005 A/B is provided in the individual discharge of
the UREA/DAP dosing pumps to monitor the pump discharge pressure locally..
of urea/DAP dosing pump-Bio tower for safety purpose.
9) Two numbers of UREA/DAP dosing pumps 230-P-146A/B is provided to dose the UREA/DAP
solution to the splitter box-III. These pumps work on duty/standby mode of operation.
10) A diaphragm type pressure gauge PG 7006 A/B is provided in the individual discharge of
the UREA/DAP dosing pumps to monitor the pump discharge pressure locally.
of urea/DAP dosing pump-Aeration tank for safety purpose.
1) 230-I-1990/2000:
operator.
Low level(Set point 2) - Generate alarm in DCS HMI and stop the agitator
Low Low Level(Set point 3)-Stop all the running pumps
C) Operation:
1) Soft push buttons are provided in the DCS HMI to select the makeup tanks in fill mode or
draw mode.The stop protection for the dosing pumps is enabled from the level transmitter
of the tank selected in draw mode.
2) The preparation of the UREA/DAP solution is to be carried out manually from the field.
3) The UREA/DAP dosing pumps and agitators for bio tower/aeration tank feed sump and
splitter box-III are to be started and stopped manually by the operator from the DCS HMI.
9.8.4 HYPO DOSING SYSTEM:

P&ID Ref:- PDRP0451-8110-25-230-0014
The hypo solution will be transferred to hypo dosing tank and the same will be dosed in the
treated effluent gardening pumps discharge and in the sanitary screen washer.
1) A hypo dosing make up tank 230-TK-129 is provided to store the chemical obtained from
the market and dose the same to screw conveyor/compactor and to treated effluent
transfer pump gardening.

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2) A radar type level transmitter 230-LT-7006 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm setpoints as defined in 5.6.4.B.(1).
This transmitter is connected to the DCS.
3) A reflex type indicator 230-LG-7002 is provided in the tank to monitor the level locally.
4) One number hypo dosing pumps 230-P-147A is provided to dose the hypo solution to the
screw conveyor.
5) A diaphragm type pressure gauge 230-PG-7007A/B is provided in the discharge of the hypo
dosing pumps to monitor the pump discharge pressure locally.
of Hypo dosing pump-sanitary for safety purpose.
7) One number hypo dosing pumps 230-P-148 is provided to dose the hypo solution to the
treated effluent transfer pump(gardening).
8) A diaphragm type pressure gauge 230-PG-7007C is provided in the discharge of the hypo
dosing pumps to monitor the pump discharge pressure locally.
9) A Pressure safety valve 230-PSV-7007C is provided across the suction and discharge line of
Hypo dosing pump-Gardening for safety purpose.
10) One number pump 230-P-147B is provided as a common standby for both hypo dosing
pumps 230-P-147A and 230-P-148.
1) 230-I-2010:
High level (Set point 1)- Generate alarm in DCS HMI and further action to be taken by the
operator.
Low level (Set point 2)- Generate alarm in DCS HMI
Low Low Level(Set point 3)-Stop all the running pumps
C) Operation:
1) The hypo dosing pump for screw conveyor is started if there is a demand for the screw
conveyor to start and will stop after the screw conveyor stops operation.
2) The hypo dosing pumps for treated effluent pump gardening is started and stopped
manually by the operator from the DCS HMI.
9.8.5 DOPE DOSING SYSTEM:

P&ID Ref:- PDRP0451-8110-25-230-0015

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The DOPE dosing system is provided to prepare the DOPE solution and dose the same to the
oily DAF system.
1) A PLC based package DOPE preparation system is provided for preparing the DOPE solution
from powder. This package consists of the following:
a) The DOPE preparation tank 230-TK-126 is provided for the preparation of the DOPE
solution. This tank consists of three sections. In the first section the powder is mixed
with service water and the solution overflows into the second chamber. In the second
chamber the solution is matured and overflows in the third chamber from where it is
pumped by the dosing pumps to the oily DAF system.
b) A screw feeder 230-FD-001 is provided above the first chamber for feeding the DOPE
powder to the first chamber at a variable rate from the powder holder. The screw
feeder is controlled by a VFD for varying the feeding rate depending on the required
concentration of solution.
c) A flow indicator switch 230-FS-7018 is provided to monitor the inlet flow to the tank
and also for detecting the no flow/low flow condition.
d) A solenoid valve 230-XV-7002 is provided at the service water inlet line provided for
primary dilution.
e) A pressure reducer and a pressure regulating valve is provided to control the service
water inlet at 2 kg/cm2.
f) The first and second chambers are provided with agitators, 230-M-125A and 230-M-
125B respectively for mixing the powder to the service water.
g) A level transmitter 230-LT-7007B is provided in the third chamber for generating
various operational setpoints based on which the DOPE preparation system works.
2) Another radar type level transmitter 230-LT-7007 is provided in the third chamber for
generating various operational and high and low alarm setpoints as defined in 5.6.5.B.(1).
3) Six numbers of DOPE dosing pumps 230-P-149 A/B/C/D/E/F are provided for dosing DOPE
to the oily DAF system. The dosing pump A,B,C,D are dedicated to the oily DAF’s
109,209,309,409 respectively. The dosing pump E acts as a common standby for pumps
A&B. The dosing pump F acts as a common standby for pumps C&D. As part of phase Istage
II two more dosing pumps are considered.
4) A diaphragm type pressure gauge 230-PG-7008A/B/C/D/E/F is provided in the discharge of
the individual discharge of the DOPE dosing pump to monitor the pump discharge pressure
locally.
5) A Pressure safety valve 230-PSV-7008A/B/C/D/E/F is provided across the suction and
discharge line of DOPE dosing pump-Gardening for safety purpose.

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6) To the discharge of each of the dedicated pumps, a secondary dilution line is provided.
Each of the secondary dilution line contains a flow indicator 230-FI-
7001/7002/7003/7004/7005 to monitor the flow locally.
1) 230-I-2020:
High level(Set point 1) – Generate alarm in DCS HMI and further action to be taken by the
operator.
Stop level(Set point 2) – Stop solution preparation.
Start level(Set point 3) – Start solution preparation.
Low level(Set point 4) – Generate alarm in DCS .
Low Low level(Set point 5) –Stop all dosing pumps.
C) Operation:
1) The process solution preparation is an automatic batch process. When the level in the third
compartment reaches the start level,
a) The screw feeder starts operating and discharges the powder in the first
compartment.
b) The service water inlet On/Off valve is opened.
c) The agitator in the first compartment and the second compartment shall operate.
2) When the level in the third compartment reaches stop level,
a) Powder feeder stops operation.
b) Water inlet On/Off valve is turned off.
c) Agitator is switched off.
2) After the completion of the solution preparation, the agitators are switched off and on for
every 15 minutes for a duration of 15 minutes.
4) The operator shall ensure, that the powder feeder is filled with the chemical on a daily
basis.
5) The manual throttling valve in the water inlet line is adjusted during commissioning to set
the flow rate at the required value for the required concentration. The flow rate adjusted
with the help of the flow indicator.
6) The DOPE dosing pumps are started and stopped when the dedicated oily DAF unit is
started or stopped.
7) The standby pump of the DOPE dosing pump for oily DAF will start only after manual
intervention. The operator shall set the valves such that the discharge from the standby
pump reaches the failed duty pump discharge pipe.

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9.8.6 POLYMER DOSING SYSTEM
P&ID Ref:- PDRP0451-8110-25-230-0016
The polymer dosing system is provided to prepare the polymer solution and dose the same
to the flocculation tank of LLPP and bio DAF units.
1) A PLC based package polymer preparation system is provided for preparing the polymer
solution from powder. This package consists of the following
a) The polymer preparation tank 230-TK-130 is provided for the preparation of the polymer
solution. This tank consists of three sections. In the first section the powder is mixed
with service water and the solution overflows into the second chamber. In the second
chamber the solution is matured and overflows in the third chamber from where it is
pumped by the dosing pumps to the bio DAF system and flocculation tank of LLPP.
b) A screw feeder 230-FD-002 is provided above the first chamber for feeding the polymer
powder to the first chamber at a constant rate from the powder holder. The screw
feeder is controlled by a VFD for varying the feeding rate depending on the required
concentration of solution.
c) A flow indicator switch 230-FS-7019 is provided to monitor the inlet flow to the tank and
also for detecting the no flow/low flow condition.
d) A solenoid valve 230-XV-7003 is provided at the service water inlet line provided for
primary dilution.
f) The first and second chambers are provided with agitators, 230-M-128A and 230-M-
128B respectively for mixing the powder to the service water.
g) A level transmitter 230-LT-7008B is provided in the third chamber for generating
various operational setpoints based on which the DOPE preparation system works.
2) Another radar type level transmitter 230-LT-7008A is provided in the third chamber for
generating various operational and high and low alarm setpoints.
3) Two numbers of polymer dosing pumps-LLPP 230-P-150A/B is provided for dosing the
polymer to the flocculation tank of the LLPP. These pumps work in duty standby modes of
operation.
4) A diaphragm type pressure gauge 230-PG-7009A/B is provided in the discharge of the
individual discharge of the polymer dosing pump to monitor the pump discharge pressure
locally.
of Polymer dosing pump-LLPP for safety purpose.

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6) To the common discharge of the dosing pumps a secondary dilution line is provided. The
secondary dilution line is provided with a flow indicator FI 7006 to monitor the flow locally
and set the initial flow.
7) Six numbers of polymer dosing pumps 230-P-151 A/B/C/D/E/F are provided for dosing
polymer to the bio DAF system. The dosing pump A,B,C,D are dedicated to the bio DAF’s
116,216,316,416 respectively. The dosing pump E acts as a common standby for pumps
A&B. The dosing pump F acts as a common standby for pumps C&D. As part of stage I phase
II two more dosing pumps are considered.
8) A diaphragm type pressure gauge PG-7010 A/B/C/D/E/F is provided in the discharge of the
individual discharge of the polymer dosing pump to monitor the pump discharge pressure
locally. As part of phaseI stage II two more dosing pumps are considered.
9) A Pressure safety valve 230-PSV-7010A/B/C/D/E/F is provided across the suction and
discharge line of polymer dosing pump-Bio DAF for safety purpose.
10) To the discharge of each of the dedicated pumps, a secondary dilution line is provided.
Each of the secondary dilution line contains a flow indicator 230-FI-
7007/7008/7009/7010/7011 to monitor the flow locally.
1) 230-I-2030:
operator.
Low level(set point 4) – Generate alarm in DCS
Low Low level(set point 5) –Stop the dosing pumps.
C) Operation:
compartment reaches the start level.
a) The screw feeder starts operating and discharges the powder in the first compartment.
a) powder feeder stops operation.
every 15 minutes for duration of 15 minutes.

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4) The operator shall ensure that the powder feeder is filled with the chemical on a daily basis.
6) The polymer dosing pumps are started and stopped when the dedicated oily DAF unit is
started or stopped.
7) The standby pump of the polymer dosing pump for LLPP will start automatically in case of
failure of the duty pump.
8) The standby pump of the polymer dosing pump for bio DAF will start only after manual
9.8.7 DWPE DOSING SYSTEM:
P&ID Ref:- PDRP0451-8110-25-230-0017
The DWPE dosing system is provided to prepare the DWPE solution and dose the same to the
oily centrifuge, bio centrifuge and leachate sludge sump

1) A PLC based package DWPE preparation system is provided for preparing the DOPE solution
from powder. This package consists of the following:
a) Two numbers of DWPE preparation tank 230-TK-131/132 is provided for the preparation
of the DWPE solution. This tank consists of three sections. In the first section the powder
is mixed with service water and the solution overflows into the second chamber. In the
second chamber the solution is matured and overflows in the third chamber where it is
stored for dosing. From the tank 230-TK-131 the DWPE is dosed to the oily centrifuge
and from tank 230-TK-132 the DWPE is dosed to the bio centrifuge and leachate sludge
sump.
b) A screw feeder 230-FD-003/004 is provided in each of the DWPE preparation tank above
the first chamber for feeding the DWPE powder to the first chamber at a constant rate
from the powder holder.
c) A solenoid valve 230-XV-7004/7005 is provided in the service water inlet line to the first
chamber for controlling the inlet water flow in each of the tank.
d) A flow indicator switch 230-FS-7020/7021 is provided to monitor the inlet flow to the
tank and also for detecting the no flow/low flow condition.

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f) The first and second chambers of tank 230-TK-131 are provided with agitators 230-M-
129A and 230-M- 129B and tank 2 are provided with agitators 230-M-130A and 230-M-
130B for mixing the powder to the service water.
g) A level transmitter 230-LT-7009B/7010B is provided in the third chamber for generating
various operational set points based on which the DOPE preparation system works.
2) A radar type level transmitter 230-LT-7009A/7010A is provided in the third chamber of
tanks 230-TK- 131/132 for generating various operational and high and low alarm set
points.
3) Three numbers of DWPE dosing pumps 230-P-152A/B/C are provided for dosing the DWPE
to the oily centrifuge. These pumps are connected to tank 230-TK-131. Pump A is dedicated
to oily sludge centrifuge 301 and pump B is dedicated to oily sludge centrifuge 401. Pump
C acts as a common standby for both pump A and B.
4) A diaphragm type pressure gauge 230-PG-7011A/B/C is provided in the discharge of the
individual discharge of the DWPE dosing pump and oily sludge centrifuge to monitor the
pump discharge pressure locally.
5) A Pressure safety valve 230-PSV-7011A/B/C is provided across the suction and discharge
line of DWPE dosing pump-Oily centrifuge for safety purpose. To the discharge of each of
the dedicated dosing pumps a secondary dilution line is provided. The secondary dilution
line is provided with a flow indicator 230-FI-7012/7013 to monitor the flow locally and set
the initial flow.
6) Three numbers of DWPE dosing pumps 230-P-153A/B/C is provided for dosing the DWPE
to the bio centrifuge. These pumps are connected to tank 132. Pump A is dedicated to
centrifuge 201 and pump B is dedicated to centrifuge 101. Pump C acts as a common
standby for both pump A and B.
7) A diaphragm type pressure gauge 230-PG-7012A/B/C is provided in the discharge of the
individual discharge of the DWPE dosing pump to monitor the pump discharge pressure
locally.
8) A Pressure safety valve 230-PSV-7012A/B/C is provided across the suction and discharge
line of DWPE dosing pump-Bio centrifuge for safety purpose.
9) To the discharge of each of the dedicated dosing pumps a secondary dilution line is
provided. The secondary dilution line is provided with a flow indicator 230-FI-
7014/7015/7016 to monitor the flow locally and set the initial flow.
10) Two numbers of DWPE dosing pumps 230-P-154A/B is provided for dosing the DWPE to
the leachate sludge pump. These pumps are connected to tank 132. These pumps work as
duty/standby modes of operation.
of the DWPE dosing pump to monitor the pump discharge pressure locally.
of DWPE dosing pump-LLPP for safety purpose.

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13) To the common discharge of the dosing pumps a secondary dilution line is provided. The
secondary dilution line is provided with a flow indicator 230-FI-7016 to monitor the flow
locally and set the initial flow.
1) 230-I-2040/2050:
operator.
Low level(Set point 4) – Generate alarm in DCS
Low Low level(Set point 5) –Stop the dosing pumps.
2) 231-I-1020:
High level – Stop DWPE dosing pumps
C) Operation:
compartment reaches the start level,
a) The screw feeder starts operating and discharges the powder in the first compartment.
a) Powder feeder stops operation.
every 15 minutes for duration of 15 minutes.
4) The operator shall ensure that the powder feeder is filled with the chemical on a daily basis.
6) The DWPE dosing pumps for oily centrifuge are started and stopped when the dedicated
oily centrifuge unit is started or stopped.
7) The standby pump of the DWPE dosing pump for oily centrifuge will start only after manual

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8) The DWPE dosing pumps for bio centrifuge are started and stopped when the dedicated
bio centrifuge unit is started or stopped.
9) The standby pump of the DWPE dosing pump for bio centrifuge will start only after manual
10) The DWPE dosing pump for leachate sludge sump is started and stopped by the operator
manually from the DCS HMI.
9.8.8 SULPHURIC ACID DOSING SYSTEM:

P&ID REF: PDRP0451-8110-25-231-0007
The sulphuric acid dosing system is provided for storing the acid in day tank and dosing the
same to the pH adjustment tank-2 in LLPP and carbon contact tank in HCOD.
1) Sulphuric acid day tank 231-TK-012 is provided for storing acid for LLPP system.
2) Pneumatic On/Off valve 231-XV-4001 is provided at the acid inlet to the tank to control the
inlet.
3) A radar type level transmitter 231-LT 4001 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm set points. This transmitter is
4) A reflex type level indicator 231-LG- 4001 is provided the tank to monitor the level locally.
sulphuric acid solution to the pH adjustment tank-2 of the LLPP system. These pumps work
on duty/standby mode of operation. These pumps are provided with stroke actuators.
6) A diaphragm type pressure gauge 231- PG- 4001 A/B is provided in the individual discharge
7) A pressure transmitter231- PT 4001 A/B is provided to generate the Low pressure alarm on
each dosing pumps and it is used for diaphragm rupture detection system.
8) Sulphuric acid day tank 231-TK-010 is provided for storing acid for HCMP system.
9) Pneumatic On/Off valve231- XV-4002 is provided at the acid inlet to the tank to control the
inlet.
10) A radar type level transmitter 231-LT- 4002 is provided in the tank for monitoring the tank
11) A reflex type level indicator 231-LG -4002 is provided the tank to monitor the level locally.
sulphuric acid solution to the carbon contact tank of the HCOD system. These pumps work
on duty/standby mode of operation.

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13) A diaphragm type pressure gauge 231-PG 4002 A/B is provided in the individual discharge
14) A pressure transmitter 231-PT 4002 A/B is provided to generate the low pressure alarm
on each dosing pumps and it is used for diaphragm rupture detection system.
1) 231-I-1140/231-I-1150:
High level(Set point 1) - Generate alarm in DCS HMI and Operator to check the service water
inlet Valves.
Close level(Set point 2) – Close acid inlet On/Off valve
Open level(Set point 3) – Open acid inlet On/Off valve.
Low level(Set point 4) - Generate alarm in DCS HMI and stop all running pumps associated
with the tank.
2) 231-PT-4001A/B & 4002A/B:

Low pressure – Generate alarm in DCS and operator to check the performance of dosing
pumps.
C) Operation:
1) The tank is selected online by pressing the online soft push button provided in the DCS
HMI.
2) The acid inlet On/Off valves work automatically when the tank is put online.
3) The dosing pumps are started and stopped manually by the operator from the DCS HMI.
4) The dosing rate of the acid dosing pumps for LLPP and HCMP is controlled by the control
system by operator setpoint. Dosing rate can also varied by the operator from the DCS
HMI.
9.8.9 CAUSTIC DOSING SYSTEM:
P&ID REF: PDRP0451-8110-25-231-0007
The caustic dosing system is provided for storing the chemical and dosing the same to the pH
adjustment tank-1 in LLPP and carbon contact tank in HCMP.
1) Caustic day tank 231-TK-011 is provided for storing caustic for LLPP system.

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2) Pneumatic On/Off valve 231-XV-4003 is provided at the caustic inlet to the tank to control
the inlet.
3) A radar type level transmitter 231-LT- 4003 is provided in the tank for monitoring the tank
levels and to generate various operational and alarm set points. This transmitter is
4) A reflex type level indicator231- LG- 4003 is provided the tank to monitor the level locally.
5) Two numbers of caustic dosing pumps 231-P-015A/B is provided to dose the caustic
solution to the pH adjustment tank-2 of the LLPP system. These pumps work on
6) A diaphragm type pressure gauge231- PG- 4003 A/B is provided in the individual discharge
of the caustic dosing pumps to monitor the pump discharge pressure locally.
7) A pressure transmitter231- PT- 4004 A/B is provided to generate the Low pressure alarm
on each dosing pumps and it is used for diaphragm rupture detection system..
8) Caustic day tank 231-TK-009 is provided for storing caustic for HCOD system.
9) Pneumatic On/Off valve 231-XV-4004 is provided at the caustic inlet to the tank to control
the inlet.
10) A radar type level transmitter 231-LT 4004 is provided in the tank for monitoring the tank
11) A reflex type level indicator231- LG 4004 is provided the tank to monitor the level locally.
12)Two numbers of caustic dosing pumps 231-P-013A/B is provided to dose the caustic soda
solution to the carbon contact tank of the HCOD system. These pumps work on
13) A diaphragm type pressure gauge 231-PG 4004 A/B is provided in the individual discharge
14) A pressure transmitter 231-PT -4004 A/B is provided to generate the Low pressure alarm
on each dosing pumps and it is used for diaphragm rupture detection system.
1) 231-I-1160/231-I-1170:
High level (Set point 1)- Generate alarm in DCS HMI and operator to check Service water inlet
Valve
Close level(Set point 2) – Close caustic inlet on/off valve
Open level(Set point 3) – Open caustic inlet on/off valve.
with the tank.
2) 231-PT-4003A/B & 4004A/B:

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Low pressure – Generate alarm in DCS .and operator to check the performance of the Dosing
Pumps
C) Operation:
HMI.
2) The caustic inlet On/Off valves work automatically when the tank is put online.
4) The dosing rate of the Caustic dosing pumps for LLPP is controlled by the control system by
operator set point. Dosing rate can also varied by the operator from the DCS HMI.
9.8.10 CHEMICAL DOSING SYSTEM -PAC:

P&ID REF: PDRP0451-8110-25-231-0009:
The PAC Dosing system is provided for dosing the PAC to the carbon contact tank in HCMP to
reduce the chemical oxygen demand (COD) of the fluid so that COD level of the pumped
effluent to sea can be maintained.
1. Two PAC Slurry preparation tank(231-TK-014A/B) is provided in to prepare PAC Slurry

2. Agitators (231-M-007A/B) is provided for PAC slurry preparation tank (231-TK-014A/B)
respectively.
3. Level Transmitter (231-LT-5001/5002) is provided for PAC Slurry preparation Tank(231-TK-
014 A/B) respectively for generating the various operational set points and alarm set
points.
4. Service Water Inlet Valve (231-XV-5001/5002) is provided for PAC slurry preparation tank.
5. PAC Slurry Transfer Pump (231-P-018A/B) is provided to transfer PAC slurry to Carbon
Contact Tank. These pumps works on basis of Duty and Standby Selection. The speed of
the pump is controlled by operator through VFD.
6. Temperature Transmitters (231-TT-5001A/B) is provided to stop the PAC Slurry Transfer
Pump when rotor Temperature is High due to no flow of fluid.
7. Pressure Transmitters (231-PT-5001 A/B) is provided to stop PAC Slurry Transfer Pump
when discharge Pressure is High
8. Burst Disc (231-PSE-1001A/B) is provided to stop pump against Ruptured Disk.

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1) 231-I-1180/231-I-1210:
High level (Set point 1)- Generate alarm in DCS HMI and operator to check the service water
inlet Valve.
Close level(Set point 2) – Close Service Water Inlet on/off Valve
Open level(Set point 3) – Open Service Water Inlet on /off Valve.
with the tank.
2) 231-PT-5001A/B :
High pressure – Generate alarm in DCS and Stop the respective pump. Requires operator
intervention to re-start the pump by resetting soft HMI in DCS.
3) 231-TT-5001A/B :
High Temperature – Generate alarm in DCS and Stop the respective pump. Requires operator
intervention to re-start the pump by resetting soft HMI in DCS.
4) 231-PSE-5001A/B :
Burst Disk-Ruptured – Generate alarm in DCS and Stop the respective pump. Requires
operator intervention to re-start the pump by resetting soft HMI in DCS and also after the
replacement of the ruptured disk.
C) Operation:
HMI.
2) The Service Water inlet On/Off valves work automatically when the tank is put online.
4) The dosing rate of the PAC Slurry Transfer pumps for Carbon Contact Tank can be varied by
the operator in the DCS HMI.

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CHAPTER 10
HAZARDS & SAFETY

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Safe operating practices are an important aspect of plant operation and proper safety
instructions must be laid out and scrupulously followed. This becomes especially significant
when handling inflammable and corrosive materials. Some of the important safety
considerations are highlighted below:
 The plant area to be kept clean and free of spillage.
 Proper precautions must be taken while doing maintenance work of equipments

especially equipments handling oil.
 While preparation of chemical solutions, safety gloves & goggles must be worn.
 Safety gloves & goggles must be worn while collecting samples.
 Safety showers must be checked at regular interval for proper operation.
 Chemical splashes must be immediately washed with copious quantity of water. Seek
medical aid if necessary.
 Contact with the effluent must be avoided as far as possible. However, if contact is
unavoidable, ensure that hands are washed with soap.
EMERGENCY HANDLING
The most likely emergency situations are:

1. Oil spillage
2. Fire
1. Oil spillage – Oil spillage may occur due to accidental overflow/ leakage of equipments.
Action –
 Isolate the equipment & take action to arrest leakage.
 Clean plant area with water.
 Inform Shift In-Charge & Plant In-charge.
2. Fire
Action –
 Immediately take action to stop the fire.
 Inform Fire Station.

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Inform Shift In-Charge & Plant In-charge.
CHAPTER 11
EQUIPMENT LIST

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EQUIPMENT LIST :
Unit-230 ETP ( Oily & Bio Section)

Sr.No Equipment Tag No. Service
1 230-TK-001 Desalter Water/Brine Equalization Tank
2 230-OS-001 Oil Skimmers - Brine Eq. Tank
3 230-P-001 A/B Desalter Water / Brine Pumps
230-P-002 A/B Desalter Water/ Brine Equalization Tank

4
Recirculation Pumps
5 230-A-002 A/B/C/D API Oil Separator Mechanism (Chain Sprocket)
6 230-OS-002 Oil Skimmer- Common Oily Sludge Sump
7 230-M-010 Common Oily Sludge Sump Agitator
8 230-P-033 A/B/C Common Oily Sludge Transfer Pumps
9 230-A-003 A/B/C TPI Oil Separator
10 230-P-106 A/B/C/D/E API OWS (Eq. Feed) Pumps
11 230-TK-006 A/B Equalisation Tanks
12 230-P-004 A/B/C/D Equalisation Tank Recirculation Pumps
13 230-OS-004 A/B Oil Skimmers - Equalization Tank
14 230-P-003 A/B/C/D/E DAF Feed Pumps
15 230-M-101/201/301/401/501 Flash Mixer-Oily DAF
16 230- M-103/203/303/403/503 Flocculator -Oily DAF
17 230-A-003 A/B/C/D/E DAF Mechanism/oily DAF Package
18 230-V-101/201 Saturation vessel for Phase-I Stage-I

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19 230-V-301 Saturation vessel for Phase-I Stage-II
230-P-113 A/B/C, 230-P-213 A/B/C, DAF Recycle Pumps

20
230-P-313A/B
21 230-K-001 A/B DAF Air Compressor
22 230-P-126 A/B/C/D Biotower Feed Pumps for Phase-I Stage-I
23 230-P-126 E/F/G/H Biotower Feed Pumps for Phase-I Stage-II
24 230-R-101/201/301 Biotower Mechanism with media
25 230-K-103 Centrifugal Fan
26 230-P-127 A/B/C/D/E Aeration Tank Feed Pumps
27 230-DF-001 Aeration Tank Diffusers
28 230-K-102 A/B/C & 202 A/B/C Aeration tank Air Blowers
29 230-P-115 A/B/C Sludge recirculation - RAS Pumps
30 230-P-128 A/B SAS pumps
31 230- CLR-112 /212 Secondary Clarifier Mechanism
32 230-M-104/204/304/404/504 Flash Mixer-Bio DAF
33 230-M-105/205/305/405/505 Flocculator-Bio DAF
34 230-A-005- A/B/C/D/E Bio-DAF Mechanism
230-P-120 A/B/C, 230-P-220 A/B/C, Bio-DAF Recycle Pumps

35
230-P-320 A/B
36 230-K-104 A/B Bio-DAF Air Compressor
37 230-V-102/202 Saturation vessel for Phase-I Stage-I
38 230-V-302 Saturation vessel for Phase-I Stage-II
39 230-P-022 A/B/C Treated Effluent Transfer Pumps (Phase I, Stage I)

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230-P-022 A/B/C Treated Effluent Transfer Pumps (Phase I, Stage

40
II)
41 230-P-022 A/B/C Treated Effluent Transfer Pumps Phase-I
42 230-P-021 A/B/C Offspec/excess effluent Transfer
43 230-P-021 A/B/C/D Offspec/excess effluent Transfer
44 230-P-025 A/B Treated Effluent Transfer Pumps - Gardening
45 230-M-119 DAF Sludge Sump Agitator
46 230-P-036 A/B DAF Sludge Transfe Pump
47 230-THK-121 Oily Sludge Thickener
48 230-M-110 Thickened Oily Sludge Sump Agitator
49 230-P-132 A/B/C Oily Centrifuge Feed Pumps
50 230-DEW-301/401 Oily Sludge Centrifuge
51 230-CR-001 A/B Sludge Conveyor
52 230-P-133 A/B Oily Supernanent Transfer Pumps
53 230-M-121 Reslurry Sump Agitator
54 230-P-134 A/B Oily Sludge Transfer Pump to DCU
55 230-THK-120 Bio Sludge Thickener
56 230-M-118 Thick. Bio Sludge Sump Agitators
57 230-P-124 A/B/C Bio Centrifuge Feed Pumps
58 230-DEW-101/201 Bio Sludge Centrifuge
59 230-CR-002 A/B Sludge Conveyor
60 230-P-023 A/B Bio Supernanent Transfer Pumps
61 230-P-137 A/B Weathered Sludge Liquor Transfer Pumps

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62 230-P-012 A/B Wet Slop Oil Transfer Pumps
63 230-P-011 A/B Dry Slop Oil Transfer Pumps
64 230-TK-010/011 Slop Oil Tank
65 230-P-135 A/B Drained Effluent Transfer Pump
66 230-TK-133 H2SO4 Day Tank - Oily DAF
67 230-P-144 A/B H2SO4 Dosing Pump - Oily DAF
230-TK-127 A/B Urea/DAP make-up tank - Biotower/Aeration

68
Tank
230-M-126 A/B Urea/DAP make-up tank Agitator-

69
Biotower/Aeration Tank
70 230-P-145 A/B Urea Dosing pumps - Aeration / Biotower
71 230-P-146 A/B DAP Dosing pumps - Aeration / Biotower
72 230-TK-125 A/B FeCl3 make-up tank
73 230-M-124 A/B FeCl3 make-up tank Agitator
74 230-P-141 A/B FeCl3 Dosing pumps - Oily DAF
75 230-P-142 A/B FeCl3 Dosing pumps - Bio DAF
76 230-P-143 A/B FeCl3 Dosing pumps - LLPP
77 230-TK-126 DOPE preparation system
78 230-M-125 A/B DOPE preparation system Agitator
79 230-P-149 A/B/C/D/E/F/G/H DOPE solution dosing Pumps - Oily DAF
80 230-TK-132 DWPE-Preparation System (Bio Sludge)
81 230-M-130 A/B DWPE-Preparation System Agitator (Bio Sludge)

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230-P-153 A/B/C DWPE solutions dosing Pumps -Centrifuge (Bio

82
sludge)
230-P-154 A/B DWPE solutions dosing Pumps - Filter press (Bio

83
sludge)
84 230-TK-131A/B DWPE-Preparation System (Oily Sludge)
85 230-M-129 A/B DWPE-Preparation System Agitator (Oily Sludge)
230-P-152 A/B/C DWPE solutions dosing Pumps -Centrifuge (Oily

86
sludge)
87 230-TK-130 Polymer Preparation System
88 230-M-128 A/B PolymerPreparation Agitator
89 230-P-151 A/B/C/D/E/F/G/H Polymer dosing Pumps - BioDAF
90 230-P-150 A/B Polymer dosing Pumps - LLPP
91 230-TK-129 Hypo make-up tank
92 230-P-148 Hypo Dosing pumps - Gardenin
93 230-P-147 A/B Hypo Dosing pumps - Sanitary
94 230-CR-201 Electrical Hoist - Chemical house (first floor)
230-CR-101 Scissor type lift with bag splitter - Chemical

95
House
96 230-CR-102 Chain Pulley block - Aeration Blower room
97 230-CR-103 Chain Pulley block - Bio Centrifuge shed
98 230-CR-104 Chain Pulley block - Oily Centrifuge shed
99 230-CR-105 Chain Pulley block- Effluent Check Basin
100 230-CR-106 Chain Pulley block - Filtered Effluent Tank
101 230-CR-107 Chain Pulley block - TPI

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102 230-CR-108 Chain Pulley block - PAC Dosing Tank
230-SCR-003 Bar Screen -Manual, Sewage channel from

103
township & refinery
104 230-SCR-004 Bar Screen -Manua,l API Inlet
105 230-SCR-001 Bar Screen -Manual, CRWS
106 230-SCR-005 Bar Screen -Manual, Oily Supernatant Sump
107 230-SCR-006 Bar Screen -Manual, Bio Supernatant Sump
108 230-SCR-007 Bar Screen -Manual, Weathered Sludge Sump
109 230-SLG-0503 O3 Sluice Gate - (Screen chamber inlet)
230-SLG-0504 O3 Sluice Gate - (Sewage chamber outlet to splitter

110
box-II)
111 230-SLG-0501/0502 O3 Sluice Gate - SplitterBox-III
230-SG-0601/0602 O3 Sluice Gate - (Aeration Tank outlet launder to

112 secondary clarifier
inlet
113 230-SLG-0605/0606 O3 Sluice Gate - RAS Sump(PAC discharge launder)
114 230-WR-0601/0602 O3 Sluice Gate - RAS Sump(to SAS Supm)
115 230-SLG-0201/0202/0203/0204 Sluice Gate - API Tank inlet channel
230-XG- Sluice Gate - (Outlet from check basinto rapid

116
0101/0103/0105/0107/0109/0111 gravity sand filter)
230-XG- Sluice Gate - (From rapid gravity sand filter-dirty

117
0102/0104/0106/0108/0110/0112 back wash sump)
118 230-SLG-0801 O3 Sluice Gate - inlet to check basin
119 230-SLG-0201/0202 O3 Sluice Gate - inlet to plate type clarifier-HCOD
120 230-JS-301 O3 Static Mixers - Treated effluent truck loading line

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121 230-P-005 Portable Dosing Package for Metal Control
230-A-006 Portable Dosing Package for Maintenance

122
Effluents
123 230-P-136 A/B CRWS transfer pumps
LANDFILL LEACHATE TREATMENT

Sr.No Tag No Service
1 231-TK-001 Leachate Equalisation Tank
2 231-OS-001 Oil Skimmer
3 231-P-007 A/B Leachate Equalization Transfer Pumps
4 231-P-005A/B Leachate Equalization Tank Recirculation Pumps
5 231-M-001 pH Adjustment tank - 1 agitator
6 231-M-002 Flash Mixer (LLPP)
7 231-M-003 Flocculator(LLPP)
8 231-TK-005 Plate clarifier
9 231-M-004 pH Adjustment tank -2 agitator
10 231-M-005 Leachate Sludge Sump Agitators
11 231-P-008 A/B Leachate Filter Press Feed Pumps
12 231-GN-002 A/B Leachate Filter Press
13 231-P-006 A/B Leachate Drainage Pump
14 231-P-009 A/B Treated Leachate Transfer Pumps
15 231-TK-006 Aeration pot

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16 231-TK-012 H2SO4 Day tank - LLPP
17 231-P-016 A/B H2SO4 Dosing Pump - LLPP
18 231-TK-011 Caustic Day tank - LLPP
19 231-P-015 A/B Caustic dosing Pumps - LLPP
20 231-SCR-001 Bar Screen - LLPP Drainage Sump
HARD COD MANAGEMENT PACKAGE

21 231-M-006 Carbon contact Tank Agitators
22 231-M-007 PAC Sludge sump agitator
23 231-CLR-007 A/B Plate clarifier with Scrapper Mechanism
24 231-P-010 A/B/C PAC Sludge transfer pumps
25 231-P-011 A/B O3 Clean Effluent Transfer Pumps - Sea disposal
26 231-GN-001 Gravity Disc / Drum filter/Guard filter
27 231-TK-010 H2SO4 Day tank - HCMP
28 231-P-014 A/B H2SO4 Dosing Pump - HCMP
29 235-P-131 A/B Catridge filter feed pump for reject Stage RO
30 235-P-127 A/B Coke Dust Suppression Pumps
31 231-TK-009 Caustic Day tank - HCMP
32 231-P-013 A/B Caustic dosing Pumps - HCMP
33 231-SLG-0201/0202 Sluice Gate - Plate Clarifier
PAC DOSING SYSTEM (231-A-001)

34 231-M-007A/B PAC Slurry Preparation Agitator

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35 231-P-018A/B PAC Slurry Transfer Pump

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CHAPTER 12
MAJOR EQUIPMENT AND THEIR
OPERATION

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OPERATION OF PUMPS AND OTHER MOTOR DRIVEN EQUIPMENT
A. Valve Positions
For normal operations, valves in the suction and discharge of pump sets shall be set such that
the duty pumps or standby pumps can start without many visits to the field by the operator.
However incase of duty failure, the standby pump shall start only after operator intervention.
B. Starting, Stopping, Flow Control, Enabling, Inhibition and Trips.
Normal pump operating modes include:

 Automatic start / stop on level control.
 Inhibition in case conditions in connected equipment are out of normal range.
 Trips in case of conditions which become unsafe or compromise the process.
C. Automatic Start / Stop on Level Control:
The pump will start when the liquid level rises above the start level and stop when the level
drops below the stop level. The pump will only operate at full speed and thus deliver the
design capacity (except where the discharge is manually throttled by the operator).
D. Enabling and Inhibition of Equipment
Some pumps/drives are started and stopped manually by the operator from the DCS HMI and
normally run continuously. Some are connected to large tanks which will run automatically
based on levels. Some are connected to small suction wells and again run automatically based
on water levels. Some are connected to small dosing tanks which runs based on parameters
of the effluent. In case of larger pumps the automatic restarting of the pump is enabled only
after an appropriate preset minimum time has elapsed in order to prevent excessive starting.
In case of conditions in connected equipment are out of normal operating range, equipment
will be inhibited, e.g. to prevent overflows / overloads. Inhibition is intended to be a
temporary stop which can be automatically reset, if it is not a trip.
E. Trips
Motor driven equipment will trip in case the parameters monitored by the instruments and
control system indicate that conditions have become unsafe or compromise the process. In

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case of a trip condition, all drives in the related group will trip to prevent starting in an unsafe
condition.
In case of progressive cavity pumps the following trips are provided:

- Pressure transmitter is provided in the discharge to detect the high pressure and trip the
pump
- Stator temperature monitoring is provided to trip the pump in case of high stator
temperature.
In case of double diaphragm pumps, rupture detection is provided to trip the pumps.
In case of a trip, the operator will be required to examine the cause and go to the MCC and
manually rest the trip at the supply panel. The system will not be energized until the condition
which caused the trip is cleared or reviewed by Electrical / Control Groups / Process. Other
Trip management philosophies may apply or be allowed.
DUTY / STANDBY/ CYCLIC OPERATION OF PUMPS:
The Duty / Standby selection of the drives shall be done from the DCS HMI manually by the
operator. The cyclic operation of Duty / Standby drives shall be ensured by the operator by
operating the drives at equal intervals. The cyclic changeover time can be programmed from
the DCS HMI and an alarm will be raised if the drive crosses the programmed run time. A reset
button shall also be provided to reset the run time of the drive. In case of drives in the
discharge line for batch tank applications, the alternate selection of Duty / Standby drives are
done after each operation cycle. In case a pump fails to start when required to do so, the
standby pump shall start after getting the clearance from site except that this does not over-
ride a trip.
All the motor driven equipments will be provided with total running hours indication in the
DCS HMI to ensure duty rotation of the drives and also to decide on the maintenance of the
drives.
A. Pump Protection:
Pumps will trip when there is a low low level in the tank. Note that in most instances this is to
prevent the pump from running dry, overheating and becoming an ignition source.
B. Motor Drive Protection:

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All motors are provided with an emergency stop push button in the field. If the motor is
stopped using the emergency stop push button then the same has to be reset from the MCC
before starting the drive again.

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CHAPTER 13
MATERIAL SAFETY DATASHEETS

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Name of Chemicals
A. Sulphuric acid 98%
B. Ferric Chloride
C. De-oily polyelectrolyte
D. Di Ammonium Phosphate
E. Urea
F. Polyelectrolyte
G. Sodium Hypochlorite
H. Dewatering Polyelectrolyte
I. Caustic 20%
J. Powdered Activated Carbon
K. Poly Aluminium Chloride
L. Hydrogen Peroxide
M. Sodium Meta Bi-Sulphate
N. Sodium Lauryl Sulphate
O. Citric Acid

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CHAPTER 14
FIRE FIGHTING AND COMMUNICATION
FACILITIES

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SAFETY & FIRE FIGHTING SYSTEMS
The aim of the fire protection design is to minimize loss of life or serious injury, contain and
prevent the spread of a fire, extinguish it in the early stages if possible and thus minimize the
damage and financial loss caused by such an incident.
List of Fire Fighting Equipment
S.No Description No. of

Equipment
1 Fire Hydrant – 2 way 35
2 Fire hose cabinet with hose 15
3 Fire extinguisher (5 kg CO2) 20
4 Foam cum Fire monitor 04
Note: For details on locations, please refer to please refer to Fire fighting layout for Effluent
treatment plant and water recovery plant. Units 230, 231 and 235. (Dwg.No. PDRP 0451-8140-29-
230-0001).
List of Fire & Gas Detection Systems

Equipment
1 CO Detector 06
2 LEL Detector 19
3 Gas sounder 11
4 Fire beacon 08
5 Gas beacon (Toxic) 08
6 Gas beacon (Flammable) 08
7 Manual call point 14
8 Flame detector 09
9 Fire sounder 08
Note: For details on locations, please refer to F&G layout for Effluent treatment plant and water
recovery plant. Units 230, 231 and 235. (Dwg.No. PDRP 0451-8551-61-230-0201)
List of Other Safety Equipment


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Equipment
1 Safety shower and eye wash 8
Note: For more details, please refer to please refer to Overall plot plan for Effluent treatment plant
and water recovery plant. Units 230, 231 and 235. (Dwg.No. PDRP 0451-8140-29-230-0001) –
Attached in Volume II of the Operation and Maintenance Manual.
PERSONAL PROTECTIVE DEVICES
 Helmets
 Face Masks
 Breathing Apparatus (for confined entry)
 Goggles
 Protective Clothing
 Boots gloves
 Fire Blankets
Appropriate protection devices should be worn in all hazardous areas/chemical plant/when

operating with any hazardous fluids like Acids, Caustics, Dosing Chemicals etc. No Personnel
should be allowed to operate near hazardous fluids without appropriate eye protection.
1. Fire Fighting layout for Effluent Treatment Plant and Water Recovery plant
2. F&G Layout for Effluent Treatment Plant and Water Recovery plant.
3. Material Safety Data Sheets List For Detail Please Refer Vol-II (MSDS)

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CHAPTER 15
CONSEQUENCE DUE TO UPSETS IN
OUTGOING B/L STREAMS

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Feed quality changes in any process plant are imperative and any impacts or consequences
that may arise must be mitigated by taking appropriate steps or actions that offset the
unlikely conditions. Upsets in feed quality may lead to
1. Deterioration of treated effluent quality,

2. Upsets in downstream unit processes,
3. Reduction in unit treatment efficiencies,
4. Increased chemical consumption,
5. Shock loading of biological treatment unit and upset the biological process,
6. Increased sludge generation,
7. Increased power consumption.
Such Abnormalities/Upsets may be detected through notification given by

Client/downstream units/upstream units, OSBL conditions, Lab analysis of samples, alarm
notifications from analyser’s installed, defective equipment or any physical observations.
Such observations must be immediately notified to the central control room. Upon notice of
such abnormality/upsets, the shift-in-charge should investigate and effect promptly all the
required remedial measures/procedures/actions.
Some of the possible consequences if for any upsets in Feed are indicated below
Note: In the case of no availability of the feeds to the respective or any significant decrease
in the quantity of the feed, planned shutdown of the unit can be undertaken as described in
other sections.

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TROUBLE SHOOTING - PROCESS
S SIGNS & SYMPTOMS POSSIBLE CAUSES SUGGESTED ACTION

NO
1 Effluent Flow is not  Low flow from the  Confirm with the process
equalized process stream  Clear the blocks if any
 Incoming line blocked  Check the isolation valves
 Isolation valve closed  Check the suction line and
 Pump suction line clean them.
choked.  Clean the level switch or
 Electrical connections check for power
to be verified. connections if it is
electronic operated.
 Check the cable connection
and power supply to the
motor and panel.
2 Abnormal level of oil  Process disturbance.  Process must look into the
in effluent  Dumping of oil from problem and corrective
storage tanks to action to be taken.
Influent.  In such dumping ETP should
be informed.
 ETP will bypass when
abnormal oil dumps are
seen.
3 Recirculation to the  Pumps not running, Check the pump thoroughly

DAF unit is not good  Discharge line blocked, and rectify the problems.
 Discharge valve closed.
 Drain open
 Power supply not
available.
4 Air Supply  Wrong setpoint of Check the source of air supply

flowrate/presure to Pressure control valve. and resume air supplies. Adjust
the DAF unit seems  Wrong setpoint of Flow the pressure of the vessel as
to be low indicator. described in the manual.

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5 No Bubble formation Insufficient air pressure and As per Sl.No 4.

and no rising of oil flowrate.
droplets to the
surface of the DAF
and improper de-
emulsification.
6 Floating scum too  Skimmer speed is high,  Visual inspection and adjust
thin in DAF/ Float  Unit overloaded, as required
appears very frothy;  Excessive air/solids  Rise rate, turn off feed
ratio. sludge and allow the unit to
clear and purge the unit
with auxiliary recycle
 Reduce air flow to
pressurization system.
7 Low Dissolved air in  Recirculation pumps off  Clean the pump as

DAF clogged or required.
malfunctioning.  Poor float formation with
 Low air/solids ratio. solid settling; increase air
flow to pressurization
system.
8 High water level in Air supply pressure low, Check the air line and check the
saturation vessel level insufficient air flow meter for the flow of air,
injection. check for other
instrumentation problems.
9 Low Recirculation Back pressure, high Reduce the pressure of the

pump capacity pressure in the saturation saturation vessel.
vessel.
10 Choking of Sludge Sludge too thick. Withdraw sludge more often

pipes and flush it clean, as required.

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11 Sludge thickener not Scrapper mechanism not Check the scrapper mechanism
functioning properly operating properly, scum and run it continuously. Scum
removal not proper, removal system to be operated
thickened sludge outlet of regularly. Remove the choke
thickener is choked. and confirm free flow of sludge
from the thickener. Draw
sludge at regular interval.
Check the flow of sludge to
excess sludge sumps is proper.
12 Free oil found to be  Increase in flow rate or  Reduce the flow rate and
more in TPI outlet more free oil in the operate the oil skimmer in
influent. the TPI frequently
 Oil skimmer not  Check the rotation of the
operated properly. skimmer by rotating
manually and attend to the
problem if it is stiff or
struck. Check the ports are
clean and not blocked.
13 More emulsified oil Oil is of a higher specific Remove source of high specific
found in TPI outlet gravity than specified. gravity oil or decrease flow
rate.
14 Emulsified oil more in Increase in flow rate or Reduce the flow rate and
the DAF outlet more emulsified oil in the operate the DAF as per the
influent. manual.
15 Sludge in DAF and TPI  Influent TSS to the plant  Reduce the flow rate and
drain seems to be is more than design operate the DAF & TPI as
more and scum value or flow rate to the per the manual.
formation on the top plant is more.  Increase the frequency of
of the DAF is more.  Decreased desludging sludge draining from API.
activity in API.
16 Change in sludge High soluble organic loads Decrease aeration and mixed
volume index in effluent. liquor suspended solids.

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17 Excessive air rates  Leaks in aeration  Arrest the leakage of the

being used with system piping. leaky flanges.
difficulty to maintain  Plugged diffusers,  Clean the plugged
adequate D.O. level resulting in the diffusers.
in aeration tank. discharge of air at  Reduce the inflow
flexible hose suitably.
connections.
 High organic loadings.
18 Frothing in Aeration Synthetic detergents cause, Increase aeration liquor SS
tank frothing. The froth concentration, by minimizing
increases with decrease in sludge wasting. Dose
Mixed liquor suspended antifoaming agent if required.
solids or increase in
atmospheric temperature.
Excessive D.O > 4.0mg/l can
cause foaming problems.
19 BOD in secondary BOD in the influent may be Reduce the flow,

clarified effluent is higher than the design proportionately. Ensure DO is
high. value. maintained consistently.
20 Turbid or cloudy High BOD or TSS, high Increase MLSS/MLVSS, increase

effluent, Disinfection nitrogenous loading. aeration, increase MLSS and
problems. increase alkalinity if any surge
in inlet nitrogenous load.
21 Floc formation is not Dosage of chemicals to be Adjust coagulant dosage, adjust

proper In the verified and TSS of the inlet the pH, adjust poly & Deoiling
flocculation basin. effluent to be monitored. Polyelectrolyte dosage and
validate with jar testing.
22 Improper chemical  Low level in dosing  Makeup the level.

dosing. pumps trouble  Correct the stroke as per
 Stroke rate is not demand.
according to the
demand.

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23 Sludge cake from the Dewatering poly not dosing Check the dosing of poly and
centrifuge is not upto properly make sure the Belt filter press is
the expected working properly.
consistency.
Refer Equipment manual.
24 Thickened Sludge Sludge formation is low or Check the treatment units like
feed to centrifuge is abnormality of the sludge Clarifier, chemical preparation
less. feed pumps. units and flash mixers for
process conditions.
Check the stator of the
pump. Remove the air lock Keep the suction fully flooded
or check the stator of the pump
for any gaps in between the
stator and the rotor.
TROUBLE SHOOTING - PUMPS
SIGNS &
S.NO POSSIBLE CAUSES SUGGESTED ACTION
SYMPTOMS
Check the section valve and

level in suction tank. Stop this
a. Pump is not properly pump, close the suction valve
primed and clean the impeller. Put the
b. Clogged impeller standby pump in operation.
Pump fails to start
1. c. Incorrect direction of Stop the pump. Correct the
pumping.
rotation direction of rotation and
d. Delivery valve not check. Start the standby pump
opened and check flow.
Open the Delivery valve
Air leaking into suction line

Pump does not or stuffing box Shut down this unit and put
deliver its rated the standby pump in
2 b. Clogged impeller
discharge or operation. Shut down this unit
pressure. c. Low suction head or low and put the standby pump in
voltage operation.

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d. Wearing ring might have

been worn out impeller
might have been damaged. This is an unlikely cause.
Shaft sleeve may be loose. Inform the foreman. Shut
Stuffing box may be down this unit and put the
defective. Casing gasket standby pump in service.
might have been worn out.
Check suction piping and

Pump work for a a. Pump improperly primed suction valve.
3. while and then while and stops.
stops. Shut this unit and put the
b. Air pockets in suction line
standby pump in operation.
Coupling bolts Shut this unit and put the

4 Misalignment
rapidly erode standby pump in operation.
Check bearings grease cups

Bearings run hot. Impeller lubrication
5. and refill with lubricant oil.
Check alignment
Shut down this unit and put

the standby pump in
a. Misalignment
operation.
Motor runs hot. b. Defective motor
6. - do-
c. Over loading
- do-
d. Voltage low
Inform electrical section
immediately and foreman.
a. Clogged foot valve
b. Foreign matter in impeller Shut down this unit and put

Pump is noisy. the standby pump in
7 c. Misalignment operation.
d. Insecure foundation.
e. Bearings worn out.

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f. Damaged impeller
a. Seal gauge improperly

located in stuffing box.
Shut Down this unit and put
Stuffing box b. Misalignment the standby pump in
8. operation.
c. Packing installed
improperly
d. Dirt in sealing liquid.
Packing has short a. All causes of leaking

life stuffing box.
9. - do –
b. Bearings worn out.
c. Gland is too tight.
Close discharge
a. Some break down.
10. Pump fails valve and follow
b. Failure of electricity.
start up procedure for standby
unit
Upset in case of higher than normal values

Feed to OWTP
Parameter (on)
(in mg/l Contingency
Oily waste
Desalter
Product
Quality
Process
water
CRWS
water
Chem.
during upset
Upset
Cons.
except pH) Consequence
pH 6 - 10 6-9 6-9 Increased Acid/Caustic 1. In case of Oil

consumption D/S. Upset of and grease in
biological system desalter water,
TSS 2465 496.4 330 Increase sludge generation Maximise oil
in API/TPI/DAF. Increased recovery in the
FeCl3 dosing. Equalization
Free OG 10000 500 10000 Oil Carryover possibility from tank prior to API
OWTP to BTP. oil separator.

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Total OG 12500 600 12500 Oil Carryover possibility from 2. Adjust

OWTP to BT. Acid/caustic
Ammonia 50 2 37.2 Shock loading of Bio. dosing rates for
Treatment. DO depletion in pH correction.
aeration tank 3. For other
Sulphide 75 1 25 Shock loading of Bio. parameters,
Treatment. Desalter water
Phenol 100 10 68.5 Shock loading of Bio. to be equalized
Treatment. DO depletion in by storing in
aeration tank equalization
COD 1054.2 93.3 1054.1 Shock loading of Bio. tank.
Treatment. DO depletion in 4. In case of CRWS
aeration tank and oily waste
TDS 10000 253 1413.1 N.A (1) water upset,
Increase API/TPI
oil skimming
frequency or
maximise
CTBD1/3/4 or
Desalter feed to
OWTP for
pollutant load
dilution.
5. Notify
Authorities if any
other abnormal
upset.
Feed to BTP
sour water
Stripped
Product
Quality
Sewage
Process
Chem.
Contingency
Upset
Cons.
Consequence
during upset
pH 6–9 6-9 Increased Acid/Caustic 1. In case of Oil

consumption D/S. Upset of and grease in
biological system stripped sour
TSS 100 600 No significant effect. water, Maximise
Free OG 10 100 Oil Carryover possibility from oil recovery in
BTP to D/S. the Equalization
Total OG 25 100 Oil Carryover possibility from tank, followed
BTP to D/S. by DAF
Ammonia 100 37.6 Shock loading of Bio. treatment, prior
Treatment. DO depletion in to biological
aeration tank treatment.
Sulphide 20 87.6 Shock loading of Bio. 2. Adjust
Treatment. Acid/caustic

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Phenol 50 - Shock loading of Bio. dosing rates for

Treatment. DO depletion in pH correction.
aeration tank 3. For other
COD 458.3 596.6 Shock loading of Bio. parameters,
Treatment. DO depletion in stripped sour
aeration tank water to be
TDS 2500 500 N.A (1) equalized by
storing in
equalization
tank, followed by
DAF treatment,
prior to
biological
treatment.
4. Notify
Authorities if any
other abnormal
upset.
Feed to Effluent Check basin

B/D down
systems
Product
Quality
Process
Steam
1/3/4
Chem.
CTBD
Contingency during
Upset
Cons.
Consequence
upset
pH 6–9 9 - 10 Upset of feed Quality to WRP. 1. In case of upset of

TSS 100 17.9 Upset of feed Quality to WRP. CTBD 1/3/4, subject
Increase in turbidity. CTBD effluent to
Free OG 500 - Upset of feed Quality to WRP. treatment in OWTP.
COD 458.3 11 Upset of feed Quality to WRP. 2. Notify Authorities if
TDS 2100 547.4 any other abnormal
N.A (1)
upset.
Feed to LLTP
leachate
Product
Quality
Landfill
Process
Chem.
Contingency during
Upset
Cons.
Consequence
upset
pH 8 - 10 Increased Acid/Caustic 1. Maximise oil recovery

consumption D/S. in Equalization tank.
TSS 341.9 Increased FeCl3 dosing. 2. Equalize effluent by
Total OG 1.4 No significant effect. storing in equalization
TDS 7150.4 N.A (1) tank.

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3. Adjust FeCl3 dosing

rates suitably for TSS
reduction.
4. Adjust Acid/caustic
dosing rates for pH
correction.
5. Notify Authorities if
any other abnormal
upset.
Feed to OWS sump II
coke pile
Product
Quality
Settled
Process
runoff
Chem.
Contingency during
Upset
Cons.
Consequence
upset
pH 6-9 Increased Acid/Caustic 1. Adjust Acid/caustic

consumption D/S. dosing rates for pH
TSS 1000 Increased sludge generation in correction in OWTP.
API. 2. Increase API/TPI oil
Free OG 300 Oil Carryover possibility from skimming frequency
OWTP to BTP. or maximise
Ammonia 50 Shock loading of Bio. CTBD1/3/4 or Desalter
Treatment. DO depletion in feed to OWTP for
aeration tank pollutant load
Sulphide 20 Shock loading of Bio. dilution.
Treatment. 3. Notify Authorities if
Phenol 200 Shock loading of Bio. any other abnormal
Treatment. DO depletion in upset.
aeration tank
COD 600 Shock loading of Bio.
Treatment. DO depletion in
aeration tank
TDS 2500 N.A (1)
NOTE 1: TDS is not amenable to treatment in ETP section. Above TDS indicated has no effect on
biological treatment. Highly saline effluents/untreated spent
caustics/detergents/surfactants/mineral oils have a detrimental effect on biological
activity in biological treatment plant. Effect of TDS on product quality of WRP shall be
discussed in WRP sections.
CONTINGENCY PLANS DURING UPSET OF OUTGOING B/L CONDITIONS

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S.No Effluent Normal Operation Contingency during Upset
To Storm water Reservoir

1 Treated effluent in Check basin To RGSF To Bio tower feed sump
To Equalization tanks
To Storm water reservoir /To -
2 Excess Effluent in Check basin
Clean Effluent sump
3 Clean Effluent (HCOD Management) To Sea (Long Outfall Package) To Storm water Reservoir

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CHAPTER 16
EQUIPMENT DATASHEETS

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Refer the data sheet in the e-library:
Path: Intranet/Engineering services/e-library/vendor data book
Intranet: http://10.100.128.110/

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CHAPTER 17
EQUIPMENT HANDOVER PROCEDURES

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CHECK BASIN SUMP

Handing over:
a) Isolate the Sump from inlets by closing the inlet portion of channel / pipework with
necessary brick work or sluice gate as appropriate.
b) Disconnect the inlet piping and blind it as appropriate.
c) Fill the sump with service water, up to 80% level.
d) Using the duty pump empty the sump to system.
e) Once emptied, and then isolate the pump discharge valves.
f) Do the Blinding at the Pump discharge valve.
g) Fill the sump again with water to 60% level.
h) Drain out the water using portable or temporary arrangement
i) Remove concrete covers
j) Make arrangement of ladders to go inside the sump for any maintenance activity.
k) Raise Vessel entry permits, taking all precautions of good ventilation, necessary
lighting.
l) Hand it over for maintenance/cleaning.
Depending on duration and nature of work inside the sump, decision to remove the pump
from its place can be taken.
Taking over:
a) Check that the maintenance job is over.
b) Inspect the sump, clean of all debris and left out foreign materials.
c) Remove the ladder or approach stairs provided.
d) Reinstall the pumps if they had been taken out.
e) Energize the motor. Kick-start & check the direction of rotation of motor.
f) Line up the pump discharge valves.
g) Fill the sump with water up to 80% level.
h) Run one pump and empty the water to system.
i) Check for any leaks.
j) Stop the pump.
k) Now the sump is ready, and open the inlet sluice gates as applicable

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l) Remove brickwork blocakge or connect inlet line from respective sewer inlet.
m) The system is ready to use.
n)
Pumps
Handing over:
The safe procedure for handing out of pumps in the system is as follows.
a) Isolate the discharge valve of the pump that is to be handed over to maintenance
b) The pump that is to be handed over to maintenance should be drained completely
and depressurized and ensure there is no stored or held up energy.
c) Blind and positively isolate the equipment from pipelines and any other live
system.
d) Take Electrical lock out and de-energize the pump at the MCC.
e) Follow the Lock out /Tag out Procedure, Safety precautions recommended and
Permit to work procedure by IOCL is to be followed before handing over any
equipment to maintenance.
Taking over:
a) Check that the maintenance job is over. Check & ensure that the pump casing vent,
drain, seal flush & other lines opened for maintenance jobs are properly boxed up.
If any abnormality is observed, get it attended.
b) Ensure that the coupling guard is properly fixed.
c) All the cables & earthing connections are fixed.
d) Check the freeness of shaft by rotating it with hand.
e) Check oil level in bearings. Top up, if required.
f) Energize the motor. Kick-start & check the direction of rotation of motor.
g) Stop & keep the pump as stand by.

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CHAPTER-18
SAMPLING, LABORATORY ANALYSIS AND
QUALITY CONTROL

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18.1 SAMPLING SCHEDULE
During normal operation of the plant, the performance of the plant is to be monitored to
ensure the intended purpose of establishing the plant. This can be done by means of collecting
the samples at regular intervals and analysis of the same in the laboratory. Apart from
meeting the treated effluent quality, the sampling schedule shall also include analysis of
pollutants in different treatment stages of the plant.
A tentative sampling schedule is indicated in this section of the manual for implementation
during normal operation of the plant and will be updated/modified as and when required by
the concerned authority or as per On Field Requirement. This helps in assessing the data on
the various parameters of effluent and to check the performance of the plant, at regular
intervals.
All the data obtained from the laboratory shall be properly logged on a day to day basis along
with any appropriate remarks/observations. This data registry shall complement the data
already available through the online DCS monitoring.
Note:
1. The samples shall be collected in the appropriate designated sampling bottles. Before
collection the samples, one should ensure proper cleaning & rinsing of sampling bottle,
and adding any preservatives if required (in case of time delay in analyzing the sample),
proper sealing etc.,
2. The samples collected shall be labelled properly indicating the sample source, time and
date. The sample details shall be registered in the sample register and sent to laboratory
for analysis. On obtaining the laboratory results of the above samples, the same shall be
verified accordingly with respect to sample identification code. The results shall be
compiled and maintained in the log register. The plant in-charge/process concern will
review and analyze the sample results. During this process, the necessary modifications
in the plant operation shall be decided and implemented to maintain the performance
of the plant. All above records shall be maintained properly by the plant operating staff.
3. Though the above schedule is to be followed during normal running of the plant, it may
be required to take more frequent sampling, during commissioning and plant upset
conditions, in order to optimize the operating conditions more favourably.

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PARAMETERS TO BE ANALYZED AND THEIR DESIGN VALUE

FREQUENCY OF
S.No FEED SAMPLING TYPE
SAMPLING Oily waste
Parameters Desalter water CRWS
water
FEED to OWTP
Once a shift Grab pH 6-10 6-9 6-9
TSS 2465 496.4 330
Desalter O&G 12500 600 12500
water/CRWS/ Sulphide 75 1 25
1 Once in a day
Oily waste Composite Phenol 100 10 68.5
water COD 1054.2 93.3 1054.1
BOD (1) 400-450 30-50 400-500
Once in Three days Ammonia 50 2 37.2
Stripped sour
FEED to BTP Sewage
water
Once a shift Grab pH 6-9 6-9
TSS 100 600
O&G 25 100
Stripped sour Sulphide 20 87.6
2 Once in a day
water/Sewage Composite Phenol 50 -
COD 458.3 596.6
BOD (1) 150-200 200-250
Once in Three days Ammonia 100 37.6
Steam
FEED to Effluent Check Basin CTBD 1/3/4
systems B/D
Once a shift Grab pH 6-9 9-10
CTBD 1/3/4,
TSS 100 17.9
3 Steam systems
Once in a day Composite O&G 500 -
blow down
COD 458.3 11
FEED to LLTP Leachate
Once per batch Grab pH 8-10
Landfill TSS 341.9
4 Once in three days
leachate Composite O&G 1.4
(or per batch)
COD Note 2
Cokepile
FEED to OWS sump II
runoff
Once per batch Grab pH 6-9
TSS 1000
O&G 300
Settled coke Sulphide 20
5 Once in a week 9or
pile runoff Composite Phenol 200
per batch)
COD 600
BOD (1) 250-300
Ammonia 50
FEED to HCOD MP RO Reject
pH 6-8
6 RO Reject Once a day Composite
COD 270

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PARAMETERS TO BE ANALYZED AND

INTERMEDIATE SAMPLING FREQUENCY OF SAMPLING
S.No THEIR REFERENCE VALUE (for
LOCATION SAMPLING TYPE
Optimal conditions)
A API and TPI Separators:
Once a shift Grab pH 6-10
TSS, mg/l 60-80
O&G, mg/l 1000
Sulphide, mg/l 20-25
1 API/TPI Outlet
Once in a day Composite Phenol, mg/l 40
COD, mg/l 650-750
BOD, mg/l 250-350
Ammonia, mg/l 15-25
B Secondary Oil Removal Facilities /Biotower
TSS, mg/l 95
O&G, mg/l 820
2 Oily DAF Inlet Sulphide, mg/l 30
Once in a day Composite
Phenol, mg/l 43.5
COD, mg/l 600-700
BOD, mg/l 200-300
TSS, mg/l 55
O&G, mg/l 10-15
3 Oily DAF Outlet
Once in a day Composite COD, mg/l 600-700
BOD, mg/l 200-300
Ammonia, mg/l 30-40
C Biological Treatment Facilities
Once a shift pH 7-9
TSS, mg/l 70-80
4 Biotower Outlet/Aeration tank Inlet. Grab Phenol, mg/l 20
Once in a day
COD, mg/l 200-250
BOD, mg/l 100
pH 6.5-8
Sludge volume
Once in a day Index, ml/g 100-120
5 Aeration tank Grab Dissolved oxygen,
mg/l 1.5-2.0
MLSS, mg/l 2000
Once in three days
MLVSS, mg/l 1200
pH 6-8
TSS, mg/l 300
O&G, mg/l 2
Sulphide, mg/l 0.8
6 Secondary clarifier Outlet Once in a day Grab
Phenol, mg/l 0.5
COD, mg/l 100
BOD, mg/l 10
Ammonia, mg/l 20
pH 6-8
7 Bio DAF outlet Once in a day Grab TSS, mg/l 10
O&G, mg/l 2

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D Treated Effluent
pH 6-8.5
TSS, mg/l < 20
O&G, mg/l <5
Once in a day Sulphide, mg/l < 0.5
Phenol, mg/l < 0.35
COD, mg/l < 125
BOD, mg/l < 15
Cyanides, mg/l 0.2
Phosphorus, mg/l < 3.0
Ammonia as N,
15
mg/l
8 Effluent Check Basin Composite TKN, mg/l 40
Cr(IV), mg/l 0.1
Total Cr, mg/l 2
Whenever Pb, mg/l 0.1
necessiated Hg, mg/l 0.01
Zn, mg/l 5
Ni, mg/l 1
Cu, mg/l 1
V, mg/l 0.2
Benzene, mg/l 0.1
Benzo(a) pyrene,
0.2
mg/l
E Sludge Handling system:
9 Oily & Chemical sludge from API Once a week TSS, mg/l 30000
10 Oily & Chemical sludge from TPI Once a week TSS, mg/l 30000
11 Excess biosludge from Sec. clarifier Once a week TSS, mg/l 6000
12 Oily Sludge thickener O/F chamber Once in a fortnight TSS, mg/l 3000
Thickened sludge from Oily Sludge
13 Once in a fortnight TSS, mg/l
Thickener 45000 - 50000
14 Bio Sludge thickener O/F chamber Once in a fortnight Grab TSS, mg/l 1000
Thickened sludge from Bio Sludge
15 Once in a fortnight TSS, mg/l 40000 - 45000
Thickener
16 Centrifuge sludge cake – Bio sludge Once in a fortnight TSS, mg/l 200000
17 Centrate – Bio sludge Once in a fortnight TSS, mg/l 3000-4000
18 Centrifuge sludge cake – Oily sludge Once in a fortnight TSS, mg/l 200000
19 Centrate from centrifuge - Oily sludge Once in a fortnight TSS, mg/l 3000-4000
F Landfill Leachate Treatment system:
pH 6-8
Once in three days TSS, mg/l 10
20 Treated Leachate Composite
(or per batch) O&G, mg/l 1.4
COD, mg/l Note 1
G Hard COD Management
pH 6-8
21 Treated RO Reject Once a Day Composite
COD, mg/l 125

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18.2 ANALYTICAL PROCEDURES FOR LABORATORY

18.2.1 DETERMINATION OF BIO-CHEMICAL OXYGEN DEMAND (BOD):
BIOCHEMICAL OXYGEN DEMAND (BOD)
The rate at which microorganisms use oxygen in water or wastewater while stabilizing or
during biological oxidation of decomposable organic matter under specified experimental
conditions of time and temperature in aerobic conditions. During decomposition, organic
matter serves as food for the bacteria (and other microbes) and energy production occurs
from this oxidation.
SIGNIFICANCE of BOD:
As bacteria and other microorganism metabolize the organic material and consume oxygen,
the organics are broken down into simpler compounds such as carbon dioxide and water, and
the microbes use the energy released for their growth and reproduction. When this process
occurs in water, the oxygen consumed is the dissolved oxygen (DO) and it is not continuously
replaced in the water by artificial or natural means, then DO levels will decrease as the
organics are continuously decomposed by the microbes.
This need for oxygen is called biochemical oxygen demand, in effect, the demand for oxygen
for use in the biochemical reaction that sustain them, which is directly proportional to the
amount of biodegradable matter present in the wastewater under aerobic conditions. Hence,
BOD is a direct measure of the oxygen requirements and an indirect measure of the quantum
of biodegradable organic matter it is expressed as the milligrams of oxygen required by the
microorganisms to oxidize the organics in a litre of water.(mg/l)
Outline of the Method
BOD is the quantity of oxygen required by a definite volume of the liquid effluent for oxidizing
the organic matter contained in it by microorganism under specified condition. For its
determination, the DO content of the sample, with or without dilution is measured before
and after incubation at 20° C for 5 days.
Apparatus
Glass – stoppered bottles – narrow-necked bottles of about 250 ml cap, with suitable water
sealing.
Reagents
a. NaOH solution - approx. 1 N
b. HCl acid - approx. 1 N

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c. Sodium sulphite - dissolve 1.5 g of anhydrous sodium sulphite in 1 litre water. Prepare
fresh solution daily for use.
d. Dilution Water: Distilled water of good quality, free from metals particularly and
aerated.
e. Phosphate Buffer Solution: Dissolve 8.5 g of potassium di hydro phosphate (KH2P04),
21.75 g of di potassium hydrogen phosphate (K2HPO4), 33.4 g of disodium hydrogen
phosphate (Na2HP04) and 1.7 g of ammonium chloride in about 500 ml of water and
dilute to 1 litre. The pH of this solution should be 7.2.
f. Magnesium Sulphate Solution: Dissolve 22.5 g of magnesium Sulphate (MgS04.7H20) in
water and dilute to 1 litre.
g. Calcium Chloride Solution: Dissolve 27.5 g of Calcium Chloride in water and dilute to 1
litre
h. Ferric Chloride Solution: Dissolve 0.25 g of ferric chloride (FeCl3, 6H20) in water and
dilute to 1 litre.
i. Seeding Material: Supernatant liquor of domestic sewage stored for 24-36 hours at
20°C.
Procedure:
 Samples containing acidity or alkalinity should be neutralized to pH about 7.0 with
NaOH solution or HCl respectively by adding a pre-determined quantity.
 Samples containing residual chlorine or chloramines should be dechlorinated if
chlorine is not dissipated on standing for 2 hours. To dechlorinate, first determine the
quantity of sodium sulphite solution required for a known aliquot of the sample by
titration. The sample should be acidified either with acetic acid (1:1) or sulphuric acid
(1:50), 10 ml of potassium iodide should then be added and the resulting solution
titrated to the starch-iodine end point. Then add the requisite volume of the sample.
The quantity of sodium sulphite can be added to the sample, avoiding any excess and
check for the absence of chlorine after 20 minutes.
 Samples containing toxic substances in large amounts would require special
treatment. However, the effect of small amounts may be overcome by using the
proper dilution so that toxicity is removed and the maximum BOD value is measured.
If increasing dilutions show an increasing BOD, the dilution should be increased to a
level where BOD levels off at a maximum.
 To check the quality of dilution water and the effectiveness of the seed, determine
the BOD of a standard solution of either glucose or glutamic acid in the dilution water.
 Store the dilution water at 20° and use when near that temperature. Take the desired
volume of dilution water required for the test sample and add for every 1 litre of water
1 ml each of phosphate buffer solution, magnesium sulphate solution, calcium

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chloride solution and ferric chloride solution. Seed the dilution with seed material. The
quantity of seed material (0.1 to 1% of settled sewage or 1 to 5% receiving water)
added should be such that oxygen depletion in the dilution water control is between
0.2 and 0.8 after incubation at 20°C for 5 days.
 Prepare as follows several dilutions of the sample (usually 0.1 to 1.0% for storing
industrial effluents and 5 to 25% for treated effluents) so as to obtain a depletion of
at least 2 mg/l of DO
 After incubation for 5 days. In the case of dilutions greater than 1:100, prepare a 10%
primary dilution in a volumetric flask and from this make the final dilutions from it.
 Carefully Siphon the prepared seeded dilution water into a graduated 1000 ml
measuring cylinder and fill up to the 500-ml. mark. Add the requisite quantity of the
carefully well - mixed sample to make the particular dilution and fill with dilution water
to 1 litre. Mix thoroughly but gently with a plunger type of rod without entraining air.
Siphon the dilution into two glass-stoppered bottles, fill completely and stopper.
Prepare succeeding dilutions of lower concentrations in the same manner.
 Determine the initial DO concentration in one of the two bottles of each dilution by
the method given below. Water seal the other bottles and incubate the other at 20°C
for five days. After incubation for 5 days, determine the DO in the dilutions and the
blank in the same manner, as the initial DO content was determined.
Calculations:
BOD (5 days 20°C) mg/l = (D1 –D2) – (C1 – C2) x F
D1 = Initial DO content of the diluted sample
D2 =DO of the diluted sample after incubation
C1= DO (initial) of the seeded dilution water (blank)
C2= DO of the seeded dilution water (blank) after incubation
F = Ratio of the seed in the sample to that in the control, i.e. percent seed in D1divided
by % seed in C1
P = Decimal fraction of the sample used
Note : Express the result to the nearest 0.2 mg/l.

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18.2.2 DETERMINATION OF DISSOLVED OXYGEN (DO) – WINKLER METHOD
DISSOLVED OXYGEN (DO)
Free or elemental oxygen that is dissolved in water.
SIGNIFICANCE of DO:
DO is vital in biological wastewater treatment facilities to promote the aerobic decomposition

and stabilization of the organic wastes. DO concentrations can be determined by using
standard wet chemistry methods of analysis, like the Winkler’s test in the laboratory or
membrane electrode meters in the field. The concentration of oxygen will reflect whether
processes of oxidation undergoing are aerobic or anaerobic and also the degree of
contamination.
Reagents:
a. MANGANESE SULPHATE SOLUTION:
Dissolve 480 g of manganese Sulphate tetra hydrate (MnSO4.4H20) in water, filter if not clear;
and make up to 1 litre. The solution should not liberate more than a trace of iodine when
added to an acidified KI solution.
b. ALKALINE IODIDE SOLUTION:

Dissolve 500 g of NaOH (or 700 g of KOH) in its own weight of water and allow it to cool. The
caustic solution should be virtually free from carbonate. Dissolve separately 150 g of KI in a
small quantity of freshly boiled and cooled water and add this solution to the caustic solution.
Dilute the mixture to 1 litre.
c. CONCENTRATED H2SO4
d. STANDARD SODIUMTHIOSULPHATE WORKING SOLUTION

Exactly 0.025 N of freshly standardized against K2Cr207. One ml of this solution is equivalent
to 0.2 mg of oxygen.
e. STARCH INDICATOR SOLUTION:

Titrate 5 g of starch and 0.01 g of mercuric iodide with 30ml of cold water and slowly pour it
while stirring into 1 litre of boiling water. Boil for 3 minutes. Allow the solution to cool and
decant the supernatant clear liquid.
Procedure 1
Remove the stopper from a 250 to 300 ml bottle containing the sample and add 1.5 ml of
manganese Sulphate solution followed by 1.5ml of alkaline iodide solution, keeping the tip of

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the pipette in each case well below the liquid. Carefully replace the stopper without the
inclusion of air bubbles and thoroughly mix the contents by inverting and rotating the bottle
several times, allowing the precipitate formed to settle. When the precipitate settles leaving
a clear supernatant above the manganese hydroxide floc, repeat mixing a second time and
allow settling.
When further settling produces at least 100 ml of clear supernatant, carefully remove the
stopper and add immediately 2ml of concentrated H2SO4 by running down the acid down the
neck of the bottle, stopper and mix well to ensure uniform distribution of iodine in the bottle.
Take 200 ml of the solution and titrate immediately against standard sodium thio Sulphate
solution, adding 1 ml of starch indicator solution when the colour becomes pale yellow and
completing the titration to the disappearance of the blue colour. The error due to the
displacement of sample by reagent is insignificant.
Dissolved oxygen, mg/l = V1
Where ‘V’ is the volume in ml of the standard sodium thio Sulphate solution used in the
titration.
Note : In case of presence of organic matter, easily oxidised at the pH of the alkaline iodide
treatment.
Procedure 2:
Reagents:
All the reagents used in the above procedure except that an alkaline iodide – sodium azide
solution shall substitute for the alkaline iodide solution.
Procedure:
Remove the stopper of the bottle containing the sample, add 2 ml of manganese Sulphate
solution followed by 2ml of alkali iodide – sodium azide solution, stopper and mix by inversion
for 20 seconds. Immediately add 2 ml of concentrated sulphuric acid before the precipitate
settles, remix and titrate as described earlier.
Calculation: Same as above
Procedure 3:
Alum Flocculation Modification: (In the presence of high amounts of suspended solids).
Reagents: All the reagents as above, in addition to the following reagents:
Alum Solution: Dissolve 10 g of potassium Aluminium Sulphate in water and dilute to 100 ml.

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Procedure:
Collect the sample in a glass-stoppered bottle of 500 – 1000 ml capacity; using the same
precautions as are necessary for the 300 ml sample. Add 10 ml of alum solution followed by
1 to 2 ml of ammonium hydroxide. Stopper and invert gently for about 1 minute. Allow
settling for about 10 minutes and then siphoning the clear supernatant into 250 to 300 ml DD
bottle until it overflows. Avoid aeration and keep the siphon submerged at least 20cms. Then
follow the same procedure and calculate the result as given above.
18.2.3 DETERMINATION OF TOTAL SUSPENDED SOLIDS (TSS):
TOTAL SUSPENDED SOLIDS (TSS)
All suspended matter (both organic and inorganic) in water or wastewater sample that is
retained on the filter paper are referred to as total suspended solids (TSS).
SIGNIFICANCE of TSS:
High concentrations of TSS in effluents can cause increased sedimentation and thereby
increase sludge production. TSS in Aeration tank liquor is termed as Mixed Liquor suspended
solids (MLSS), which is the suspended solids concentration of organic matter(activated
sludge) in the aeration tank liquor. This concentration is used as a first order approximation
to represent the amount of organisms in the liquor or the amount of organism in the activated
sludge process (ASP), which is normally in the range of 1500 to 4000 mg/l in conventional ASP.
Outline of the method

Suspended matter is determined by filtering the sample through an asbestos pad in a Gooch
crucible.
Reagent
Asbestos cream: Make a cream of acid-washed medium fiber gooch asbestos with water. Add
one litre of water for every 15g of asbestos. If the asbestos contains too much of fine powder,
remove the latter by repeated decantation.
Procedure
 Carefully make an asbestos mat in the gooch crucible by adding sufficient asbestos
cream to produce a mat about 3 mm thick. In preparing the mat, first fill the crucible
with well-mixed asbestos cream, let stand for about 10 minutes to allow the heavier
particles to settle and then apply suction to the same extent, as it will be used for
filtering the sample. Wash the mat with water with the suction on by filling and
drawing through.

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 Dry the crucible with the asbestos mat in an oven at 103° to 105°C for 1 hr. Cool in a
desiccator and weigh.
 Filter the sample through the weighed Gooch crucible after moisturizing with a few
drops of water. Add successive increments of 10 ml of well-shaken sample for filtration
using suction. Add each increment of sample before the mat becomes dry. The use of
a pipette with an orifice wide enough to prevent clogging with suspended matter is
recommended. Continue successive 10 ml additions of the sample until the filtration
becomes inconveniently slow or until about 10 to 20 mg of suspended matter has
been filtrated.
 Carefully wash the mat with 10 ml of water to remove soluble salts. Continue suction
until draining is complete. Dry the crucible in an oven at 103 to 105°C for 1 hr, cool to
room temperature in a desiccator and weigh.
Calculations:
Total suspended solids, mg/l = 1000 x W
Where,
W = Weight in mg of suspended matter and
V = Volume in ml of the sample taken for filtration.
Note : Express the result to the nearest 5 mg/l.
18.2.4 DETERMINATION OF VOLATILE SOLIDS (VSS):
VOLATILE SOLIDS (VS)
A measure of the volatile solids in water or wastewater sample that can be volatilized and
burned off when the total solids are ignited at around 500 oC.
SIGNIFICANCE of VS:

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The concentrations of volatile organic matter in the mixed liquor suspended solids. It is a
measure of concentration of microorganisms participating in a particular metabolic process
of the system. This is the true representation of the amount of organisms present in the
process. MLVSS is normally about 60 to 80% of MLSS. This volume of volatile organic solids is
measured by evaporation at relatively high temperature (550 oC) from the mixed liquor of an
aeration tank.
Principle:
The principle involved is evaporation of the liquid at high temperature to get fixed, volatile
and dissolved solids.
Apparatus:
a) Crucible to withstand 650°C temp.
b) Chemical balance
c) Muffle furnace
Procedure:
a) Take the empty crucible and clean it thoroughly, make it perfectly dry. Take the weight
of the empty crucible, say W1 g.
b) Add to the crucible 25 ml of liquid sample.
c) Heat the crucible till the entire liquid in the crucible evaporates and dry residue
remains at the bottom.
d) Take the weight of the crucible with residue after cooling for 20 minutes. Weight, say
W2 g.
e) Take the same crucible and keep it in muffle furnace at a temperature of 650°C for 30
minutes. During this time the volatile and organic matter in the solids is evaporated.
What remains in the crucible is “Fixed Solids”
f) Cool the crucible and weight it with the fixed solids residue, say W 3 g.
Calculations:
Total solids in mg/l = W2 – W1 X 106 mg/l ------ (A)

ml of sample
Fixed solids in mg/l = W2 – W3 X 106 mg/l ------ (B)

ml of sample

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Volatile solids (MLVSS) in mg/l = (A) – (B)
18.2.5 DETERMINATION OF SLUDGE VOLUME INDEX (SVI):
SLUDGE VOLUME INDEX (SVI)

A process control calculation used for the evaluation of settling quality of activated sludge. VI
is the volume in millilitres occupied by 1 g of activated sludge in 30 minutes in one litre
graduated cylinder.
SIGNIFICANCE OF SVI
SVI is a measure of the settling quality and compatibility (a quality indicator) of the activated
sludge and it’s also referred to as Mohlman index. As the SVI increase the sludge settles
slower, which does not compact well, it is likely to result in an increase in effluent suspended
solids concentration. As the SVI decreases, the sludge becomes denser and the settling is
more rapid.
When SVI is less than 100, sludge is old and possesses pin flocs, effluent turbidity tends to
increase. When SVI is between 100 and 200, the process is under normal operation with good
settling and low effluent turbidity (optimal being 100-120). When SVI is greater than 250,
bulking sludge takes place with poor settling and high effluent turbidity. The SVI is used as a
trend indicator to evaluate the system behaviour.
Reagent / Equipment
1 litre graduated cylinder
Procedure
1. Fill the 1 litre graduated cylinder to mark with the effluent mixed liquor of an activated
sludge tank.
2. Note the volume occupied by the sludge after half an hour settling.
3. Thoroughly mix the sample in the cylinder and determine the suspended solids as
mentioned in procedure for Total Suspended solids.
Calculations

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Sludge Volume Index = Volume of settleable sludge x 1000

Suspended solids in sample (mg/l)
18.2.6 DETERMINATION OF CHEMICAL OXYGEN DEMAND (COD)
CHEMICAL OXYGEN DEMAND (COD)

A measure of the oxygen needed to chemically oxidise all the organic matter in the
wastewater. It is an indication of pollution level in the water sample determined by boiling
the sample in presence of an oxidising agent, usually potassium dichromate (K 2Cr2O7) with a
mixture of concentrated sulphuric acid and a catalyst (silver sulphate), and measuring the
amount of oxygen consumed by the same over a given period of time. Mercuric sulphate may
be added to avoid the interference of Chlorides.
SIGNIFICANCE OF COD
COD test indicates the total oxidizable organic material present in the sample and does not
differentiate between biologically oxidisable and inert organic matter. The COD test can be
completed within 2 hours, and is much more convenient than the BOD test. The COD value is
normally higher than the BOD value because, more organics can be oxidised by these
chemicals than are biodegradable in BOD test. A high COD:BOD ratio for an industrial wastes
may be an indication of the presence of either organics that are hard to biodegrade, or toxic
material inhibiting the BOD results.
Reagents
a. Potassium dichromate solution – 0.25 N:
Dissolve 12.259 g of dried analytical reagent grade potassium dichromate in distilled water to
make 1 litre of solution
b. Potassium dichromate solution – 0.025 N:
Dilute 0.25 N potassium dichromate 10 times (100 to 1000 ml)
c. Ferrous ammonium sulphate – 0.1 N:

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Dissolve 39.2 g of ferrous ammonium sulphate in water adding 20 ml conc. Sulphuric acid to
make 1 litre of solution. Standardise this solution with potassium dichromate. For
standardisation dilute 10 ml of potassium dichromate to about 100 ml, add 30ml of conc.
Sulphuric acid and titrate with ferrous ammonium sulphate using ferroin as indicator.
d. Ferrous Ammonium Sulphate – 0.01N:
Dilute 0.1 N ferrous ammonium sulphate to 10 times.
e. Ferroin Indicator
Dissolve 1.485 g of 1,10 Phenanthroline and 0.695 g of ferrous sulphate in distilled water to
make 100 ml of solution.
f. Sulphuric Acid Conc.
g. Mercuric Sulphate Solid
h. Silver Sulphate Solid
Procedure
1. Take 20ml of sample in a 250-500 ml COD flask (a round bottom flask with Leibig Reflux
Condenser).
2. If the sample is expected to have COD more than 50 mg/l, add 10 ml of 0.025 N
potassium dichromate solutions. Extreme care should be taken in case of low COD.
3. Add a pinch of silver sulphate and mercuric sulphate. If the sample contains chlorides
in higher amount, it is added in the ratio of 10:1 to the chlorides.
4. Add 30 ml of conc. Sulphuric acid.
5. Reflux at least for 2 hours on a water bath or hot plate. Remove the flask, cool and add
distilled water to make the final volume to about 140 ml.
6. Add 2-3 drops of ferroin indicator, mix thoroughly and titrate with 0.01 N ferrous
ammonium sulphate.
7. Run a blank with distilled water using same quantity of the chemicals.
Calculation

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COD mg/l = (b-a) x N of K2Cr2O7 x 1000 x 8]/volume of sample
Where
a = ml of titrant with sample.
b = ml of titrant with blank.
18.2.7 DETERMINATION OF PH
pH
The pH value is the logarithm to base 10, of the reciprocal of the hydrogen ion concentration
in gram per litre.
pH = - log 10 (H+)
SIGNIFICANCE OF pH
pH is the way of representation or the measure of the acidity or alkalinity of water on a
negative logarithmic scale of 0 to 14 based on hydrogen ion concentration. Acidic waters
have pH values between 0 and 7; alkaline waters range between 7 and 14 and a pH of 7 is
considered neutral.
Principle
The basic principle of electrometric pH measurements is determination of the activity of

hydrogen ions by potentiometric measurement using a standard hydrogen electrode and a
reference electrode.
Interferences
The glass electrode is relatively free from interferences from colour, turbidity, colloidal
matter, oxidants, reductants, or high salinity, except for a sodium error at pH>10. Reduce this
error by using special “low Sodium” electrodes. Temperature causes some interferences in
pH measurement. Therefore standard pH buffers have specified pH at indicated
temperatures.
Apparatus
a. pH meter consisting of potentiometer, a glass electrode, a reference electrode, and a

temperature-compensating device.

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b. Reference electrode consisting of a half-cell that provides constant electrode

potential. Commonly used are calomel and silver: Silver chloride electrodes. Use
manufacturer’s standard operating instructions and recommendations on use and
care of electrodes.
c. Beakers: Preferably use Polyethylene or TFE beakers.
d. Use either a magnetic, TFE coated stirring bar or a mechanical stirrer with inert plastic
coated impeller.
e. Flow chamber: Use for continuous flow measurements or poorly buffered solutions.
Calibration
Calibrate the electrode system against standard buffer solutions of known pH. Because buffer
solutions may deteriorate as a result of mold growth or contamination, prepare fresh as
needed for accurate work. In each case follow the manufacturers recommendation for
storage and preparation of electrodes for use. Before use remove the electrodes from the
storage solution, rinse and blot dry. Place it in the initial buffer solution and set the
isopotential.
Select a buffer within 2 pH units of the sample pH and bring sample and buffer to the same
temperature. Remove electrodes, rinse, dry and immerse in second buffer. Record
temperature and adjust temperature dial on meter so that the meter indicates the pH value
of the buffer at test temperature (as per available data on pH values of standard solutions at
specific temperatures). Remove electrodes form the second buffer, rinse, dry and immerse in
a third buffer solution of pH 3 units different from the second. The reading should be within
pH units from the expected value. If this is not so, check for trouble with electrodes or
potentiometer. Repeat the calibration and standardization procedure at regular intervals.
Sample Analysis: Establish equilibrium between the electrodes and sample by stirring sample
to ensure homogeneity: Stir gently to minimize carbon di oxide entrainment. For buffered
samples or those of high ionic strength, condition electrodes after cleaning by dipping them
into sample for one minute. Dry and immerse in afresh portion of sample and read pH.
With dilute poorly buffered solutions, equilibriate the electrodes by immersing in three or
four successive portions. Take a fresh sample to measure pH.
18.2.8 DETERMINATION OF OIL & GREASE (O&G)

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OIL & GREASE (O&G)

The term oil and grease includes fats, oils, waxes and other related constituents found in
wastewater.
SIGNIFICANCE OF O&G
Petrochemical effluents have very high levels of grease and fat and can adversely affect
biological wastewater treatment process. An organic solvent extracts the oils and grease. The
solvent is distilled off and the weight of the extracted matter is determined.
Apparatus
Separating funnel of 500 ml capacity; the stopper or stopcock should not be lubricated with
matter soluble in petroleum ether.
Reagents
a. Magnesium Sulphate Solution: Dissolve 1gm of MgSO4, 7H2O in 100 ml of water.

b. Milk of Lime: Mix 2 gm of calcium oxide with water into a paste and dilute the suspension
to 100 ml.
c. Light Petroleum (Petroleum Ether): Boiling range 40° - 60 °C
d. Dilute Hydrochloric Acid – 1:3
e. Sodium Sulphate – Anhydrous
Procedure
Take 250 ml or an aliquot containing 50 to 150 mg of extractable matter of the well-mixed

sample in a beaker. If a noticeable layer of floating matter is present on it, carefully transfer
as much of it as possible by decantation into a separating funnel. Draw into the beaker
containing the residual portion of the sample any liquid that separates out in the funnel. To
the sample in the beaker, add 5 ml of magnesium sulphate solution. Stir in a rotational
direction with a glass rod and keep adding continuously small amounts of milk of lime until
flocculation** occurs. Continuous stirring for 2 minutes, then withdraw the glass rod and
wash it down to the separating funnel with a small quantity of light petroleum. Allow the
precipitate to settle for 5 minutes. When it has settled completely, siphon the clear,
supernatant liquid to within about 1-cm of the top of the sediment. Allow any remaining
floating oil to be in the beaker itself. Dissolve the precipitate in the beaker with dilute
hydrochloric acid and transfer the contents to the separating funnel, taking care not to
transfer any large adventitious solids like twigs, leaves, etc. Rinse the beaker with about 50
ml of light petroleum and add this to the liquid in the funnel. Shake the funnel continuously,
but not vigorously for one minute. Allow the liquid layers to separate. Draw the aqueous

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layer into another separating funnel and extract again with a 50-ml portion of light petroleum.
Reject the aqueous layer and combine the petroleum extracts.
** Note: Some effluents do not readily flocculate with lime. In such cases, determine the
suitable flocculating agent (flocculant) by a preliminary trial and use them. The following
flocculant agents are suggested.
a. Aluminium sulphate : 1% solution with pH adjustment of the sample
b. Ferric Chloride : 1% solution & ammonium hydroxide
c. Zinc acetate : 10% solution & sodium carbonate 5% solution
Add 2 gm of powdered anhydrous sodium sulphate to the combined petroleum extract, and
shake intermittently over a period of 30 minutes. Filter through a small size filter paper
(Whatman no.30 or equivalent).
Collect the filtrate in a dry, weighed wide-neck flask of 250 ml capacity. Wash the paper with
two successive 20 ml portions of light petroleum and collect the filtrate in the flask. Finally
evaporate the last traces in a current of warm air. Place in a water bag for 10 minutes, wipe
the outside. Dry with a filter paper; cool in a desiccator and weigh. The difference in weight
is the weight of the residue. (If, after the solvent has evaporated the residue all contains
water, add 2 ml of acetone and evaporate in a water bag. Repeat the acetone addition and
evaporation until the contents are free of water).
Calculations
Oil and grease, mg/l = 1000 x W

V
Where
W = Weight in mg of the residue, and
V = Volume in ml of the sample taken for the test.
Note: Express the result to the nearest milligram.
18.2.9 DETERMINATION OF AMMONIA

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AMMONIA (O&G)
Ammonia is colorless, pungent gas composed of nitrogen and hydrogen, extermelsy soluble
in water. The quantiy of elemental nitrogen present in the form of ammonia is represented
as NH3-N (Ammonical Nitrogen).
SIGNIFICANCE OF AMMONIA
Petrochemical effluents have very high levels of grease and fat and can adversely affect
biological wastewater treatment process. An organic solvent extracts the oils and grease. The
solvent is distilled off and the weight of the extracted matter is determined.
Principle
The sample is buffered at pH 9.5 with a borate buffer to decrease hydrolysis of cyanate and
organic nitrogen compounds. It is distilled into a solution of boric acid when titration is to be
used.
Apparatus
a. Distillation apparatus: Arrange a borosilicate glass flask of 800 to 2000 mL capacity attached
to a vertical condenser so that the outlet tip is submerged below the surface of the
receiving acid solution.
b. pH meter
Reagents
a. Ammonia –free water

b. Borate buffer solution: Add 88 mL 0.1 N NaOH solution to 500 mL approximately 0.025 M
sodium tetraborate solution and dilute to 1 L.
c. Sodium hydroxide, 6 N
d. Dechlorinating reagent: Dissolve 3.5 g sodium thiosulphate in water and dilute to 1 L.
Prepare fresh weekly. Use 1 mL reagent to remove 1 mg/L residual chlorine in 500 mL
sample.
e. Neutralization agent
f. Sodium hydroxide, 1 N
g. Sulphuric acid, 1 N
h. Absorbent solution, plain boric acid: Dissolve 20 g H3BO3 in water and dilute to 1 L.
i. Mixed indicator solution: Dissolve 200 mg methyl red indicator solution in 100 mL 95% ethyl
or isopropyl alcohol. Dissolve 100 mg methylene blue in 50 mL 95% ethyl or isopropyl
alcohol. Combine solutions. Prepare monthly.
J .Indicating boric acid solution: Dissolve 20 g H3BO3 in water, add 10 mL mixed indicator
solution and dilute to 1 L. Prepare monthly.

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k. Sulphuric acid, 0.04 N: Dilute 1.0 mL conc H2SO4 to 1 L.
Procedure
1. Equipment preparation: Add 500 mL water and 20 mL borate buffer, adjust pH to 9.5
with 6 N NaOH solution and add to a distillation flask. Add a few glass beads or boiling
chips and use this mixture to steam out the distillation apparatus until distillate shows
no trace of ammonia.
2. Sample preparation: Use 500 mL dechlorinated sample or a known portion diluted to

500 mL with water. Remove residual chlorine by adding, at the time of collection,
dechlorinating agent equivalent to the chlorine residual. If necessary, neutralize to
approximately pH 7 with dilute acid or base, using a pH meter. Add 25 mL borate
buffer solution and adjust to pH 9.5 with 6 N NaOH using a pH meter.
3. Distillation: To minimize contamination, leave distillation apparatus assembled after
steaming out and until just before starting sample distillation. Disconnect steaming
out flask and immediately transfer sample flask to distillation apparatus. Distill at the
rate of 6 to 10 mL/min with the tip of delivery tube below the surface of acid receiving
solution. Collect distillate in a 500 mL Erlenmeyer flask containing 50 mL indicating
boric acid solution. Collect at least 200 mL distillate. Lower distillation receiver so that
the end of the delivery tube is free of contact with liquid and continue distillation
during the last minute or two to cleanse condenser and delivery tube. Dilute to 500
mL with water.
4. Ammonia determination: Determine ammonia by titrimetric method as below;
5. The following table is useful in selecting sample volume for the distillation and
titration method.
Ammonia nitrogen in Sample volume, mL

sample, mg/L
5 – 10 250
10 – 20 100
20 – 50 50

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50 – 100 25
Reagents
1. Mixed indicator solution: Dissolve 200 mg methyl red indicator solution in 100 mL 95%
ethyl or isopropyl alcohol. Dissolve 100 mg methylene blue in 50 mL 95% ethyl or
isopropyl alcohol. Combine solutions. Prepare monthly.
2. Indicating boric acid solution: Dissolve 20 g H3BO3 in water, add 10 mL mixed indicator
solution and dilute to 1 L. Prepare monthly.
3. Standard Sulphuric acid titrant, 0.02 N
Procedure
1. Titrate ammonia in distillate from the distillation step with standard 0.02 N H 2SO4
titrant until indicator turns a pale lavender.
2. Blank: Carry a blank through all steps of the procedure and apply the necessary
correction to the results.
Calculation
mg NH3-N/L = (A – B) x 280
mL sample
where:
A = volume of H2SO4 titrated for sample, mL
B = volume of H2SO4 titrated for blank, mL

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CHAPTER -19.0
PLANT PERFORMANCE MONITORING

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Performance monitoring of the plant not only involves complying to the Treated effluent
standards but shall also include close monitoring of intermediate unit operations/processes
with respect to
1. Equipment performance,
2. Treatment process,
3. Upsets,
4. Power consumption,
5. Chemical dosing rates and consumption,
6. Sludge production,
7. Reaction/process time period.
19.1 OILY WATER TREATMENT SECTION

19.1.1 Sludge Generation Calculation in API Separator
Volume of sludge = Influent flow x TSS concentration x TSS removal efficiency in API
1000 x Density of settled sludge x Settled sludge consistency
Where,
Volume of sludge generation is in m3/d,
Influent flow is in m3/d,
TSS concentration in Influent in mg/L,
TSS removal efficiency shall be considered as 60%
Density of settled sludge shall be considered as 1020 kg/m3
Settled sludge consistency shall be considered as 3 %
Significance and Control

1. Based on the quantity of sludge generated, the timing and frequency of manual
desludging of API is decided and accordingly, the downstream sludge handling activities
planned. It is recommended to desludge API at least once per shift (i.e every 8 hr
duration).

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2. Ensure sufficient sludge removal and oil skimming in API to reduce the loading on
downstream units (TPI and DAF) and thereby oil carryover to biological treatment.
19.1.2 Sludge Generation Calculation in TPI
Volume of sludge = Influent flow x TSS concentration x 0.4 x TSS removal efficiency in TPI
Where,
TSS concentration in Influent to API in mg/L,
TSS removal efficiency of TPI shall be considered as 85 %

1. Based on the quantity of sludge generated, the timing and frequency of desludging
TPI (pneumatic valve) is set and accordingly, the downstream sludge handling
activities planned. It is recommended to desludge TPI at least once per shift (i.e every
8 hr duration).
2. Ensure sufficient sludge removal and oil skimming in TPI to reduce the loading on
downstream units (DAF) and thereby oil carryover to biological treatment.
19.1.3 Sludge generation Calculation in DAF
Volume of sludge = Influent flow x ((Influent TSS conc. – Outlet TSS Conc) + (Ferric
chloride dosage x 0.65))
Where,

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TSS concentration in Influent to DAF in mg/L,

TSS concentration in outlet of DAF in mg/L,
Volume of sludge settled = apprx. 75 % of the total sludge generated in DAF.
Volume of scum formed = apprx. 25 % of the total sludge generated in DAF.

1. Based on the quantity of sludge settled, the timing and frequency of desludging DAF
(motorized auger) is set and accordingly, the downstream sludge handling activities
planned. It is recommended to desludge DAF at least once every 2 hrs.
19.1.4 Air Requirement for DAF
Air reqt. = Influent flow x (O&G conc.+TSS conc.) x A/S ratio x 1.5 x No of DAF units.
1000 x 1.293
Where,
Air requirement is in Nm3/hr,
Influent flow is in m3/hr,
O&G and TSS concentration is in mg/l,
Air/Solids (A/S) ratio shall be 0.02 to 0.022 kg/kg.
1. Based on the incoming solids and oil load, the air requirement shall be adjusted
accordingly, for efficient performance of the DAF unit.
2. Sufficient air as calculated above shall always be maintained for proper saturation of
air and water and ensure oil carryover to downstream biological treatment is within
the specified limits.

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19.1.5 Chemical dosing and control
Density Typ. Typ.

of dosing dosage
Dosing chemical Dosing point Control Effect
solution, strength, rate,
kg/L % mg/L
Ferric chloride(1) Inlet to Oily Auto Coagulation of Incoming TSS and effect
DAF flash stroke the TSS removal in DAF unit. 1.1 10 10 to 20
mixing tank
98% Acid Inlet to Oily Manual Reduction of pH in the effluent/to
(H2SO4) (2) DAF flash achieve the optimal pH or efficient 1.82 98 20
mixing tank Ferric chloride coagulation.
DeOiling Oily DAF Auto Effects flocculation of coagulated
0.05 to
Polyelectrolyte(1) Flocculation stroke microflocs and thereby improve TSS 1.0 1 to 3
0.1
tank reduction efficiency of DAF.
Calculation of Chemical dosing rate and consumption
Chemical dosing rate = Influent flow rate x dosage rate

1000 x dosing strength x density
Chemical consumed = Influent flow rate x dosage rate

1000 x purity
Where,
Chemical dosing rate is in Litres per hour (LPH),
Dosage rate is in mg/L,
Dosing strength is in %,
Density is in kg/L and
Chemical consumed is in kg/day,
Purity of chemical in %.

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Note 1: The dosages indicated are tentative and may be adjusted as per the Jar test conducted
on the effluents.
2. pH shall be established after jar test trials for optimum ferric chloride coagulation.
The optimal pH shall fall in the range of 6 to 7.
3. For the appropriate test methods and schedule of testing, Please refer to Section 10:
Sampling, Laboratory analysis and quality control.
19.1.6 Critical Process Parameters
Parameter Monitoring location Desired Unit Troubleshooting

range
pH Inlet of oily DAF – AE 6.5-7.5 - High pH in any of Incoming effluents
1001A/B
Dosing rate of H2SO4 needs to be checked
and adjusted.
19.2 BIOLOGICAL TREATMENT SECTION

19.2.1 Dissolved Oxygen (DO) in Aeration tank
The dissolved oxygen is very critical for the functioning of the Biological treatment in the
Aeration tank. The DO is maintained by the Aeration air blowers. The desired D.O that is
required to be maintained in the Aeration tank is around 1.5 – 2.0 mg/l. The DO is monitored
with the help of two no analyzers in the Aeration tank (AE 2002/2004).
19.2.2 Food to Microorganism (F/M) ratio in Aeration tank
This control parameter helps to control the balance between available food materials (BOD)
and available organisms (MLVSS), and is written as
F/M = Influent Flow x Influent BOD

MLVSS x Volume of Aeration tank
Where,

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MLVSS is in mg/l, and
Volume of Aeration tank is in m3.
The optimal value of F/M ratio for the biological treatment process shall be 0.1 to 0.2

1. Comparison of the F/M ration with the plant effluent quality (at the outlet of bio DAF
system) is the primary means to identify the most effective range of F/M value.
2. Higher F/M rates indicate the amount of food (BOD, in mg/l) available per kilogram
of mixed liquor volatile suspended solids (microorganisms) is more than optimal and
Lower F/M is vice versa.
3. Control of the F/M rates is effected by adjustment of the sludge waste rate
discharges. (SAS pumps). Increasing in rate results in decrease in the MLVSS and
increase in F/M ratio and vice versa.
19.2.3 Excess sludge discharge rate (SAS)
Volume of sludge = Influent flow x Influent BOD conc. x Excess sludge Generation rate
1000 x Density of settled sludge x settled sludge consistency
Where,
Volume of Excess sludge generation is in m3/d,
Influent flow to Aeration tank is in m3/d,
BOD concentration in Influent to Aeration tank in mg/L,
Excess sludge generation rate is in kg Solids/kg BOD and varies from 0.7 to 0.8
Settled sludge consistency shall be considered as 0.6 to 0.8 %
19.2.4 Calculation of Recirculation Rate (RAS) to Aeration tank

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Recirculation flow = Q x [MLSS/(6000 – MLSS)]
Where,
Recirculation flow is in m3/hr,
Q is Influent flow to Aeration tank in m3/hr,
MLSS is in mg/L.
6000 indicates the Concentration of the settled sludge from Secondary clarifier in mg/L.
19.2.5 BioDAF Performance monitoring

Same as for Oily DAF.
Density Typ. Typ.

of dosing dosage
kg/L % mg/L
Urea (1) Biotower/Aeration Manual Nitrogen Nutrient source for 22 mg/l
feed sump and biological activity of microorganisms per 100
1.0 10
Splitter box II mg/l
BOD
Di Ammonium Biotower/Aeration Manual Phosphorus Nutrient source for 4.22
phosphate(2) feed sump and biological activity of microorganisms mg/l per
1.0 10
Splitter box II 100 mg/l
BOD
98% Acid Biotower/Aeration Manual Reduction of pH in the effluent
(H2SO4) (3) feed sump optimal for biological treatment. 1.82 98 20
Ferric chloride(4) Inlet to Bio DAF Auto Coagulation of Incoming TSS and
1.1 10 10 to 20
flash mixing tank stroke effect the TSS removal in DAF unit.
Polyelectrolyte(4) Bio DAF Auto Effects flocculation of coagulated
0.05 to
Flocculation tank stroke microflocs and thereby improve TSS 1.0 1 to 3
0.1
reduction efficiency of bioDAF.

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1000 x purity
Where,
Note 1: Urea dosing is eventual only. Normally nitrogen is available in the effluent. Shall be
dosed whenever nitrogen is absent in the incoming effluent. Typical value is 5 mg/L
as Nitrogen to every 100 mg/L of BOD.
2. Di Ammonium phosphate dosing is mandated for continuous dosing. Typical value is
1 mg/L as Phosphorus to every 100 mg/L of BOD.
3. pH shall be established after jar test trials for optimum ferric chloride coagulation.
4. The dosages indicated are tentative and may be adjusted as per the Jar test
conducted on the effluents.
19.2.7 Critical Process Parameters

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Parameter Monitoring location Desired Unit Troubleshooting

range
Biotower/Aeration Low pH in any of Incoming effluents

pH
feed sump – AE 7.5 – 8.0 - Dosing rate of Caustic needs to be
2001A/B checked and adjusted.
High Oil in incoming influents
Biotower/Aeration Insufficient oil skimming in Pretreatment
Oil feed sump – AE 10-15 mg/l section (i.e API, TPI and DAF units)
2011
Insufficient oily sludge bleeding in
Pretreatment (i.e API, TPI and DAF units)
High/Low pH in the Incoming effluents
Aeration tank – AE No proper pH control in the Pretreatment
pH 2003A/B & AE 6.5 – 8.0 - (DAF Inlet) and Biotower feed sump.
2005A/B
Dosing rate of Acid/Caustic needs to be
checked and adjusted.
Insufficient Aeration/air flow from
Aeration tank air blowers.
VFD setting for D.O control to be
rechecked and set in the DCS HMI.
High temperature of Air discharge from
Aeration tank air blowers. Air cooler not
running.
Dissolved Aeration tank – AE High BOD load in incoming effluents.

1.5 – 2.0 mg/l
Oxygen 2002 & AE 2004 High Oil & grease load in incoming
effluents.
Higher MLSS concentration than desired.
Insufficient Waste activated sludge
bleeding from secondary clarifier.
High Ammonia content in incoming
effluents leading to rapid oxygen
consumption.

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Very High Sulfide content in incoming

effluents
Sudden toxic shock load from incoming
effluents. Sudden or discontinuous
feeding of effluents into Aeration tank.
When SVI is less and when turbidity of the
clarified effluent is high, it indicates pin
flocs. Check if
1. If high DO/mixing is prevailing.
2. Check for optimal F/M ratio.
3. Reduce organic overload, if any
Sludge
Aeration tanks (230-
Volume 100-120 - When SVI is more and, it indicates sludge
TK-111/230-TK-211)
Index (SVI) bulking and has poor settleable
characteristics. Check if
1. If Low DO is prevailing.
2. Check for optimal F/M ratio.
3. Reduce organic overload, if any
4. Increase Desludging of the MLSS.
When F/M is less than optimal, Check if
1. Insufficient sludge bleeding from
secondary clarifier.
2. Higher Recycled Activated sludge
Aeration tanks (230- flow rates (RAS).
F/M Ratio 0.1 – 0.2 -
TK-111/230-TK-211) When F/M is more than optimal, check if
1. Excessive sludge bleeding from
secondary clarifier.
2. Lower Recycled Activated sludge
flow rates (RAS).
19.3 OILY SLUDGE TREATMENT SECTION

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19.3.1 Sludge generation Calculation in Oily sludge thickener

Total solids to thickener = Sludge from API x density of sludge x sludge consistency
+
Sludge from TPI x density of sludge x sludge consistency
+
Sludge from DAF x density of sludge x sludge consistency
Where,
Total solids to thickener is in kg/d,
Sludge from API, TPI and DAF are in m3/d,
Density of sludge is in kg/m3, and
Sludge consistency is in %. (for API 3%, TPI 3% and DAF 2%).
Thickened sludge calculation
Thickened sludge = (total solids to thickener x efficiency) /sludge consistency/density
Where,
Total solids to thickener is in kg/d,
Efficiency shall be 90%,
Density of sludge is in kg/m3, and
Sludge consistency shall be 4 to 5%.
1. Based on the quantity of thickened sludge generated, the timing and frequency of
desludging thickener (pneumatic valve) is set and accordingly, the downstream
sludge handling activities/centrifuge operation run time is planned. It is
recommended to desludge thickener at least once every shift to avoid choking and
any solidification.
19.4 BIO SLUDGE TREATMENT SECTION

Same as described for oily sludge treatment section, wherein here the sludge source shall
only be surplus activated sludge (SAS) from aeration tanks.

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Density Typ. Typ.

of dosing dosage
kg/L % kg/MT
Dewatering Oily sludge manual Enhanced thickening and improved
0.1 to
polyelectrolyte – centrifuge dewatering of oily sludge 1.0 1 to 2
0.25
oily sludge(1)
Dewatering Oily sludge manual Enhanced thickening and improved
0.1 to
polyelectrolyte – centrifuge dewatering of bio sludge 1.0 1 to 2
0.25
bio sludge(1)
Dewatering Filter press manual Enhanced thickening and improved
polyelectrolyte – dewatering of leachate sludge 0.1 to
1.0 1 to 2
Leachate 0.25
sludge(1)
Note 1: The dosages indicated are tentative and may be adjusted as per the Jar test conducted
on the sludge or as advised by dewatering polyelectrolyte suppliers.
19.5 LANDFILL LEACHATE TREATMENT SYSTEM
Volume of sludge = Influent flow x ((Influent TSS conc. – Outlet TSS Conc) + (Ferric
chloride dosage x 0.65))
Where,
TSS concentration in Influent to LLTP in mg/L,

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Required TSS concentration in outlet of Plate type clarifier in mg/L, shall be less than
10 mg/L.
Settled sludge consistency shall be considered as 1.5 %

plate type clarifier (pneumatic valve) is set and accordingly, the downstream sludge
handling activities/filter press operation run time is planned. It is recommended to
desludge thickener at least once every shift to avoid choking.
Density Typ. Typ.

Dosing of dosing dosage
Dosing point Control Effect
chemical solution, strength, rate,
kg/L % mg/L
20 % Caustic (1) pH adjustment Auto Increase of pH
tank I stroke 1.2 20 20
Ferric Flash mixing Manual Coagulation of Incoming TSS and effect

chloride(2) tank the TSS removal in plate type clarifier. 1.1 10 10 to 20
Polyelectrolyte Flocculation manual Effects flocculation of coagulated

(2) 0.05 to
tank microflocs and thereby improve TSS 1.0 1 to 3
0.1
reduction efficiency in Plate type clarifier.
98% Acid pH adjustment Manual Reduction of pH in the effluent/to
1.82 98 20
(H2SO4) tank II achieve the optimal pH.


1000 x purity

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Where,
Note 1: pH shall be established after jar test trials for optimum ferric chloride coagulation.
2. The dosages indicated are tentative and may be adjusted as per the Jar test
conducted on the effluents.
19.6 HARD COD MANAGEMENT SYSTEM
Volume of sludge = PAC dosed

Density of settled sludge x Settled sludge consistency
Where,
Amount of PAC dosed in kg/d,

plate type clarifier (pneumatic valve) is set and accordingly, the downstream sludge
handling activities/pumping to RAS sump is planned. It is recommended to desludge
thickener at least once every shift to avoid choking.

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Density Typ. Typ.

Dosing of dosing dosage
Dosing point Control Effect
chemical solution, strength, rate,
kg/L % mg/L
98% Acid Carbon contact Auto Reduction of pH in the effluent/to
(H2SO4) tank stroke achieve the desired pH. 1.82 98 20
Powdered Carbon contact Manual Reduction of COD in RO reject

activated tank 1.1 5 Note 1
carbon
20 % Caustic Clean effluent manual Increase pH in the effluent/to achieve the
1.2 20 20
sump desired pH.
Calculation of Chemical dosing rate and consumption (Not applicable for PAC)


1000 x purity
Where,
Dosage rate is in mg/L, Dosing strength is in %, Density is in kg/L and
Note 1: PAC dosing shall be 1.0 kg for every 0.3 kg of Incoming COD or as advised by PAC
supplier.
2. For the appropriate test methods and schedule of testing, Please refer to Section
10: Sampling, Laboratory analysis and quality control.

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CHAPTER-20
INSPECTION REQUIREMENTS

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INSPECTION REQUIREMENTS
Plant maintenance by frequent Inspection of various equipment is very important in achieving

highest availability of the plant. In addition, a proper preventive maintenance schedule
ensures highest plant availability resulting in better value for money.
The detailed maintenance program which shall be carried out at site for ensuring optimum
upkeep of all machinery shall include the following.
a) Daily & Monthly maintenance checks,
b) General Monthly Equipment Maintenance Checklist.
c) Overall Equipment Preventive Maintenance Checklist.
The preventive maintenance program shall be as below:
 Daily maintenance
 Weekly maintenance
 Monthly Maintenance
Standardized maintenance schedules & procedures, which are accepted and recommended
by all the equipment manufacturers, shall be followed.
The Plant In charge with the assistance of his team shall maintain the following reports to
monitor the performance of plant,
 Daily log sheets for operation for each equipment

 Weekly Maintenance reports
 Monthly maintenance report

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CHAPTER-21
DCS, PLC AND ONLINE ANALYZERS

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The DCS will function as the central information centre, controlling devices for all process equipment
in the plant. The DCS shall be installed in Satellite Rack Rooms (SRRs) and in the following Main Control
Buildings:
1. Main Control Building (MCB),

2. Utility Control Building (UCB),
3. Effluent Treatment Units Control Building (ECB),
4. Oil Movements and Shipping (OM&S) Control Room
Operator consoles shall be located in the Main Control Room (MCR) of each of the Control Buildings.
Operating functions of all the main process, utility, and offsite units shall be carried out from these
consoles. There shall also be a DCS HMI and engineering workstation in each Satellite Rack Room
(SRR). Local Operator Shelters, where specified shall be provided with DCS operator
consoles/workstations with ‘view only’ facilities to enable viewing of Process graphics of the Refinery
and Petrochemical Complex (including offsites, utilities, associated units and Licensed Process Units),
as required.
Objectives
The objective of the DCS is to support the high reliability and availability of the whole facility.
Operations shall be automated as much as is practical, thereby minimising personnel involvement and
maximising reliability. The DCS shall control and monitor the plant to continuously produce on-
specification product whilst maximising plant energy efficiency, and minimising adverse
environmental impact and maintenance downtime.
Normal plant operations shall be controlled from a suite of Operator Consoles in the corresponding
Control Building. Console mounted DCS Operator Workstations (HMI’s) shall form the man machine
interface and provide the operators with a universal “Single Window” for remote control and
monitoring of the Plant.
All safety critical functions shall be implemented in the ESD system. Sequential logic (pump starts,
batch operations etc) shall be implemented in the DCS.
System Structure
The DCS shall comprise discrete types of functional hardware elements interconnected to provide the
required overall system functionality. The separate major elements shall have a hierarchical
relationship via a DCS communication network. A hierarchical hardware and database structure shall
enable the more essential elements of the system to survive failures of the less critical but more
powerful elements.
The required major system elements in hierarchical order, (most critical last) are:
• Engineering Stations

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• Operator stations
• Control and data acquisition systems
The DCS highway utilises Fibre Optic Cable Technology for redundant communications between the
MCB, UCB, ECB, OM&S Control Building, and SRRs.
All HMI’s have the capability to access information globally across the entire refinery without recourse
to a single point source database. HMI console groups shall normally be configured to allow operation
of only the process area associated with that group. It shall however, be possible to view process
graphics and information across the whole refinery. In the event of highly abnormal circumstances it
should be possible however, under strict password or key control, for an HMI from one group to be
able to operate a plant area outside of its normal grouping.
Note: For more details, please refer to attached system architecture diagram.
21.1 LIST OF ONLINE ANALYZERS
S.No Analyzer Location Fluid Measuring Type

Functional Range
Range
pH – Effluent Treatment Plant
1 pH – Common discharge of DAF feed 5 to 9 0 to 14 Flow through
230AT1001A/B pumps
2 pH – Treated effluent transfer pumps 5 to 9 0 to 14 Flow through
230AT2007A/B common discharge
3 pH – Biotower/Aeration feed sump 5 to 9 0 to 14 Dip type
230AT2001A/B
4 pH – Aeration tank I 5 to 9 0 to 14 Dip type
230AT2003A/B
5 pH – Aeration tank 2 5 to 9 0 to 14 Dip type
230AT2005A/B
pH – Landfill leachate treatment
1 pH – pH adjustment tank -I 5 to 9 0 to 14 Dip type
231AT1001A/B
2 pH – pH adjustment tank -II 5 to 9 0 to 14 Dip type
231AT1002A/B
pH – Hard COD management
1 pH – Carbon contact tank 5 to 9 0 to 14 Dip type
231AT2001A/B
2 pH – Clean effluent sump 5 to 9 0 to 14 Dip type
231AT2002A/B
Oil in water analyzer – Effluent treatment plant

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1 pH – 230AT2011 Biotower feed sump 0 to 15 ppm 0.1 to 15 ppm Dip type

2 pH – 230AT2010 Cooling tower blowdown inlet 0 to 120 ppm 0.1 to 150 ppm Flow through
COD analyzer – Effluent treatment plant
1 pH – 230AT2011 Treated effluent transfer pump 0 to 300 ppm 0.1 to 400 ppm optical type
common discharge (located in analyzer
room)
DO analyzer – Effluent treatment plant
1 DO – Aeration tank I and II 0 to 4 ppm 0 to 20 ppm Dip type
230AT2002/2004
DO analyzer – Landfill leachate treatment
1 DO – 231AT2002 Aeration pot 0 to 4 ppm 0 to 20 ppm Dip type
21.1.1 Calibration of Online Analyzers
S.No Analyzer Calibration Frequency

1. Oil in water Process calibration with results of a grab sample analysis. Once in 3
analyzer months
2. Dissolved Air calibration (operator to enter barometric pressure) Once every
oxygen fortnight
analyzer
3. pH Analyzer Manual two point calibration is made by immersing the Once every
sensor in two different commercially available standard fortnight.
buffer solutions and entering the pH values (or) one point
calibration by entering a pH value of a grab sample.
4. COD analyzer Process calibration with results of a grab sample analysis. Once in 3
months
Note: For more details, please refer to Datasheets on Analyzers and respective vendor manuals. The
Datasheets for Analyzers are provided in Volume II of the Operation and Maintenance Manual.

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CHAPTER-22
UTILITY & AUXILIARY NETWORKS

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The utilities indicated are as provided at the unit battery limit of the consumer, unless
otherwise noted. All pressures are referenced to grade.
22.1 UTILITY NETWORKS
22.1.1 Steam Network
22.1.2 Raw Water

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22.1.3 Service Water
22.1.4 Potable Water
22.1.5 Fire Water
22.1.6 Stripped sour water
22.1.7 Plant Air

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22.1.8 Instrument Air
22.1.9 Power Supply
The system characteristics shall be as follows
Incoming supply: 220k Volts 3 Ph. 50 Hz 300 MVA
Inplant Generation: 11k Volts 3 Ph. 50 Hz 60 MW
Inplant Distribution voltage: 66 kV, 3 Ph, 50 Hz
Emergency Power supply
An emergency power supply is provided by the Power Distribution Contractor to supply

process critical loads and emergency lighting.

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Un Interruptible Power supply
An un-interruptible power supply is provided by the Power Distribution Contractor for the
Following services:
1. DCS, PLC and Instrumentation.

2. HV Switchgear closing/tapping.
3. Telecommunication requirements.

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CHAPTER-23
STANDING INSTRUCTIONS FOR SAFER

OPERATION

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23.1 INTRODUCTION
Special design features are incorporated for the efficient and safe operation and shutdown of
systems and equipment. However, precautionary measures should be adopted for smooth
operation of the plant. Safety should be observed for preventing accidents to the personnel
and equipment. This section of the manual will cover all the basic needs of the safety
management and emphasizes the necessity of proper planning and management.
23.1.1 CAUSES OF ACCIDENTS
Causes of accidents can be classified as due to:
 Lack of knowledge or negligence on the part of workman about situations or

character of materials/equipment handled.
 Unsafe working habits.
 Over confidence and error of judgment.
 Under the influence of alcoholic drugs while on work.
 Failure to use protective equipment.
23.1.2 PLANNING TO AVOID ACCIDENTS
Deficiency free plant:
The plant should not be operated showing deficiencies, which may risk damage to staff or to
persons of third parties. Immediate measures to be undertaken as to reduce or at least
minimize the dangerous conditions/replace defective equipment, which may cause accident.
Limited Access
Only practiced persons should enter the plant. Any operation & maintenance shall be allowed
only for the persons who have experience with the plant, safety provisions and with the
equipment.
Training & Standardization
The staff concerned should be trained in safe working methods. The safe working methods
should be practiced for each job. Safe working habits should be practiced as a matter of
routine by the staff, for avoiding accidents

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Special Instructions
For some specific and dangerous operation, the plant in-charge shall give special instructions
to the staff – e.g. for handling of chemicals or for entering any of the tanks.
Use of Safety devices
Safety devices to be maintained properly and to be retested in regular intervals. All staff,
operating and maintaining the plant should use the prescribed safety systems, like special
clothing, safety glasses or safety ropes. It is not allowed to manipulate any safety device.
23.2 POTENTIAL HAZARDS

23.2.1 MECHANICAL HAZARDS
These hazards involve mechanical parts trapped, etc., pulled out, burnt, etc.
These risks may be due to the machine design and construction, its installation, its use and its
operation and maintenance.
 Ensure adequate Safety signage in the plant

 The installation of these machines should comply with applicable rules and standards
 There shall not be any risks in normal use or the risks shall be clearly defined in
accurate procedures
 The places currently under maintenance should be of easy access (draining, greasing.)
 Should an exceptional maintenance operation, which may involve specific risks, be
needed only qualified personnel shall intervene after an operation procedure has
been established.
 Safety operations take priority over all other work. It is of particular importance that
appropriate safety precautions are taken before any major maintenance work is
undertaken in the plant. Safety precautions shall never be sacrificed to save time.
 Any repair work to attend mechanical breakdown should be undertaken only in the
authority of safety work permit.
 All guards on machinery, fencing and railing around machinery, walkways, stairways
platform, sumps, pits etc must be maintained in good condition and must not be
removed without proper authority and without displaying caution boards to warn the
people to that effect.
 When plant is laid off for defects or maintenance work and when deviation have to
be made from the normal circuits of operation, necessitating the closing of valves or
interruption of electric circuits etc, it will be normal procedure to "Label" or" Tag"
valves and switches.

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 In certain circumstances locks will be affixed to valves & switches in addition to tags
to avoid inadvertent operation.
 Whenever guards or safety devices are removed to carry out repairs, adjustments or
servicing of the machinery/equipment such as lubrication and maintenance, the
power for the machinery/equipment should be isolated while switches locked and
tagged.
 Proper tools must be used for the job. Tools must be maintained in good condition.
This applies not only to hand tools but also to power operated hand tools and lifting
tackles etc.
 To ensure safety in jobs of opening equipment or pipeline, it is good practice to treat
the equipment/line as if it were under considerable pressure even though all steps
have been taken to relieve the pressure.
 When work has to be done on roofs, towers or any other lofty position, ensure the
use of safety harness.
23.2.2 ELECTRICAL HAZARDS
These hazards involve electric shock, burns, electrical injuries, etc. Electrical accidents
generally take place due to unauthorized interference or misuse of electrical apparatus.
 If any defect develops in electrical apparatus, it should be brought to the notice of

the authority concerned
 Comply with the regulations regarding electrical equipment and installations
 When it is necessary to work on an electrical circuit or other electrical equipment or
to dismantle or remove machinery driven by motors, the proper switches must be
opened and tagged. As an additional precaution, fuses must also be pulled out.
 All electrical equipment, stationary or portable must be properly earthed before
energizing.
 Cover plates that have been removed from lighting and power cabinets or other
electrical enclosures must be replaced immediately after the completion of the work.
 Keep the area around electrical equipment as dry as possible to minimize Possibility
of shock.
 Make sure the installations are in conformity and call for a registered organization to
check them each year.
 Easily accessible emergency shut down buttons shall be installed next to the main or
hazardous machines (these buttons shall not be used in ON / OFF mode).
 Automatic start-up machines showing specific risks shall be signalled (warning sign or
preventive signal before start-up)
 Qualified personnel shall carry out intervention on electrical equipment.
 Regular material tests shall be scheduled

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 All fail-safe controls shall be kept in good working order and in conformity (circuit
breaker, fuses, emergency shut down).
23.2.3 FALLING HAZARDS

Life-buoys and poles shall be usefully installed close to the tanks.
But above all:
 Make sure there is no direct access to the various tanks

 Ensure handrails are in conformity and in good condition
 Handrails shall be such, as they cannot be disassembled without tools. The use of
chains shall be limited.
 In some cases, a tug-rope may be installed 40cm above water in order that a person
fallen down into the tank can haul himself out to a ladder.
 When work has to be done on roofs, towers or any other lofty position, ensure the
use of safety harness.
 Points to hand onto should be provided above hazardous areas (sumps with
submerged pumps or mixers, aeration tank etc.)
 Make out intervention procedures, especially for the cleaning of troughs in settling
tanks.
23.2.4 CHEMICAL HAZARDS
 Hazardous chemicals do always present risk in the operation of the plant. Employees
must always be aware of the chemicals used in the plant and their physical, chemical
& hazardous properties and information regarding counter measures to be taken in
dealing with them.
 Safety equipment prescribed for particular job such as goggles for protection of eyes,
hand gloves for protection of hands aprons/suits to protect against corrosive liquid
splash, respirators/masks to protect against poisonous gases etc. must be worn.
 Ensure proper ventilation in laboratory/chemical handling areas.
 In case of hazardous operational or maintenance work, necessary safety equipment’s
must be kept in readiness and if necessary stand by rescue men must be posted till
the completion of such work
 Safety data sheet regarding this product shall be available.
 Discharge operations shall be carried out in the presence of the deliveryman and one
plant manager.
 Emergency shower and eye wash should be accessible and available all the time.

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23.2.5 GAS HAZARDS
 Gases may come from the following network:

a. Nitrogen compounds and sulphides. Septic effluents produce H2S.
b. Volatile pollutants, solvents, hydrocarbon gases may be found due to accidental
or illegal discharge.
 Gases may also form on the installation, mainly in badly aired sumps and pits further
to fermentation (H2S).
 An increase in CO2 and NH3 concentration may be followed by a shortage of oxygen.
 An intervention procedure shall be imposed, as follows:
a. The person visiting the tank must be equipped with a safety harness:
b. Another person shall remain in the open air ready to help him if necessary.
 Make sure beforehand nothing prevents an unconscious person to be lifted out (i.e
ladder with safety cage).
23.2.6 NOISE
 Noise shall be taken into account as early as the design phase to prevent the
neighborhood from being bothered.
 On the work site, noise pollution may cause tiredness and may have:
 Occasional consequences like tinnitus (permanent and irreversible hissing in the ears)
 And in the long run loss of hearing and deafness.
 Sound measurements shall be performed on the work site and in the rooms
 Interventions in some noisy plant rooms shall be carried out with hearing protection
equipment.
Noise exposure standards
Noise Levels Effects
 75 dBA No dangerous effect
80 dBA Information of the worker
Protection if requested
Medical surveillance if requested

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85 dBA Training
Measures to plan the work and limit exposure
90 dBA Restricted area signaled
Limited access to the area
Individual protection
105 dBA Increased risks subject to declaration and to appropriate

measures
23.2.7 ODOR
 Odor pollution is often a disaster for the environment and has an important and
lasting effect on the relationships with the neighborhood leading to tensions of
whatever nature, even in the political field.
 Odors on work site reveal improper operation and presence of a gas, which may be
corrosive (for example H2S changed into hydro sulphuric and sulphuric acid). Apart
from the structures (concrete and metal parts), odors can also have long-term effects
on public health.
 Pre-treatment is the first source of odor. The nitrogen compounds and sulphides that
are commonly found in the raw water come from bacterial decomposition and any
volatile pollutants; they are released at the first aeration stage (screening/oil removal
facilities.)
23.2.8 Infections
Sewage is the ideal medium for the growing of most bacterial species which feed on the
decomposition of material or which are discharged with excrement.
Wastewater contains a large range of pathogenic germs.
The five groups hereafter listed are the most common:
Class Parasites Diseases Caused
Pathogenic Dysentery, Tetanus, Typhoid and

1
Bacteria Leptospirosis

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2 Viruses Poliomyelitis and Hepatitis A, B etc
Mycotoxicosis, Rhinitis, Sinusitis, Bronchial

3 Mushrooms
asthma, Chronic mycosis
4 Algae Gastroenteritis
5 Parasites Parasitic worms and Tape worm
Managers shall inform the personnel working on the installations of these risks. This
information shall be reminded and explained in detail by the company doctor.
 The following vaccinations shall be recommended or even imposed by the company

doctor: tetanus: typhoid, poliomyelitis, leptospirosis, A and B hepatitis.
 Make the personnel use masks near spray generation areas (aeration tank, sludge
treatment units).
 Make sure hygiene facilities for the personnel are not insalubrious and that they
include.
 Changing room with one cupboard for street clothing and one for working clothing
 Shower and washbasin
 A lunch area after working clothing has been taken off
 Display of hygiene conditions to be respected
 Appropriate protective clothing, as well as glove, masks etc
23.2.9 Basic preventive measures
 Make sure the rules related to hygiene, cleanliness and cleaning of rooms and
installations are respected
 Make sure the personnel is well informed of all the risks and trained accordingly
 Information and training shall be provided regularly
 Authorize some people in a team to become action man in the following fields:
1. Electrical supplies
2. Fires
3. First aid at work
23.2.10 Restricted Areas
The Areas in the plant, which are restricted for access without proper permission and
precautions. These areas include

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 Sludge Sumps, Pump houses & Manholes, Chances of Hazardous Gas H2S emission
 Electrical Panel Room
 Chlorination Building
23.3 EMPLOYEE TRAINING
Training classes for both new and old employees should be conducted periodically to
keep them conscious and informed of the hazards. There should be periodic drill and
instruction regarding location, purpose and use of personal protective equipment, safety
showers, eye fountains, first aid kits, etc. They should be auctioned to prevent leaks avoid
inhalation of gas and direct contact with the liquid. They should be told to report to proper
authorities immediately in case of an equipment failure.
All workers should be instructed and trained to adopt preventive measures in case of
emergency. Such training should include knowledge of emergency, fire fighting equipment,
fire alarms, crash shut down procedures for valves and switches, steps to be taken before
starting repairs anywhere in the plant, use of personal protective equipment and first aid.
Regular and surprise drills for the above should be conducted to improve further the training
in preventive and emergency aspects.
23.4 PROTECTION DEVICES
 Helmets
 Face Masks
 Breathing Apparatus (for confined entry)
 Goggles
 Protective Clothing
 Boots gloves
 Fire Blankets
Appropriate protection devices should be worn in all hazardous areas/chemical plant/when

operating with any hazardous fluids like Acids, Caustics, Dosing Chemicals etc. No Personnel
should be allowed to operate near hazardous fluids without appropriate eye protection.
23.5 FIRST AID
23.5.1 General

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Suitable notices should be fixed in convenient placed regarding first aid measures. The
need for speed in all first aid shall be impressed on everyone concerned, together with the
necessity of avoiding further shock to the patient. All employees should be informed of the
urgent necessity in their own interests of reporting immediately for first aid treatment, all
minor accidents and also report any sickness which may be thought to be connected with
their employment.
All employees should be given comprehensive instructions on the use of first aid
equipment mentioned below and nay other that may be available with the authorities.
Properly designed emergency showers and eye baths should be provided in convenient
locations and they should be properly maintained.
Oxygen administration apparatus should be available in the plant’s first aid or ambulance
room or medical dispensary. Such equipment should be in the charge of a person knowing
use of such apparatus in an emergency. The big manufacturers and large-scale consumers
should train several persons in the use of oxygen administration apparatus and make a
trained person available all the time.
Boxes or Cupboards – Distinctly marked with the words “First Aid” shall be provided in
readily accessible positions. These should not contain anything except the prescribed medical
appliances and requisites. A list of contents should be fixed to the inside of the box. A
sufficient number of persons should be imparted effective training in First-Aid.
23.6 SAFETY PRECAUTIONS
23.6.1 Against Gas Hazards
When a sewer or a manhole is required to be entered for cleaning or clearing an

obstruction, where dangerous gas or oxygen deficiencies may be present, the following
precautions shall be taken:
a. Allow no smoking or open flames and guard against spark
b. Erect warning signs:
c. Use only safety gas-proof electric lighting equipment or mirror for reflection of light;
d. Test the atmosphere for noxious gases and oxygen deficiencies. In case of scum formation
the water and sediments in the manhole should be agitated with the help of rod or any
other suitable instrument for trapped gases and the manhole should be checked for
noxious gases and oxygen deficiencies;

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e. If the atmosphere is normal, workmen may enter with a safety belt attached and with at
least two men available at top. For extended jobs, the gas tests shall be repeated every
three minutes while men are in the sewer.
f. If oxygen deficiency or noxious gas is found, the structure shall be ventilated with pure air
by keeping open at least one manhole cover each on upstream and downstream side for
quick exist of toxic gases or by forced ventilation using a portable blower. The gas tests
shall be repeated before entering. Adequate ventilation shall be maintained during the
work and the gas test shall be repeated every three minutes.
g. If the gas or oxygen deficiency is present and it is not practicable to ventilate adequately
before workers enter a hose masks shall be worn and extreme care shall be taken to avoid
all sources of ignition. Workers shall be taught how to use the hose equipment. In these
cases, they shall always use permissible safety lights (not ordinary flash lights) rubber
boots or non-sparking shoes and non-sparking tools.
h. Workmen descending a manhole shaft to inspect or clean sewers shall try each ladder
step or rung carefully before putting the full weight on it to guard against insecure
fastening due to corrosion of the rung at the manhole wall. When work is going on in deep
sewers, at least two men shall be available for lifting workers from the manhole in the
event of serious injury.
i. Portable air blowers, for ventilating manhole, are recommended for all tank, pit or
manhole work where there is a possibility of presence of noxious gas, vapours or oxygen
deficiency. The motor of these air blowers shall be of Weatherproof and flameproof type,
compression-ignitions-diesel type (without sparking plug). These shall be placed not less
than 2m away from the opening and on the leeward side protected from wind so that
they will not serve as a source of ignition for any inflammable gas, which may be present.
Blower located at ground level with suitable flexible ducting to displace out air from the
manhole should provide forced type ventilation.
23.6.2 Against Infection
The personnel working in sewerage maintenance systems/handling of sewage are prone to

infections and hence the following precautions should be taken:
a. The works should be educated about the hazards of waterborne diseases such as typhoid
and cholera through sewage and tetanus through cuts and wounds. Cuts and grazes
should be covered with waterproof plasters. Effective immunization of workers against
diseases such as typhoid, cholera, tetanus etc. should be done by vaccination.
b. The importance of personal hygiene should be emphasized and the worker should be
instructed to keep finger nails short and well trimmed, wash hands with soap and hot

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water before taking food or smoking and to keep fingers out of nose, mouth and eyes,
because the hands carry most infection.
c. Use of rubber gloves shall be insisted so that sewage or sludge does not come in direct
contact with hand. Before starting work, sling likely to be exposed to sewage should be
covered with barrier cream.
d. The worker should be provided with a complete change of work clothes to be worn
during working hours. Gumboots should be also be provided for the workers.
e. When the work is completed, thoroughly wash all contaminated parts of the body.
23.6.3 Safety Precautions to be undertaken while entering each buildings
23.6.3.1 Sludge Sump, Manholes, Inlet Screen & Sump
 Area is susceptible for H2S, CO & Methane gas collection, which is dangerous.
 Always to enter any openings only in the presence of plant head / his representative
 To check presence of gases using gas detector’s & to remove gas from the area, if it is
detected
 To run all exhaust fans
 To check the working of safety equipment’s like gas mask with air respirator, safety
belts, etc. Before starting of work.
 Plant head to check the area from safety point of view along with the safety officer
before clearing the area for further operation inside the openings
 Explain the worker about the dangerous aspects & risk factors of the activity involved
and the precautions to be taken in case of emergency in the local language to the
worker.
 Only one person is to enter inside the sump with proper back up personnel for
removing the worker in case of emergency
 In case of emergency, leave the job as it is and run for safety
 If one person is in danger, no other should rush to help without wearing any safety
equipment / without knowing how to operate the equipment. It will put his life also
in danger.
 At any point without plant safety officer's permission / clearance no work is to be
started inside the openings.
23.6.3.2 Sludge Handling
 Hand Gloves and Apron are compulsory while handling sludge for disposal
 The worker should wash his Hands properly before going out of the Plant / before
eating any food

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23.6.3.3 Safety Precautions to be taken before doing any ELECTRICAL Work
 Before doing any electrical maintenance during breakdown

 Isolate the Supply
 Remove the fuses in the feeder (MCC Panel)
 Put “MEN ON LINE” board
 Remove Control fuses, if any.
 DO NOT use cutting pliers and screw drivers without insulation
 Before starting of the work, check the line again for power supply
 Ensure sand and proper fire extinguishers are available near the place of electrical
work
 Check electrical equipment for proper earthing and while meggering ensure there is
no supply
 Use Electrical Safety Gloves while working in HT line
 During working on HT line and capacitor banks, isolate the supply and discharge with
earth bar
 DO NOT do any work in electrical line with wet hands / in wet conditions
 While making electrolyte for battery, pour acid into water and not water into acid
 While working on HT feeder, draw out the breaker and remove close fuses. Also take
line clearance from the Mechanical operator & Plant Head before taking shut down
 Close the HT Room with lock and keep the key with the operator, while doing work on
HT lines in the Transformer or in the PCC panels
 DO NOT place your head in front of switch fuse units in MCC panels and PCC panels
 When Earth Fault Relay occurs wherever in DG Sets, PCC panels and HT panels DO NOT
ENERGISE the feeder. Inform the supervisor and Plant Head immediately.
 DO NOT renew a blown fuse until you are satisfied as to the cause and have rectified
the irregularity.
 DO NOT close any switch unless you are familiar with the circuit, which it controls and
know the reason for its being open
 DO NOT touch or tamper with any electrical gear or conductor unless you have made
sure that it is dead and earth
 DO NOT work on live circuit without the express orders of the supervisor. Make certain
that all the safety precaution has been taken and you are accompanied by second
person competent to render First Aid and artificial respiration
 DO NOT disconnect earthing connection or render ineffective the safety gadgets
installed on main and apparatus
 DO NOT open or close switch or fuse slowly or hesitantly do it quickly and positively
 DO NOT use wire with poor insulation
 DO NOT touch an electric circuit when your hand is wet or bleeding from a cut or
abrasion

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 DO NOT throw water on live electrical equipment in case of fire

 DO NOT use fire extinguisher on electrical equipment unless it is clearly marked for
that purposes
 DO NOT attempt to disengage a person in contact with a live apparatus which you
cannot switch off immediately. Insulate yourself from earth by standing on the rubber
mat or dry board before attempting to get him clear. Do not touch his body. Push him
clear with a dry piece of wood.
 DO NOT discontinue artificial respiration until recovery
 DO NOT allow visitors and unauthorized person to touch or handle electrical
apparatus or come within danger zone of HV apparatus
 DO NOT test circuit with bare finger
 DO NOT CHANGE THE OVERLOAD SETTINGS Without PLANT HEAD’s PERMISSION
 If any feeders trips don’t energize without thorough check
 Observe motors, cables and panels for over heating

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CHAPTER-24
WORK PERMIT SYSTEMS

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The Contractor shall ensure that any hazardous work that needs to be carried out in the site
premises will require a specific permit. This hazardous work will include the following items
and any others identified by the Risk Assessment for that task:
 All lifts (both routine lifts and those requiring a lifting study).
 All confined space entries
 Hot work
 All NDT and Radiography
 Lockout and tag out
 Road closures
 Excavations
 Electrical connections and disconnection
 Chemicals
 Line break
 Hot tapping
 Scaffold erection
 installation of temporary and permanent facilities
 Night work
 Elevated work
Permits will only be issued by the Authorities (HSE – IOCL) after the necessary/required Risk
Assessments have been submitted / carried out and approved. In addition to the above
activities, permits will also be considered for any other potentially hazardous activity where
an extra degree of work control is felt to be appropriate by the HSE authorities (IOCL).
24.1 ACCIDENT REPORTING PROCEDURES
All incidents and near misses shall be reported through an overall project reporting system.
The Contractors shall produce an 'Initial Notification' procedure and documentation for the
immediate reporting of all injuries, property damage, spills/environmental incidents and
serious near misses to the Project Team.

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The site Incharge shall immediately inform the respective HSE Authorities (IOCL). The HSE
Authorities (IOCL) shall initiate further actions where appropriate.
The EPC Contractor and the relevant Construction Contractor shall conduct investigations to
all injuries, property damage, spills/environmental incidents and serious near misses,
Managing PMC HSE Manager or nominated person shall attend and assist the investigations.
Investigations of incident reports will always include root cause analysis. Additionally, incident
reports will be analyzed to identify trends that may indicate a need for adjustments in
controls, training, or procedures.

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CHAPTER-25
STANDING INSTRUCTIONS

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1. ETP declared as restricted area. Unauthorized movement of vehicles / persons

is not allowed in this area.
2. ‘Shift-In-Charge’ to report the plant conditions/ unit upsets/ tripping of critical
equipment etc. to the ‘Unit-In-Charge’.
3. All the Shift Officers must sign the Instruction register after going through the
Instructions given by the Unit-in-charge.
4. Log of the previous shift, current log-book, Laboratory results should be signed
by every ‘Shift-in-charge’.
5. Reasons for deviation from instructions and corrective actions taken should be
recorded in the ‘Shift-In-Charge’ log book.
6. Shift-in-charge and Panel officer to ensure that the following records are maintained
in Control Room.
Documents to be Maintained in Control Room
S.No. Description
1. Shift OfficerLogbook
2. Laboratory Results Register
3. Steam /Hydrocarbon Leak Register
4. Interlock Bypass Register
5. Energising/Deenergising status in E-Lock
6. Shutdown Joblist Register
7. Chemical /Lube Oil Consumption Record
8. PSV Checking Record
9. Blinding/Deblinding register
10. Sub Standard Condition Register
11. Chemical and lube Oil stock Inventory

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7. Field-in-Charge to countersign respective Engineering Assistant logbooks.

8. Shift-in-charge & Field-in-charge to routinely ‘pass on’ Plant-in-charge’s important
instructions in the Field instruction Book.
9. Shift-in-charge to ensure that ‘Activity Matrix’ jobs are strictly adhered to; its
compliance to be mentioned in SIC’s logbook.
10. Night Shift-in-Charge to note down all the jobs to be carried out the next day and
issue Notifications of the same.
11. Normally, all job requests are required to be issued as SAP notifications.
12. Jobs which cannot be attended during Unit running are to be logged in the Shutdown
jobs register.
13. Slop oil tank dip to be recorded twice in a shift & ensure water draining in every shift.
14. Do not drain water from slop tank in absence of operating personal.
15. Before pumping out slop oil to Refinery header ensure proper water draining of slop
tanks. Quantity of slop pumped out to be recorded.
16. Night Shift-in-charge to ensure that previous days’ DOR is prepared and updated on
Intranet.
17. All Absentees shall be made ready for Time Office within forty-five minutes of the
commencement of the shift.
18. Shift changes are only allowed for extra-ordinary cases with the approval of
DMPN/PNM.
19. Regularization of any attendance is normally not accepted, however as a special case,
it can be done only with approval of Unit-in-Charge.
20. No shift person shall leave the plant unless properly relieved or permitted by ‘Shift-
In-Charge’ (in case of staff) or by ‘Unit-In-Charge’ (in case of officers). However
persons completing 16 hrs duty shall be released by making alternative arrangements.
21. Any Unit personnel person going out of station should take the approval from ‘Unit-
In-Charge’ before leaving the station.
22. Always Remove Shoes before entering the DCS Area.
SAFETY
1. Use proper Personnel Protective Equipment (PPEs) i.e. helmet, safety shoes, hand
gloves while working/ moving inside the unit. No person should be allowed to work
in the area without proper PPEs.
2. Use personal protective equipments as applicable while handling chemicals and for
other unit operations.

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3. Fire of any nature & intensity must be immediately reported by Shift-in-Charge to

F&S Control Room and Unit-in Charge.
4. Ensure good house keeping, proper illumination and cleaning of the operating area.
5. Ensure that all safety apparatus and first aid equipment are easily available and
accessible. Operating team must be properly trained in using them. Get the fire
extinguishers charged/replaced immediately after use.
6. Oxygen/ hydrocarbon content must be checked along with fire & safety before issuing
clearance for man-entry inside any equipment. Hydrocarbon (Nil) & oxygen content
(not less than 19%) to be ascertained
7. Always ensure stand-by person while working inside the vessel. Vessel entry register
is to be kept near the vessel for entry
8. Operability of utility hose stations/ plant communication system/ PPEs etc. to be
ensured.
9. Ensure that man-hole covers/ gratings/ ladders are in healthy condition.
10. Check the surface drains surrounding the operational area and ensure that drains are
free from chokage and oil accumulation.
11. Always ensure standby person while other one is working inside the vessel.
12. Temporary lighting inside any vessel should be of 24 volts.
13. Only approved safety torches are permitted inside the Unit.
14. Electrical line clearance must be taken before maintenance job is taken up on any
rotary equipment.
15. Regularly check the eyewash and safety showers for its operability.
16. In case of any hydrocarbon leak following actions to be taken:
a) Inform shift in charge, RSM and fire station to review the situation and block
the vehicular movement in the area
b) Stop all hot jobs in unit immediately
c) Identify the leak if possible; isolate the source if possible; shutdown the unit if
required
d) Stop draining of hydrocarbon, if any.
18. Always keep all trips, interlocks & securities in-line. For Bypass Refer Section E and
for Trip Setting Change Refer Section F.
19. Maintain good house keeping in and around Unit area
a) Identify any cleaning required. Record in logbook.
b) Initiate action for cleaning. Issue work request to Civil Maintenance.

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c) Check the completion of cleaning job. Advice about safety aspects if any, to the
persons involved.
d) Inspect the roads/ open channels around the unit and in case of any abnormality
initiate action.
20. Inform any change in process parameter to Unit-in-charge, if it was not advised.
21. Follow the operating guidelines as mentioned in Unit Operating Manual. Any
deviation to be discussed and approved by PNM
22. Report the plant conditions to RSM at the end of the shift.
23. Inform to RSM and connecting upstream and downstream Units facilities, TPS &
Laboratory in case of upset or trip of Unit
24. No hydrocarbon draining/ venting is to be done unmanned STRICTLY. Only closed
draining/venting to be done in presence of concerned engineering assistant/shift
officer.
25. RSM and Unit-in-charge are to be informed immediately for any disturbance in the
plant operation without fail.
26. Any major changes in utility consumption pattern should be communicated by ‘Shift-
In-Charge’ to ‘Unit-In-Charge’ and UCR/TPS.
27. Ensure that lube-oil/chemical drums and other consumables are available in the Unit
and are stored safely.
28. If any excavation or construction activity is going on, ensure that the area is cordoned
off.
29. In case of any oil spillages inform ‘Shift-In-Charge’, RSM and Fire & Safety. Take
adequate precautions to avoid further spreading. Keep firewater/ extinguisher/ steam
hose ready. Take preventive measures depending on site condition and barricade the
area. Inform ‘Unit-In-Charge’.
30. Proper stenciling in all process lines/utilities/equipment must be done. Depending on
the criticality of the operational requirements use Tags/display boards marked with
‘DANGER’/ DON’T TOUCH/ NOT IN OPERATION/DISCONNECTED/DO NOT
OPERATE etc.
31. Follow the standard operational procedure for starting/stopping of rotary equipment,
commissioning & de-commissioning of exchangers, commissioning and de-
commissioning of utilities. In case of any confusion/operational problem/deficiencies
bring to the notice of PNM (Unit-in-charge).

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32. All emergencies/abnormalities must be handled as per guidelines given in operating

manual. Corrective/appropriate actions are to be taken in consultation with Unit-in-
charge/PNM.
33. As far as possible any leakage in utilities/process streams should be attended at the
earliest.
34. While taking round of the unit, check for any oil spillage/general leakage. No oil to
be allowed to go open channel. If oil is noticed, divert it to OWS. Locate and stop the
oil leak from the source. Special care should be taken for leakage from sample
points/drains/vents etc.
35. At CRWS/Open channel junction at each B/L always CRWS will be lined up. During
heavy rain, divert the water to open channel after checking oil lenient. Inform
RSM/WWTP.
36. Clearance to be issued for all maintenance jobs on the clearance certificate & record
the clearances issued in the Log-Book. Jobs completed by the different maintenance
agencies to be recorded in the ‘Shift-In-Charge’ log-book. In case the jobs are not
getting liquidated, bring it to the notice of ‘Unit-In-Charge’
WORK PERMIT SYSTEM
1. All maintenance jobs must have permits i.e. either hot job or cold job. No job is to be
allowed without permit from authorized person from Production Department.
2. In cold work permit all the entries must be filled properly and potential Hazards if
any should be clearly mentioned.
a) Use of any special PPE to be clearly mentioned.
b) In case if any electrical equipment requires de-energization, its de-energisation
number should be also mentioned.
c) No Blinding/deblinding operation in toxic gases (H2S), hydrocarbon vapors to
be done without wearing proper PPE.
d) All jobs have to be shown at site by the Issuing Authority.
e) HOT-WORK PERMIT
Normally hot jobs should be avoided in the operating Unit / hazardous areas
like area close to OWS & CRWS lines, etc. In case of exigencies, where such
hot jobs become extremely necessary, the following procedure is to be
followed –

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a) A multi-disciplinary team comprising of representatives from

operation, execution and Fire & Safety departments should
jointly do a “What-if- Analysis” to assess the hazards and
identify the precautionary measures to be taken.
b) These precautionary measures will be recorded in the work
permit after approval by concerned HOD of user department and
implemented without any deviation.
c) Fire permit signatory and the permittee shall be one grade higher
than approved authorities.
The following procedure should be followed for performing the gas test
before issuing Hot Work Permit/Clearances.
a) Check battery level indication every time.

b) Do fresh air calibration and check for Zero Error of the
Explosimeter/gas detector.
c) Check whether the filters are clean.
d) Check whether the pump is working or not by feeling the suction
(applicable to pump models only).
e) Check whether the probe (wherever provided) is free from any
kind of blockage or foreign matter.
f) Never put the probe inside the liquid hydrocarbon.
g) Check the instrument functioning with a light hydrocarbon
before use.
h) Record the readings of gas test in the Permit Clearance Form
ACCIDENTS/INCIDENTS/NEAR MISS
1. All near miss incidents/accidents must be brought to the notice of PNM, who after
discussions with SPNM/CPNM would take the appropriate measures. The record of
all such incidents must be recorded and properly deliberated with all the operating
staff about the possible consequences.
2. Whenever any accidents takes place Shift-in-Charge shall act as follows:
a) Report the matter to PNM/CPNM/RSM/F&S.

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b) Arrange for ambulance to transfer the injured to First Aid/ Hospital. .

c) Fill-up form A-1 for accident reporting & send one copy each to fire
station & medical & also inform on phone to fire station Shift-in-
Charge & PNM. .
d) Shift-in-Charge to make quick investigation regarding cause of the
accident and record it on the office copy of A-1 from and also in the
Shift Log Book.
e) Supervisor investigation report to be filled in by the Shift-in-Charge
concerned (in whose shift accident occurred) and submit to PNM for
further action. This report should preferably be submitted within the
same shift but not later than 48 hours of occurrence accident.
3. All incidents of fire/ accidents/incident/near miss should be reported to Fire and Safety
using the prescribed forms. Keep ‘Unit-In-Charge’ informed.
4. Online reporting of Incident/ accident/ Near miss is encouraged. Use ‘i-to-e’ to fill up
the same.
PROCEDURE & AUTHORITY FOR BYPASSING INTERLOCKS
Safety interlocks are provided to ensure a safe shutdown of equipment/plant in case any
critical process or machine variable has exceeded its safe operating value making it unsafe
to continue its operation and/or result in damage to the equipment or plant.
Endeavour should be made to keep all interlocks in line for the safety of the
equipment/plant, however, at times bypassing of interlocks is called for on account of the
following reasons:-
 Defective instrumentation.
 Preventive/breakdown maintenance.
 Change in operating practices like discontinuation of fuel oil/fuel gas firing
in certain heaters.
The following system is proposed for bypassing of interlocks and maintaining records for
the same:

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Notes:
1. Interlocks may be bypassed from bypass switches provided in DCS HWC, PLC
Console or directly from PLC. The approving authority is applicable for all
bypassing, irrespective of the location.
2. Interlock Bypass Register shall be maintained with Operations.
3. The Interlock Bypass Register shall be readily available at all times at DCS Panel of
Unit/Section.
4. In case interlock bypass is being taken due to process/operational reasons, then
approving authority shall be from operations only.
5. In case bypassing is due to maintenance requirements, then concerned
maintenance authority is required to countersign the bypass record.
6. For process interlocks prior to approval by CGM(T), the proposal has to be
countersigned by GM(TS) also.
7. When bypassing an interlock, Panel officer should clearly mention time and reason
for bypass in his log book along with alternate safety precautions to be
taken/already taken during interlock bypass period.
8. When interlock bypassing is beyond one day, the same is to be mentioned by
Unit/Section In-charge in the Instruction Book along with alternate safety
precautions to be taken/already taken during interlock bypass period.

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9. The updated status of interlock bypass shall be included in the Daily Operating
Report generated by operations.
10. The status of bypassed interlocks shall be displayed in DCS graphics for easy
awareness of the Panel Officer.
11. This procedure applies only to bypassing of interlocks for a fixed period of time. In
case of permanent changes, the Procedure/Authority for Changing of Trip Set
Points/ Modification of Interlocks is applicable.
12. This procedure supersedes the earlier procedure dated 13th November,2001 and
provides for additional authority for bypassing of interlocks with HOD and DGM.

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Paradip Refinery
CHAPTER-26
ATTACHMENTS

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Paradip Refinery
ATTACHMENTS
A) PROCESS FLOW DIAGRAMS

B) PIPING INSTRUMENT DIAGRAMS

Page 304
NOTES
DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE

SIGNATURE
DATE
REFERENCE DRAWINGS
DRAWING NO. REV TITLE
ENGINEER'S APPROVAL APPROVED FOR CONST

REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
S2 28.05.13 ISSUED FOR CONSTRUCTION PB RR PSK

S1 14.06.12 ISSUED FOR CONSTRUCTION BAS RR PSK
B1 17.01.12 ISSUED FOR DETAILED DESIGN VPK RR PSK
A2 03.10.11 ISSUED FOR DESIGN EN RR PSK
A1 11.07.11 ISSUED FOR DESIGN VPK RR PSK
H 23.03.11 ISSUED FOR HAZOP JAI RR PSK
01 26.10.10 FW COMMENTS UPDATED GNR RR PSK
00 10.09.10 FOR APPROVAL VPK MTK PSK
REV DATE DESCRIPTION BY CHKD APPD
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG LIMITED
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-001 7
PARADIP REFINERY PROJECT
Paradip, Orissa State, India
This Drawing is the Property of
INDIAN OIL CORPORATION LTD
and is lent without consideration other than the
Borrower's agreement that it shall not be
reproduced, copied lent or disposed of directly or
indirectly, nor used for any purpose other than that
for which it is specifically furnished. The apparatus
shown in the drawing is covered by patents
information contained in this drawing may be proprietary
to Indian Oil Corporation Ltd and/or licensors, and is
subject to obligations of confidentiality.
TITLE:
PIPING AND INSTRUMENTATION DIAGRAM

FOR DESALTER WATER / BRINE EQUALISATION
TANK AND PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0001 S2
CONTRACT No. CLASS DSN
451/4200 19874
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H 23.03.11 ISSUED FOR HAZOP EN RR PSK
00 10.09.10 FOR APPROVAL VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-002 7
TITLE:

FOR API & TPI SEPARATOR AND
OILY SLUDGE SUMP AND PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0002 S2
451/4200 19878
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS

S2 28.05.13 ISSUED FOR COSTRUCTION PB RR PSK

S1 14.06.12 ISSUED FOR COSTRUCTION BAS RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-003 7
TITLE:
FOR API SUMP AND PUMPS,
PRIMARY EQUALISATION TANKS AND
DAF FEED PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0003 S2
451/4200 19880
NOTE

SIGNATURE
DATE
REFERENCE DRAWINGS


H 23.03.11 ISSUED FOR HAZOP GNR RR PSK
O2 22.12.10 FW COMMENTS UPDATED JAI RR PSK
00 10.09.10 FOR APPROVAL JAI MTK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-005 8
TITLE:

FOR BIO-TOWER SYSTEM
SCALE: DWG NO: REV:

NTS PDRP0451-8110-25-230-0005 S2
451/4200 19882
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


00 10.09.10 FOR APPROVAL JAI MTK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-006 8
TITLE:

FOR AERATION TANK AND
SECONDARY CLARIFIER
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0006 S2
451/4200 19883
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


A2 03.10.11 ISSUED FOR HAZOP VPK RR PSK
A1 12.07.11 ISSUED FOR HAZOP VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME:
10P2-D0015-007 ( SH 1 OF 2) REV: 8

TITLE:

FOR BIO-DAF SYSTEM
SCALE: DWG NO: SHT NO: REV:

NTS PDRP0451-8110-25-230-0007 1 OF 2 S2
451/4200 19884
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


O2 14.01.11 FW COMMENTS UPDATED GNR RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME:
10P2-D0015-007 ( SH 2 OF 2) REV: 8

TITLE:

FOR BIO-DAF SYSTEM

NTS PDRP0451-8110-25-230-0007 2 OF 2 S2
451/4200 19884
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H 25.03.11 ISSUED FOR HAZOP VPK RR PSK
00 16.09.10 FOR REVIEW VPK MTK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-008 8
TITLE:

FOR EFFLUENT CHECK BASIN AND
TREATED TRANSFER PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0008 S2
451/4200 20338
NOTES
ST
ST
SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-009 6
TITLE:

FOR SLOP OIL SUMP ,TANK,
INTERMEDIATE DRAIN SUMP AND PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0009 S1
451/4200 20339
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


01 03.11.10 FW COMMENTS UPDATED VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-010 8
TITLE:

FOR OILY SLUDGE TREATMENT
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0010 S2
451/4200 20340
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


O1 08.11.10 FW COMMENTS UPDATED VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-011 8
TITLE:

FOR BIO-SLUDGE TREATMENT
SCALE: DWG NO: REV:

NTS PDRP0451-8110-25-230-0011 S2
451/4200 20341
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H1 03.05.11 ISSUED FOR HAZOP JAI RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-014 8
TITLE:
FOR CHEMICAL DOSING SYSTEM
- UREA , DAP & HYPO
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0014 S2
451/4200 20343
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


O0 15.11.10 FOR REVIEW VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-031 7
TITLE:

FOR CHEMICAL DOSING SYSTEM - DOPE
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0015 S2
451/4200 24340
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H 28.03.11 ISSUED FOR HAZOP VPK RR PSK
O0 15.11.10 FOR REVIEW VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-032 7
TITLE:
FOR CHEMICAL DOSING SYSTEM
- POLYMER
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-230-0016 S2
451/4200 24341
Independent DCS
indication is required
Provide drain
valve(typical)
DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECT TITLE:
TITLE:
TITLE: IOCL
IOCL PARADIP
PARADIP
IOCL EPCM-1
REFINERY
PARADIP PROJECT (PDRP)
EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN
INDIANOILOIL
CORPORATION
CORP LTDLIMITED (IOCL)
CLIENT NAME: INDIAN OIL CORP LTD
SUPPLIER NAME: VA TECH WABAG LIMITED, CHENNAI.
SUPPLIER
SUPPLIERNAME:
NAME: VAVA TECH
TECH WABAG
WABAG LTD
LTD
PROJ NO: 1-14-00-004305/399 PROJ. LOCN.: PARADIP, ORISSA STATE, INDIA
PROJECT NO: 1-14-4200/399
PROJECT PROJECT LOCATION: PARADIP,ORISSA
PROJECT
NO: 1-14-4200/399 CLIENT DOC. LOCATION: PARADIP,ORISSA
PO NO: 4200/0451 NO:
PO
PONO: 4200/451
NO:ORDER
CLIENT 4200/451
NO: CLIENT
CLIENT ORDER
ORDER NO:
NO:
TAG
REQNOS:
REQ NO:
NO:4200-4305A003
4200-4305A003
TAG
TAGNOS:
NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003 REV E1

SUPPLIER DOC. NO.: PDRP0451-8110-20-230-0001
SUPPDOCNO:
SUPPDOCNO:PDRP0451-8110-20-230-0001
PDRP0451-8110-20-230-0001
DOC. TYPE: SUPPLIER REV: 04
CLDOCNO:
CLDOCNO:
DSN: 18482 FW REV:
DOC
DOCTYPE:
TYPE:F50STATUS:
F50 SUPPLIER
SUPPLIER REV:
REV: O4
O4
SIGNED:
DSN:
DSN:18482
18482 FW
FW REV:
REV: 55
DEPARTMENT:
Status:
Status: Code 4
DATE:
Signed:
Signed:
COMMENT STATUS CODE:MohanRao Ramarao
1- REJECTED; (J1983)
2- COMMENTS AS NOTED; 3-
Dept:
MINOR COMMENTS ACCEPTABLE;
Department: 4-NO COMMENTS; 5-INFO ONLY
Engi
Date:
Date: 13/Jan/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
1-Rejected; 2-Comments
2-Comments as
as Noted;
Noted;
3-Minor
3-Minor Comments
Comments Acceptable;
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-Info Only
Only
COMPLIANCE STATEMENT
Project EFFLUENT TREATMENT PLANT & WATER RECOVERY

PLANT FOR PARADIP REFINERY, Paradip, Orissa State,
India.
Wabag Project No. 10P2M
Client INDIAN OIL CORPORATION LIMITED
Consultant FOSTER WHEELER (I) LIMITED
Contractor VA TECH WABAG LTD., CHENNAI
Drg. / Doc. Title PROCESS FLOW DIAGRAM FOR EFFLUENT
TREATMENT PLANT.
Commented drg./doc. No. PDRP0451-8110-20-230-0001 (Sheet-1 of 8) Rev: O3
Revised drg./doc. No. PDRP0451-8110-20-230-0001 (Sheet-1 of 8) Rev: O4
Sl.No. CLIENT / CONSULTANT COMMENTS VA TECH WABAG REPLY
1. Duplicated Stream Numbers. Please check Noted and removed.
Check working capacity of Wet Slop Oil sump Agreed and changed inline with ITT
2.
( 230 SU 007). ( it is 44m3 as per tender PFD) specifications.
To check Intermediate drain sump ( OWS

Noted and matched with the
3. Sump1) The volume is not matching with
calculations.
calculations.
230- P-002 (Desalter water / Brine recirculation
pump), 230-P-004A/B (Equilization tank
4. Noted and provided.
recirculation pumps) - spec calls for stand by
for all pumps.
230 TK-004- skimmer to be provided as per

5. tender PFD, other requirements specified in Noted and provided.
spec such as recirculation line to be provided.
230-SU-123 - cover is only required if VTW

need to control the flammable atmosphere
6. Noted and cover is removed.
radius. (see response to item 13 in compliance
statement).
It was an error earlier and hence it is
Reason for deletion of line from check basin to removed. Dilution line is only required
7. oily sludge thickener to be explained in the for bio-sludge thickener to maintain
comment resolution sheet. hydraulic loading rate or it will turn
septic.
Date Prepared by Checked by Approved by No. of sheets

16.12.11 SS PSK YP Page 1 of 7
Equipment data box to be consistent with
8. Checked and verified.
design calculation, data sheet and P&ID's.
DELETIONS:
1. Thermal Dilution line from check basin to Wet slop oil tank drain system is
removed and it was confirmed that separated water from slop oil tank will not
damage the underground drainage system.
COMMENTS ON COMPLIANCE SHEET
Sheet 2 of 4 - of Compliance sheet
The comment in 13. below is incorrect. The

spec states "IF the LSTK Contractor requires
the CRWS sump to be covered...." This was to
allow a large sump to be easily located in the
plot plan with the hazardous area radius
reduced by adding a cover but the spec also
As per the comment and the subsequent
alerted the LSTK to the requirement for blow-off
1. discussions the CRWS sump is kept
panels, etc. if the sump were to be covered.
open.
The preference is to avoid covering the sump if
at all possible to minimize the risks associated
with flammable atmospheres in sumps which
tend to dissipate quicker from open sumps
rather than covered sumps. The PTG
preference is to keep this sump open.

India.
TREATMENT PLANT.
Consistency with Process Design calculation to

1. be ensured. Noted and modified.
230- TK-108/208/308/408/508
230- M-101/201/301/401/501
230- TK-109/208/308/408/508
230- M-103/203/303/403/503
230- TK-110/210/310/410/510
2. Noted and modified.
230- M-101/201/301/401/501
Not matrching with calculation- Consistency to

be ensured.
3. 230-TK-003- Check Volume Noted and modified.
Data mentioned here is correct, however

230-P-126- check Capacity. ( 890 & 230 m3 as
4. the same will be updated in process
per calc).
calculations.
230 SCR-002- DLT Interlock system mentioned

5. Noted and provided.
in P&ID is not reflected.
230-TK-116/216/316/416/516. Noted and modified as per revised

6.
Check volume. (130.43 m3 as per calc.) process calculations.

India.
TREATMENT PLANT.
Mentioned tag number is inline. The

highlighted tag no. 230-SCR-006 refers
1. 230- SCR-005, 006 - check tag number
to that one in Bio-sludge supernatant
sump.
230-P-134 A/B - check head. As per material
2. balance and pump data sheet differential Noted and modified.
pressure 16 kg/cm2.
Check consistency with Process Design
3. Noted.
calculation.

India.
TREATMENT PLANT.
230-TK-125A/B check consistency with Noted and modified.

1.
Process Deisgn Calculation.
Noted and modified.
230-TK-129- check volume- 220 Litres as per
2.
calculation.
Check requirement of flow control to H2SO4

3.
dosing rate to oily DAF,
230-P-154A/B- check capacity. 100LPH as per

4. Noted and modified.
calcs.

India.
TREATMENT PLANT.
1. Note peak Hydraulic Flow at inlet of API. Noted and mentioned.

India.
TREATMENT PLANT.
Design flow during pumping at inlet of RGSF-

It is typographical error and it corrected
1. WRP. Why is the flow during pumping less than
now.
design flow?
Check pressure of Oily Sludge pump to DCU-
2. ensure consistency with pump data provided in Noted and modified.
equipment data box in Sh3/8.
*********

NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


2 11.10.10 FOR APPROVAL VPK MTK/RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-B0003-001 (SH 4 OF 8) 4
TITLE:
PROCESS FLOW DIAGRAM
FOR EFFLUENT TREATMENT PLANT
- CHEMICAL SECTION
NTS PDRP0451-8110-20-230-0001 4 0F 8 04
451/4200 18482
DOCUMENT CODING BOX
PROJECTTITLE:
PROJECT
PROJECT TITLE:
TITLE: IOCL
IOCL
IOCL PARADIP
PARADIP
PARADIP EPCM-1
EPCM-1
REFINERY PROJECT (PDRP)
CLIENT
CLIENTNAME:
CLIENT NAME:
NAME: INDIAN OILOIL
INDIAN
INDIAN CORPORATION
OIL CORP LTD
SUPPLIER
SUPPLIERNAME:
NAME:VA TECH WABAG LIMITED, CHENNAI.
VATECH
TECH WABAG
WABAG LTDLTD
SUPPLIER NAME: VA
PROJECTNO:
PROJECT NO:1-14-4200/399
1-14-4200/399 PROJECT LOCATION: PARADIP,ORISSA
PROJECT PARADIP,ORISSA
PO NO: 4200/0451 CLIENT DOC. NO:
PONO:
PO NO:ORDER
CLIENT 4200/451
4200/451
NO: CLIENT ORDER NO:
CLIENT
TAG
REQNOS:
REQ NO:4200-4305A003
NO: 4200-4305A003
TAGNOS:
TAG NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003

SUPPDOCNO:PDRP0451-8110-22-230-0001
SUPPDOCNO: PDRP0451-8110-22-230-0001
DOC. TYPE: SUPPLIER REV: O3
CLDOCNO:
CLDOCNO:
DSN: 19538 FW REV: 4
DOCTYPE:
DOC TYPE:F50STATUS:
F50 SUPPLIER REV: O3
SUPPLIER
SIGNED:
DSN:19538
DSN: 19538 FW REV:
FW REV: 4
DEPARTMENT:
Status: Code 4
Status:
DATE:
Signed:
Signed:
Dept:
Engi
Date: 14/Feb/2012
Date:
COMMENTSTATUS
COMMENT STATUS CODE:
CODE: 1-Rejected;
1-Rejected; 2-Comments as Noted;
3-MinorComments
3-Minor Comments Acceptable;
Acceptable; 4-No
4-No Comments; 5-Info Only
An ISO 9001 Company
VA TECH WABAG LTD
COMPLIANCE TO COMMENTS
Project : IOCL PARADIP REFINERY PROJECT
Project no. : 10P2
Client : INDIAN OIL CORPORATION LIMITED
Consultant : M/s FOSTER WHEELER
Title : DESIGN PRESSURE AND TEMPERATURE DIAGRAM FOR
EFFLUENT TREATMENT PLANT – OILY TREATMENT SECTION
Revised VA Tech Doc No : 10P2-B0002-010 Rev: 3
Revised Client Doc No : PDRP0451-8110-22-230-0001 Rev: 3
Sl. VA TECH WABAG CLARIFICATION /

CLIENT / CONSULTANT COMMENTS
No COMPLIANCE
Check the conditions. It will be IBR line at these conditions –
1. It will be IBR throughout the entire plant.
Comment made on inlet LP steam line at the B/L.
Is it PSV or PVRV? Check and correct the symbol. Indicate
It is PVRV and symbol is corrected
2. vacuum set pressure also. (typical-applicable to all PVRV on
wherever applicalble.
all storage tanks)
3. Please ensure consistency with IMDB. Noted and confirmed.
Updated inline with the approved

4. Appears to be mismatch with data sheet. Please check.
datasheets.
Noted and corrected. Rupture disc is
Is it rupture disc or PSV? Correct the Symbol. (Typical for
5. provided at the discharge of all sludge
all Sludge pumps)
pumps.
In all applicable cases design pressure
6. pls check design pressure. Shall reflect pump shut off. is equal to the shut off pressure of
pumps only.
GENERAL COMMENT APPLIABLE FOR ALL DPDT’s
Applicable to all DPTDs - Basis of Rupture Disc/ pressure
relief valve set pressure for helical screw pumps is not clear.
For positive displacement pumps, the Rupture Disc/ PRV set
pressure shall be 10% of rated discharge pressure or 1.7
1.
kg/cm2g, whichever is higher, over and above the discharge
Noted and corrected.
pressure. The set pressure shall be consistent with line design
pressure (design pressure >= Set Pressure).
Relief discharge routing to be shown back to the appropriate

destination
02.02.12 SS RR PSK
DATE PREP.BY CHED.BY APPD.BY
DOCUMENT CODING BOX
PROJECTTITLE:
PROJECT TITLE: IOCL
IOCL PARADIP
PARADIP EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN OIL OIL
INDIAN CORPORATION
SUPPLIER
SUPPLIERNAME:
NAME: VAVA
TECH WABAG
TECH LIMITED,
WABAG LTDCHENNAI.
PROJECT NO: 1-14-4200/399 PROJECT LOCATION: PARADIP,ORISSA
PO NO:ORDER
CLIENT 4200/451
TAG
REQNOS:
NO: 4200-4305A003
TAG NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003

SUPPDOCNO: PDRP0451-8110-22-230-0002
CLDOCNO:
DOC TYPE: F50STATUS: SUPPLIER REV: O3
DSN: 19539 SIGNED: FW REV: 4
DEPARTMENT:
Status: Code 4
DATE:
COMMENT STATUS
Signed: MohanRao Ramarao (J1983)
Signed:
CODE: 1- REJECTED; 2- COMMENTS AS NOTED; 3-
Department:
Dept:
MINOR COMMENTS Engi
ACCEPTABLE; 4-NO COMMENTS; 5-INFO ONLY
Date: 14/Feb/2012
COMMENT STATUS CODE: 1-Rejected; 2-Comments as Noted;
3-Minor Comments Acceptable; 4-No Comments; 5-Info Only
An ISO 9001 Company
VA TECH WABAG LTD
Project no. : 10P2
EFFLUENT TREATMENT PLANT – BIOLOGICAL TREATMENT
SECTION

No COMPLIANCE
1.
kg/cm2g, whichever is higher, over and above the discharge

destination
VA Tech to update the document considering the impact
2. of comments on all relevant documents and discussions. Noted.
Ensure consistency with other documents/ calculations.
Please check comment on HFD for this system and

3. accordingly estimate the operating and design Noted and corrected.
pressures.
Engineering for all stages is in VA Tech's scope. The

document shall cover/ address requirements of all
4. Noted.
stages including constructibility, scope/interface between
stages.
Please read the specifications/addendum and
5. incorporate all the requirements/ comments before Noted.
resubmission
02.02.12 SS RR PSK
DOCUMENT CODING BOX
PROJECTTITLE:
PROJECT TITLE: IOCL
IOCL PARADIP
PARADIP EPCM-1
EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN OIL OIL
INDIAN CORPORATION
LTDLIMITED (IOCL)
CORP LTD
SUPPLIER
SUPPLIERNAME: VA TECH WABAG LIMITED, CHENNAI.
WABAG LTD
LTD
NAME: VA TECH WABAG
PROJECT NO: 1-14-4200/399 PROJECT LOCATION:
PROJECT LOCATION: PARADIP,ORISSA
PARADIP,ORISSA
PO NO:ORDER
CLIENT 4200/451
NO: CLIENT ORDER
CLIENT ORDER NO:
NO:
TAG
REQNOS:
NO: 4200-4305A003
TAG NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003

SUPPDOCNO: PDRP0451-8110-22-230-0003
PDRP0451-8110-22-230-0003
CLDOCNO:
DOC TYPE: F50 STATUS: SUPPLIER
SUPPLIER REV:REV: O3
O3
SIGNED: FW
DSN: 19540 FW REV:
REV: 44
DEPARTMENT:
Status: Code 4
DATE:
Signed:
Signed:
Dept:
Engi
Date:
Date: 14/Feb/2012
COMMENT STATUS
CODE: 1-Rejected;
2-Comments as
as Noted;
Noted;
An ISO 9001 Company
VA TECH WABAG LTD
Project no. : 10P2
EFFLUENT TREATMENT PLANT – SLUDGE TREATMENT
SECTION

No COMPLIANCE
GENERAL NOTE APPLICALBE TO ALL DPDT’s

1. kg/cm2g, whichever is higher, over and above the discharge

destination
Add all relevant notes from other DPDTs (such as note Noted and incorporated wherever
2.
related to steam out) required.
02.02.12 SS RR PSK
DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECT TITLE:
TITLE:
TITLE: IOCL
IOCLIOCL PARADIP
PARADIP
PARADIP EPCM-1
EPCM-1
CLIENT
CLIENTNAME:
CLIENT NAME:
NAME: INDIAN
INDIANOIL OIL
INDIAN CORPORATION
OIL CORP
CORP LTD LIMITED (IOCL)
LTD
SUPPLIER
SUPPLIER NAME:
NAME: VAVA TECH
TECH WABAG
WABAG LTD
LTD
PROJECT
PROJECT NO:
NO: 1-14-4200/399 PROJECT
PROJECT
1-14-4200/399CLIENT DOC. LOCATION:
LOCATION: PARADIP,ORISSA
PARADIP,ORISSA
PO NO: 4200/0451 NO:
PO
PO NO: 4200/451
NO:ORDER
CLIENT 4200/451
NO: CLIENT
CLIENT ORDER
ORDER NO:
NO:
TAG
REQNOS:
REQ NO:
NO: 4200-4305A003
4200-4305A003
TAG
TAG NOS:
NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003

SUPPDOCNO:
SUPPDOCNO: PDRP0451-8110-22-230-0004
PDRP0451-8110-22-230-0004
CLDOCNO:
CLDOCNO:
DOC
DOC TYPE:
TYPE: F50STATUS:
F50 SUPPLIER
SUPPLIER REV:
REV: O3
O3
SIGNED:
DSN:
DSN: 19741
19741 FW
FW REV:
REV: 44
DEPARTMENT:
Status:
Status: Code 4
DATE:
Signed:
Signed:
Dept:
Engi
Date:
Date: 14/Feb/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-Comments as
as Noted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-Info Only
Only
NOTES
LEGEND

SIGNATURE
DATE
REFERENCE DRAWINGS


1 15.10.10 FW COMMENTS UPDATED JAI RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-B0002-013 3
TITLE:
DESIGN PRESSURE AND TEMPERATURE
DIAGRAM FOR EFFLUENT TREATMENT PLANT
CHEMICAL SECTION
NTS PDRP0451-8110-22-230-0004 O3
451/4200 19741
DOCUMENT CODING BOX
PROJECT TITLE: IOCL PARADIP EPCM-1
PROJECT
PROJECTTITLE:
TITLE:IOCL PARADIP
IOCL REFINERY
EPCM-1
CLIENT NAME:
CLIENT
INDIAN OIL CORP LTDLIMITED (IOCL)
CLIENTNAME:
NAME:INDIAN
INDIANOIL OIL
CORPORATION
CORP LTD
SUPPLIER
SUPPLIER NAME:
NAME: VA VA TECH
TECH WABAG
WABAG LTD
LIMITED, CHENNAI.
SUPPLIER NAME: VA TECH WABAG LTD
PROJ NO: 1-14-00-004305/399
PROJECT NO: 1-14-4200/399PROJ. LOCN.: PARADIP,
PROJECT ORISSA STATE,
LOCATION: INDIA
PARADIP,ORISSA
PO NO: 4200/451 CLIENT ORDER NO:
PO NO: 4200/451
CLIENT ORDER NO: CLIENT ORDER NO:
REQ NO: 4200-4305A003
TAG
REQNOS:
NO: 4200-4305A003
TAG NOS:
TAG NOS:
REQ. NO.: PDRP4240-8820-SC-4305-003

SUPPLIER DOC. PDRP0451-8110-22-230-0005
SUPPDOCNO:
SUPPDOCNO: NO.:
PDRP0451-8110-22-230-0005
PDRP0451-8110-22-230-0005
DOC. TYPE:
CLDOCNO: SUPPLIER REV: 0
CLDOCNO:
DSN: FW REV:
DOC TYPE: F50
DOC TYPE: F50STATUS: SUPPLIERREV:
SUPPLIER REV:OO
DSN: 41553
DSN: 41553 SIGNED: FWREV:
FW REV:11
DEPARTMENT:
Status: Code 4
Status:
DATE:
Signed:
COMMENT STATUS CODE: 1- REJECTED; 2- COMMENTS AS NOTED; 3-
Department:
Dept:
MINOR COMMENTS Engi
Date:
Date: 01/Dec/2011
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-CommentsasasNoted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-NoComments;
Comments; 5-Info
5-InfoOnly
Only
VA TECH WABAG
No. 11 Murray's Gate Road, Alwarpet
Chennai 600 018 India
CLIENT : Indian Oil Corporation Limited, Paradip Refinery
CONSULTANT : Foster Wheeler
PROJECT : 10P2M - IOCL Paradip Refinery Project
PLANT : Effluent Treatment Plant and Water Recovery Plant
DOCUMENT TITLE:
DESIGN PRESSURE AND TEMPERATURE DIAGRAM FOR

VOC ABATEMENT PACKAGE
CLIENT DOC. NO. : PDRP0451-8110-22-230-0005 REV. : O

VA TECH DOC. NO. : 10P2-B0002-023 REV. : 0
STAMPING AREA
0 21.10.2011 Submitted for Review and Approval VNU PSK PSK

Rev No Date Description Prepared Checked Approved
Discipline : PROCESS
Total No of Sheets : 3 (Including cover sheet)

NOTES
LEGEND

SIGNATURE
DATE
REFERENCE DRAWINGS

0 21.10.11 FOR REVIEW & SUBMISSION VNU PSK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-B0002-023 (Sheet- 1OF2) 0
TITLE:
FOR VOC ABATEMENT PACKAGE

NTS PDRP0451-8110-22-230-0005 1 OF 2 O
451/4200
NOTES
LEGEND

SIGNATURE
DATE
REFERENCE DRAWINGS

INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-B0002-023 (Sheet- 2OF2) 0
TITLE:
DESIGN PRESSURE AND
TEMPERATURE DIAGRAM

NTS PDRP0451-8110-22-230-0005 2 OF 2 O
451/4200
PARADIP REFINERY
STANDARD OPERATING PROCEDURES (SOPs)

EFFLUENT TREATMENT PLANT , SCTP & WRP UNITS
Standard
operating
procedure
(effluent treatment plant)
1 Prepared By Reviewed By Approved By
T Bhattacharjee, SPNM Bharat Bhushan, CPNM S Mahajan, DGM-PN

PARADIP REFINERY

INTRODUCTION
15 MMTPA Paradip Refinery has put up a Waste Water Treatment Plant comprising of
Effluent Treatment Plant(ETP-U230) (Design Capacity-1034m3/hr), Spent Caustic
Treatment Plant (SCTP-U231) (Design Capacity-10.4 m3/hr ) & Water Recovery Plant (WRP-
U235)(including UF& RO sections ) as Design Capacity of 1640m3/hr.
Today’s equipments in a refinery has become complex with advancement of technology.

The operation of these complex equipments in a safe manner requires a well laid operating
procedure to be followed day in day out.
Standard Operating procedures lay down the sequence of activities to be performed or the
step-by step tasks to be done in order to complete a desired job. Hence, Standard operating
Procedures for day to day job are developed for better operation of the unit, to improve
reliability and safety of working personnel and equipments.
Standard Operating procedures (SOPs) incorporate the guidelines which have been
standardized by industry practices and are proven reliable and safe for equipments and
personnel alike. Hence, SOPs are to be adhered to and deviations are to be minimized.
These Standard Operating Procedures have been prepared with inputs from operating
manuals, Licensors/OEMs guideline & recommendations and operating experience of
operating personnel, staff and officers. Standard Operating Procedures will be revised every
two years.

PARADIP REFINERY

SL No Contents Page No
1 Procedure for start-up / Normal operation of API /TPI Separators 4
2 Procedure for start-up / Normal operation of Desalter tank / Pumps 6
3 Procedure for start-up / Normal operation of Oily DAF mechanism 7
4 Procedure for start-up / Normal operation of Bio-tower 8
5 Normal operation of Aeration tank/ Secondary Clarifier 9
6 Procedure for start-up / Normal operation of Bio DAF mechanism 10
7 Procedure for Effluent Check Basin/Treated Transfer Pumps Normal 11

Operation
8 Procedure for Slop tanks Operation / Handling 12
9 Procedure for Oily/Bio Sludge handling / Centrifuge operation 14
10 Sulphuric Acid unloading procedure 16
11 Sulphuric Acid dosing procedure 17
12 Change over procedure for pumps 18
13 Handing over procedure for pumps 19
14 Taking over procedure for pumps 20
15 Handing over procedure for SCTP Oxidation Reactor 22
16 Procedure for Change over exchanger’s 231-E-101A/B (PLATE TYPE) 23
17 Routine start up compressor (231-KA -101A/B) 24
18 Routine stopping of Compressor (231-KA -101A/B) 24
19 Procedure for start-up / Normal operation of RGSF filters 25
20 Procedure for start-up / Normal operation of UF System 27
21 Procedure for start-up / Normal operation of RO System 28
22 Decantation of off-spec tanker truck at slop oil tank through (230-P- 29

112A/B)
23 PAC batch preparation 31
24 Emergency SOPs 33

PARADIP REFINERY

Procedure for start-up / Normal operation of API /TPI Separators
Sl.No FPR
Activity
1 Get the instruction from SIC & panel operator SIC,PO,FO
2 Open the inlet gate of API channel. (230-TK-105/205/305). FO
3 Check all level transmitters, flow transmitters and gauges are in operation. PO,FO
4 Ensure the level in the API Sump (230-TK-004) is low, and the level
PO,FO
transmitters and the API OWS pumps (230-P-106A/B/C) are ready.
5 Ensure the sludge drain valves in the TPI separator tank are ready for SIC,FO
operation and are closed.
6 Start the Desalter water/Brine pumps (230-P-001A/B SIC,FO
7 The effluent from the desalter water/brine equalization pump is received in SIC,FO
the splitter box along with other effluents from the battery limit.
8 Observe the level in the API feed channel (LT 1003) and the flow rate in Flow SIC,FO
transmitter indicator (FT 1002).
9 Bring on line sufficient no.s of API’s according to the desired flow rate. SIC,FO
10 After gradual filling of the API tank, start the mechanism manually (230-A- SIC,FO
002A/B/C). No AUTO operation is envisaged for API.
11 Observe for smoothness of the API chain scrapper mechanism, noise etc. SIC,FO
12 De-oiling operations through slotted skimmer pipes to be carried out 2-3 SIC,FO
times manually in a shift of 8 hours.
13 In case of high oil inlet and de-oiling operation is made continuous, ensure a SIC,FO
min. oil layer of 5-10 mm in the API and skim oil accordingly. This is must to
avoid effluent entry to slop oil system (keep water / effluent content in slop
oil to minimum for steam optimization in wet slop oil tank).
14 Before commencing the de-oiling operations, ensure the levels in the Wet SIC,FO
slop oil sump (230-SU-007) is low and the Wet slop oil transfer pumps (230-
P-012A/B) are ready for operation.
15 Drain sludge by opening the drain valve minimum once a shift for a few SIC,FO
minutes. Adjust drain depending on incoming solids load to plant. Ensure
the sludge level in common oily sludge sump (230-SU-010) is minimum to
avoid any overflow.
16 Before commencing the desludging operation ensure the readiness of the SIC,FO
Common oily sludge sump (230-SU-010) and the common oily sludge sump
agitator (230-M-10), oil skimmer in Common oily sludge sump (230-OS-002)
and common sludge transfer pumps (230-P-033A/B/C).
17 Start steam sparging if oil solidification is seen. Optimize steam SIC,FO
consumption for good operation. This will be essential during winter
conditions.
TPI Separator
18 Ensure the effluent after filling up the API tank will start to overflow into the SIC,FO
TPI tank (230-TK-105/205/305).
19 Ensure the flow to the each bay of the TPI Separator is uniform for its SIC,FO
effectiveness.
20 The floating oil to be skimmed and the sludge is drained at regular intervals. SIC,FO

PARADIP REFINERY

(Minimum once per shift). The timing and frequency of sludge drain valve
shall be set as desired. Ensure the sludge level in common oily sludge sump
is minimum to avoid any overflow.
21 Start steam sparging/heating if oil solidification is seen. Optimize steam SIC,FO
consumption for good operation. This will be essential during winter
conditions.

PARADIP REFINERY

Procedure for start up / Normal operation of Desalter tank / Pumps

operation
Sl.No FPR
Activity
2 Ensure all the drain valves in the desalter tanks are closed. FO
3 Close the influent Desalter water bypass valve to Splitter box-I. PO,FO
4 Open the valve in the desalter water influent line to desalter water/brine
PO,FO
tank (230-TK-001)
5 While in the filling condition, ensure the level transmitter indicator (LI 1001) SIC,FO
is indicating the increase in level.
6 Open the suction valves of the Desalter water/Brine pumps (230-P-001A/B).
SIC,PO,FO
Switch the mode of the pumps to REMOTE.
7 The Brine pumps are started /stopped automatically after start permissive
FO
condition in Desalter water/Brine equalization tank.
8 Open the respective working pump’s discharge valve and set the desired
pressure of pump discharge by throttling the discharge valve very gently by PO,FO
observing the pressure gauge.
9 Now, Set the desired flowrate to be pumped in the VFD/PID controller
PO,FO
available in DCS HMI.
10 The pumps are to be checked for its vibration, seal leakages, noise and other
SIC,PO,FO
parameters locally.
11 Open the outlet valve of floating oil skimmer (230-OS-001), or any of the oil
outlet valves periodically to discharge any floating oil in the tank. This
FO
operation is manual and the frequency is decided based on the actual site
conditions, and influent characteristics.
12 Operate the desalter water/brine recirculation pump (230-P-002A/B)
intermittently or when the effluent in the desalter water/brine equalization
SIC,PO,FO
tank is stagnant for significantly longer periods of time. The operation is
similar to that as described for the Brine/Desalter water pumps.
13 Changeover working/standby pumps every 24 hours. FO

PARADIP REFINERY

Procedure for start up / Normal operation of Oily DAF mechanism
Sl.No FPR
Activity
1 Before start up of the Oily DAF system, ensure the readiness of the Chemical
SIC,PO,FO
dosing system
2 Allow effluent from FT to DAF as the level builds up overflow will start and
adjust the flow rate as required no.s of flash mixing tanks are to be taken FO
online and adjust the isolation stop logs accordingly
3 As the flash mixing tanks and flocculation tanks are filled in gradually, start
PO,FO
the Flash mixer (230-M-201) and Flocculator (230-M-203).
4 Open the valve in the FeCl3 dosing line PO,FO
5 Observe the pH in the pH analysers (AE1001A and AE1001B) and dose H2SO4 SIC,FO
6 Start dosing DOPE in the flocculation tanks SIC,FO
7 Get instruction from SIC & panel operator for start up SIC,FO
8 DAF Start up Sequence SIC,FO
Close all the drain valves , isolation valve for pressurised distribution
header, air flow regulating valve and air flow by pass valve
Open LT & LG isolation valves, shutoff valve of air bleed line, upstream/
downstream FT valves and discharge of compressor outlet line
9 Each pump discharge flow should be 120m3/hr for perfect saturation of SIC,FO
each DAF. Recycle ratio should be 35%
10 Allow saturation vessel to be filled with effluent, operate outlet valve of SIC,FO
saturation vessel to maintain pump pressure
11 Each pump discharge pressure should be 4.5-5.5kg/cm2 SIC,PO,FO
12 Start air compressor (230-K-001A/B) and adjust air flow to be 4.5 to 6.5
FO
kg/cm2
13 Inlet air pressure for each saturation vessel should be 5.5 -6.0 kg/cm2 PO,FO
14 Check the fine air bubbles are released in DAF surface PO,FO
15 Open sludge valve to remove the settled sludge once a shift or as per SIC,FO
requirement
16 Maintained all parameter & checked data logged in logbook. SIC,FO

PARADIP REFINERY

Procedure for start up / Normal operation of Biotower
Sl.No FPR
Activity
2 Check the Effluent from the DAF tank shall be collected in the
FO
Biotower/Aeration tank feed sump (230-TK-003).
3 Start dosing Urea/DAP solution in the Biotower/Aeration feed tanks PO,FO
4 Ensure and observe and record the Oil level and pH readings in the
PO,FO
analyser and start dosing the H2SO4
5 Check the complete plastic media quantity is filled uniformly in the SIC,FO
bio tower
6 Check all the nozzles of distribution arm are properly installed SIC,FO
7 Ensure free movement of distribution arm by moving it manually SIC,FO
8 Ensure oil & grease < 20 ppm, sulphide <5 ppm SIC,FO
9 Ensure the distribution arm is moving by hydrostatic pressure SIC,FO
10 Check the rotation of arm & uniform distribution of waste water over SIC,FO
filter media regularly
11 Routine checked data to be logged in logbook for each shift SIC,PO,FO

PARADIP REFINERY

Normal operation of Aeration tank/ Secondary Clarifier

Sl.No FPR
Activity
1 Get the instruction from SIC & panel operator for taking over the Aerators SIC,PO,FO
2 Open the gates feeding the Aeration tanks FO
3 Ensure that all the diffusers are checked prior to start up and that the air
PO,FO
distribution is uniform
4 Start the Aeration tank feed pumps (230-P-127A/B/C) and gradually fill the
PO,FO
Aeration tank.
5 Start 2 nos. aeration tank air blowers (230-K-102 A/B/C, 230-K-202 A/B/C) SIC,FO
each of 2050 Nm3/h when the liquid level in the aeration tank is around 0.5
M above Fine bubble fixed type Membrane Tube Diffusers.
6 Once the tank level is around 3.0 m deep start the other two air blowers SIC,FO
7 Ensure Air Blowers are running, without any unusual noise SIC,FO
8 Ensure Dissolved oxygen level of 1.5 – 2.0 mg/l in the Aeration tank and SIC,FO
operate the Blowers accordingly.
9 Regular analysis of aeration tank content for maintain of MLSS (2000- SIC,FO
2500mg/l), MLVSS and SVI as per the sampling schedule
10 Open the outlet sluice gate in the Aeration tank to allow the Mixed liquor to SIC,FO
flow to the secondary clarifier
11 Check regularly for overheating & unusual noise of blowers SIC,PO,FO
12 Adjust recirculation depending on MLSS requirement FO
13 Nutrients are dosed regularly or as per requirement PO,FO
14 If MLSS grows beyond 5500mg/l then waste more amount of sludge PO,FO
15 If MLSS drops below 2000mg/l then increase the nutrients dosing or SIC,FO
increase the rate of circulation
Once the Mixed liquor from the aeration tank is received in the Secondary SIC,FO
17 clarifier, start the mechanism
18 Check the scrapper of secondary clarifier for proper functioning and ensure SIC,FO
smoothness of running
19 Ensure clarified effluent starts overflowing in the outer launder of the SIC,FO
clarifier and is feed to Bio DAF section
Ensure the levels in the RAS sump (230-SU-104) are low to avoid any SIC,FO
20 overflows
21 Routine checked data to be logged in logbook for each shift SIC,FO

PARADIP REFINERY

Procedure for start up / Normal operation of Bio DAF mechanism
Sl.No FPR
Activity
1 Before start up of the Bio DAF system, ensure the readiness of the Chemical
SIC,PO,FO
dosing system
2 Allow effluent from FT to DAF as the level builds up overflow will start and
adjust the flow rate as required no.s of flash mixing tanks are to be taken online FO
and adjust the isolation stop logs accordingly
3 As the flash mixing tanks and flocculation tanks are filled in gradually, start the
PO,FO
Flash mixer and Flocculator
4 Ensure to open the valve in the FeCl3 dosing line PO,FO
6 Ensure to start dosing poly in the flocculation tanks SIC,FO
7 Get the instruction from SIC & panel operator for start up. SIC,FO
8 Bio DAF Start up Sequence SIC,FO
Close all the drain valves , isolation valve for pressurised distribution
header, air flow regulating valve and air flow by pass valve
Open LT & LG isolation valves, shutoff valve of air bleed line, upstream/
downstream FT valves and discharge of compressor outlet line
9 Each pump discharge flow should be 120m3/hr for perfect saturation of SIC,FO
each DAF. Recycle ratio should be 35%
10 Allow saturation vessel to be filled with effluent, operate outlet valve of SIC,FO
saturation vessel to maintain pump pressure
11 Each pump discharge pressure should be 4.5-5.5 kg/cm2 SIC,FO
12 Start air compressor and adjust air flow to be 4.5 to 6.5 kg/cm2
13 Inlet air pressure for each saturation vessel should be 5.5 -6.0 kg/cm2
14 Check the fine air bubbles are released in DAF surface SIC,PO,FO
15 Open sludge valve to remove the settled sludge once a shift or as per
FO
requirement
16 Maintained all parameter & checked data logged in logbook. PO,FO

PARADIP REFINERY

Procedure for Effluent Check Basin/Treated Transfer Pumps Normal

Operation
Sl.No FPR
Activity
2 Check the biologically treated effluent from the Bio-DAF system is collected in
FO
the Effluent Check basin (230-SU-101)
3 Ensure all the delivery valves are in open condition for the OFF SPEC/EXCESS
EFFLUENT Transfer pumps/Treated effluent transfer pumps are started PO,FO
automatically
4 Ensure for changeover working/standby pumps every 24 hours PO,FO
5 Treated effluent transfer pumps (230-P-022A/B/C), to Water Recovery Plant SIC,FO
and is recorded with the flow transmitter (FT-2010)
6 Ensure no oil film is present and floating oil skimmers are operated SIC,FO
periodically

PARADIP REFINERY

Procedure for Slop tanks Operation / Handling

Sl.No FPR
Activity
2 Isolate receiving / inlet line. FO
3 Gravitate the product in another empty tank. PO,FO
4 Isolate steam coils & put the blinds. PO,FO
5 Keep the tank in pumping to OM&S, pump out the tank up to lowest level. SIC,FO
6 Drain the product from bottom drain line in drain pit and take out by gully SIC,FO
sucker. Oily sludge to be put in oily sludge sump. It should be drained till no
material comes out from the drain line.
7 Take the dip of the tank and measure the dip of the sludge in tank SIC,FO
8 If the level of sludge is lower than manhole height then open all the SIC,FO
manhole covers & skylight covers after putting the blinds in inlet & outlet
lines, the tank should have positive isolation.
9 Ensure that the tank is positively isolated. SIC,FO
10 Take out oily product from the tank by gully sucker & put it oily sludge sump. SIC,FO
11 Keep the tank for 2- 3 days for natural ventilation. SIC,PO,FO
12 Keep flameproof fan near manhole cover to remove vapours from the tank. FO
13 Check the HC vapours & oxygen level in the tank by explosive meter. PO,FO
14 Hand over the tank for cleaning if the tank does not have HC vapours &
PO,FO
oxygen level is sufficient.
15 Take out all the sludge and put it in the melting pit for oil removal. SIC,FO
16 After removal of all the sludge , clean it thoroughly SIC,FO
17 After complete cleaning, fill the water in tank up to SFH. SIC,FO
18 Drain the water at slow rate in OWS & check the water quality & oil level. SIC,FO
Again fill the water in tank & drain it, it should be repeated till drained water
is normal.
19 Check the tank from inside by explosive meter for any hydrocarbon/ oxygen SIC,FO
level
20 Ensure the steam heating is continuous. This ensures efficient oil water SIC,FO
interface in the tank.
21 Once the tank is filled to more than a half & as a result of phase separation
in the tank, the excess water is to be periodically drained off by in the SIC,PO,FO
Intermediate drain sump (230-SU-118)
22 Once the level reaches the maximum in the Slop oil tank, start feeding the
wet slop oil to the alternate tank. The selection can be made by the operator FO
in the DCS HMI
23 Select the Slop oil tank for the DRAW mode as operated from the DCS HMI.
Open the pneumatic valve in the outlet line of the slop oil tank. PO,FO
24 The dry slop oil pumps (230-P-011A/B) are stopped / started automatically
w.r.t. dry slop level in slop oil tanks (230-TK-010/011). Ensure all the suction PO,FO
and delivery valve are in open condition.

PARADIP REFINERY

25 The dry slop oil is to be transferred to OSBL for further slop oil processing by SIC,FO
client.

PARADIP REFINERY

Procedure for Oily/Bio Sludge handling / Centrifuge operation

Sl.No FPR
Activity
2 Ensure oily sludge collected in the common oily sludge sump and DAF
FO
sludge sump, is to be thickened in the Oily sludge Thickener (230-TK-121).
3 Ensure all the suction and delivery valve of the common oily sludge
PO,FO
transfer pumps / DAF sludge pumps are in open condition.
4 Check the scrapper of oily sludge thickener for proper functioning and
PO,FO
ensure smoothness of running
5 Allow the thickener is filled up, the supernatant starts overflowing in the SIC,FO
outer launder of the thickener and is conveyed to the Oily supernatant
sump (230-SU-011) by gravity
6 After reaching the maximum level in the tank, allow the sludge to be SIC,FO
pumped to Oily sludge centrifuges (230-DEW-301/401)
7 Ensure the readiness of oily centrifuge feed Pumps and DWPE dosing SIC,FO
system and the 0.5% DWPE solution is prepared and kept ready for dosing,
before preparing for the dewatering operation.
8 Start the Belt Conveyor (230-CR-001A/B) for carrying the Dewatering cake SIC,FO
into Tipper trolley
9 Start the Centrifuge (230-DEW-401/301) prior to start of the centrifuge SIC,FO
feed pumps for the centrifuge to reach the desired speed.
10 Start the Oily centrifuge feed pump (230-P-132A/B/C). SIC,FO
11 The centrifuge and feed pumps are to be checked for any vibration and
other parameters for the smooth operation of the pump.
12 After the desired time of operation of the centrifuges, the oily centrifuge
feed pumps are stopped first followed by centrifuge.
13 Always run the centrifuges for a short while with water before shut down.
14 Arrange to cart away the dewatered cake from the area, so that the next
batch of operation can be started
15 After reaching the maximum level in the tank, the sludge shall be pumped
to DCU
16 Check for completion certificate from maintenance
17 Check alignment along with process and mechanical maintenance.
18 Start drive motor & allow centrifuge to run at full speed, this will take
around 40 -50 seconds after getting clearance from panel.
19 Run centrifuge by introducing service water through flushing fine at the
pipe & check tightness of effluent chute. Then stop the water.
20 Operate the sludge chute gates either for sludge discharge to trolley or the
sludge storage area

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21 Turn on thickened sludge pump to feed thickened sludge into centrifuge

for dewatering
22 Start dewatering polyelectrolyte dosing pump to add DWPE solution in
centrifuge based on jar test.
23 Ensure dosing of 1 to 1.5 kg poly per ton of dry basis. Fine tuning of poly
dose will be done during plant trial.
24 Route cent rate from effluent chute to surge sump via process drain
system & dispose off solid cake from solid chute.
25 Always flush the machine after stopping the thickened sludge feed &
dewatering poly.
26 Flushing should be done for at least 10-15 minutes & then centrifuge
should be stopped.
27 Routine checked data to be logged in logbook for each shift

PARADIP REFINERY

CHEMICAL HANDLING PROCEDURE
Sulphuric Acid unloading procedure:
Sl.No FPR
Activity
1 Check the documents and take reading before start unloading SIC,PO,FO
2 Take sample of Acid & sent to lab for testing. Always wear PPEs. FO
3 Take the lab result and compare supplier quality report. PO,FO
4 Connect the hose to unloading line flange tanker & secure it with
PO,FO
clamps. Check any leak.
5 Open the tanker outlet valve. Wear PPE SIC,FO
6 Gradually open the suction valve of acid unloading pump & release the SIC,FO
trapped air through vent valve.
7 As soon as air stops coming from vent, close the vent valve. SIC,FO
8 Start the acid unloading pump from local push button. SIC,FO
9 Check the discharge pressure & gradually open the discharge valve. SIC,FO
10 As soon as the pump pressure comes down check the tanker level SIC,FO
physically.
11 Stop the pump after emptying out of the tanker or achieved required FO
level in tank.

PARADIP REFINERY

Sulphuric Acid dosing procedure:
Sl.No FPR
Activity
1 Line up acid dosing system SIC,FO
2 Start dosing pump if everything normal FO
3 Check & observe for any leakage in acid dosing system. FO
4 Check the decreasing rate of tank dip. FO,PO
5 Maintain the required dosing rate. FO
6 In case of leakage use appropriate PPE FO
while isolating the valves.
7 Always keep portable gas detector in any condition with you. FO

PARADIP REFINERY

Change over procedure for pumps:
Sl.No FPR
Activity
1 Following tasks to be performed on the pump to be started.
2 Drain water from the pump casing drain if any which may cause a process
SIC,PO,FO
upset.
3 Check lube oil quality & lube oil in lube oil cup / bearing. If required, top-up FO
4 Check the shaft movement &ensure that it is free. PO,FO
5 Check coupling / coupling guard. PO,FO
6 Check / adjust / commission bearing CW system if any SIC,FO
7 Check CW flow to seal/bearing house. SIC,FO
8 Adjust quenching steam/water to seal if any SIC,FO
9 Inform panel regarding changeover of pump. SIC,FO
10 Slightly open the discharge valve SIC,FO
11 Switch on the motor and wait till it attains the full RPM. SIC,FO
12 Gradually open discharge valve FO
13 Check Amp (Load). If the Amperage increased, gradually close the discharge
valve of former (Running) pump. Repeat this operation till the pump attains FO
a full load.
14 Check the discharge pressure. Bleed if necessary to avoid vapour locking PO,FO
15 Open the discharge valve slowly. Keep watch on the current drawn by the
motor, if ammeter is provided. In other cases check load at Substation PO,FO
Flow to be monitored from panel
16 Following tasks to be performed on the pump to be stopped. SIC,FO
17 Once started pump takes normal toad, start pinching the discharge valve of SIC,FO
the pump to be stopped in coordination with panel operator.
18 Close discharge valve of the pump to be stopped SIC,FO
19 Confirm the flow with panel operator and then stop the pump. SIC,FO
20 Check for any abnormality such as Vibration/ abnormal sound / abnormal SIC,FO
temperature etc. Report to shift in-charge.

PARADIP REFINERY

Handing over procedure for pumps:
Sl.No FPR
Activity
1 Inform panel operator about the change over so that associated
SIC,PO,FO
interlock can be bypassed
2 Lock the stop button of pump to be handed over.
FO
3 De-energize the motor and confirm power cut off locally by pressing the
start button of pump to be handed over. PO,FO
4 Close the discharge block/suction block valve

PO,FO
5 Allow 2 to 3 hours for cooling hydrocarbon SIC,FO
6 Drain hydrocarbon from casing and discharge to OWS. Keep a running SIC,FO
hose near the drain point
7 Wait for pump suction pressure/discharge to come down to zero. SIC,FO
8 Make hydrocarbon free with steam if required. SIC,FO
9 Open vent valve to drain remaining liquid completely SIC,FO
10 Hand over pump to maintenance after suction, discharge, blinding SIC,FO

PARADIP REFINERY

Taking over procedure for pumps:
Sl.No FPR
Activity
1 Job completion certificate received from maintenance SIC,PO,FO
2 Inspect the isolated pump and see if all mechanical jobs are completed FO
3 Confirm that all drains / vents lines are boxed up PO,FO
4 Visually check bolts for looseness/short bolting PO,FO
5 Visual check flanges for tightness and proper gasket. SIC,FO
6 Check for soaked insulation, oil, rags, mechanical debris. SIC,FO
7 Check for proper fitting of earthing strip SIC,FO
8 Check that suction line / discharge line is de-blinded SIC,FO
9 Check that local TGs, PGs, PSV are in position SIC,FO
10 Check lubricant in the bearing housing and top up if require. SIC,FO
11 Slowly open 2-3 thread suction valve & vent out air / liquid through vent
SIC,PO,FO
cooler. Visually check for any leakage/abnormality
12 Open suction valve. Bleed if necessary, from the drain/vent valve to OWS FO
13 Open the warm up valve across the NRV and discharge valve gradually PO,FO
14 Ensure that pump is getting warmed up , open discharge valve PO,FO
15 Rotate the shaft by hand to ensure that it is free and coupling is secured. SIC,FO
Coupling guard should be in position and secured properly.
16 Motor energized and ready for start up SIC,FO

PARADIP REFINERY

Handing over procedure for Oxidation Reactor:
Sl.No FPR
Activity
2 Column to be isolated/closed/disconnected Column pressure to be
FO
depressurized.
3 Column to be properly depressurized & drained. De-blind the closed blow
down (C.B.O) and OWS connection/pipes of column and connected piping, PO,FO
such as pump suction headers
4 Drain the column material to C.B.D/OWS PO,FO
5 Drain the pumps suction headers of Caustic to OWS. Drain the other SIC,FO
connected pipelines at LP.D. through to C.B.D or O.W.S.
6 Ensure complete draining by opening O.W.S. line. Close all drain B/V and SIC,FO
watch the column pressure and level, if any increase then again draining to
be done.
7 De-Cap the low point drain (L.P.D) and high point vents (H.P.V) as pipelines,
SIC,PO,FO
level gauges, stand pipes and other tapping's connected.
8 Columns containing chemicals like caustic etc. to be drained in chemical
FO
blow down (C. B.D.) vessel only
9 Column to be disconnected/ blinded/ wedge open: Ensure complete
draining De-blind top vent and utility steam Blind/wedge open all the take PO,FO
off (draw off) and return lines
10 Column to be properly steamed/purge PO,FO
11 Open vent and other High Point Vent instruments and other connected SIC,FO
piping
12 Open all L.P.D of level gauges and stand pipes etc., SIC,FO
13 Watch Column pressure and level SIC,PO,FO
14 If required wedge to be increased and/or increase the steam FO
15 Ensure that all H.P.V & L.P.D are clear/dechocked PO,FO
16 Column to be water flushed/Hot water washed: Water flushing is an
PO,FO
effective means of cleaning gas freeing and cooling
17 Columns containing hydrocarbons-Hot water flushing to be done Columns SIC,FO
and metallurgy must be checked
18 Considered before using service water for washing SIC,FO
19 Hot water washing to be done by using steam from bottom and water from
SIC,PO,FO
top Ensure proper draining of column
20 Observe for any abnormal sound like steam hammering in the column FO
21 Ensure complete washing by checking condensate drains PO,FO
22 Stop steaming and continue water washing for sufficient cooling PO,FO
23 Open alternate man ways starting from top of the column SIC,FO
24 Install exhaust fan/ evacuator on top man way SIC,FO
25 Gas/Oxygen deficiency test is to be done, Check inside through man ways
SIC,PO,FO
e.g. safety torch for any foreign material/hydrocarbon/coke etc.

PARADIP REFINERY

26 Do gas (hydrocarbon) test by explosive meter FO

27 Oxygen deficiency test by oxygen meter PO,FO
28 Column entry where no hot job is to be carried out
PO,FO
may be permitted if combustible gases are up to 5% of LEL.
29 The oxygen level should be at least 19.5% by volume and the concentration SIC,FO
of toxic gases below the Threshold limit
30 No hot job shall be permitted unless the explosive meter reading is zero SIC,FO
31 After man entry get open the trays man ways for inspection and open all
SIC,PO,FO
the man ways
32 Proper ventilation and lighting to be provided: Where natural (sufficient)
FO
ventilation is not available fan/air ejector/air hose to be provided
33 Proper means of exit to be provided: To prevent any unwanted entry in the
work area precautionary tags/boards to be provided such as "No Entry" or PO,FO
"Caution-man at work inside" on the manhole of the column.
34 Stand by persons are to be provided outside the column (minimum-2) near
PO,FO
the man way.
35 Entry with an air mask may be permitted LEL of 5% SIC,FO

PARADIP REFINERY

HEAT EXCHANGER OPERATIONS
Procedure for Change over exchanger’s 231-E-101A/B (PLATE TYPE)
Sl.No FPR
Activity
1 Inform Panel operator & SIC for this & open standby HE cold fluid inlet
SIC,PO,FO
valve.
2 Open standby HE hot fluid outlet valve
FO
3 Open standby HE cold fluid outlet valve

PO,FO
4 Open standby HE hot fluid inlet valve. PO,FO

5 Close working HE hot fluid inlet valve. SIC,FO
6 Close working HE cold fluid outlet valve. SIC,FO
7 Close working HE hot fluid outlet valve. SIC,PO,FO
8 Close working HE hot fluid inlet valve. FO
9 Drain liquid from hot & cold side from isolated HE. FO
10 Flush isolated HE with water on both sides. FO

PARADIP REFINERY

Routine start up compressor (231-KA -101A/B)
Sl.No FPR
Activity
1 Inform Panel operator & SIC before start up SIC,PO,FO
2 Check the oil level in the frame sump & refill as required. FO
3 Refill the lubricator oil reservoir PO,FO
4 If the compressor has been shut down for several days, it may be necessary to
PO,FO
prime the oil pump
5 Manually operated each lubricator pumping unit, by push down on the SIC,FO
plunger cap several times, to ensure an initial supply of oil to the cylinder
bore & piston rod packing.
6 Manually turn the compressor through at least one complete revolution to be SIC,FO
sure all moving parts are clear.
7 Unload the compressor & ensure atmosphere is fully open SIC,FO
8 Turn on CWS & check to be sure the cooling system is operative. SIC,FO
9 Prepare the driver for start-up SIC,FO
10 Start the driver & run the compressor with no load for a few minutes to warm SIC,FO
up the unit.
11 Check the oil pressure in the frame lubrication system (1.1 to 2.8 Kg/cm2). SIC,PO,FO
12 Check the cooling water temperature & flow. Adjust cooling water flow &
FO
temperature as required
13 When the unit is warmed up & running satisfactorily, the compressor can be
PO,FO
loaded.
14 Compressor load increased to 50% & close air vent to atmosphere. Take
minimum five minutes for this operation & pressurized system about PO,FO
4.0Kg/cm2.
15 Close air vent gradually & take load of compressor up to 100% & route air into SIC,FO
the system.
Routine stopping of Compressor (231-KA -101A/B)
Sl.No FPR
Activity
2 Unload the unit from 100% to 50% & wait for stabilization, if found everything
FO
normal then unload from 50% to 0%.
3 Take 2-3 minutes for normalization the system PO,FO
4 Stop the compressor driver PO,FO
5 Shut off the cooling water on applicable units. SIC,FO

PARADIP REFINERY

Procedure for start up / Normal operation of RGSF filters

Sl.No FPR
Activity
2 Filter backwashing is manually initiated and controlled using PLC
3 Select the bed, which is operated for 24 h cycle or which is clogged. Keep the
PO,FO
other beds in service
4 Ensure water level in overhead backwash tank not low, level in dirty wash
PO,FO
water collection tank not high and no other filter is in backwash mode.
5 The backwashing sequence is set by the program in PLC SIC,FO
6 The following sequence is followed for backwashing SIC,PO,FO
7 Close the inlet gate and let the filter drain starts. When the water level in the
FO
bed reaches to about 100 mm above the filter media, close the outlet valve
8 Now open the washout valve PO,FO
9 After the filter drain, open air inlet valve. Start one no. air blower and agitate
PO,FO
the bed for about 3- 5 minutes.
10 Now open backwash water inlet valve and backwash bed with combined air- SIC,FO
water wash for about 2 minutes backwash water
11 Stop air blower and close air inlet valve. Release the trapped air through air
SIC,PO,FO
vent valve of the filter which is under backwashing
12 Without stopping the wash water sequence, open the motorized backwash
outlet gate and rinse the bed with wash water for about 4 minutes. FO
13 After completing the above steps, close the wash water. Close the backwash
outlet gate after used wash water is drained out from the central gullet. Close
PO,FO
the air vent valve.
FILTRATION MODE
14 Ensure the two inlet channels feeding to the filters on both rows are charged SIC,FO
with the clarified water from the Check basin water.
Ensure all the Filters for ready to take into service
15 Ensure the pneumatic air is available at required pressure for the operation of
SIC,PO,FO
all the pneumatically operated filter valves
16 Open the inlet valves of the Filters FO
17 Stagger the schedule of bringing the Filters one after the other by fully opening
the filtered water inlet valve and allow the clarified water to filter through the
PO,FO
beds.
18 Let the excess incoming clarified water overflows the weir in the Clarified water
PO,FO
feeding channels to the Filters, till the filtering operation is streamlined
19 Maintain individual filter service run for 24 hours, achieving the required SIC,FO
filtrate quality
BACKWASHING MODE
20 When a filter clocks 24 hours service run or when its differential indicator
SIC,PO,FO
senses the pre set high differential head loss, filter will be taken out for

PARADIP REFINERY

backwashing operation, while the others will continue with the filtration.
21 Prior to backwashing operation during start-up, ensure adequate amount of

water is available in the Backwash water Storage Tank. If adequate water to
meet the backwashing water requirement is not available, defer the
FO
backwashing till adequate level of water builds up in Storage Tank, receiving
the filtered water from Treated Water Reservoir by pumping.
22 Select the Filter for backwashing, after ensuring the water level in the Dirty
PO,FO
wash water tank is low, to accommodate the wash water of one filter
23 Do the backwashing operation of the Filters, from the dedicated Manual Wash
PO,FO
Control Console for each Filter.
24 Bring the washed filter back to service run SIC,FO
25 PARTIAL SHUTDOWN
Before isolating, it is preferred to identify the filter which has run for longer
hours and isolate them one after the other, after backwashing.
SIC,PO,FO
For isolating purpose, it is adequate to close the filtered water outlet valve,
keeping the filter inlet valve open. Leave the isolated filters with standing water
over the sand bed, to avoid bed cracking.
26 The bed shall be drained, only when it is required to attend to the false bottom
floor nozzles or when going in for the replacement of sand by sieving, more FO
than the requirement of just topping up
27 After draining is completed, ensure proper ventilation to the maintenance
person who will enter the filter box through the man hole, located below the PO,FO
false bottom floor of the filter
28 Stop the running equipment at local and at MCC. PO,FO
29 Ensure all the valves and gates are in close position, once the plant is shut SIC,FO
down

PARADIP REFINERY

Procedure for start-up / Normal operation of UF System

Sl.No FPR
Activity
2 Monitor DP type flow transmitter 235-FT-3001 &
FO
flow control valve 235-FV-3001 at the inlet of the UF
3 Observe pressure transmitter 235-PT-3001 monitor the inlet feed pressure.
PO,FO
Check the pressure on 235-PG-3001.
4 Monitor pressure transmitter 235-PT-3002 is provided to monitor the
permeate pressure at the permeate outlet of UF unit. Check the outlet
pressure on 235-PG-3002. The difference between the inlet pressure PO,FO
transmitter and the permeate pressure transmitter is used to calculate the
trans-membrane pressure.
5 Record 235-FT-3002 in to service to measure the total permeates flow. SIC,FO
6 Closely monitor Air blowers 235-K-105A/B to supply air to the UF filter
SIC,PO,FO
operation
7 Check the flow on indicator 235-FI-2002 of air blower FO
8 Check the Pressure of air flow through pressure transmitter 235-PT-2001 PO,FO
9 Check the SDI on analyzer 235-AT-3002 PO,FO
10 Check the turbidity on analyzer 235-AT-3001. And also analysed to generate SIC,FO
high and low alarm set points in DCS.
11 A solenoid valve 235-SV-3020/3021/3022/3023/3024 is provided at the
individual discharge line of UF unit’s 235-A-002A/B/C/D/E to allow the
SIC,PO,FO
samples to combine in a steel pipe. One number solenoid valve 235-SV-3029
is provided at the pipe discharge for drain purpose.

PARADIP REFINERY

Procedure for start-up / Normal operation of RO System

Sl.No FPR
Activity
2 Start cartridge feed pumps 235-P-113 A/B/C/D the UF permeate water into
FO
cartridge filters.
3 Monitor total flow transmitter 235-FT-4001 of the cartridge feed pumps to
monitor the total flow into cartridge filter bank and flow control valve PO,FO
235-FV-4001 in recirculation line to regulate the flow to the RO system.
4 Record/ check Pressure transmitter 235-PT-4001 PO,FO
5 Check Conductivity analyzer 235-AT-4002 SIC,FO
6 Check pH analyzer 235-AT-4003 SIC,PO,FO
7 Check SDI analyzer 235-AT-4004 FO
8 Check ORP analyser 235-AT-4005 PO,FO
9 Monitor the dosing rate of the SBS is varied manually by the operator from
PO,FO
the DCS HMI.
10 Check silica analyzer 235-AT-4006 in to service SIC,FO
11 Start On-off valves 235-XV-4001 & 235-XV-4002 are provided to dump the
off spec water and to SIC,PO,FO
allow the normal water
12 Five numbers of cartridges filters 235-GN-101 A/B/C/D/E have been
provided for removing the micro particles from the fluid. These filters work FO
on four duty and one standby principle.
13 Check Differential Pressure transmitter 235-DPT-4001 for continuous
PO,FO
monitoring of differential pressure across the filter bank

PARADIP REFINERY


PARADIP REFINERY


PARADIP REFINERY

Powder Activated Carbon (PAC) Batch Preparation

1. Legends
 PO : Panel Operator
 SIC : Shift In charge
 PIC : Panel In charge
 FO : Field Operator
S. N. PROCEDURE Responsibility Remarks
Date:
Prechecks
1 Ensure Chain pulley is working and tested FO
2 Ensure the PAC dosing screw conveyor is working. FO
3 Ensure PAC bags are available FO
4 Ensure PAC dosing tank agitator is working FO
5 Ensure DAP is available FO
Ensure H2SO4 is available in 231-TK-010 and its pumps 231-PM-

6 FO
14A/B are working
Procedure
Fill the jumbo bags with carbon powder (800 kg*) and lift the
1 FO
bag to the charging station
Take 17000 L water to tank (level up to 70%) and start the
2 FO
agitator.
3 Charge PAC to the tank slowly. FO
After the whole carbon will be charged to the tank and allow
4 FO
agitation for 30 mins.
Add DAP (160 kg*) solution in two steps to the tank. During
5 FO
DAP dosing continuous agitation to be ensured.

PARADIP REFINERY

After DAP dosing H2SO4 (2.55 KL) to be added slowly to the

6 tank and pH is to be monitored. H2SO4 to be added to FO
maintain pH of the solution <4.
The prepared solution shall be kept for activation for 12 hrs.
7 SIC/FO
for activation of carbon.
Start dosing carbon from the tank and start batch

8 FO
preparation in the other tank following same steps
*Amount of the carbon will vary depending on the HCOD inlet water COD load. Accordingly
DAP dosing quantity will also vary (0.2% of PAC amount). H2SO4 dosing quantity depends on
the pH.

PARADIP REFINERY

EMERGENCY
Handling
SOP

PARADIP REFINERY

High ammonia in ETP Inlet Stream
2. Legends
 PM : Plant Manager
 SI : Shift In charge
 PI : Panel In charge
3. Procedure
TIME
Step Action FPR
(Hrs.)
Inform IOCL-In charge of ETP about the abnormality of inlet streams. Also
1. inform the SWS unit & crude section (Boot-3) for checking their end. 0.15 SI
Lined-up the stripped sour water to one equalization tank & close the
2. stripped sour water to Biotower feed sump isolation valve if it was lined- FO/PI
up in Biotower feed sump.
0.5
The API-TPI O/L is to be lined-up to other equalization tank & the feeding
3. FO/PI
to Oily DAF is to be done from this tank only.
4. Start the recirculation pump of high ammonia contained tank. FO/PI
The Dilution from Strom water pond to Biotower feed sump is to be
5. 1.0 PI
started.
Monitor the DO level in Aeration tank. If it is down ward trend, increase the
6. 1.5 PI
aeration air flow.
Decrease the wasting flow rate to increase the sludge age for better control on
7. ammonia. PI/FO
2.0
Try to reduce COD load at the inlet for better result of ammonia treatment.
7. PI
Monitor the water quality of clarifier. If outlet water having higher TSS,
8. PI/FO
then start de-sludging through SAS.
Bio-DAF skimming is to be done continuously, so that TSS carry over to
9. 8.0 PO
check basin can be minimized.
10. RGSF backwash frequency is to be increased to 2 times/bed PI/SI
Monitor the UF membrane TMP & accordingly take action as per WRP
11. PI/SI
SOP manual.
The high ammonia contained equalization tank is to be lined-up to Oily
12. DAF partially (10~20%) & the downstream section parameter is to be 16.0 PI/FO
monitored.

PARADIP REFINERY

Once the high ammonia contained equalization tank level comes below
13. 35-40% , again lined-up API-TPI outlet to that equalization tank to dilute 24.0 PI/FO
the tank up to 60~70%.
Monitor the aeration tank water physical appearance & quality
14. FO/SIC
parameters in every 2 hrs.
When the Biological section will be stabilized, lined –up is to be changed
15. 72 FO/SIC
to normal.

PARADIP REFINERY

High O&G in ETP Inlet Stream
1. Legends
2. Procedure
TIME
Step Action FPR
(Hrs.)
Inform RSM and IOCL-In charge of ETP about the abnormality of inlet streams.
3. Also inform OWS, CRWS operator for checking their end. 0.1 SI
4. Check whether the oil is coming from Desalter or not. FO/PI

5. API & TPI skimming & de sludging frequency increasing.
6. API & TPI section steaming is to be started on continuous basis. 0.12 FO/PI
Equalisation tank skimming is to be done as per the level in the
7. equalization tank. FO/PI
Chemical dosing rate is to be changed as per the JAR test of equalization

8. 0.15 PI
tank O/L water.
Monitor the oily DAF outlet water physical appearance & quality
9. parameters in every 2 hrs. 0.25 PI
Monitor the water quality of Aeration tank & check any floating oil in
8. aeration tank or not. PI/FO
9. then start de-sludging through SAS.
1.0
10. check basin can be minimized. PO

12. SOP manual. PI/SI

13. parameters in every 2 hrs. FO/SIC

14. 8.0 FO/SIC
to normal.

PARADIP REFINERY

High amine content in oily DAF
1. Legends
2. Procedure
TIME
Step Action FPR
(Hrs.)
Inform RSM and IOCL-In charge of ETP about the abnormality of inlet streams.
3. Also inform the crude section, OWS & CRWS for checking their end. 0.15 SI
The API-TPI O/L is to be lined-up to other equalization tank & the feeding
4. FO/PI
to Oily DAF is to be done from this tank only.
5. 1.0 PI
started.
6. 1.5 PI
aeration air flow.
Decrease the wasting flow rate to increase the sludge age for better control on
7. amine. PI/FO
2.0
Try to reduce COD load at the inlet for better result of amine treatment.
7. PI
8. PI/FO
9. 8.0 PO
11. PI/SI
SOP manual.
The high amine contained equalization tank is to be lined-up to Oily DAF
12. partially (10~20%) & the downstream section parameter is to be 16.0 PI/FO
monitored.
Once the high amine contained equalization tank level comes below 35-
13. 40% , again lined-up API-TPI outlet to that equalization tank to dilute the 24.0 PI/FO
tank up to 60~70%.
14. FO/SIC

PARADIP REFINERY


15. 72 FO/SIC
to normal.

PARADIP REFINERY

High COD & TSS in HCOD outlet to sea stream
1. Legends
2. Procedure
TIME
Step Action FPR
(Hrs.)
Diverted the HCOD outlet flow from sea to south storm water pond.
8. 0.15 SI
Inform to PM/HSE/Instrument department.

9. FO/PI
Checking of analyser by instrument is to be done if any chocking. 0.5

10. FO/PI
11. PAC dosing rate is to be checked in field. FO/PI

Poly electrolyte & poly aluminium chloride dosing is to be checked in
12. 1.0 PI
field.
Desludging from plate type clarifier is to be done.
13. 1.5 PI
RO recovery is to be reduced from 78% to 72%.

14. PI/FO
2.0
PAC dosing rate is to be increased to reduce COD.
7. PI
If come down below 125ppm take analyser in service.

8. PI/FO
8.0
Diverting the HCOD outlet to sea again.
9. PO

PARADIP REFINERY

High COD in oily DAF Inlet Stream
1. Legends
2. Procedure
TIME
Step Action FPR
(Hrs.)
Inform IOCL-In charge of ETP about the abnormality of inlet streams. Also
3. 0.25 SI
inform the crude unit & OWS, CRWS for checking their end.
The API-TPI O/L & stripped sour water receiving is to be lined-up to
4. FO/PI
different equalization tanks.
0.5
The oily DAF feeding is to be done from low COD content equalization
5. FO/PI
tank.
6. 0.75 PI
started.
Open the isolation valve ~ 20% from the high COD content equalization
7. 1.0
tank.
8. Start the peroxide dosing if required as per the JAR test.
Chemical dosing rate in oily DAF is to be done as per the JAR test. 1.0
9.
10. 1.5 PI
aeration air flow.
7. Treated spent caustic dosing rate decrease to bio tower feed sump. 1.5 PI
9. PI/FO
10. PO
If check basin COD is in higher range (> 80 ppm), start sending high COD
water to storm water pond through off spec pump. During that time 8.0
dilution is to be stopped in Biotower feed sump.

12. PI/SI
SOP manual.
13. FO/SIC

PARADIP REFINERY


14. 24 FO/SIC
to normal.

PARADIP REFINERY

High Sulphide in ETP Inlet Stream
4. Legends
5. Procedure
Step Action FPR

Inform RSM and IOCL-In charge of ETP about the abnormality of inlet streams. Also
15. inform the SWS unit & OWS, CRWS for checking their end. SI
Lined-up the stripped sour water to one equalization tank & close the stripped
16. sour water to Biotower feed sump isolation valve if it was lined-up in Biotower FO/PI
feed sump.
17. The API-TPI O/L is to be lined-up to other equalization tank. FO/PI
High sulphide water feeding to oily DAF low quantity, maximum feeding to oily
18. FO/PI
DAF is to be done from another tank.
The Dilution from Strom water pond to Biotower feed sump is to be started.
19. PI
Monitor the DO level in Aeration tank. If it is down ward trend, increase the aeration air
20. flow. PI
Hydrogen per oxide chemical dosing start at oily DAF outlet section & other
21. PI/FO
chemical dosing rate changing priority basis.
8. Treated spent caustic dosing rate decrease to bio tower feed sump. PI
9. Increase the bio sludge wasting and maintain aeration tank MLSS.
10. Monitor the water quality of clarifier. If outlet water having higher TSS, then
PI/FO
start de-sludging through SAS.
Bio-DAF skimming is to be done continuously, so that TSS carry over to check
11. PO
basin can be minimized.
Monitor the UF membrane TMP & accordingly take action as per WRP SOP
13. PI/SI
manual.
Monitor the aeration tank water physical appearance & quality parameters in
14. FO/SIC
every 2 hrs.

PARADIP REFINERY

When the Biological section will be stabilized, lined –up is to be changed to

15. FO/SIC
normal.

PARADIP REFINERY

MP Steam failure in ETP B/L
6. Legends
7. Procedure
TIME
Step Action FPR
(Hrs.)
22. Inform RSM and IOCL-In charge of ETP about the MP Steam failure. SI
23. Spent caustic treatment unit to be shut down immediately as per SOP. 0.15 FO/PI
24. Isolate the steam inlet valve. FO/PI
Open the steam trap bypass valves for the MP steam header from ETP B/L to
25. 0.20 FO
SCTP unit.
26. Acid injection in SCTP inline mixture is to be stopped. 0.5 FO
Spent Caustic dosing from Neutralization tank to Biotower feed sump is to be

27. continued till low level. PI/SI
After resumption of MP steam , Heating of steam line is to be done up to SCTP

7. FO/PI
B/L.
8. Start the SCTP unit as per the SOP. FO/PI

Document No: PDR/PN/SCTP/OM
Issue Date Rev. No. Rev. Date
Operating Manual for
Indian Oil Spent Caustic Recovery Unit August, 2012 7 Jan, 2022
Paradip Refinery
Operating Manual
Spent Caustic Treatment Unit

(U-231)
1 Prepared by Reviewed By Approved By

Paradip Refinery
CONTENTS
SL No Topic Page no
1.0 Process Design Basis 3
1.1 Feed Characteristics 3
1.2 Design Basis 3
1.3 Quality of Oxidized Spent Caustic 4
1.4 Turn Down & On Stream Factor 4
1.5 Battery Unit Conditions 4
2.0 Treatment Philosophy 5
2.1 Process Description 7
2.2 Process Chemistry 9
3.0 Material Balance 9
4.0 Control Philosophy 13
5.0 Equipment List 14

Paradip Refinery
1.0 PROCESS DESIGN BASIS
1.1 Feed Characteristics

The Naphthenic Spent Caustic and Sulphidic Spent Caustic stream shall be collected separately in
Naphthenic Spent Caustic Equalization Tank and Sulphidic Spent Caustic Equalization Tank respectively. The
Naphthenic Spent Caustic stream shall be pretreated by Acid Neutralization.
The Sulphidic Spent Caustic stream shall be subjected to Wet Air Oxidation. The final pH adjustment of all
the treated streams shall be done by Sulphuric Acid and Sodium Hydroxide.
The Treated Spent Caustic streams shall be sent to Biological Section of ETP.
The Quality of the Naphthenic Spent Caustic and Sulphidic Spent Caustic streams shall be as indicated
below:
Stream 1: Naphthenic Spent Caustic: 0.331 m3/hr.
Parameter Concentration
pH 12-13
Oil & Grease (ppm) 1000
COD (ppm) 80000
Total Sulfides (as S in ppm) 30000
Total Dissolved Solis ( ppm ) 120000
NaOH (ppm) 1-5 %Density (Kg/m3) 1000
Stream 2: Sulphidic Spent caustic: 8.358 m3/hr
Parameter Concentration
pH 12-13
Oil & Grease (ppm) 1000
COD (ppm) 80000
Total Sulfides (as S in ppm) 30000
Total Dissolved Solis ( ppm ) 120000
NaOH (ppm) 1-5 %Density (Kg/m3) 1000

Paradip Refinery
1.2 Design Basis

The WAO (WET AIR OXIDATION) Unit shall be designed for Average Composition and Flow of the incoming
Spent Caustic Effluent streams. The design flow shall also include 0.2 m3/hr maintenance effluents and a
margin of 20%.
Design Flow: 11 m3/hr
1.3 Quality of Oxidized spent Caustic :
Parameter concentration
Oil & Grease <20
COD 12000
Total Sulfides (as S) 300
pH 7-9
NaOH 1-5%
TDS >120000
All units are in mg/except pH.
1.4 Turn Down & On-Stream Factor:
Minimum Turndown requirement in terms of hydraulic load shall be 60% .Plant shall be able to operate
8000 hours per annum continuously.
1.5 Battery Unit Conditions: Normal feed line and Utilities available at plant B/L along with their
specifications shall as bellow ;
Spent Caustic feed Lines

Line specification A19A
Pressure , kg/cm2.g MIN04 NORMAL 2.5 MAX 12
Temperature ,0C MIN25 NORMAL 45 MAX 50
Oxidized Caustic to Biological Treatment
Line specification A19A
Pressure , Kg /cm2. g MIN. HOLD NORMAL 05 MAX.05
Temperature,0C MIN AMB NORMAL 40 MAX.
Low Pressure (LP) Steam

Paradip Refinery
Line Specification A2A

Pressure kg /cm2 g. MIN 03 NORMAL 04 MAX.
Temperature , C MIN. STD. NORMAL 179 MAX. 190
SERVICE WATER
Pressure kg /cm2 g. MIN. NORMAL.05 MAX
Temperature , C MIN NORMAL.AMB MAX.
PLANT AIR
Pressure kg /cm2 g. MIN.04 NORMAL. 07 MAX.08
Temperature , C MIN NORMAL MAX
INSTRUMENT AIR
Pressure kg /cm2 g. MIN.4.5 NORMAL07 MAX.08
Temperature , C MIN NORMAL. MAX.
COOLING WATER
Pressure kg /cm2 g. MIN.4.5 NORMAL 5.5 MAX. 06
Temperature , C MIN. NORMAL.33-45 MAX
2.0 TREATMENT PHILOSOPHY

The Naphthenic Spent Caustic stream have a high content of Organic/Acid Oils, mainly Naphthenates that
are not readily oxidized and are responsible for foaming in the typical Wet Air Oxidation Units. Strong acids,
such as mineral acids, can neutralize such caustic effluents. Typically, Concentrated (98 Wt %) Sulfuric acid
(H2SO4) is used to neutralize spent caustic. The H2SO4 reacts with NaOH, sulfides, Phenolates, and
Naphthenates to form sodium sulfate (Na2SO4), water, H2S, phenols and naphthenic Acids respectively.
The caustic effluent is typically neutralized at a specific pH range depending on spent caustic composition
and availability of treatment facility after the neutralization step. Neutralized solution shall be skimmed to
remove the organic layer and shall be then discharged after pH adjustment.
Neutralization of spent caustic proceeds as:
2NaOH + H2SO4 - Na2SO4 + 2H20

Paradip Refinery
2NaSR + H2SO4– Na2S04 + 2RSH

2RONa + H2SO4 - Na2SO4 + 2ROH
Na2CO3 + H2SO4 - Na2SO4 + CO2 + H2O
Na2S + H2SO4 - Na2SO4 + H2S
2NaSH + H2SO4 - Na2SO4 + 2 H2S
2NaHCO3 + H2S04 - Na2SO4 + 2H20 + 2C02
2RCOONa + H2SO4 - Na2SO4 + 2RCOOH
The pH required for the neutralization reaction decreases moving from the top to down in the above
reactions.
The H2S liberated in the Neutralization step can be scrubbed through a Scrubber column Employing NaOH
to trap the hydrogen sulphide and release the off gas to Atmosphere. The Caustic, after having absorbed
hydrogen sulphide is sent to the Oxidation Tank in the WAO Unit.
The Sulphidic Spent Caustic stream in the Oxidation Tank shall be treated in the Oxidation Reactor of WAO
unit. The main contaminants of the spent caustic stream are oil & grease, sulphide, phenol, organic matters
contributing to high BOD and COD, high alkalinity, etc. This stream must be pretreated before it is finally
taken for air oxidation. The pretreatment steps may necessarily involve removal of free oil and suspended
solids if present in the effluent. It is also important that due to presence of free sodium hydroxide in solution
aldol condition may occur due to the polymerization of carbonyls. Furthermore, additional polymerization
of dienes is catalyzed by oxygen, oxidizing agents and heavy metal ions. The organic constituent of the
spent caustic is present in two forms: a dissolved phase and a free separate phase. The organic components
dissolved in the aqueous phase have different concentrations defined by their solubility limits. On the other
hand, the unsaturated hydrocarbons and light aromatic components have significantly higher solubility
limits than the saturated and heavy organics. The organics present in the spent caustic beyond their
solubility limit in the aqueous phase exist as a separate phase in the form of oily droplets and solid polymer
particles that are visible within the spent-caustic solution.

Paradip Refinery
2.1 Process Description.

The Naphthenic Spent Caustic stream shall be first collected in a separate tank for removal of free oil and
suspended solids. The disperse phase, which is mostly spent caustic along with free sodium hydroxide, shall
be further led to the Neutralization Tank through an Oil Coalescer. Concentrated (98 Wt%) sulfuric acid
(H2S04) shall be used to neutralize spent caustic. The H2SO4 reacts with NaOH, sulfides, phenolates, and
Naphthenates to form sodium sulfate (Na2SO4), water, H2S, phenols and naphthenic acids respectively.
The caustic effluent is typically neutralized at a specific pH range depending on spent caustic composition
and availability of treatment facility after the neutralization step. The neutralized stream shall have a
provision of being routed to either the Oxidation Tank in the WAO Unit or directly to the pH Adjustment
Tank for final disposal to Biological Section of ETP.
The H2S liberated in the Neutralization step can be scrubbed through a Scrubber column employing NaOH
to absorb Hydrogen Sulphide and release the off gas to Atmosphere. The Caustic, after absorbing Hydrogen
Sulphide are sent to the Oxidation Tank in the WAO Unit.
The Naphthenic Oil sprung during the neutralization step shall be sent to Naphthenic Oil Storage Tank. This
naphthenic oil shall be pumped either to Slop Oil Tanks/Road Tankers or to Saponification Tank. Sodium
Hydroxide dosing shall be carried out in the Saponification Tank to form slurry which shall be pumped to
DCU of the refinery.
The Sulphidic Spent Caustic shall be pumped to the Oxidation Tank from the Spent Caustic Equalization
Tank in the ETP. After partial oxidation of the Spent caustic the stream shall be pumped to the Oxidation
Reactor through Guard Filters that prevent oil passage thus avoiding foam formation in the Oxidation
Reactor.
The spent caustic stream shall be pumped from the Process Units to the Storage tanks (in ETP) with the
help of low shear pumps. The tanks shall have arrangement of gooseneck type spent caustic withdrawal
system with siphon breaker so that separated free oil is retained at the top and periodically removed. The
separated free oil shall be directly routed to an oil sump from where it will be pumped to the existing slop
oil tank. After removal of free oil, spent caustic stream is routed to Oxidation Tank through Oil Coalescers
which shall further remove any oil present in the stream. The Waste Water from the Scrubber Column shall
also be mixed with the spent caustic stream in the oxidation tank. The spent caustic stream may be further
diluted with water to decrease load on the reactor and catalyst solution shall be added. Aeration is also

Paradip Refinery
provided in the tank for effective mixing of the incoming streams. This effluent is then pumped to air
oxidation system.
Air Oxidation Process
EIL'S WAO Process
Sulphidic Spent caustic is stored in a tank and Oil is skimmed off, free Oil separating due to gravity
difference. It is then passed through an Oil Coalescer. This oil free spent caustic is diluted with water in
Oxidation Tank. Copper based catalyst solution is also added in this tank. The airflow rates are adjusted in
such a way that the foam formation is lowered if small quantities of napthenates are present. The aeration
is required for providing intimate mixing of spent caustic with the catalyst and air for oxidation. The spent
caustic is pumped through an Oxidation Reactor Feed Pump to a Guard Filter and the filtered caustic
Solution is routed through the Feed / Off Gas Effluent Exchanger where the Off Gas coming out of the
Oxidation Reactor cools giving heat to the Feed Caustic Stream. The cooled off gas is sent to the Adsorption
Column and the Feed Spent Caustic is sent to the Feed / Effluent exchanger where it picks up heat from the
Oxidized Spent Caustic Stream coming from the bottom of the Oxidation Reactor. To achieve the desired
temperature of around 137 C at the inlet of the Oxidation Reactor, a Steam Heater is provided. It will also
heat the inlet to Oxidation Reactor to 140 C during start-ups as well as for normal operation when sulphide
levels are well below the design of the system. This heated spent caustic solution is then led to the
Oxidation Reactor. The operating principle is that the waste stream, following preheating, is oxidized in a
counter-current method by air in a tray Reactor to provide intimate contact for sulphide oxidation. The
Caustic stream is fed to the Oxidation Reactor from the top through an inlet distributor. Air inlet is from the
bottom of the Reactor from where it passes through the liquid hold up of the Reactor and over to the top
through the Trays positioned in the column. The holdup volume in the Reactor provides for sufficient
retention time of the air in the system to react with spent caustic. The off gas from the Oxidation Reactor
will contain unreacted oxygen, carbon dioxide, nitrogen, water vapors and traces of hydrocarbons. Off
gases released from the process before being vented to Atmosphere are cooled in Feed Off Gas Exchanger
and then led to the Gaseous Adsorption Column where any remnant HCs are adsorbed on the activated
Carbon bed and the off Gas is thereafter vented to Atmosphere.
The temperature is maintained at 140 degree C and the operating pressure in the Oxidation Reactor is 6.0
Kg/cm2g. The oxidized caustic product, after passing through conical filters is cooled in the Feed Effluent

Paradip Refinery
Heat Exchange The oxidized caustic is then led to the pH Adjustment Tank where it is neutralized with
Sulphuric acid and Sodium Hydroxide before sending it for disposal to Biological Section of ETP.
2.2 Process Chemistry
The spent caustic is contacted with air at 140°C at about 6 kg/cm2 gauge pressure in the Oxidation Reactor
and the sulphides are oxidised to sodium thiosulphate and sodium sulphate according to the following
equations:
Reactions:
(i) 2Na2S + 202 + H2O – Na2S203 + 2 NaOH
(ii) 2NaRS + 0.502 + H2O – RSSR + 2NaOH
(iii) 5Na2S2O3 + 402 + H20 – 5Na2SO4 + 4S + H2SO4
(iv) 2NaOH + H2SO4 – Na2SO4 + 2H20
Oxidation to Thiosulphate is the predominant reaction. The thiosulphate will be further oxidised to the
sulphate. Approximately 80% of thiosulphate will be converted to sulphate. Release of hydrogen sulphide
is minimal at high pH.
The only obnoxious sulphide present is Na2S and its oxidation will release caustic soda. Further oxidation
of thiosulphate to sulphate will release Sulphuric acid. Caustic soda and Sulphuric acid will react to produce
sodium sulphate. The Hydrogen Sulphide released in the neutralization step shall be absorbed in the H2S
Scrubber. The following reactions shall take place:
1) H2Saq+ NaOHaq – NaHSaq +H2O
2) NaHSaq + NaOHaq – Na2Saq + H2O
The extent of reactions 1 and 2 depend on the strength of caustic, with higher pH favoring reaction 2.
3.0 MATERIAL BALANCE
NAPHTHENIC SPET CAUSTIC TREATMENT

NUTRALIZATION TANK
FRICTION OF NaSH in Marcaptans 0.96
FRICTION OF NaSR in Marcaptans 0.04

Paradip Refinery
Molecular weight of R 29
Bicarbonates in spent caustic (ppm) 50
BALANCE
COMONENTS INLET OUT LET
NaSR (gmoles) 0.000716
0.025792
NaSH (gmole)
Na2S (gmole) 212.18
H2O (gmole) 15XXX.33 15435.81
NaHCO3(gmole) 0.179113
RCOONA(gmole) 0.114747
NaOH(gmole)
Na2SO4(gmole) 261.99
RSH(gmole) 0.000716
H2S(gmole) 212.2053
RCOOH(gmole) 0.114747
H2SO4(gmole) 264.0856 2.095917
CO2(gmole) 0.179113
Density of 98% H2SO4 =1863 Kg /m3

Volume of 98% H2SO4 required =14.38litters/hr
SCRUBBER CACULATIONS
NaOH Consumption
Total H2S liberated =212.2 gmoles/hr.
NAOH required =414.4 gmoles/hr
Required Flow Rate of Spent Caustic from =270 Liters/hr
FCC and DCU LPG Treater With 100% Excess---540 Liter/hr

Paradip Refinery
SULPHIDIC SPENT CAUSTIC TREATMENT

Total Sulphides (as S, Design) 30000
Fraction of Na2S in Sulphides 0.996
Fraction of mercaptides in sulphides 0.004
OXIDATION REACTOR
Fraction of Sodium Sulphide reacted 0.95
Fraction of Sodium Thiosulphate converted to Sodium Sulphate 0.8
Intel COD 80000
Fraction of COD converted 0.85
Molecular wt. Of R 29
Temperature of the reactor (C) 140
Pressure of the reactor (kg /cm2g) 6
Excess Air 50%
OXIDATION TANK
COMPONENTS INLET OUTLET

Spent caustic (m3/hr) 11 18.5
Na2S (gram moles) 933.75 933.75
NaRS (gram moles) 3.75 3.75
H2O (gram moles) 6111111.11 1027777.8
COD (ppm) 80000 47567.6
NaOH (gram moles) 10114.625 10114.625
Catalyst (m3/hr) 0.02
Service water (m3/hr) 7.5
H2O (gram moles) 416666.7
COD (ppm) 100

Paradip Refinery
OXIDATION REACTOR
COMPONENTS INLET OUTLET

Spent caustic (m3/hr) 18.5 18.5
Na2S (gram moles) 933.75 46.7
NaRS (gram moles) 3.75 -
H2O (gram moles) 1027777.8 102777.8
COD (ppm) 47567.6 7141.2
Na2S2O3(gram moles) 88.7
Na2SO4(gram moles) 354.8
RSSR(gram moles) 1.875
NaOH (gram moles) 10114.625 11005.425
Sulpher(gram moles) 354.8
Air (Nm3/hr) 4370
N2 (gram moles) 139282.85
O2 (gram moles) 37024.55
Off Gas(Nm3/hr) 4340
O2 (gram moles) 12341.52
N2 (gram moles) 139283
CO2 (gram moles) 23395
Note: The balance has been done considering sodium sulphide equivalent to actual Sulphidic components
(Sodium Sulphide, Tiosulphates, mercaptans etc.) in the streams. This overdesigns the system as Sulphidic
components other than Sodium Sulphide require less oxygen than Sodium Sulphide.
PH ADJUSTMENT TANK
Gmoles of NaOH to be neutralized 11005.425
Gmoles of H2SO4 dosed in PH Adjustment Tank 5502.7
Flow Rate of H2SO4 required (Iph) 300

Paradip Refinery
4.0 CONTROL PHILOSOPHY

The Neutralization step for the Naphthenic spent caustic streams shall be Manual. Depending on the quality
of the spent caustic received, the flow rates of the acid required for neutralization reaction shall be
adjusted. The NaOH flow rate in the scrubber shall also be maintained in the column depending upon H2S
liberation from the Neutralization Tank.
The Wet Air Oxidation Unit shall be a PC/PLC based control system with the provision of integration with
the DCS based control system in ETP control room. The process is envisaged to be continuous process with
controlled flow of Spent Caustic from the Sulphidic Spent Caustic Transfer pumps.
The major controls in the unit shall include the following,
Feed to the Oxidation Reactor
The feed to the Oxidation Reactor shall be regulated manually by controlling the discharge of the Oxidation
Reactor feed pumps. A flow Indication shall be provided at the discharge of the pumps to control the feed
to the Oxidation Reactor.
Inlet temperature of the Oxidation Reactor
The inlet temperature of the Oxidation Reactor shall be 137 C and the outlet temperature from the
Oxidation Reactor shall be 140C at the outlet as the reactions are exothermic. The inlet temperature of the
Oxidation Reactor shall be controlled by regulating the steam flow in the Steam Heater. The temperature
transmitter and controller on the Steam Heater Outlet line shall be provided to regulate the flow of steam
to the Heater to maintain the required inlet temperatures.
Pressure of the Oxidation Reactor
The operating temperature and pressure for the Oxidation Reactor are 140 C and 6 kg/cm2g respectively.
A Pressure Controller Valve shall be provided to at the top of the Reactor to Maintain the Reactor pressure.
The PCV shall be designed to achieve a downstream pressure reduction of Gas to around 1.2 kg/cm2g.

Paradip Refinery
Level in the Oxidation Reactor

A minimum level shall be maintained at the bottom of the Oxidation Reactor to provide a Water seal and
prevent gas breaking into the downstream section. This shall be accomplished through a level control valve
at the outlet line of the Oxidation Reactor that shall control the Liquid level in the Reactor.
Level indications for all tanks i.e. Catalyst Dosing Tank, Oxidation Tank, Reaction Chamber etc., shall also be
provided with interlocking mechanisms for trip conditions and permissive For respective pumps as per good
engineering practices. Temperature and pressure indications are envisaged as indicated in the P&IDs to
facilitate Control of the process.
5.0 EQUIPMENT LIST
Sl. No EQUIPMENT DESCRIPTION EQUIPMENT TAG
1 AIR COPRESSOR 231-K-101 A/B

2 SPENT CAUSTIC PREHEATER 231-E-101 A/B
3 SPENT CAUSTIC COOLER 231-E-102 A/B
4 OFF-GAS COOLER 231-E-103
5 OXIDATION REACTOR 231-R-101
6 NEUTRALISATION DRUM 231-V-102
7 SULIDICSPENT CAUSTIC STORAGE TANK 231-TK-101
8 NAPTHENIC SPENT CAUSTIC STORAGE TANK 231-TK-102
9 SPENT CAUSTIC EQUALISATION TANK 231-TK-103
10 SULPHIDIC SPENT CAUSTIC CHARGE PUMP 231-P-101A/B
11 NAPTHENIC SPENT CAUSTIC V PUMP 231-P-102 A/B
12 NAPTHENIC SPENT CAUSTIC CHARGE PUMP 231-P-103 A/B
13 EQUALISED SPENT CAUSTIC PUMP 231-P-104A/B
14 MIXER 231-JS-101
15 STATIC MIXER 231-JS-102
16 F-COALSCER 231-F-101
17 SPENT CAUSTIC SEAL DRUM 231-TK-112
18 SULPHURIC ACID DOSING TANKS 231-TK-104A/B
19 SULPHURIC ACID CHARGE PUMP 231-P-106 A/B
20 NEPTHENIC SPENT CAUSTIC DAY TANK 231-TK-106

Paradip Refinery
21 EQUALISED SPENT CAUSTIC DAY TANK 231-TK-105

22 SULPHIDIC SPENT CAUSTIC SLOP DRUM 231-TK-108
23 NAPHTHENIC SPENT CAUSTIC SLOP DRUM 231-TK-109
24 SULPHIDIC SLOP SUCTION PUMP 231-P-108 A/B
25 NAPTHENIC SLOP SUCTION PUMP 231-P-109 A/B
26 CAUSTIC SAPONIFICATION TANK 231-TK-111
27 COOLOING TOWER SCTP 231-CT-101/102
28 CIRCULATION PUMP CT 231-P-110

NOTES
REVISION
FW DWG. NO. VA-TECH DWG. NO. LEI DWG. NO. DWG.TITLE
DATE
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0003 10-P2-D0015-017 &AG-P-FB 1001 LIST OF DOCUMENTS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0004 10-P2-D0015-018 &AG-P-FB 1002 SYMBOLS AND ABBREVIATIONS-I
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0005 10-P2-D0015-019 &AG-P-FB 1003 SYMBOLS AND ABBREVIATIONS-II
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0006A 10-P2-D0015-020A &AG-P-FB 1004A INSTRUMENATATION SYMBOLES & LEGEND
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0006B 10-P2-D0015-020B &AG-P-FB 1004B INSTRUMENATATION SYMBOLES & LEGEND
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0007A 10-P2-D0015-021A &AG-P-FB 1005A SYMBOLOGY SHEETS EQUIPMENT
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0007B 10-P2-D0015-021B &AG-P-FB 1005B SYMBOLOGY SHEETS EQUIPMENT
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 AS BUILT
PDRP0451-8110-25-231-0008A 10-P2-D0015-022A &AG-P-FB 1006A P&ID TYPICAL DETAIL
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0008B 10-P2-D0015-022B &AG-P-FB 1006B PUMP & RELIEF VALVE ISOLATION
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 GENERAL NOTES
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
PDRP0451-8110-25-231-0008C 10-P2-D0015-022C &AG-P-FB 1006C ISOLATION HOOKUP DIAGRAM - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
PDRP0451-8110-25-231-0008C.
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0011 10-P2-D0015-040 &AG-P-FP 1001 SULPHIDIC SPENT CAUSTIC STORAGE TANK
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 HOLDS
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0012 10-P2-D0015-041 &AG-P-FP 1002 SULPHIDIC SPENT CAUSTIC CHARGE PUMPS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0013 10-P2-D0015-042 &AG-P-FP 1003 NAPHTHENIC SPENT CAUSTIC STORAGE TANK
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0014 10-P2-D0015-043 &AG-P-FP 1004 NAPHTHENIC SPENT CAUSTIC CHARGE PUMPS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
PDRP0451-8110-25-231-0015 10-P2-D0015-044 &AG-P-FP 1005 SPENT CAUSTIC PREHEATERS SIGNATURE
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
DATE
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0016 10-P2-D0015-045 &AG-P-FP 1006 OXIDATION REACTOR REFERENCE DRAWINGS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 DRAWING NO. REV TITLE
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0017 10-P2-D0015-046 &AG-P-FP 1007 OFF GAS COOLER
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0018A 10-P2-D0015-047A &AG-P-FP 1008A SPENT CAUSTIC NEUTRALISATION-I
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0018B 10-P2-D0015-047B &AG-P-FP 1008B SPENT CAUSTIC NEUTRALISATION-II
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 ENGINEER'S APPROVAL APPROVED FOR CONST
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
PDRP0451-8110-25-231-0019 10-P2-D0015-048 &AG-P-FP 1009 SPENT CAUSTIC COOLERS
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 Z1 06.05.15 ISSUED AS BUILT MK MM CU
PDRP0451-8110-25-231-0020 10-P2-D0015-049 &AG-P-FP 1010 COMPRESSOR-A A3 10.12.12
REVISED AS PER 90% DESIGN
MK MM CU
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 REVIEW
A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 ISSUE FOR DESIGN (HAZOP
PDRP0451-8110-25-231-0021 10-P2-D0015-050 &AG-P-FP 1011 COMPRESSOR-B A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12
O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
PDRP0451-8110-25-231-0022 10-P2-D0015-051 &AG-P-FP 1012 SPENT CAUSTIC EQUALIZATION TANK
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1
PDRP0451-8110-25-231-0023 10-P2-D0015-052 &AG-P-FP 1013 EQUALIZED SPENT CAUSTIC CHARGE PUMPS CLIENT:
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 INDIAN OIL
PDRP0451-8110-25-231-0024 10-P2-D0015-053 &AG-P-FP 1014 COALESCER
O/D1 O1/D1 O2/D2 A/E1 A2/G1 A3/G1 CORPORATION
18.05.11 20.06.11 08.07.11 03.08.11 15.02.12 10.12.12 LIMITED
O/D2 A/E1 A2/G1 A3/G1 LSTK:
WABAG
PDRP0451-8110-25-231-0030 10-P2-D0015-059 &AG-P-FP 1015 UTILITIES-I
08.07.11 03.08.11 15.02.12 10.12.12 VA TECH WABAG
O/D2 A/E1 A2/G1 A3/G1 VA TECH WABAG LIMITED
PDRP0451-8110-25-231-0031 10-P2-D0015-060 &AG-P-FP 1016 UTILITIES-II No.11, MURRAY'S GATE ROAD,
08.07.11 03.08.11 15.02.12 10.12.12 ALWARPET, CHENNAI-600 018, INDIA.
REV:
A/E1 A2/G1 A3/G1
FILE NAME: 10-P2-D0015-017 Z1
PDRP0451-8110-25-231-0032 10-P2-D0015-061 &AG-P-FP 1017 STEAM TRAP DETAILS PACKAGE VENDOR:
03.08.11 15.02.12 10.12.12
LINDE ENGINEERING INDIA PVT. LTD.,
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FB 1001 .
Z1

TITLE:
PIPING AND INSTRUMENT DIAGRAM
SPENT CAUSTIC TREATMENT PLANT
LIST OF DOCUMENTS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0003 Z1
451/4200
NOTES
ABBREVIATIONS LINES
LINE SERVICE DESIGNATION EQUIPMENT DESIGNATION LINE IDENTIFICATION GENERAL NOTES:
1. P & ID`S ARE ONLY SCHEMATIC AND INDICATIVE OF

000 - P - 010 - 1101 - A1AP - IH RELATIVE POSITIONS OF EQUIPMENT.
PROCESS LINES OTHERS
AC ACID 2. ONLY HIGH VENTS AND DRAINS THAT HAVE A
P PROCESS CA A T PROCESS RELATED FUNCTION ARE SHOWN.
CAUSTIC PACKAGED UNITS TURBINE
INSULATION TRACING TYPE
PSC SPENT CAUSTIC AM AMINE AC AIR COOLERS TE THERMISTOR 3. A GATE VALVE WITH SCREWED CAP OR BLIND
PSO OXIDISED CAUSTIC C AP TH FLANGE IS TO BE PROVIDED FOR ALL VENTS ON
OTHER CHEMICALS ALARM PANEL TANK HEATER TOWERS AND DRUMS.
PIPING MATERIAL SPECIFICATION
PTC TREATED CAUSTIC CO CARBON MONOXIDE APH AIR PRE-HEATERS TK TANKS
(NOTE 1)
PC PROCESS CONDENSATE CO2 CARBON DIOXIDE B STEAM GENERATORS AND BOILERS TM THERMOSTAT 4. DRAIN, VENT, BY-PASS AND START-UP VALVES ARE
LINE SEQUENCE NUMBER NORMALLY CLOSED.
CT CATALYST BAT BATTERY TR TRANSFORMERS
EGT ETHYLENE GLYCOL BC UPS UNINTERRUPTIBLE POWER SUPPLY 5.
WATER LINES BAROMETRIC CONDENSERS DRAIN AND VENT VALVES ARE TO BE INSTALLED
UNIT NUMBER BETWEEN ALL DOUBLE SHUT-OFF VALVES. PLEASE
RP PROPYLENE/PROPANE REFRIGERATION BCH BATTERY CHANGERS V VESSEL & DRUMS
WB BOILER FEED WATER REFER TO 3210-8110-PH-0001 FOR ISOLATION
RE ETHYLENE REFRIGERATION BD BUS DUCT VD VISIBILITY DETECTOR PHILOSOPHY.
WCS RO PERMEATE SUPPLY LINE SERVICE DESIGNATION
RA AMMONIA REFRIGERATION C COLUMNS & TOWERS VSD VARIABLE SPEED DRIVE
WCR RO PERMEATE RETURN 6. MANIFOLDS AND VALVES ON INSTRUMENTS ARE
ME METHANOL CA CAPACITOR BANK W WEIGHERS NOT SHOWN; PLEASE REFER TO TYPICAL
WDK DRINKING WATER LINE SIZE (IN MILLIMETRES)
ETH ETHANOL CB WHB WASTE HEAT BOILER ARRANGEMENTS SECTION FOR DETAILED TYPICAL
CIRCUIT BREAKER
WDM DEMINIRALIZED WATER SCHEMATICS.
BE BENZENE CH BATTERY CHARGER X EXTRUDERS
WF FIRE WATER
ST STYRENE CIP CLEAN INTERFACE Y MISCELLANEOUS
LINE LEGEND 7. LINES TO FLARE SHALL SLOPE DOWN TOWARDS
WGR GLYCOL WATER RETURN
CO Z THE FLARE HEADER AND NOT CONTAIN ANY
CONVERTER LOADING ARMS
POCKETS.
WGS GLYCOL WATER SUPPLY PROCESS LINE
GENERAL ABBREVIATIONS CP CONTROL PANEL
WIR CHILLED WATER RETURN
CR MATERIAL CONVEYING EQUIPMENT
WIS AA AERATION AIR UTILITY LINE
CHILLED WATER SUPPLY
CS CONTROL STATION CONNECTORS AS BUILT
WP AG AERATION GAS
PROCESS WATER
AP CT COOLING TOWERS
WQ QUENCH WATER AIR PURGE B BURIED LINE
AR CY CYCLONES
WR RAW WATER AUTO RESET 14135 600-0001 OFF DRAWING CONNECTOR
AS
DB DISTRIBUTION BOARDS GENERAL NOTES
WRT TREATED WATER AERATION STEAM TRACED LINE
ATM ATMOSPHERE DCB D.C. DISTRIBUTION BOARDS - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
WS SERVICE WATER - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
BL DEW DE-WATERING SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
WT TEMPERED WATER BATTERY LIMIT JACKETED LINE 14137 600-0001 OFF UNIT CONNECTOR PDRP0451-8110-25-231-0008C.
DG DIESEL GENERATOR
BMS BURNER MANAGEMENT SYSTEM
STEAM & CONDENSATE LINES DR DRIERS (PROCESS,INSTRUMENT AIR, ETC) HOLDS
CC CORROSION PROBE DUCT
CMR CONTROL ROOM MANUAL RESET (FOR SOV) DS DESUPERHEATERS
SH HIGH PRESSURE STEAM BI-DIRECTIONAL OFF DRAWING
14138 600-0001
CSC CAR SEAL CLOSED E EXCHANGERS (SHELL & TUBE, DOUBLE PIPE, ETC) CONNECTOR
SHH HIGH HIGH PRESSURE STEAM
EB EARTH BAR DEFERRED FUTURE LINE / ITEM
SM CSO CAR SEAL OPEN
MEDIUM PRESSURE STEAM
D EJ EJECTORS
SL LOW PRESSURE STEAM DRAIN BI-DIRECTIONAL OFF UNIT
VENDOR LIMIT LINE 14139 600-0001
DCS DISTRIBUTED CONTROL SYSTEM EL ELECTRICAL LINES. CONNECTOR
CC CLEAN CONDENSATE
F HEATERS (FUMACES AND INCINERATORS)
CL ESD EMERGENCY SHUT DOWN
LOW PRESSURE CONDENSATE INSTRUMENT LINES
FA FLAME ARRESTORS 14140 UTILITY CONNECTOR
CM FB FULL BORE
MEDIUM PRESSURE CONDENSATE (INCLUDING FLUID CODE DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
FC FC FUSED CONTACTOR
CH FAIL CLOSE & PARTNER DRAWING NUMBER)
HIGH PRESSURE CONDENSATE MECHANICAL LINK SIGNATURE
FF FD FEEDERS P&ID N°
FOUNDATION FIELDBUS DATE
FH
AIR LINES FL FAIL LOCK FOG HORN REFERENCE DRAWINGS
ELECTRICAL SIGNAL 14141 600-0001 UTILITY OFF UNIT CONNECTOR
FMR FIELD MANUAL RESET (FOR SOV) FI INCINERATORS DRAWING NO. REV TITLE
AI INSTRUMENT AIR
FO FL FLARES
AP PLANT AIR FAIL OPEN
CAPILARY TUBING (FILLED SYSTEM)
G GENERATOR
GDS GAS DETECTION SYSTEM
AB BREATHING AIR
( )G GEAR UNIT SC- SAMPLE CONNECTION
HH HAND HOLE
PA PROCESS AIR SOFTWARE SIGNAL (WITH TYPE)
HLL GN FILTERS (SOLID SEPARATING EQUIPMENT)
IG INERT GAS (NITROGEN) HIGH LIQUID LEVEL
HS GT GAS TURBINES
HOSE STATION
PNEUMATIC SIGNAL
H
VENT LINES LC LOCKED CLOSED BINS, HOPPERS & SILOS
IP - P - 205 / 212 - 1234
INTERFACE POINT
LLL HE ANTI-CONDENSATION HEATER.
V LOW LEVEL LIQUID REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
VENT ATMOSPHERIC / OFF GAS HYDRAULIC SIGNAL
HS STORAGE SPHERES TP01 TERMINATION POINT
SV LO LOCKED OPEN
SAFETY VALVE OUTLET
(OTHER THAN FLARE ROUTING) MCR MAIN CONTROL PANEL ROOM IR INTERPOSED RELAY BOX
ELECTROMAGNETIC / SONIC SIGNAL Z1 06.05.15 ISSUED AS BUILT MK MM CU
ISL
FLARE LINES MOV MOTOR OPERATED VALVE ISOLATOR A3 10.12.12
REVIEW
MK MM CU
MW IV INVERTER
FAG ACID GAS FLARE MANWAY
ELECTROMAGNETIC / SONIC SIGNAL (UNGUIDED)
DESIGN CONDITIONS: A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
NC JA EDUCTORS (VACUUM EQUIPMENT) ISSUE FOR DESIGN (HAZOP

FAR NORMALLY CLOSED A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
AROMATIC FLARE
NLL JB JUNCTION BOX 1. X X
FHP NORMAL LIQUID LEVEL O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
HIGH PRESSURE FLARE
NNF NORMALLY NO FLOW JE EVAPORATORS O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
FLP LOW PRESSURE FLARE DESIGN TEMPERATURE (°C)
NO JS STATIC MIXER O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
FLT NORMALLY OPEN DESIGN PRESSURE (kg/cm2g)
LOW TEMPERATURE FLARE
K
LINE CHANGES ATTRIBUTE REV DATE DESCRIPTION BY CHKD APPD
NP NITROGEN PURGE COMPRESSORS, BLOWERS, FANS & EXHAUSTERS CASE 1 - 4
FPP P P FLARE
LT CLIENT:
OPC OFF PAGE CONNECTOR LIGHT FITTING
INDIAN OIL
DRAIN & BLOW DOWN LINES OSBL OUTSIDE BATTERY LIMIT M MIXERS AND AGITATORS CORPORATION
ACBD ACID CLOSED BLOW DOWN PB PUSH BUTTON
( )M MOTORS LIMITED
MCC MOTOR CONTROL CENTRE END OF LINE (LINE NUMBER CHANGE)
BD BLOW DOWN PLC PROGRAMMABLE LOGIC CONTROLLER LSTK:
WABAG
MOV MOTOR OPERATED VALVE
i
CBD CLOSED BLOW DOWN PSO POSITIVE SHUT OFF (CL. V) MATERIAL BALANCE POINT:
VA TECH WABAG
CBDH HIGH PRESSURE BLOWDOWN PV MS MOTOR STARTER (LOCAL) PIPING MATERIALS CLASS CHANGE
PROCESS VARIABLE VA TECH WABAG LIMITED
CCBD CAUSTIC CLOSED BLOW DOWN RO P PUMPS (ALL TYPES) XX-XX
No.11, MURRAY'S GATE ROAD,
RESTRICTION ORIFICE ALWARPET, CHENNAI-600 018, INDIA.
OWS OILY WATER SEWER SC PA PANELS INSULATION REQUIREMENTS CHANGE FILE NAME: REV:
SAMPLE CONNECTION
10-P2-D0015-018 Z1
SS SO PC EXTERNAL SUN SWITCH (PHOTO VOLTAIC CELL) SEQUENTIAL NUMBER
STORM SEWER STEAM OUT PACKAGE VENDOR:
CS SP PD PULSATION DAMPERS
CHEMICAL SEWER SET POINT HEAT TRACING REQUIREMENTS CHANGE LINDE ENGINEERING INDIA PVT. LTD.,
DW PRT POWER RECOVERY TURBINE VADODARA-GUJARAT
DRAIN WATER (CLEAN) SRR SATELLITE RACK ROOM
CRWSCONTAMINATED RAIN WATER SEWER R REACTORS
TGS TANK GAUGING SYSTEM SLOPE BREAK
DS RD RUPTURE DISKS LINDE DWG. NO. REV:
SANITARY SEWER TL TANGENT LINE
RR
&AG-P-FB 1002 Z1
.
RESISTOR (EARTHING)
TSO TIGHT SHUT OFF (CL. IV & V) MAX DESIGN PRESSURE / TEMPERATURE CHANGE
UTILITY OIL LINES RTD RESISTANCE TEMPERATURE DETECTOR PARADIP REFINERY PROJECT
UC UTILITY CONNECTION
DSO DI-SULPHIDE OIL RU REFRIGERATION UNIT Paradip, Orissa State, India
VAC VACUUM SUPPLY RESPONSIBILITY
SKO STRAIGHT KEROSENE OIL RX REACTOR ELECTRICAL This Drawing is the Property of
V VENT
FO FUEL OIL SG SWITCHGEAR
VF VENDOR FURNISHED and is lent without consideration other than the
HO HYDRAULIC OIL SC DESIGN RESPONSIBILITY
SAMPLE COOLERS Borrower's agreement that it shall not be
FLO FLUSHING OIL SK
NEW

TYPE OF INSULATION / TRACING TYPE STACKS
SL SILENCERS CONSTRUCTION STATUS BREAK (DEFERRED) for which it is specifically furnished. The apparatus
SO shown in the drawing is covered by patents
SOCKET OUTLET
STR STRAINERS MATERIAL BALANCE BREAK to Indian Oil Corporation Ltd and/or licensors, and is
IH HEAT CONSERVATION
SW SWITCH
PP PERSONAL PROTECTION
TITLE:
NI NO INSULATION
STG STEAM TURBINES
NOMINAL DIAMETER BREAK PIPING AND INSTRUMENT DIAGRAM
SU SUMP
CONSTRUCTION AREA BREAK SYMBOLOGY SHEET ABBREVIATIONS
SCALE: DWG NO: REV:
NTS
PDRP0451-8110-25-231-0004 Z1
451/4200
NOTES
PIPING VALVES AND COMPONENTS INSTRUMENT SYMBOLS FIRE & SAFETY SYMBOLS
VALVE NORMALLY OPEN

SG SIGHT GLASS FF
FIELD MOUNTED INSTRUMENT FIRE HYDRANT WITH MONITOR NOZZLE
CONTROL VALVE (FOUNDATION FIELDBUS)
VALVE NORMALLY CLOSED
(DOWNSTREAM SELF ACTUATING)
NC
GATE VALVE ST STEAM TRAP
CONTROL VALVE FIELD MOUNTED INSTRUMENT
(UPSTREAM SELF ACTUATING) FIRE HYDRANT 2-WAY
GATE VALVE NORMALLY CLOSED
AT AIR TRAP
NC P LOCAL PANEL
GLOBE VALVE
UNION PILOT OPERATED VALVE
REAR LOCAL PANEL INSTRUMENT FIRE HYDRANT 3-WAY
CHECK VALVE
BLIND FLANGE
BUTTERFLY VALVE CONTROL VALVE WITH HANDWHEEL CONTROL ROOM PANEL MOUNTED INSTRUMENT
FOAM CHAMBER
PLUG VALVE
REAR CENTRAL PANEL MOUNTED INSTRUMENT
CAP THREADED
HOSE RACK STATION
BALL VALVE CYLINDER/ PISTON OPERATED VALVE
DUTY
CAP WELDED SELECTION
SWITCH
NEEDLE VALVE M
HOSE COUPLING/ADAPTOR
DUTY SELECTION SWITCH
HOSE REEL
DIAPHRAGM VALVE MOTOR OPERATED VALVE
S
ANGLE VALVE
DRIP RING
SOLENOID VALVE (2 WAY)
SLOP Down
E AS BUILT
FIRE MONITOR
SLOPE (DOWNWARD) S
R DCS FUNCTION
SOLENOID VALVE(3WAY) WITH
BLOWDOWN ANGLE VALVE Up
SLOPE MANUAL RESET.
SLOPE (UPWARD)
SHARED DIPLAY DEVICES WITH LIMITED ACCESS GENERAL NOTES
TO ADJUSTMENTS LOCATED IN FIELD - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
S FIRE MONITOR ELEVATED
FLAME ARRESTOR - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
ANGLE GLOBE VALVE SOLENOID VALVE (3 WAY) AUXILLARY OPERATORS INTERFACE DEVICE FOR EXAMPLE PDRP0451-8110-25-231-0008C.
BACK UP CONTROLLER OR MANUAL STATION
FLEXIBLE LINE/HOSE HOLDS
S
COMPUTER COMPONENTS NOT ACCESSIBLE TO OPERATOR LIKE I/O
INTERFACE BUND CONTROLLER OR SOFTWARE CALCULATION BOX
DUAL COIL SOLENOID VALVE (4 WAY) FIRE MONITOR REMOTE OPERABLE
PULSATION DAMPENER
ANGLE CHECK VALVE
S
INDICATOR CONTROLLER / RECORDER OR ALARM POINT NORMALLY
ACCESSIBLE TO OPERATOR THROUGH VIDEO DISPLAY
SP FLOW ELEMENT (ORIFICE)
3 WAY VALVE SPECIAL PIPING
AUXILLARY COMPUTER COMPONENTS NORMALLY ACCESSIBLE
TO OPERATOR
FOAM MONITOR
INSTRUMENT SYMBOLS TURBINE METER /
SIGNATURE
4 WAY VALVE PROGRAMMABLE LOGIC CONTROLLER LIMITED ACCESS
TO OPERATOR DATE
REFERENCE DRAWINGS
PRESSURE/ VACUUM SAFETY VALVE PD METER FOAM MONITOR ELEVATED
DRAIN VALVE WITH PLUG DRAWING NO. REV TITLE
IZ
ESD INTERLOCK FUNCTION
DRAIN VALVE WITH BLIND FLANGE PILOT OPERATED RELIEF VALVE VORTEX
I
DCS INTERLOCK FUNCTION FOAM MONITOR REMOTE OPERABLE
DRAIN WITH THREADED CAP PRESSURE / THERMAL SAFETY VALVE ULTRA SONIC METER SUBSYSTEM / PLC FUNCTION ENGINEER'S APPROVAL APPROVED FOR CONST
EG. TANK GAUGING SYSTEM (TGS)
TGS REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
STOP CHECK VALVE RELIEF RUPTURE DISC M MAGNETIC METER EYE WASH
ISSUED AS BUILT
FUNCTION BLOCKS-FUNCTION DESIGNATIONS Z1 06.05.15
MK MM CU
A3 10.12.12 MK MM CU
REVIEW
SWING ELBOW A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
VACUUM VALVE PITOT TUBE ISSUE FOR DESIGN (HAZOP
NO. FUNCTION A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
REMOVABLE SPOOL
RS 1 SUMMING
O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
T- TYPE STRAINER 2 AVERAGING SAFETY SHOWER O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

ANNUBAR n
BACK PRESSURE VALVE REV DATE DESCRIPTION BY CHKD APPD
3 DIFFERENCE CLIENT:
Y-TYPE STRAINER
INDIAN OIL
4 PROPORTIONAL K
VENTURI METER CORPORATION
TS TEMPORARY STRAINER
5 INTEGRAL
LIMITED
CONTROL VALVE (GENERAL / GLOBE)
LSTK:
SAFETY SHOWER & EYE WASH WABAG
SEGMENTAL WEDGE FLOWMETER 6 DERIVATIVE d/dt
CONE TYPE STRAINER
VA TECH WABAG
7 MULTIPLYING X VA TECH WABAG LIMITED
BASKET STRAINER ALWARPET, CHENNAI-600 018, INDIA.
CONTROL VALVE (BALL) STRAIGHTENING VANES 8 DIVIDING REV:
FILE NAME: 10-P2-D0015-019 Z1
n PACKAGE VENDOR:
9 ROOT EXTRACTION PRE-ACTION SPRINKLER
SPECTACLE BLIND NORMALLY OPEN
n
CORIOLIS METER 10 EXPONENTIAL X VADODARA-GUJARAT
SPECTACLE BLIND NORMALLY CLOSED CONTROL VALVE (DIAPHRAGM) SPRAY SPRINKLER
NON LINEAR OR
11 f(x)
FI UNSPECIFIED FUNCTION LINDE DWG. NO. REV:
ROTAMETER WET SPRINKLER
&AG-P-FB 1003 .
Z1
RING SPACER 12 TIME FUNCTION f(t)
13 HIGH SELECTING
SPADE BLIND CONTROL VALVE (BUTTERFLY) RTU REMOTE TRANSMISSION UNIT
ALARM ABBREVIATIONS Paradip, Orissa State, India
DIAPHRAGM SEAL 14 LOW SELECTING This Drawing is the Property of
OPEN DRAIN FUNNEL H HIGH VALUE ALARM
15 HIGH LIMITING and is lent without consideration other than the
3 WAY CONTROL VALVE LOCAL INDICATING LAMP Borrower's agreement that it shall not be
16 LOW LIMITING
EXPANDER REDUCER CONCENTRIC HH HIGH HIGH VALUE ALARM indirectly, nor used for any purpose other than that
17 REVERSE PROPORTIONAL -K shown in the drawing is covered by patents
EXPANDER REDUCER ECCENTRIC L LOW VALUE ALARM information contained in this drawing may be proprietary
CONTROL VALVE (ANGLE TYPE) MAIN PANEL INDICATING LAMP to Indian Oil Corporation Ltd and/or licensors, and is
BELLOWS LL LOW LOW VALUE ALARM
BIAS TITLE:
18 PIPING AND INSTRUMENT DIAGRAM
FLANGE SET/ SPOOL, ISOLATING
IA
LOCAL PANEL INDICATING LAMP SPENT CAUSTIC TREATMENT PLANT
INSTRUMENT AIR
SYMBOLOGY SHEET PIPING & INSTRUMENTS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0005 Z1
451/4200
INSTRUMENTATION SYMBOLS AND LEGEND NOTES
1. ROOT / BLOCK VALVES / MONOFLANGES WILL NOT
IDENTIFICATION LETTERS BE SHOWN ON P&ID.
DCS FUNCTION INSTRUMENT TYPICAL ARRANGEMENTS 2. REFER TO VENT AND DRAIN SPECIFICATION
(PREPARED BY PIPING GROUP), INSTRUMENT /
FIRST LETTER SUCCEEDING - LETTERS
PIPING INTERFACE STANDARD (PREPARED BY
READOUT OR FY H INSTRUMENT GROUP) FOR ISOLATION AND
MEASURED OR INTIATING VARIABLE MODIFIER OUTPUT FUNCTION MODIFIER H H H CONNECTION DETAIL.
PASSIVE FUNCTION XY XXXX L LY PY 3. LEVEL TRANSMITTER TYPE.
A ANALYSIS ALARM XXXX AT
H XXXX XXXX TT
H
AI TY 4. FIRST ISOLATION VALVE SHALL BE LOCKED OPEN.
PIPING
L L L
C&I
B BURNER, COMBUSTION USERS CHOICE USERS CHOICE USERS CHOICE XXXX XXXX FT LI XXXX XXXX
L L LT
C USERS CHOICE CONTROL XT AE XXXX XXXX TE
XXXX
D USERS CHOICE DIFFERENTIAL XXXX XXXX LT PDT XXXX X TRANSMITTER TYPE
DETAIL
E VOLTAGE SENSOR (PRIMARY ELEMENT) C&I H LT XXXX XXXX
LY TW
C&I C&I PIPING X C&I
F FLOW RATE RATIO (FRACTION) PIPING PIPING XXXX XXXX XXXX
L PIPING
X C&I CA CAPACITANCE
G MOTOR STATUS GLASS VIEWING DEVICE PIPING
RADAR RADAR TYPE
PIPING
H HAND (MANUALLY) OPERATED HIGH
RF RADIO FREQUENCY
C&I
I CURRENT (ELECTRICAL) INDICATE SERVO SERVO TYPE
J POWER SCAN US ULTRASONIC
RADIATION RADIATION TYPE
K TIME, TIME SCHEDULE TIME RATE OF CHANGE CONTROL STATION FE GW RADAR GUIDED WAVE RADAR
L LEVEL LIGHT LOW ZZZZ M MAGNETIC
M USERS CHOICE MOMENTARY MIDDLE INTERMEDIATE
N USERS CHOICE USERS CHOICE USERS CHOICE USERS CHOICE
TRANSMITTER TYPE
O USERS CHOICE ORIFICE RESTRICTION
H H H H H H H LT
XY AI FY LY LY PY TY
P PRESSURE, VACUUM POINT (TEST) CONNECTION XXXX XXXX XXXX XXXX L XXXX XXXX XXXX XXXX
L L L L L L X
Q QUANTITY, QUALITY INTEGRATE TOTALLIZE LT LI
R RADIATION RECORD XT AT FT XXXX XXXX PDT TT DP DIFFERENCIAL PRESSURE
P&ID NOTE 1,2

S SPEED, FREQUENCY SAFETY SWITCH XXXX XXXX XXXX X LT XXXX XXXX DISPLACER DISPLACER TYPE
X
T TEMPERATURE TRANSMIT XXXX
X-SEE NOTE 3 FOR X
U MULTI VARIABLE MULTI FUNCTION MULTIFUNCTION MULTI FUNCTION TRANSMITTER TYPE
AS BUILT
V VIBRATION, MECHANICAL ANALYSIS VALVE, DAMPNER LOUVER Y-APPLICABLE SUCCEEDING
X-MEASURED VARIABLE X-DEFINE ANALYSER TYPE
Y-APPLICABLE LETTER AS SHOWN ON P&ID Y-APPLICABLE SUCCEDING
W WEIGHT, FORCE WELL AS SHOWN ON P&ID SUCCEEDING LETTER LETTER AS SHOWN ON P&ID
X UNCLASSIFIED X AXIS UNCLASSIFIED UNCLASSIFIED UNCLASSIFIED AS SHOWN ON P&ID
Y-APPLICABLE SUCCEEDING Y-APPLICABLE SUCCEDING GENERAL NOTES
Y EVENT, STATE OR PRESENCE Y AXIS RELAY, COMPUTE, CONVERT LETTER AS SHOWN ON P&ID LETTER AS SHOWN ON P&ID - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
DRIVER, ACTUATOR UNCLASSIFIED X-SEE NOTE 3 FOR - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
Z POSITION DIMENSION Z AXIS TRANSMITTER TYPE
FINAL CONTROL ELEMENT SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
PDRP0451-8110-25-231-0008C.
Y-APPLICABLE SUCCEEDING
LETTER AS SHOWN ON P&ID
ESD TRIP 2OO3 VOTING INSTRUMENT TYPICAL ARRANGEMENTS HOLDS
PIPING
HH ESD TRIP INSTRUMENT TYPICAL ARRANGEMENTS
C&I
XA FZT TA
XXXX 1oo3 XXXXA LA LZAHH XXXX
1oo3 IZ FZAHH
IZ XXXX XXXX IZ
PIPING
HH 1oo3 HH
ZZZZ XXXX HH
C&I
ZZZZ XZAHH FZT FA ZZZZ TZAHH XZT IZ XZAHH LZAHH TZT IZ TZAHH
XXXX XXXXB XXXX XXXX XXXX ZZZZ XXXX HH XXXX XXXX ZZZZ XXXX
1oo3 HH HH HH FZT
IZ DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
IZ LZT LZT LZT TE
HH ZZZZ HH HH HH C&I XXXX SIGNATURE
DETAIL
HH HH HH FZT FZAHH ZZZZ XXXXA XXXXB XXXXC TZT TZT TZT PIPING IZ LZT HH TW XXXX
DETAIL
X DATE
XXXXC XXXX X X XXXXA XXXXB XXXXC XXXX
XZT XZT XZT C&I C&I ZZZZ XXXX
X REFERENCE DRAWINGS
XXXXA XXXXB XXXXC TE TE TE PIPING PIPING
NOTE 4 XXXXA XXXXB XXXXC
PIPING
C&I C&I C&I
C&I
PIPING PIPING PIPING TW TW TW
XXXX A XXXX B XXXX C
C&I PIPING PIPING C&I
FE
FE XXXX
XXXX
(600-0050) ENGINEER'S APPROVAL APPROVED FOR CONST
IZ IZ IZ REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
ZZZZ ZZZZ
IZ IZ IZ ZZZZ
P&ID NOTE 1,2

ZZZZ ZZZZ ZZZZ
HH HH HH Z1 06.05.15 REVISED AS PER 90% DESIGN MK MM CU
P&ID NOTE 1,2
XZT FZT HH REVISED AS PER 90% DESIGN

TZT A3 10.12.12
REVIEW
MK MM CU
HH HH HH HH XXXX IZ LZT
XZT FZT IZ LZT TZT XXXX XXXX A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
ZZZZ XXXX
ISSUE FOR DESIGN (HAZOP
2oo3 XXXX 2oo3 XXXX ZZZZ XXXX A,B,C XXXX X A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
A,B,C A,B,C 2oo3 2oo3 A,B,C
X O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK

X-MEASURED VARIABLE X-SEE NOTE 3 FOR
AS SHOWN ON P&ID TRANSMITTER TYPE O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
X-MEASURED VARIABLES AS REV DATE DESCRIPTION BY CHKD APPD

SHOWN ON P&ID X-SEE NOTE 3 FOR TRANSMITTER TYPE. CLIENT:
INDIAN OIL
CORPORATION
ACTUATED VALVE TYPICAL ARRANGEMENTS ACTUATED VALVE TYPICAL ARRENGEMENTS LIMITED
ON/OFF VALVE WITH DCS INTERLOCK / DCS ON/OFF VALVE WITH ESD TRIP, MANUAL TRIP ON/OFF VALVE WITH ESD TRIP AND PARTIAL LSTK:
ON/OFF VALVE WITH ESD TRIP AND MANUAL TRIPON/OFF VALVE WITH ESD TRIP
POSITION AND PARTIAL STROKE TESTING STROKE TESTING WABAG
H RESET RESET
HS HL TRIP RESET TRIP RESET RESET VA TECH WABAG
H XXXX XXXX HS HZS HZS HZS HZS HZS HZS VA TECH WABAG LIMITED
YIC IZ YL L I IZ IZ IZ IZ
XXXX ZZZ XXXX ZZZZ XXXX ZZZ XXXXB XXXXA ZZZZ XXXX ZZZZ XXXXB XXXXA ZZZZ XXXX ALWARPET, CHENNAI-600 018, INDIA.
L REV:
FILE NAME: 10-P2-D0015-020 Z1
S HS H XL H XL H XL H XL H XL H PACKAGE VENDOR:
DETAIL
DETAIL
S YS H XXXX XXXX XXXX HS XXXX HS XXXX LINDE ENGINEERING INDIA PVT. LTD.,
IA L L L L L
VADODARA-GUJARAT
XC XXXX XXXX
IA H IA H IA H H H
HS XXXX XS XS XS XS XS
LINDE DWG. NO. REV:
YS
XXXX XXXX XXXX XY XXXX XY XXXX &AG-P-FB 1004A Z1
L L L L L L
L H OPEN HV XV
XXXX
XV XZV XZV XXXX XZV XXXX XZV PARADIP REFINERY PROJECT
H OPEN YV L CLOSED IA XXXX
XXXX XXXX XXXX XXXX XXXX Paradip, Orissa State, India
L CLOSED XXXX
IA IA IA
ESD LOGIC Borrower's agreement that it shall not be
ZZZ SEQUENCE YIC HS HZS HS HZS reproduced, copied lent or disposed of directly or
NUMBER FOUR DIGIT indirectly, nor used for any purpose other than that
XXXX XXXX XC XXXX XXXX XXXX
XXXX SEQUENCE for which it is specifically furnished. The apparatus
FOUR DIGIT NUMBER XXXX shown in the drawing is covered by patents
XXXX SEQUENCE
FOUR DIGIT H information contained in this drawing may be proprietary
NUMBER IZ X MEASURED
XXXX SEQUENCE HV ESD LOGIC I ESD LOGIC IZ ESD LOGIC IZ ESD LOGIC IZ ESD LOGIC HS IZ to Indian Oil Corporation Ltd and/or licensors, and is
P&ID
P&ID
S
Y VARIABLE AS subject to obligations of confidentiality.

MEASURED VARIABLE ZZZ NUMBER XXXX L XV ZZZZ SEQUENCE ZZZZ ZZZZ SEQUENCE ZZZZ ZZZZ SEQUENCE ZZZZ ZZZZ SEQUENCE ZZZZ ZZZZ SEQUENCE XXXX ZZZZ
SHOW ON
AS SHOWN ON P&ID NUMBER NUMBER NUMBER NUMBER NUMBER
H H OPEN P&ID XXXX TITLE:
H OPEN
YV
L CLOSED FOUR DIGIT H FOUR DIGIT H FOUR DIGIT H FOUR DIGIT H FOUR DIGIT H PIPING AND INSTRUMENT DIAGRAM
XXXX
L CLOSED L XXXX SEQUENCE XV XXXX SEQUENCE XZV XXXX SEQUENCE XZV XXXX SEQUENCE XZV XXXX SEQUENCE XZV
POSITION OF PROXIMITY NUMBER XXXX NUMBER XXXX NUMBER XXXX NUMBER XXXX NUMBER XXXX
POSITION OF PROXIMITY SWITCH SHALL BE THE L L L L L INSTRUMENTATION SYMBOLES AND LEGEND
SWITCH SHALL BE THE FAILED POSITION OF VALVE H OPEN H OPEN H OPEN H OPEN H OPEN
FAILED POSITION OF VALVE SCALE: DWG NO: REV:
L CLOSED L CLOSED L CLOSED L CLOSED L CLOSED
NTS PDRP0451-8110-25-231-0006AA Z1
451/4200
NOTES
1. ROOT / BLOCK VALVES / MONOFLANGES WILL NOT
EMERGENCY DEPRESSURISATION VALVE TYPICAL ARRANGEMENTS MOV TYPICAL ARRANGEMENT LOCAL GAUGE TYPICAL ARRANGEMENTS-APPLICABLE BE SHOWN ON P&ID.
2. REFER TO VENT AND DRAIN SPECIFICATION
TO PRESSURE, TEMPERATURE AND FLOW. (PREPARED BY PIPING GROUP), INSTRUMENT /
PIPING INTERFACE STANDARD (PREPARED BY
INSTRUMENT GROUP) FOR ISOLATION AND
CONNECTION DETAIL.
HZS HZS IZ
LOCAL/ 3. LEVEL TRANSMITTER TYPE.
XXXXA XXXXB ZZZZ CLOSED OPEN REMOTENOT IN REMOTE
MHS MHS MHS MHA ML H LT
H XXXXA XXXXB XXXXC XXXX XXXX L XXXX
DETAIL
HZL
S X TRANSMITTER TYPE
S NDE NDE XXXX
L H
MS XG TG
XXXX XXXX CA CAPACITANCE
IZ RADAR RADAR TYPE
C&I RF RADIO FREQUENCY
ZZZZ MOV MS PIPING TW
+
M + SERVO SERVO TYPE
XXXX XXXX
US ULTRASONIC
H L
HZS RADIATION RADIATION TYPE
XXXX GW RADAR GUIDED WAVE RADAR
PG HZV
+ L
XXXX XXXX
TRANSMITTER TYPE
IA LT
FO
XXXX
X
DP DIFFERENCIAL PRESSURE
DISPLACER DISPLACER TYPE
4. FIELD MOUNTED ELECTRICAL LOCAL CONTROL

STATIONS (LCS) NOT SHOWN FOR CLARITY. FOR
IZ MHS DETAILS OF LCS TYPE, REFER TO UNIT CONTROL
ZZZZ XXXX FOUR DIGIT XXXX INDICATION SCHEDULE
ESD LOGIC
SEQUENCE
ZZZZ SEQUENCE
NUMBER XG TG
NUMBER H AS BUILT
P&ID
HZV
H MOV XXXX XXXX
FOUR DIGIT
XXXX SEQUENCE
+
M +
XXXX XXXX
NUMBER L L
H OPEN
GENERAL NOTES
L CLOSED FO X MEASURED
NOTE 4 - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
VARIABLE AS SHOWN - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
ON P&ID SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
PDRP0451-8110-25-231-0008C.
HOLDS
MOTOR CONTROL TYPICAL ARRANGEMENTS
LOW VOLTAGE FIXED SPEED LOW VOLTAGE FIXED SPEED FIXED SPEED LV DRIVE WITH ESD FIXED SPEED LV DRIVE WITH ESD FIXED SPEED DRIVE WITH DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
VARIABLE SPEED DRIVE
TRIP & AUTO START FROM DCS SIGNATURE
MOTOR (CRITICAL) MOTOR (NON-CRITICAL) & AUTO START FROM ESD ESD TRIP
DATE
REFERENCE DRAWINGS
RUN AVAILABLE FAULT RUN AVAILABLE FAULT RUN AVAILABLE FAULT RUN AVAILABLE FAULT RUN AVAILABLE FAULT RUN AVAILABLE FAULT
ML ML ML ML ML ML MZL MZL MZL ML ML ML ML ML ML ML ML ML
XXXXA XXXXB XXXXC XXXXA XXXXB XXXXC XXXXA XXXXB XXXXC XXXXA XXXXB XXXXC XXXXA XXXXB XXXXC XXXXA XXXXB XXXXC
SWITCHGEAR
LOCAL STOP
LOCAL STOP LOCAL STOP REPEAT SIGNAL
IZ
DETAIL
REPEAT SIGNAL REPEAT SIGNAL ENGINEER'S APPROVAL APPROVED FOR CONST

MCC M MCC M MCC M ZZZZ TRIP MCC M IRP M IRP VSD M
RUN REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
IZ IZ AVAILABLE MS AUTO START
TRIP
IRP IRP IRP
ZZZZ ZZZZ FAULT XXXXA
LOCAL STOP TRIP Z1 06.05.15 ISSUED AS BUILT MK MM CU
TRIP AUTO START IZ REPEAT SIGNAL IZ
MS STOP LOCAL STOP A3 10.12.12
MK MM CU
REVIEW
TRIP XXXXB ZZZZ ZZZZ REPEAT SIGNAL
A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

CLIENT:
INDIAN OIL
CORPORATION
RUN RUN RUN RUN RUN RUN LIMITED
IZ ML ML IZ ML IZ MS ML IZ ML IZ ML
AVAILABLE AVAILABLE AVAILABLE AVAILABLE AVAILABLE AVAILABLE LSTK:
ZZZZ XXXX FAULT XXXX FAULT ZZZZ XXXX FAULT ZZZZ XXXX XXXX FAULT ZZZZ XXXX FAULT ZZZZ XXXX FAULT WABAG
ESD LOGIC ESD LOGIC ESD LOGIC AUTO/STOP ESD LOGIC VA TECH WABAG
P&ID
ZZZZ SEQUENCE ZZZZ SEQUENCE ZZZZ SEQUENCE ZZZZ SEQUENCE VA TECH WABAG LIMITED
NUMBER NUMBER NUMBER NUMBER No.11, MURRAY'S GATE ROAD,
ALWARPET, CHENNAI-600 018, INDIA.
FOUR DIGIT FOUR DIGIT FOUR DIGIT FOUR DIGIT
XXXX SEQUENCE M M XXXX SEQUENCE M XXXX SEQUENCE M XXXX SEQUENCE M VSD FILE NAME: 10-P2-D0015-020 REV:
Z1
NUMBER NUMBER NUMBER NUMBER
PACKAGE VENDOR:
NOTE 4 NOTE 4 NOTE 4 NOTE 4 NOTE 4 LINDE ENGINEERING INDIA PVT. LTD.,
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FB 1004B Z1

TITLE:
INSTRUMENTATION SYMBOLS & LEGEND
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0006BB Z1
451/4200
NOTES
EQUIPMENT AND EQUIPMENT COMPONENT
HEAT TRANSFER EQUIPMENT MECHANICAL EQUIPMENT MATERIAL HANDLING AND MISCELLANEOUS
RECIPROCATING COMPRESSOR (MULTI STAGE)

LIQUID SEPARATOR CENTRIFUGE
PLATE HEATER
M
SHELL & TUBE
EXCHANGER HOPPER HOPPER CATALYST ADDITION PIPE HOIST SCREW CONVEYOR
CENTRIFUGAL COMPRESSOR SCREW COMPRESSOR
AIR COOLER
AIR FILTER BAG FILTER
CETRIFUGAL BLOWER FAN OR BLOWER
STACK
G S
EVAPORATOR CATRIDGE FILTER BASKET FILTER FEEDER BELT CONVEYOR
TANK TRUCK SCREW FEEDER DEFLECTOR PLATE
GAS TURBINE STEAM TURBINE
AS BUILT
MISCELLANEOUS
G A
PLATE HEAT EXCHANGER TOP EXCHANGERSCRUBBER EXCHANGER
GENERAL NOTES
AIR DRIVEN MOTOR
DOUBLE FLOW GAS TURBINE - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
- FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
PDRP0451-8110-25-231-0008C.
M HOLDS
SAMPLE COOLER SHELL & TUBE
HEAT EXCAHGER
D ELECTRIC MOTOR VENT FILTER DRYER
COOLING BOX
DIESEL ENGINE
INLINE SILENCER
GAS CYLINDER
H PROPELLER FAN
VENT SILENCER GRADUATED CYLINDER
ST
HYDRAULIC MOTOR DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
SIGNATURE
STEAM TRAP WITH DATE
DESUPERHEATER
STRAINER
REFERENCE DRAWINGS
M DRAWING NO. REV TITLE
STEAM GENERATOR HORIZONTAL PUMP PROPORTIONING PUMP

(NUMBER OF HEADS AS REQUIRED)
SINGLE STAGE CYCLONE
VERTICAL CENTRIFUGAL PUMP CAVITY PUMP

TEMA TYPE BEM
Z1 06.05.15 ISSUED AS BUILT MK MM CU

A3 10.12.12 MK MM CU
REVIEW
CANNED PUMP LOOP REACTOR PUMP ISSUE FOR DESIGN (HAZOP


DOUBLE PIPE HEAT EXCHNAGER O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM

CLIENT:
TANK HEATER
PARAMETRIC SUMP PUMP SYRINGE PUMP INDIAN OIL
CORPORATION
LIMITED
LSTK:
WABAG
NOTE 1 VA TECH WABAG

ROTARY PUMP VA TECH WABAG LIMITED
REV:
MACERATING PUMP FILE NAME: 10-P2-D0015-062 Z1
PACKAGE VENDOR:
DIAPHRAGM PUMP ELUTRIATOR VADODARA-GUJARAT
LINDE DWG. NO. REV:

MIXING AND BLENDING &AG-P-FB 1005A Z1

AGITATOR PROPELLER AGITATOR IN-LINE MIXER EJECTOR/EDUCTOR reproduced, copied lent or disposed of directly or
COOLING TOWER subject to obligations of confidentiality.
FURNACE HEATER BASIC SYMBOL
TITLE:
EDUCTOR MIXER
FINGER AGITATOR PADDLE AGITATOR RIBBON BLENDER
FLAT BLADE AGITATOR
LOUVRE SYMBOLOGY SHEETS EQUIPMENT
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0007.AB Z1
451/4200
NOTES
EQUIPMENT AND EQUIPMENT COMPONENT
VESSELS TANKS
MIST ELIMINATOR
PACKED BED
NOZZLE
1
BUBBLE CAP
2
SIEVE TRAY
3
HORIZONTAL DRUM
CHIMNEY DRAW OFF TRAY
DAF CELL
4
GENERIC VALVE
VERTICAL DRUM
INTERNAL FLOATING ROOF TANK WITH SUMP
FLUIDIZED BED
DISTRIBUTOR
AS BUILT
REDISTRIBUTION
GENERAL NOTES
- ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
GENERIC PRESETTLEMENT TANK / POND/SUMP SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
TOTAL DRAW-OFF TRAY PDRP0451-8110-25-231-0008C.
FLOATING ROOF TANK
HOLDS
REACTOR
CLOSED BLOWDOWN DRUM BAFFLE WITH PARTITION
PLATE
VORTEX BREAKER
TOWER
TOWER DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
SIGNATURE
DATE
REFERENCE DRAWINGS
MEDIA FILTER ENGINEER'S APPROVAL APPROVED FOR CONST


STORAGE SPHERE A3 10.12.12
REVIEW
MK MM CU


CLIENT:
INDIAN OIL
CORPORATION
LIMITED
LSTK:
WABAG
VA TECH WABAG
CONE ROOF TANK No.11, MURRAY'S GATE ROAD,
REV:
FILE NAME: 10-P2-D0015-062 Z1
PACKAGE VENDOR:
VADODARA-GUJARAT
WIPED FILM EVAPORATOR LINDE DWG. NO. REV:

FLAT COVER VESSEL DRYER &AG-P-FB 1005B Z1

FIBER CONTACTOR
FLASH DRUM for which it is specifically furnished. The apparatus
DOME ROOF TANK
LARGE HORIZONTAL VESSEL TITLE:
SYMBOLOGY SHEETS EQUIPMENT
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0007AB Z1
451/4200
NOTES
HEAT EXCHANGER FLUSHING AND DRAIN PLAN PUMP VENT/DRAIN/BLEEDER CONN. DETAILS SAMPLE COOLER/ COLLECTION DETAILS
1. FLARE CONNECTION ONLY FOR HIGH VAPOUR
IF MAIN LINE "IH" OR FLASHING SERVICES. ROUTE TO SUCTION
FLARE DISCHARGE
SC-1 VESSEL PREFERABLE.
TYPE 'A' PP IH DETAIL -'A' NOTE 1 PROCESS LINE 2. LOCATION OF DRAIN CONNECTIONS AT LOW POINT
TYPE 'E' NOTE 3 FOR SAMPLING LIQUIDS
NOTE 3 FOR PUMPS IF MAIN LINE "IH" ON PIPING LOCAL TO ENCHANGER WHERE LOW
AT OR LOWER THAN 55°C
POINTS EXIST ONLY.
50 UTILITY
PP SPEC 20 3. LOCATION OF VENTS AT HIGH POINT ON PIPING,
IF MAIN LINE "IT" IH PP LOCAL TO AND ABOVE EXCHANGER.
IT PS
20x10
BOTTOM NOZZLE BOTTOM NOZZLE 20
NOTE 2 PP
NOTE 2 IF MAIN LINE "IH"
BOTTOM IF MAIN BOTTOM
IH
NOZZLE LINE "IH" NOZZLE
50 50 50 50 FOR NON-HYDRO CARBON
IH IH
SUCTION SERVICE DO NOT
PP IF MAIN PP PROVIDE CBD
NOTE 2 NOTE 2
IF MAIN 50 IF MAIN
LINE "IT" 50
M
LINE "IT" LINE "IT"
NC IF MAIN LINE "IT" 15 CCBD
PP IH PP IH 20
PROCESS PROCESS PROCESS PROCESS PROCESS IF MAIN LINE "IT"
PROCESS
50 IT 50 20
PROCESS LINE
IT SPEC 50 SPEC 15 IT SPEC 50 50 IT SPEC IT 20 IT 50 SPEC SC-2
SPEC
IF MAIN IF MAIN PROCESS
PP UTILITY UTILITY PP PP UTILITY PP UTILITY PP UTILITY PP UTILITY 20 20 SAMPLING LIQUIDS ABOVE
LINE "IH" LINE "IH" SPEC IT 20x10
SPEC SPEC SPEC SPEC SPEC SPEC 55°C CONGEALING SERVICE MIN 25-A3A
COOLING WATER OUT

OWS UTILITY PP
SPEC
50X20
PROCESS
FLO CBD OWS FLO CBD OWS CBD OWS CBD OWS SPEC
OWS CBD UTILITY
SERVICE: S/S & T/S CONGEALING HC S/S & T/S NONCONGEALING HC SPEC
10 TUBING
PIPING TO
TUBING DIRECTED
IF MAIN LINE "IH" PUMP
CONNECTION TOWARDS
SUCTION LINE 20
OWS
PP IH
NOTE 3 NOTE 3 AS BUILT
TYPE 'B' DETAIL -'B'
TYPE 'F' 10
50 STANDARD CBD CONNECTION
15
LOCATE AT LOW GENERAL NOTES
POINT CLOSE LP STEAM 500
BOTTOM NOZZLE TO SUCTION - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
IF MAIN LINE "IH" MM - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
VALVE INCASE
NOTE 2 NOTE 2 IH 50 OF PUMP SUCTION
BOTTOM PDRP0451-8110-25-231-0008C.
IF MAIN LINE "IH" IS
NOZZLE 25
NOTE 2 COOLING OWS HOLDS
IH 50 WATER IN
NOTE 2
IF MAIN 50 PP
LINE "IT" IF MAIN
NC LINE "IT" PROCESS SC-3
PP IH SPEC 50 50 IT
PROCESS PROCESS PROCESS SAMPLING LIQUIDS ABOVE 55°C
IT SPEC 50 SPEC 50 IT 20 IT SPEC 50 20 UTILITY PP NONCONGEALING SERVICE
IF MAIN SPEC IF MAIN LINE "IT"
PROCESS LINE
PP UTILITY UTILITY PP LINE "IH" PP UTILITY
SPEC SPEC SPEC
20 MIN 20x10
25-A3A
COOLING WATER OUT

SIGNATURE
FLO CBD OWS CBD OWS CBD OWS
DATE
S/S CONGEALING HC. T/S NON HC S/S NON HC T/S NON CONGEALING HC REFERENCE DRAWINGS
IF MAIN LINE "IH" 10 TUBING
DETAIL -'C' DIRECTED

NOTE 3 TOWARDS
TYPE 'C' PP IH
TYPE 'G' FOR AIR COOLER EXCHANGER 50 VENT OWS
NOTE 3
50
10
BOTTOM NOZZLE REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
BOTTOM NOZZLE NOTE 2 500
NOTE 2 IF MAIN MM
LINE "IH" 25
BOTTOM IF MAIN LINE "IH" NOTE 2 COOLING WATER IN Z1 06.05.15 ISSUED AS BUILT MK MM CU
NOZZLE 50 50 50 IH A3 10.12.12
MK MM CU
REVIEW
IH 50 PP 40 (TYP) A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
NOTE 2 IF MAIN OWS
IF MAIN 50 PP LINE "IT" 40x20 ISSUE FOR DESIGN (HAZOP
IF MAIN A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
LINE "IT" IF MAIN LINE "IT" LINE "IT"
NC 50 SC-4 O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
PP IH O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
PROCESS PROCESS PROCESS PROCESS PROCESS 25 FOR HIGHLY VOLATILE LIQUIDS AND SOUR WATER
IT SPEC 50 50 IT 20 IT SPEC 50 20 IT SPEC 50 50 IT 20 O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
SPEC SPEC VENT TO FLARE
IF MAIN PROCESS LINE
PPUTILITY UTILITY PP PPUTILITY PP UTILITY PP UTILITY 40 20 OR LOW PRESS. REV DATE DESCRIPTION BY CHKD APPD
LINE "IT"
SPEC SPEC SPEC SPEC SPEC PROCESS PIPING CLIENT:
FOR NON-HYDROCARBON SERVICE 20 INDIAN OIL
DO NOT PROVIDE CBD CORPORATION
20 LIMITED
FLO CBD OWS CBD OWS FLO CBD OWS 20
PIPING TO TUBING LSTK:
CBD OWS CONNECTION WABAG
S/S CONGEALING HC. TS NONCONGEALING HC S/S NON HC T/S CONGEALING HC
20x10 VA TECH WABAG
PIPING CLIENT PIPING TO TUBING No.11, MURRAY'S GATE ROAD,
SAMPLE BOMB ALWARPET, CHENNAI-600 018, INDIA.
CONNECTION
DETAIL -'D' 10 FILE NAME: 10-P2-D0015-063 REV:
Z1
TYPE 'D' TYPE 'H' FUEL GAS/STEAM PURGE CONNECTION PACKAGE VENDOR:
NOTE 3 NOTE 3 CLIENT PIPING
FOR UNIT FLARE HEADER
VADODARA-GUJARAT
SC-5
VENT TO FLARE
SAMPLING LIQUID ABOVE 55°C / HIGHLY
OR LOW PRESS. REV:
VOLATILE LIQUIDS AND SOUR WATER LINDE DWG. NO.
BOTTOM NOZZLE FI
PROCESS PIPING &AG-P-FB 1006A Z1
PROCESS LINE
NOTE 2 PARADIP REFINERY PROJECT
BOTTOM IF MAIN LINE "IH" BOTTOM NOTE 2 IF MAIN 20x10
NOZZLE NOZZLE LINE "IH"
20 MIN 25
COOLING WATER OUT 20
IH PP 50 50 50 50 IH FO This Drawing is the Property of
NOTE 2
50x20 NOTE 2 PP INDIAN OIL CORPORATION LTD
IF MAIN
PP IH PIPING and is lent without consideration other than the
LINE "IT"
50 IF MAIN TO TUBING Borrower's agreement that it shall not be
LINE "IT" FUEL GAS CONN. reproduced, copied lent or disposed of directly or
IF MAIN LINE "IT" IF MAIN SAMPLE BOMB
10 indirectly, nor used for any purpose other than that
LINE "IH" STEAM LC
PROCESS PROCESS PROCESS PROCESS for which it is specifically furnished. The apparatus
IT SPEC 50 20 50 IT 20 50 50 IT 20 shown in the drawing is covered by patents
SPEC IT SPEC SPEC
UTILITY PIPING CLIENT CLIENT PIPING information contained in this drawing may be proprietary
PP UTILITY UTILITY PP PP UTILITY PP PG to Indian Oil Corporation Ltd and/or licensors, and is
SPEC SPEC SPEC SPEC
TITLE:
CBD OWS CBD OWS FLO CBD OWS MIN. SPENT CAUSTIC TREATMENT PLANT
25
COOLING P&ID TYPICAL DETAILS
S/S NONCONGEALING HC. T/S NON HC S/S NONCONGEALING HC.T/S CONGEALING HC WATER IN
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0008A.BC Z1
451/4200
NOTES
PUMP ISOLATION 1. FOR MORE DETAIL ABOUT ISOLATION, REFER DOCUMENT

NO. PDRP4280-8110-PH-0001.
3, HIGH TEMPERATURE / HIGH POUR POINT SERVICE 2. FROM VESSEL OR FROM PIPING ON VESSEL WITHOUT
1, HIGH VAPOUR PRESSURE / BUBBLE POINT SERVICE 2, GENERAL SERVICE
INTERVENING VALVES.
3. ISOLATION VALVES MAY BE INTERLOCKED. DOUBLE
BLOCK AND BLEED VALVE SHOULD BE USED FOR
HIGH PRESSURE APPLICATION.
4. GIVE CONSIDERATION TO WHETHER CONDENSATION
COULD OCCUR E.G. IN STEAM SERVICE IF VALVE
LEAKS BADLY, VERY HOT WATER WILL COME FROM
DRAIN. IN THIS CASE DRAIN SHOULD BE PIPED TO
A SAFE LOCATION.
5. DOUBLE VALVES MAY BE REQUIRED IF TEMPERATURE,
PRESSURE OR DIFFERENTIAL PRESSURE SO INDICATES.
6. APPLIES TO SINGLE STAGE PUMPS > 260°C OR
MULTISTAGE PUMP > 204°C MAY ALSO APPLY TO COLD
SERVICES, WHERE PUMP NEEDS TO BE COOLED.
VENT TO SUCTION
FLARE OR BLOWDOWN SYSTEM VESSEL 7. FLUSHING POINTS MAY BE REQUIRED WHERE THE
VISCOSITY > 43CST @ 40°C OR POUR POINT IS ABOVE
NOTE 8 AMBIENT.
SPEC. BREAK SPEC. BREAK
(TYP.) 8. REQUIRED WHERE SUCTION VESSEL OPERATES UNDER
i
(TYP.)
VACUUM. TO ALLOW PUMP FILLING.
9. MAJOR PROCESS PUMPS TO BE FITTED WITH SUCTION

PG PG PG PRESSURE GAUGE TAPPING POINT LOCATED
NOTE 6 MIN DOWN STREAM OF THE PERMANENT STRAINER.
10. ALTERNATIVE DISPOSAL TO CBD OR HEAVY SLOP AS
APPROPRIATE.
SPEC. BREAK SPEC. BREAK
(TYP.) (TYP.) SPEC. BREAK MIN
NOTE 5 NOTE 5
15
15
20 NOTE 5 (TYP.)
15
i i
20 NOTE 7
NOTE 9 D NOTE 9 NOTE 9
D 20
MIN. D
NOTE 5 20 20 NOTE 5 20 FROM STANDBY PUMP
NOTE 5 20
15
15
15
20 FROM STAND BY PUMP FROM STAND BY PUMP
D D D
D D MIN. IT-
SPEC. BREAK
NI
NOTE 7 20 (TYP.) NI-
TO STAND BY PUMP D
TO STAND BY PUMP TO STANDBY PUMP
NOTE 10 AS BUILT
IT- SPEC. BREAK
NI
i
(TYP.)
NI- GENERAL NOTES
FLO - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
PDRP0451-8110-25-231-0008C.
HOLDS
ISOLATION FOR RELIEF VALVES

1, CLOSED RELIEF SYSTEM 2, OPEN RELIEF SYSTEM SIGNATURE
DATE
REFERENCE DRAWINGS
1:500
SLOPE Down SIZE : TO SAFE LOCATION SIZE : TO SAFE LOCATION
FLARE PSET : PSET :
15
SIZE : SIZE :
PSET : PSET : PSV PSV
SLOPE Down
1:500
PSV PSV 15

NOTE 3
15
NOTE 3 10.12.12
MK MM CU
A3
15
1:500
LO LO SLOPE Down REVIEW
WEEP HOLE WEEP HOLE
(NOTE 4) (NOTE 4) ISSUE FOR DESIGN (HAZOP
15
SPEC BREAK i
SPEC BREAK 20 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
20 20 20
(TYP.) (TYP.) D D
20 D 20 D O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
D D
SPEC BREAK
NOTE 3 LO NOTE 3 LC O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
(TYP.)
i
LO NOTE 3 NOTE 3 LC LC REV DATE DESCRIPTION BY CHKD APPD

CLIENT:
D INDIAN OIL
20
CORPORATION
LIMITED
15
2148915 15
NOTE 2 LSTK:
WABAG
NOTE 2 NOTE THAT ANY SPEC CHANGE VA TECH WABAG

SHOULD NOT BE SHOWN AT THE PSV VA TECH WABAG LIMITED
REV:
FILE NAME: 10-P2-D0015-063 Z1
PACKAGE VENDOR:
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FB 1006B Z1

TITLE:
PUMP & RELIFE VALVE ISLOATION
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0008AB.C Z1
451/4200
NOTES
ISOLATION PHILOSOPHY HOOK-UP NOTE 1
1. FOR MORE DETAILS ABOUT ISOLATION

PROCESS BATTERY LIMITS UTILITY BATTERY LIMITS REFER DOCUMENT NO. PDRP4280-8110-PH-0001.
2. DRAIN VALVE SIZE IS DEPENDENT ON
PROCESS/UTILITY LINE SIZE. MIN 20MM.
TO FLARE OR BLOWDOWN
3. NITROGEN MAY HAVE NRV OR TRIP SYSTEM BASED
ON DIFFERENTIAL PRESSURE CONTROLLERS.
4. CONTROL VALVE FAILURE ACTION TO BE SHOWN.
INTERCONNECT UNIT
ALSO ANY TIGHT SHUT OFF (TSO) AND TSO CLASS
MIN 1000MM
REQUIREMENTS.
IP - P - AAA / 212 - XXXX MIN 5. PIPING CLASS MAY NOT NECESSARILY CHANGE
D NOTE 10,11 ACROSS THE CONTROL VALVE.
PG 20 PG BL PG BL WHERE DOWNSTREAM SYSTEM HAS HIGHER RATING
BL
SPEC BREAK NEEDS TO BE REVIEWED.
BL BL NC
6. WHEN NITROGEN MAY BE FREQUENTLY USED DURING
20 (TYP) NORMAL OPERATION USE THIS DETAIL.
NOTE 3
15
WHEN USED AS AN ALTERNATE TO STEAM OUT USE

MIN MIN SAME DETAIL AS FOR STEAM OUT.
MIN
7. BLIND IS OPTIONAL.
20 20 20 20 20 20 20 20 20 20
SC- SC- 8. DOUBLE BLOCK AND BLEED VALVES REQUIRED FOR
D D D SC- D D D D D D D 900# AND ABOVE OR IN TOXIC SERVICE. DOUBLE BLOCK
NOTE 2 (TYPICAL) NOTE 2 NOTE 2 NOTE 2 AND BLEED VALVES BELOW 900# RATING WILL BE
NOTE 2 (TYPICAL) (TYPICAL) CONSIDERED AS PER SECTION 4.2 OF ISOLATION
(TYPICAL) PHILOSOPHY DOCUMENT NO. PDRP4280-8110-PH-0001.
INTERCONNECT UNIT INTERCONNECT UNIT INTERCONNECT UNIT INTERCONNECT UNIT INTERCONNECT UNIT
9. DELETED.
IP - P - AAA / 212 - XXXX IP - P - AAA / 212 - XXXX IP - P - AAA / 212 - XXXX IP - P - AAA / 212 - XXXX IP - P - AAA / 212 - XXXX 10. FOR EPCM-1 BATTERY LIMIT DETAILS SHOWN
NOTE 10,11 NOTE 10,11 NOTE 10,11 ON UNIT P&ID'S.
NOTE 10,11 NOTE 10,11
11. INTERFACE POINT AT CONSULTANTS PLOT LIMIT.
1) GENERAL LOW PRESSURE HYDROCARBON 2) HIGH VAPOUR PRESSURE SERVICE 3) TWO WAY ISOLATION (DOUBLE BLOCK & BLEED) 1) GENERAL UTILITY 2) STEAM CONNECTION 12. FLARE VENT FACILITY MAY BE REQUIRED FOR
LARGE SYSTEMS, ETC.
ISOLATION OF UTILITY FROM PROCESS SYSTEMS ISOLATION OF FLUSHING OIL SUPPLY $ RETURN SYSTEMS ISOLATION FROM FLARE / PROCESS SEGREGATION
UTILITY ISOLATION
MIN 1000MM AS BUILT
NI
NI- IT-
FLARE GENERAL NOTES

SL NC FLO 20 - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
20 20 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
20 D
MIN SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
D D PROCESS SPEC UTILITY SPEC PDRP0451-8110-25-231-0008C.
D
UTILITY SPEC PROCESS SPEC UTILITY SPEC/UNIT PROCESS SPEC/UNIT i
HOLDS
i
1) STEAM OUT CONNECTION 1) FLUSHING OIL SUPPLY 1) ISOLATION FROM FLARE
NI
NOTE 6 NI- IT-

NOTE 7 DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
OR EQUIPMENT SIGNATURE
TO SLOP HEADER
N DATE
20 20 20 20 REFERENCE DRAWINGS
MIN
D D D D DRAWING NO. REV TITLE
UTILITY SPEC PROCESS SPEC UTILITY SPEC / UNIT PROCESS SPEC / UNIT
i
2) FLUSHING OIL RETURN

i
2) NITROGEN PROCESS TIE-IN 2) PROCESS SEGREGATION
SLOP TANK ENGINEER'S APPROVAL APPROVED FOR CONST

TO PRODUCT REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
ISOLATION VALVES
Z1 06.05.15 ISUUED AS BUILT MK MM CU

PG REVISED AS PER 90% DESIGN
SLOP HEADER A3 10.12.12 MK MM CU
REVIEW
XXXX B/L ISOLATION VALVE 15.02.12 REVISED AS PER COMMENTS VP BT CU
NOTE 10,11 A2
IP - P - AAA / 212 - XXXX ISSUE FOR DESIGN (HAZOP

UNIT INTERCONNECT O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK

D
MIN
PG O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
TYPICAL
XXXX PG REV DATE DESCRIPTION BY CHKD APPD
XXXX CLIENT:
INDIAN OIL
CORPORATION
SLOP HEADER
LIMITED
SC-
LSTK:
D WABAG
VA TECH WABAG
3. SLOP COLLECTION HEADER - LIGHT OR HEAVY SLOP No.11, MURRAY'S GATE ROAD,
REV:
FILE NAME: 10-P2-D0015-063 Z1
CONTROL VALVE ISOLATION
PACKAGE VENDOR:
TO FLARE OR BLOWDOWN VADODARA-GUJARAT
NOTE 12
LINDE DWG. NO. REV:
&AG-P-FB 1006C Z1
MIN
1000MM D PARADIP REFINERY PROJECT
20
NC
15
NOTE 8 NOTE 8
FC NOTE 4 NOTE 4 Borrower's agreement that it shall not be
TSO reproduced, copied lent or disposed of directly or
20 NOTE 4 20 20 20 20 20
D D D for which it is specifically furnished. The apparatus
20 20 20
D D D information contained in this drawing may be proprietary
PIPING CLASS X PIPING CLASS Y (TYP) PIPING CLASS X PIPING CLASS Y PIPING CLASS X PIPING CLASS Y (TYP)
i NOTE 5 i
NOTE 5 i NOTE 5
TITLE:
1) HIGH VAPOUR PRESSURE SERVICE 2) GENERAL SERVICE 3) HIGH PRESSURE SERVICE PIPING AND INSTRUMENT DIAGRAM
ISOLATION HOOK-UP DIAGRAM
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0008ABC Z1
451/4200
TAG NUMBER UNIT 231-TK-101 TAG NUMBER 231-OS-101 NOTES
DESCRIPTION SULPHIDIC SPENT CAUSTIC DESCRIPTION OIL SKIMMER
STORAGE TANK 1. SIGHT GLASS WITH FLOW DIRECTION
TAN-TAN LENGTH mm 12200 TYPE FLOATING TYPE AT GRADE LEVEL.
DIAMETER mm 15300 DESIGN PRESSURE kg/cm2g 0.100/ / / 2. INTERPHASE MEASUREMENT.
DESIGN PRESSURE kg/cm2g 0.100/-0.020/ / DESIGN TEMPERATURE °C 120/ / / 3. SLOPE OF 2%.
DESIGN TEMPERATURE °C 120/120/ / 4. DELETED.
5. JET MIXER IS INTEGRAL PART OF TANK.
6. DELETED.
7. AT GRADE LEVEL.
0-47.5% SPLIT RANGE 52.5-100% 8. SAMPLING POINT HORIZONTAL,
END CONNECTION DOWNWARD WITH NIPPLE.
12 9. FLOW SHALL BE VISIBLE WHILE OPERATING VALVE.
CA02 CA50 10. NOZZLE C01 SHALL BE LOCATED BELOW LLL LIQUID
PV A1AA A4AN PV LEVEL.
3005A 3005B A 11. DELETED.
12. SPLIT RANGE VALVE :
NITROGEN 13 13 TO VOC OPEN
25-IG-231-3109-A1AA-NI 100-V-231-1104-A4AN-NI
149 231-0031 230-0012
1. 10.500 65 1. 0.100 65 100/50 FO 100/50 CA02
FC 100/25 LO LO BL
AP7ES
AP7ES
FROM N2 HEADER
PV-3
001B
AP7E
AP7E
CA02 25 50 SP VALVE
POSITION
001A
A2AW A4AN
PV-3
100-V-231-1106-A4AN-NI
20 20 20 20 1103
PRESS VENT
25 7 80
CLOSE VALVE VALVE
65
100-V-231-1106-A4AN-NI
NC NC 0 47.5 52.5 100
SERVICE WATER
LDI H LI LI
1. 0.100
146 231-0030 PRESSURE INCREASE
65
1. 10.500 65 3001 3001A 3001B
FROM SW HEADER NC NC PROVIDED DEAD BAND (ABOUT 5%) DEAD BAND RANGE
CA50 A1AA A4AN
50-WS-231-3052-A4AN-NI SHALL BE FURTHER ADJUSTED BY OPERATOR, IF
1. 0.100
REQUIRED.
IZ 13. LOCATE PV-3001B ASSEMBLY AT TANK ROOF AND
1. 17.000 65
0190 PV-3001A AT GRADE.

HH SIL a
I LI H
L AS BUILT
1200 3002
LZT PIC H
LI
3003 3005 L
PG 3002 RADAR LL GENERAL NOTES
3006 H
RADAR
20
XV 7 LT SIZE:50x150
SIZE:250 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
CA50 CA02 3002 3001 PSET:0.065 / -0.018 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
PSET:0.090 PDRP0451-8110-25-231-0008C.
2
SULPHIDIC SPENT L
AP7AP
A PVRV PG PT
CAUSTIC PRV HOLDS
150-PSC-231-1101-A4AN-NI 3002 3004 3005
230-0020
SLOP
E
3001
1. 17.000 65 FC 1. 10.500 120 SP
BL TP01
AP7E
AP7E
AP7E
AP7E
AP7E
20 CA50 150 53-16
MIN.
LT 1104
MIN.
RADAR
SC-1 20 20 20 20 3002 20-V-231-1115-A4AN-NI
AV7P
AV7P
AV7AP
AV7AP
100
8
N1
AV7P
20 NC
3.5M
25 Z1
N04
AP7E
N06 50-CCBD-231-1120-A4AN-NI
N03 C03 100 A04
150 80 250
PROCESS DRAIN TO CCBD C04 610 N07 N16
80-CCBD-231-2705-A4AN-NI A03 150 50 C02
231-0027 C05 80 SIGNATURE
1. 3.500 75 610 50 C06
BL 20 80 50
DATE
CA02 50 REFERENCE DRAWINGS
AP7E
OFF SPEC SPENT

CAUSTIC
N10 231-OS-101 DRAWING NO. REV TITLE
50-PTC-231-1808-A4AN-NI
158 231-0018A 50 OIL SKIMMER
1. 10.500 80 NC 150MM N2
FROM 231-LV-3011 N11 Z1
25
AP7E
CA50 A 20 20
CA50 CA02 50 10
AP7E
SPENT CAUSTIC N12

50-PSO-231-1607-A4AN-NI TO CCBD
163 231-0016 50 AV7P TT TI
50
1. 10.500 120 N13 C01
FROM 231-LV-3008 50 3001 3001 ENGINEER'S APPROVAL APPROVED FOR CONST
CA02
9 REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
9 50 N18
50-OWS-231-1103-A4AN-NI E
N14 50
SLOP
SG
1. 3.500 120
50 N17 Z1 06.05.15 ISSUED AS BUILT MK MM CU
CA02 SP SPENT CAUSTIC REVISED AS PER 90% DESIGN
1 N08 50-PSC-231-1204-A4AN-NI
A3 10.12.12
REVIEW
MK MM CU
1101 231-0012 239 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU

50 1. 17.000 120 CA02
231-JS-103 FROM 231-P-101A/B ISSUE FOR DESIGN (HAZOP
MIN. A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
CA02
A02 A01 O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK

JET MIXER 610
610 SPENT CAUSTIC O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
A N15 100-PSC-231-1102-A4AN-NI
5
50 N01 144 231-0012
CAUG
1 9 9 100 1. 17.000 120 CA02 REV DATE DESCRIPTION BY CHKD APPD

SLOP OIL N09 53-01 TO 231-P-101A/B CLIENT:
50-OWS-231-1110-A2AQ-NI 50-OWS-231-1108-A4AN-NI N02 100
231-0027 SG INDIAN OIL
1. 0.000 65 1. 3.500 120 50 3 100
CA02
TO 231-TK-108 CORPORATION
CAUG SP 25 LIMITED
EL. + 100.800 SLOP
E
A
1102 LSTK:
231-TK-101 100/50
CAUG
WABAG
VA TECH WABAG
SULPHIDIC SPENT CAUSTIC
STORAGE TANK PROCESS DRAIN
1. 0.100 120 50-CCBD-231-1109-A4AN-NI ALWARPET, CHENNAI-600 018, INDIA.
231-0027
2. -0.020 120 1. 0.000 65 CAUG FILE NAME: 10-P2-D0015-040 REV:
TO CCBD Z1
CA02
PACKAGE VENDOR:
BUND LINDE ENGINEERING INDIA PVT. LTD.,
M VADODARA-GUJARAT
150 150 LINDE DWG. NO. REV:

&AG-P-FP 1001 Z1
150-SS-231-1112-A4AN-NI
SS PROCESS DRAIN
150-CCBD-231-1111-A4AN-NI INDIAN OIL CORPORATION LTD
231-0027
1. 0.000 65 CAUG and is lent without consideration other than the
TO CCBD Borrower's agreement that it shall not be
TITLE:
SULPHIDIC SPENT CAUSTIC STORAGE TANK
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0011 Z1
451/4200 36600
NOTES
1. HOSE CONNECTION FOR SERVICE WATER.

2. OPENING RESTRICTED TO PUMP MIN.FLOW.
TAG NUMBER 231-P-101A/B 3. STRAINER MESH SIZE40.
SERVICE SULPHIDIC SPENT CAUSTIC
4. DELETED.
CHARGE PUMP 5. SEAL FLUSH LINE.
RATED FLOW RATE m3/h 19
6. SAMPLING POINT HORIZONTAL,
DIFFERENTIAL PRESSURE bar 10.83
IZ IZ IZ SHUT OFF HEAD bar 11.52
7. DELETED.
0150 0180 0190 DESIGN PRESSURE kg/cm2g 17.000/ / /
8. DELETED.
DESIGN TEMPERATURE °C 120/ / /
9. API SEAL PLANS 11 & 62 ARE APPLICABLE
AVAILABLE
TRIP START
MZS MS STOP
3002B 3002B RUN
SIL 1
LOCAL STOP
FAULT
ML
3002B SPENT CAUSTIC
231-PM-101B 50-PSC-231-1204-A4AN-NI
239 231-0011
MIN. FLOW / TANK MIXING 1. 17.000 120 CA02
SULPHIDIC SPENT CAUSTIC PG TO 231-TK-101
CHARGE PUMP MOTOR
3008
231-P-101B
1 SULPHIDIC SPENT CAUSTIC M AP7E
CHARGE PUMP
AP7AP
40 20
20
1. 17.000 120 80/40
9
AP7E
CA02
100/80 300#
AP7E
20 RO
300# AS BUILT
2
3004
3
AP7E
20 SP
20/15 VENDOR
1201
5
VENDOR
TO CCBD
GENERAL NOTES
TO CCBD 20-PSC-231-1210-A4AN-NI - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
1. 0.000 65 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
CA02 PDRP0451-8110-25-231-0008C.
CA02
50-PSC-231-1207-A4AN-NI HOLDS
CA02
1. 0.000 65
A
CA02
150/25
CAUG
PROCESS DRAIN
25-CCBD-231-1206-A4AN-NI
231-0027
1. 0.000 65 CAUG
TO CCBD
IZ IZ IZ
0150 0180 0190
53-01
CA02
100-PSC-231-1201-A4AN-NI
20-WS-231-1214-A2AW-NI

AVAILABLE
TRIP START SIGNATURE
MZS MS STOP DATE
80-PSC-231-1202-A4AN-NI
1. 17.000 120
1. 10.500 65
3002A 3002A RUN REFERENCE DRAWINGS

SIL 1 DRAWING NO. REV TITLE
1. 17.000 120
PI FIC H
53-02
LOCAL STOP 3009 3005 L
SERVICE WATER FF
25/20 FAULT
25-WS-231-3098-A2AW-NI ML
165 231-0030
1. 10.500 65 CA02 3002A
FROM SW HEADER 231-PM-101A ENGINEER'S APPROVAL APPROVED FOR CONST
PG PT FT
SULPHIDIC SPENT CAUSTIC 3007 3009 3005 REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
CHARGE PUMP MOTOR
FV
231-P-101A
M 3005
20
Z1 06.05.15 MK MM CU
20
ISSUED AS BUILT
1 REVISED AS PER 90% DESIGN
AP33
SULPHIDIC SPENT CAUSTIC A3 10.12.12
REVIEW
MK MM CU
CHARGE PUMP
AP7AP
AP7AP
40 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
80/40 SPENT CAUSTIC
1. 17.000 120
9
AP7E
80-PSC-231-1203-A4AN-NI 50-PSC-231-1203-A4AN-NI ISSUE FOR DESIGN (HAZOP
SPENT CAUSTIC CA02 M 155 231-0015 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK

100/80 300# 53-02 CA02 FC 1. 17.000 120 CA02
100-PSC-231-1102-A4AN-NI 80/50 TO 231-E-101A/B
AP7E
AP7E
AP7E
AP7E
144 231-0011 20 50 B VENT 53-03
1. 17.000 120 CA02 O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
FROM 231-TK-101 3 300#
AP7E
AP7E
53-01 20 20 20 20
SC-1 SP
20/15 VENDOR 40
40
6
1202 VENDOR CLIENT:

5
TO CCBD NC NC INDIAN OIL

B
TO CCBD CORPORATION
CA02
LIMITED
20-PSC-231-1211-A4AN-NI
TO CCBD
LSTK:
WABAG
20-WS-231-1213-A2AW-NI
65
VA TECH WABAG
1. 10.500 65 CA02 VA TECH WABAG LIMITED
1. 0.000

REV:
FILE NAME: 10-P2-D0015-041
50-PSC-231-1208-A4AN-NI Z1
PACKAGE VENDOR:
1. 0.000 65
CA02 LINDE ENGINEERING INDIA PVT. LTD.,
VADODARA-GUJARAT
CA02
LINDE DWG. NO. REV:

&AG-P-FP 1002 Z1
A
150/25 PARADIP REFINERY PROJECT
CAUG
PROCESS DRAIN
25-CCBD-231-1205-A4AN-NI Paradip, Orissa State, India
231-0027
1. 0.000 65 CAUG
TO CCBD This Drawing is the Property of
TITLE:
SULPHIDIC SPENT CAUSTIC CHARGE PUPMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0012 Z1
451/4200 36601
DESCRIPTION NAPHTHENIC SPENT CAUSTIC DESCRIPTION OIL SKIMMER
STORAGE TANK 1. SIGHT GLASS WITH FLOW DIRECTION
DESIGN TEMPERATURE °C 80/80/ / 4. DELETED
6. DELETED.
7. AT GRADE LEVEL.
0-47.5% SPLIT RANGE 52.5-100% 8. SAMPLING POINT HORIZONTAL,
END CONNECTION DOWNWARD WITH NIPPLE
12 9. FLOW SHALL BE VISIBLE WHILE OPERATING VALVE.
CA02 10. NOZZLE C01 SHALL BE LOCATED BELOW LLL LIQUID
PV A1AA A4AN PV LEVEL.
3014A 3014B A 11. DELETED
TO CAUSTIC 12. SPLIT RANGE VALVE :
NITROGEN 13 13 SEALED CHAMBER
25-IG-231-3102-A1AA-NI 50-V-231-1304-A4AN-NI 50-V-231-1306-A4AN-NI
254 231-0031 231-0025 OPEN
1. 10.500 65 CA02 FC 50/25 1. 0.100 65 LO 1. 0.100 65 CA02
50/25 FO 50/25 LO
AP7ES
AP7ES
FROM N2 HEADER
AP7E
AP7E
AP7E
25 25
PV-3
014B
VALVE
A2AW A4AN 20 20 20 20 20
POSITION
014A
PV-3
25 7 40
50-V-231-1306-A4AN-NI
PRESS VENT
NC NC
SERVICE WATER CLOSE VALVE VALVE
65
LDI H LI LI 0 47.5 52.5 100
251 231-0030
1. 10.500 65 CA50 3005 3005A 3005B
FROM SW HEADER NC NC PRESSURE INCREASE
1. 0.100
A1AA A4AN
25-WS-231-3023-A4AN-NI PROVIDED DEAD BAND (ABOUT 5%) DEAD BAND RANGE
SHALL BE FURTHER ADJUSTED BY OPERATOR, IF
IZ REQUIRED.
1. 17.000 75
0200 13. LOCATE PV-3014B ASSEMBLY AT TANK ROOF AND

HH SIL a PV-3014A AT GRADE.
I LI H
L 14. CRWS & CCBD LINES FOR TANK TK-102 ARE COMMON
1230 3004
WITH TK-101. BOTH TANKS ARE LOCATED ON THE
PG PIC H SAME BUND AREA.
LI
3058 3014 L
3004 RADAR RADAR GENERAL NOTES
H LT LZT
XV 7 3005 3006 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
LL SIZE:25x50
CA50 CA02
2
3004 PSET:0.065 / - 0.018 PDRP0451-8110-25-231-0008C.
SIZE:150
AP7AP
NAPHTHENIC SPENT L PG PT
A PSET:0.090 HOLDS
CAUSTIC PVRV 3013 3014
50-PSC-231-1301-A4AN-NI SLOP
230-0020 E
3004
1. 17.000 75 FC 1. 17.000 75 PRV
BL TP03
AP7E
AP7E
AP7E
AP7E
AP7E
20 50 53-70 3003
LT
RADAR
SC-1 20 20 20 20 3004
AV7P
AV7AP
AV7AP
8
AV7P
40 AS BUILT
AV7P
NC
N06 N04
TO CCBD N03 C03 150 50 N07 N16 DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
C04 50 80 50 50 C02
A02 80 SIGNATURE
C05 610 50 C06 DATE
80 50
REFERENCE DRAWINGS
231-OS-102
50
50/25 N10 OIL SKIMMER
25
50 10
25 50/25 N11
50 AV7P TT TI
25
C01
1 9 25 50/25 N12 50 3002 3002 ENGINEER'S APPROVAL APPROVED FOR CONST
9
25-OWS-231-1303-A4AN-NI E
50
SLOP
SG 50/25 N13 N18
1. 3.500 75 CA02 25 50 50/25
SP 25 50/25 N14 NAPHTHENIC SPENT Z1 06.05.15 ISSUED AS BUILT MK MM CU
50/25 CAUSTIC REVISED AS PER 90% DESIGN

1301 25 N17 N08 25-PSC-231-1404-A4AN-NI
A3 10.12.12
REVIEW
MK MM CU
231-0014 249 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU

50/25 50 50 1. 7.000 75 CA02
231-JS-104 MIN. FROM 231-P-103A/B A 03.08.11
COMMENTS INCORPORATED) SP NJ DK
CA02
JET MIXER A01 NAPHTHENIC SPENT

50 610 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
CAUSTIC O1
A N15 5 50/40 40-PSC-231-1302-A4AN-NI O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
N01 250 231-0014
CAUG
1 9 50 1. 7.000 75 CA02 REV DATE DESCRIPTION BY CHKD APPD

9 TO 231-P-103A/B
NAPHTHENIC OIL N09 3 50/40 53-71 CLIENT:
231-0025 SG INDIAN OIL
1. 0.000 65 CAUG 1. 3.500 75 CA02 50/25 50 50
CA02
SP
EL. + 100.800 SLOP
E 25 LIMITED
A
1302 LSTK:
231-TK-102
CAUG
100/25 WABAG
VA TECH WABAG
NAPHTHENIC SPENT CAUSTIC
STORAGE TANK PROCESS DRAIN
231-0027
TO CCBD Z1
CA02
14 PACKAGE VENDOR:
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1003 Z1

TITLE:
NAPHTHENIC SPENT CAUSTIC STORAGE TANK
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0013 Z1
451/4200 36602
TAG NUMBER 231-P-103A /B NOTES
SERVICE NAPHTHENIC SPENT CAUSTIC
CHARGE PUMP 1. HOSE CONNECTION FOR SERVICE WATER.
RATED FLOW RATE m3/h 1.2 2. DELETED.
DIFFERENTIAL PRESSURE bar 4.42 3. STRAINER MESH SIZE 40.
SHUT OFF HEAD bar NA 4. DELETED
DESIGN PRESSURE kg/cm2g 7.000/ / / 5. DELETED.
DESIGN TEMPERATURE °C 75/ / / 6. SAMPLING POINT HORIZONTAL,
SIZE:
7. DELETED
PSET:5.300
8. DELETED
PSV 9. DELETED.
3008B
PG
3016
1
25
AP7E
NAPHTHENIC SPENT
AP7AP
20
CAUSTIC
TANK MIXING 25-PSC-231-1404-A4AN-NI
249 231-0013
40 40 1. 7.000 75 CA02
40/25 TO 231-TK-102
3
AP7E
AP7E
20 SP
1401
M 20
AP7E
20
231-PM-103B
LOCAL STOP RO
NAPHTHENIC SPENT CAUSTIC TRIP FAULT
CHARGE PUMP MOTOR MZS ML 3009
AS BUILT
3006B 3006B
231-P-103B
NAPHTHENIC SPENT CAUSTIC GENERAL NOTES
CHARGE PUMP AVAILABLE
START - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
1. 7.000 75 MS STOP - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
CA02 IZ 3006B RUN
PDRP0451-8110-25-231-0008C.
0200
SIL a HOLDS
I
CA02
1210
53-71
40-PSC-231-1401-A4AN-NI
CA02
SIGNATURE
25-PSC-231-1402-A4AN-NI
DATE
75
REFERENCE DRAWINGS
SIZE:
75
1. 7.000
PSET:5.300 FF
PI
1. 7.000
PSV FIC H
53-72
3017
3008A 3010 L
PG PT ENGINEER'S APPROVAL APPROVED FOR CONST

3015 3017 FT
3010
1
FV
25 Z1 06.05.15 ISSUED AS BUILT MK MM CU
3010 REVISED AS PER 90% DESIGN
AP7E
NAPHTHENIC SPENT
AP7AP
AP7AP
NAPHTHENIC SPENT A3 10.12.12
REVIEW
MK MM CU
AP33
20
20
CAUSTIC CAUSTIC A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
40-PSC-231-1302-A4AN-NI 25-PSC-231-1403-A4AN-NI
250 231-0013 M 231-0025 ISSUE FOR DESIGN (HAZOP
1. 7.000 75 CA02 40 40 FC 1. 7.000 75 CA02 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
FROM 231-TK-102 3 40/25 25-PSC-231-1403-A4AN-NI TO 231-JS-106

AP7E
AP7E
AP7E
AP7E
AP7E
53-71 20 20 VENT 25 B VENT 53-73 O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
53-72
SC-1 SP
M 20 20 20
1402 O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

6
20 20 REV DATE DESCRIPTION BY CHKD APPD

CLIENT:
NC NC
B INDIAN OIL
TO CCBD CORPORATION
231-PM-103A LIMITED
LOCAL STOP LSTK:
NAPHTHENIC SPENT CAUSTIC TRIP FAULT WABAG
CHARGE PUMP MOTOR MZS ML
VA TECH WABAG
3006A 3006A
231-P-103A VA TECH WABAG LIMITED
NAPHTHENIC SPENT CAUSTIC
CHARGE PUMP AVAILABLE FILE NAME: 10-P2-D0015-043 REV:
START Z1
1. 7.000 75 MS STOP PACKAGE VENDOR:
CA02 IZ 3006A RUN LINDE ENGINEERING INDIA PVT. LTD.,
VADODARA-GUJARAT
0200
SIL a
LINDE DWG. NO. REV:
I &AG-P-FP 1004 Z1
1210 PARADIP REFINERY PROJECT
TITLE:
NAPHTHENIC SPENT CAUSTIC CHARGE PUPMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0014 Z1
451/4200 36603
TAG NUMBER 231-E-101A \B NOTES
SERVICE SPENT CAUSTIC PREHEATER 1. HOSE CONNECTION FOR SERVICE WATER &
TYPE PLATE EXCHANGER NITROGEN.
DUTY, RATED, EACH kcal\hr2 481000 2. EXCHANGERS ARE DESIGNED FOR 2 X 50% DUTY.
2
DESIGN PRESSURE kg/cm g 17.000/-1.000/12.000/-1.000 3. INLET & OUTLET PIPING OF 231-E-101 A/B TO BE
DESIGN TEMPERATURE °C 160/160/160/160 SYMMETRICAL.
4. AT HIGH POINT OF LINE.
5. AT LOW POINT OF LINE.
6. UTILITY CONNECTIONS FOR PROCESS SIDE CLEANING
AND MAINTANCE.
SIZE:20x25
PSET:17.000
TSV
3001A
SLOP
E 25-PSC-231-1508-A4AN-NI
1. 0.000 160 CA02
20
LO 231-E-101A
SPENT CAUSTIC PREHEATER
20-PSC-231-1513-B4AN-NI
1. 17.000 160
PSO
2. -1.000 160
A4AN B4AN 3. 12.000 160
PSC
4. -1.000 160 1 4
CA02
AP7E
AS BUILT
300# 25
3 N03 N01 3
50-PSC-231-1515-B4AN-NI 50-PSO-231-1601-A4AN-IH
1. 17.000 160 CA02 1. 12.000 160 CA02 GENERAL NOTES
50 50
4
AP7E
25 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
3
1
50-PSO-231-1507-A4AN-NI 50 50 50-PSC-231-1502-B4AN-IH 100/50 100/50 PDRP0451-8110-25-231-0008C.
1. 12.000 160 CA02 300# N02 N04 1. 17.000 160 CA02
3 HOLDS
FF
AP7P
FF FF
EL. + 100.500 PDI H PDI H TI H
3019 3018 TG TW 3003
150/50 CA02 3040 3040
A
CAUG
PDT
3018 TT
20 3003 CA02 CA01
PDT
3019
AP7AP
AP7P
20
PROCESS DRAIN 100/50 A OXIDISED CAUSTIC SIGNATURE
40
50-CCBD-231-1511-A4AN-NI 50-PSO-231-1601-A4AN-IH
231-0027 231-0016 166 DATE
1. 0.000 65 CAUG 100/50 1. 12.000 160 CA01
TO CCBD B FROM 231-R-101
REFERENCE DRAWINGS
20 CA02 CA01 53-07
AP7E
AP7AP
AP7AP
25 A
SPENT CAUSTIC SIZE:20x25 SPENT CAUSTIC
50-PSC-231-1203-A4AN-NI 50-PSC-231-1502-B4AN-IH
155 231-0012 PSET:17.000 172 231-0016
1. 17.000 120 CA02 1. 17.000 160 CA01
FROM 231-P-101A/B B B TO 231-JS-101
53-03 20 53-04
TSV
3001B
AP7AP
A
OXIDISED CAUSTIC ENGINEER'S APPROVAL APPROVED FOR CONST
50-PSO-231-1507-A4AN-NI
231-0016 171
1. 12.000 160 CA50 CA02 SLOP
25-PSC-231-1509-B4AN-NI REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
TO 231-JS-102 B E
CA02
CA02
53-08 1. 0.000 160 CA02
50-PSO-231-1504-A4AN-IH
50-PSC-231-1517-B4AN-IH
20 10.12.12
MK MM CU
A3 REVIEW
50-PSO-231-1506-A4AN-NI
50-PSC-231-1503-A4AN-NI
1. 12.000 160
1. 17.000 160
LO 231-E-101B
160
1. 17.000 120

20-PSC-231-1512-B4AN-NI

1. 17.000 160
PSO
1. 12.000

2. -1.000 160
A4AN B4AN 3. 12.000 160
PSC CLIENT:
4. -1.000 160 1 4
INDIAN OIL
CA02
CORPORATION
AP7E
25 LIMITED
3 N03 N01 300# 3
50-PSC-231-1514-B4AN-NI LSTK:
1. 17.000 160 CA02 50 50 1. 12.000 160 WABAG
4
VA TECH WABAG
25 AP7E VA TECH WABAG LIMITED
3 50 3
1
50 100/50 No.11, MURRAY'S GATE ROAD,
1. 12.000 160 CA02 300# N02 N04 100/50 FILE NAME: 10-P2-D0015-044 REV:
Z1
AP7P
PACKAGE VENDOR:
EL. + 100.500 LINDE ENGINEERING INDIA PVT. LTD.,

SERVICE WATER 6 VADODARA-GUJARAT
25-WS-231-3061-A2AW-NI TG TW
167 231-0030
1. 10.500 65 CA02 3041 3041
FROM SW HEADER LINDE DWG. NO. REV:
&AG-P-FP 1005 Z1
CA02
A
NITROGEN 6 150/50 CAUG PARADIP REFINERY PROJECT
25-IG-231-3162-A1AA-NI Paradip, Orissa State, India
168 231-0031
1. 10.500 65 CA02
FROM N2 HEADER This Drawing is the Property of
PROCESS DRAIN
50-CCBD-231-1510-A4AN-NI reproduced, copied lent or disposed of directly or
231-0027 indirectly, nor used for any purpose other than that
1. 0.000 65 CAUG
TO CCBD for which it is specifically furnished. The apparatus
TITLE:
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0015 Z1
451/4200 36604
SIZE:50J80 NOTES
ATM PSET:10.000 TAG NUMBER UNIT 231-R-101 TAG NUMBER 231-JS-101
1. AS SHORT AS POSSIBLE.
SAFE LOCATION 80-V-231-1602-A4AN-PP DESCRIPTION OXIDATION REACTOR DESCRIPTION STATIC MIXER 2. VALVE TIGHT SHUT OFF.
PSV
1. 0.000 160 3. SAEFTY RELEVANT FLOW RESTRICTION,
4 3002A TAN-TAN LENGTH mm 16520 LENGTH mm 1004
E DIAMETER mm 2900 VOLUME m3 0.017 UPTO 3910KG/HR
SLOP
P DESIGN PRESSURE kg/cm2g 10.0/-1.0/ / DESIGN PRESSURE kg/cm2g 17.000/-1.000/ / 4. TWO PHASE LINE.
SIZE:50J80 14 5. DP : DIFFERENTIAL PRESSURE.
ATM PSET:10.000 20 80/50 DESIGN TEMPERATURE °C 160/160/ / DESIGN TEMPERATURE °C 350/350/ /
6. IT SHOULD BE ON PLATFORM / UTILITY POINT.
13
SAFE LOCATION
AP7E
AP7E 25 7. DUPLEX ELEMENT.
PSV OFF GAS
150-V-231-1603-A4AN-PP 8. IBR LINE FROM BL TO 231-JS-101.
3002B LO SLOP
E
175 231-0017
1. 10.000 160 CA01 9. DELETED.
SLOP
E
FF TO 231-E-103 10. WARM UP LINE NORMALLY CLOSED.
2. -1.000 160
80-V-231-1617-A4AN-PP
AP7P TT TI 11. TIGHT SHUT OFF NRV.
80-V-231-1622-A4AN-PP 80/50 53-13
40 3004 3004 12. SAMPLING POINT HORIZONTAL,
20
IZ FIQ END CONNECTION DOWNWARD WITH NIPPLE.
AP7E TW 0150 3011 13. WEEP HOLE DRAIN LINE.
LC
3005 2oo3 14. HIGH POINT VENT.
SIL a 15. CONTROL VALVE 231-FV-3011 SHALL HAVE HAND
80-V-231-1621-A4AN-PP CORR WHEEL.
SLOP
AP7P TG
16. AT LOW FLOW ALARM FROM 231-FT-3011, CONTROL
SP
E
PT AP7AP 40 3005 CORR

3020 20 VALVE 231-HV-3001 TO BE OPEN FROM DCS.
IZ 17. REFER P&ID NO. PDRP0451-8110-25-231-0032
FIC PI TI H REV. A FOR STEAM TRAP DETAILS.
AV7AP 3011 L 0170 SIL a 3023 3022 L 80-SM-231-1604-B1AS-IH 18.STRAIGHT LENGTH OF 2.4 TIMES DIAMETER
DP DP DP
AV7E
50 HH HH HH 1. 18.000 350 REQUIRED AT OUTLET OF MIXTURE

PI H 80 LZT LZT LZT IZ IZ
C11A/B/C 2. -1.000 350
3020 N03 3007A 3007B 3007C 0160 0170
A04 150 FT PZT PT TT TG TW PG 53-50
AV7AP 5 5 5 SIL a SIL a
50 C09 CA01 CA50 3011 3024 3023 3022 3021 3021 3025
H LL
A03 80
SP
600 AV7AP 15 SP XZV 20
C10A/B/C FV
3014 1601
AP7ES
80
AP35A
3011 A 1604
AP7AS
AP7AS
AP7AS
AP7P
AP7P
L
40
53-07 DP MP STEAM
17
20
40
PG
20
AV7AP C13
20
LT LIC H ST ST ST ST 230-0020
3001 50 3008 3008 L FC FC 100/80 100/80 BL
17
AP7ES
AP7ES
AP7ES
8
B 80
AS BUILT
25
C08 AV7AP 5 20 20 2
TP04
80
80-SM-231-1604-B1AS-IH
3 TI TT TG TW SP SP 20
OXIDISED CAUSTIC GENERAL NOTES
E N02 3019 3019 3020 3020 1603 1602 NC
231-0015 166 SLOP
1. 18.000 350
2. -1.000 350
50
TO 231-E-101A/B FF - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
AP7P
AP7P
C07 AV7P TT TI PDRP0451-8110-25-231-0008C.
40
40
SPENT CAUSTIC
53-51
50 3006 3006 50-PSC-231-1502-B4AN-IH
50-PSO-231-1601-A4AN-IH 231-0015 172 HOLDS
1. 12.000 160 10 1. 17.000 160 CA01
100/50 100/50 FROM 231-E-101A/B
53-04
FF 298 &AG-P-FP 1010

C06 AV7P TT TI SIZE:25E50
TO FIC-3014
MIN.
9 50 3007 3007 PSET:12.000
(SAFE LOCATION)
231-R-101 PSV
ATM
4
OXIDATION REACTOR 8 FF 3006 SLOP
E

1. 10.000 160 AV7P TT TI
C05 40/25 25-CCBD-231-1618-A2AP-PP
2. -1.000 160 50 3008 3008
SIGNATURE
7 DATE
50-V-231-1610-A2AP-PP
FT AP7E 1. 0.000 250 REFERENCE DRAWINGS
B1AS A2AP 3014 LO
6
100/80
FF DRAWING NO. REV TITLE
13
CA01 CA50 CA50 CA03
C04 AV7P TT TI H
50 3009 3009 B 40-PA-231-1609-A2AP-IH
5 A A 53-33 PROCESS AIR
100-PA-231-2002-B1AS-IH 100-PA-231-2002-A2AP-IH
B 231-0020 174
4 7 1. 18.000 350 1. 12.000 250 CA03
AP7ES
53-33 53-32 FROM 231-K-101A
25
AV7P TT TIC H 11 B
C03
3 50 3011 3011 L DRAIN DRAIN ENGINEER'S APPROVAL APPROVED FOR CONST
PDI 299 &AG-P-FP 1011
SIZE:25E50 REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
3020 L FF PSET:12.000 TO FIC-3015
2
AV7P TT TI
C02 PSV Z1 06.05.15 ISSUED AS BUILT MK MM CU
50 3010 3010 8 4 A3 10.12.12
MK MM CU
A02 3007 SLOP
E
REVIEW
600
CA03
TW
50 ISSUE FOR DESIGN (HAZOP
CA01
AP7E
3012 IZ 20 40/25 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
25-CCBD-231-1616-A4AN-PP
N04 1 50 50-V-231-1612-A2AP-PP 13 A
6

50 1. 0.000 250
CAUG
AV7E 0160 AP7E
2oo3 PROCESS DRAIN
AV7P TG SIL a FT 25-CCBD-231-1619-A2AP-PP 50-CCBD-231-1620-A4AN-NI O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

LO 231-0027
231-JS-101
1. 0.000 160
EL. + 103.600 3012 TO CCBD 3015 1. 0.000 65 CAUG

50 TO CCBD
50 C12 HH AP7E CLIENT:
STATIC MIXER
100
C01 TZT 40-PA-231-1611-A2AP-IH
VENT INDIAN OIL
PT PI H 3014 1. 17.000 350
53-33 PROCESS AIR CORPORATION
AV7AP
3021 3021 L 2. -1.000 350 300# 20 LIMITED

2oo3 A,B,C 100-PA-231-2102-A2AP-IH
50 N02 231-0021 177
AP7ES
300# NC 1. 12.000 250 CA03

AP7P
18 LSTK:
AP7ES
N03 200/100 53-32 FROM 231-K-101B WABAG
25
N01 11 B
40
200-PSC-231-1606-B4AN-IH 200
VA TECH WABAG
200 1. 17.000 160 CA01 N01 53-34 B1AS A2AP
4 200 VA TECH WABAG LIMITED
AP7E
53-05 25 300# No.11, MURRAY'S GATE ROAD,

MIN
A01 FILE NAME: 10-P2-D0015-045 REV:
SLOP
E Z1
1 PACKAGE VENDOR:
A
CA01 50-PSC-231-1608-A4AN-IH LINDE ENGINEERING INDIA PVT. LTD.,
CAUG 1. 0.000 160 VADODARA-GUJARAT
TI H
CA01
3016
LINDE DWG. NO. REV:
&AG-P-FP 1006 Z1
50-CCBD-231-1605-A4AN-NI PARADIP REFINERY PROJECT

PROCESS DRAIN 1. 0.000 65 TT TG TW Paradip, Orissa State, India
231-0027
CAUG 3016 3017 3017
LV
3008 and is lent without consideration other than the
AP7P
AP7P
OXIDISED CAUSTIC OXIDISED CAUSTIC Borrower's agreement that it shall not be

40
40
50-PSO-231-1507-A4AN-NI 50-PSO-231-1507-A4AN-NI reproduced, copied lent or disposed of directly or

171 231-0015 176 231-0018A indirectly, nor used for any purpose other than that
1. 12.000 160 CA50 FC B 1. 12.000 160 CA50
FROM 231-E-101A/B 100/50 100/50 H HIC TO 231-JS-102 for which it is specifically furnished. The apparatus
AP7E
53-08 20 50 53-09
16
SC-1 HV shown in the drawing is covered by patents

3001
12

3001 to Indian Oil Corporation Ltd and/or licensors, and is
B L SPENT CAUSTIC subject to obligations of confidentiality.
40 50-PSO-231-1623-A4AN-NI 50-PSO-231-1607-A4AN-NI
163 231-0011 TITLE:
NC CA50 CA02 FC 1. 10.500 120 CA02 PIPING AND INSTRUMENT DIAGRAM
TO 231-TK-101
AP7E
AP7E
A 50 53-09
20 20 OXIDATION REACTOR
40 SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0016 Z1
451/4200 36605
TAG NUMBER 231-E-103 TAG NUMBER UNIT 231-Y-103 NOTES
SERVICE OFF GAS COOLER DESCRIPTION OFF GAS SILENCER 1. TWO PHASE LINE.
DUTY, RATED, EACH kcal\hr 969300 PRESSURE DROP mmWC150 2. DP : DIFFERENTIAL PRESSURE.
SHELL DESIGN PRESSURE kg/cm2g 10 / -1 DESIGN PRESSURE kg/cm2g 0.5/ / / 3. DELETED.
SHELL DESIGN TEMPERATURE °C 160 / 160 DESIGN TEMPERATURE °C 160.0/ / / 4. ROUTED TO PROCESS DRAIN.
TUBE DESIGN PRESSURE kg/cm2g 8 5. LP STEAM FOR VENT(DILUTION).
TUBE DESIGN TEMPERATURE °C 160 6. TO SAFE LOCATION.
7. BOOT SIZE 20", SPECIAL PART
8. PIPELINE SUPPORT IS DESIGNED FOR TWO PHASE
FLOW.
6 9. LV3010 SHALL BE NEAR TO V102.
250-V-231-1712-A4AN-PP
1. 0.000 160
5
PT PIC H 231-Y-103
MIN. DISTANCE
3026 3026 L
OFF GAS SILENCER RO
1. 0.500 160 3012
PV
3026
AP7AP
OFF GAS B 250/100 LP STEAM
20
150-V-231-1603-A4AN-PP SLOP
100-V-231-1715-A4AN-PP SLOP
250-V-231-1704-A4AN-PP 25-SL-231-3193-A1AS-IH
175 231-0016 E E
231-0031 181
1. 10.000 160 53-13 CA01 1. 10.000 160 FC 1. 6.000 160 CA01 1. 7.000 240 CA01
FROM 231-R-101 FROM LP STEAM
AP7E
AP7E
2. -1.000 160 53-41 100 VENT 53-42 2. -1.000 240
HEADER
AP7E
20 B 20 8
231-E-103 TW 100
OFF GAS COOLER 3024 NC
1. 10.000 160
SHELL SIDE
2. -1.000 160 AP7P TG
TUBE SIDE 3. 8.000 160 40 3024
AS BUILT
TW TG
3023 3023 FF GENERAL NOTES
20 AP7P TT TI
AP7ES
COOLING WATER AP7P
40 3025 3025 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
RETURN 40 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
200-WCR-231-1701-A2AW-NI 200-WCR-231-1716-A2AW-NI PDRP0451-8110-25-231-0008C.
231-0030 184
1. 8.000 65 CA01 1. 8.000 160
AP7ES
TO CW HEADER 53-65 HOLDS

25
AV7E
AV7E
N05 N01 N02
200 150 50 100 50
A03 A01
EL. + 113.190 A02 A04 N03 N04

50 50 200 200
AV7E
AV7E
500/200
AV7AP SIGNATURE
DATE
MIN. C01 50
REFERENCE DRAWINGS
SP
DP DRAWING NO. REV TITLE
1701 AV7AP
LT LIC H
2
1.0M
C03
500-PC-231-1717-A4AN-PP
50 DP 3010 3010 L
LT 2
3009
7
LI I
C04 50 AV7AP
3009 1250 ENGINEER'S APPROVAL APPROVED FOR CONST
LL
C02 AV7AP REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
P MIN.
50
FF
TI H REVISED AS PER 90% DESIGN
A3 10.12.12 MK MM CU
3026 A2 15.02.12
REVIEW
REVISED AS PER COMMENTS VP BT CU
TT H O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
3026 XV LV REV DATE DESCRIPTION BY CHKD APPD
3009 3010 CLIENT:

INDIAN OIL
L
AP7P
PROCESS CONDENSATE CORPORATION

40
25-PC-231-1702-A4AN-PP LIMITED
183 231-0018A
53-14 100/25 100/25 FC FC 1. 10.000 160 CA01 LSTK:
SIZE:20x25 8 1 TO 231-V-102
AP7E
AP7E
AP7E
25 B 2. -1.000 160 WABAG
PSET:8.000 53-15 VA TECH WABAG
20 20 9 20 VA TECH WABAG LIMITED
TSV
25 HOLD 3
3003 REV:
NC FILE NAME: 10-P2-D0015-046
B Z1
SLOP
E 25-V-231-1703-A2AW-NI 200-WCS-231-1705-A2AW-NI PACKAGE VENDOR:
1. 1. 8.000 160 LINDE ENGINEERING INDIA PVT. LTD.,
20 VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1007 Z1
LO
20-WCS-231-1713-A2AW-NI Paradip, Orissa State, India
1. 8.000 160 COOLING WATER
SUPPLY This Drawing is the Property of
200-WCS-231-1709-A2AW-NI 200-WCS-231-3003-A2AW-NI INDIAN OIL CORPORATION LTD
231-0030 182
1. 8.000 160 1. 8.000 65 CA01 and is lent without consideration other than the
53-64 FROM CW HEADER Borrower's agreement that it shall not be
100-WCS-231-1706-A2AW-NI 100-SS-231-1824-A4AN-NI
231-0018A 300 TITLE:
1. PIPING AND INSTRUMENT DIAGRAM
OFFGAS COOLER
SS SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0017 Z1
451/4200 36606
TAG NUMBER UNIT 231-V-102 TAG NUMBER 231-JS-102 NOTES
DESCRIPTION SPENT CAUSTIC DESCRIPTION STATIC MIXER 1. SIGHT GLASS WITH FLOW DIRECTION.
NEUTRALIZATION DRUM
TAN-TAN LENGTH mm 5500 LENGTH mm
- 940 2. DP : DIFFERENTIAL PRESSURE.
DIAMETER mm 2184 VOLUME m3
. 0.017 M3 3. M : MAGNETIC.
DESIGN PRESSURE kg/cm2g 0.100/ / / DESIGN PRESSURE kg/cm2g 10.500/ / / 4. ROUTED TO PROCESS DRAIN.
DESIGN TEMPERATURE °C 160/ / / DESIGN TEMPERATURE °C 160/ / / 5. TO SAFE LOCATION.
6. NRV SHALL BE TIGHT SHUTOFF TYPE.
I
1300
H
PROCESS CONDENSATE XV
25-PC-231-1702-A4AN-PP AV
183 231-0017 3027
1. 10.000 160 53-15 CA01 3005 L
FROM 231-E-103 2. -1.000 160 H2SO4
50 25-AC-231-2620-A1LJ-NI
231-0026
53-37 FC FC 1. 10.500 65 CA03
50/25 50/25 FROM 231-P-106A/B
AP7ES
AP7E
B 25 A A 53-36
CA01 CA50 CA50 CA03
25-AC-231-1811-A03N-NI
20 20 DRAIN
25 NC
1. 10.500 65
5 A03N A1LJ
231-V-102
80-V-231-1809-A4AN-PP
SPENT CAUSTIC B
1. 0.000 160
NEUTRALIZATION DRUM
1. 0.100 160
CA01 NAPHTHENIC SPENT
CAUSTIC
2 231-JS-102 50 25-PSC-231-2508-A4AN-NI
231-0025
150-PTC-231-1810-A03N-NI
50/25 50/25 50/25 1. 10.500 65 CA02
STATIC MIXER FROM 231-P-107A/B
A4AN
DP
HH A A 53-73
LZT N04 N02 1. 10.500 160
AV7AP C01 CA01 CA50 CA50 CA02
6
3013C 80 50 CA01 AP7E
LL
MIN
50 50 50
2
HH
A03N
DP LZT M DP 80 C09C 150-PTC-231-1803-A03N-NI
LG LT C09A C09B A03N A4AN
MIN.
3013B A01 1. 10.500 65
2 LL 3012 3011 C10A C10B 600
DP HH C10C 53-11 AS BUILT
LZT AV7AP B
2 3 80 50 50 50 150 B TREATED CAUSTIC
3013A LO 150-PTC-231-1907-A4AN-NI
LL C02 200 50 231-0019 197 GENERAL NOTES
N03 A03 N03 N01 53-10 53-25 53-24 1. 10.500 80 CA02
N01 LO M LO B
AV7AP
AV7AP
AV7AP
FROM 231-E-102A/B
AP7E
AP7E
AP7E
20 20 B A 53-22
AV7E
B - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
25
25
CA01 CA02 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
EL. + 108.100 20 RO PDRP0451-8110-25-231-0008C.
MAX
3013
MIN.
25 HOLDS
150
53-23
AP7E
SLOP
E 50-PSO-231-1823-A03N-NI
1. 12.000 160
A03N
150/100
A4AN
LIC H
3011 L LV DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
3011 OFF SPEC SIGNATURE

IZ IZ SPENT CAUSTIC DATE
50-PTC-231-1802-A4AN-NI
0180 0230 248 231-0022 REFERENCE DRAWINGS
AP7E
SIL 1 2oo3 SIL a FC 1. 10.500 80

TO 231-TK-103 DRAWING NO. REV TITLE
AP7E
AP7E
50 B 53-26 A
20
CA01 CA50
AP7E
20 20
100-PTC-231-1840-A4AN-NI
NC
25-PTC-231-1812-A03N-NI
25-PTC-231-1813-A03N-NI
100-SS-231-1824-A4AN-NI
40
OFF SPEC SPENT
B CAUSTIC
120
1. 10.500 65
1. 10.500 65
50-PTC-231-1808-A4AN-NI
158 231-0011
1. 10.500 80 ENGINEER'S APPROVAL APPROVED FOR CONST
A TO 231-TK-101
CA01 CA50
1.
CA01

OXIDISED CAUSTIC A3 10.12.12
MK MM CU
50-PSO-231-1507-A4AN-NI REVIEW
231-0017 300 A 231-0016 176 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
1. 12.000 160
CAUG
A 53-09 FROM 231-E-101A/B A 03.08.11

COMMENTS INCORPORATED) SP NJ DK
SS CA01 CA50 O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK

AIC H AIC H O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
PROCESS DRAIN 3005 L 3006 L
100-CCBD-231-1807-A4AN-NI O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
231-0027 pH pH
1. 0.000 65 REV DATE DESCRIPTION BY CHKD APPD
TO CCBD LO LO CLIENT:
INDIAN OIL
AP54AP AT AT AP54AP CORPORATION
TT 40 3005 3006 SP LIMITED
3030B AP7P 1802 LSTK:
SG
SG
SP
1
1 WABAG
1801 VA TECH WABAG

A03N

A4AN A03N ALWARPET, CHENNAI-600 018, INDIA.
REV:
FILE NAME: 10-P2-D0015-047 Z1
HH
A4AN
TI H PACKAGE VENDOR:
3030B LINDE ENGINEERING INDIA PVT. LTD.,
25-PTC-231-1832-A4AN-NI
VADODARA-GUJARAT
200-PTC-231-1804-A4AN-NI
1. 10.500 65
LINDE DWG. NO. REV:

I &AG-P-FP 1008A Z1
195 &AG-P-FP 1009
1. 10.500 120
1270 PARADIP REFINERY PROJECT

FROM TI-3030A 1oo2
53-11

53-20

TREATED CAUSTIC Borrower's agreement that it shall not be
200-PTC-231-1804-A4AN-NI reproduced, copied lent or disposed of directly or
280 231-0018B indirectly, nor used for any purpose other than that
1. 10.500 120
TO 231-P-102A/B for which it is specifically furnished. The apparatus
53-20 shown in the drawing is covered by patents
TITLE:
SPENT CAUSTIC NEUTRALISATION-I
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0018.AB Z1
451/4200 36607
/B
TAG NUMBER 231-P-102A NOTES
SERVICE SPENT CAUSTIC
CYCLE PUMP
RATED FLOW RATE m3/h 88 1. STRAINER MESH SIZE 40
DIFFERENTIAL PRESSURE bar 5.07 2. DELETED.
SHUT OFF HEAD bar 5.954 3. SEAL FLUSH LINE
DESIGN PRESSURE kg/cm2g 10.500/ / / 4. DELETED.
DESIGN TEMPERATURE °C 120/ / / 5. API SEAL PLANS 11 & 62 ARE APPLICABLE
IZ I
0230 1270
SIL a
RUN
AVAILABLE
TRIP START
MZS MS
STOP
3010B 3010B
LOCAL STOP
FAULT
231-PM-102B ML
3010B PG
SPENT CAUSTIC CYCLE
PUMP MOTOR 3029
231-P-102B
SPENT CAUSTIC M
AP7E
CYCLE PUMP
AP7AP
SP
150/80
20
1. 10.500 120
5
1805
200/100
300#
300#
20 25 20-PTC-231-1819-A4AN-NI
1
1. 0.000 120 AS BUILT
DRAIN 20/15 VENDOR
VENDOR
3
20 NC GENERAL NOTES
TO CCBD
50-PTC-231-1814-A4AN-NI SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
50
1. 0.000 120 PDRP0451-8110-25-231-0008C.
CA01
HOLDS
A
CAUG
PROCESS DRAIN
50-CCBD-231-1817-A4AN-NI
231-0027
1. 0.000 65 CAUG
TO CCBD
IZ I SIGNATURE
0230 1270 I DATE
SIL a
1300 REFERENCE DRAWINGS
RUN
AVAILABLE FF
TRIP START
MZS MS PI FI
150-PTC-231-1806-A4AN-NI
STOP
1. 10.500 120
53-21
3010A 3010A 3030 3027 L
LL
CA01
CA01
200-PTC-231-1805-A4AN-NI
20-WS-231-1839-A2AW-NI
231-PM-102A LOCAL STOP

FAULT ENGINEER'S APPROVAL APPROVED FOR CONST
SPENT CAUSTIC CYCLE ML PT FT
1. 10.500 120

1. 10.500 65
PUMP MOTOR 3010A PG 3030 3027

3028
231-P-102A
53-20

SPENT CAUSTIC M A3 10.12.12
REVIEW
MK MM CU
AP7E
CYCLE PUMP
AP7AP
AP35A
AP7AP
20
20
1. 10.500 120 150/80 TREATED CAUSTIC
1 150-PTC-231-1841-A4AN-NI ISSUE FOR DESIGN (HAZOP
5
TREATED CAUSTIC 199 231-0019 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK

200-PTC-231-1804-A4AN-NI 200/100 1. 10.500 120
280 231-0018A 300# O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
1. 10.500 120 CA01 A 53-21 TO 231-E-102A/B
FROM 231-V-102 300# O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
53-20 25 SP
CA01 CA02 O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
20
20 1804 VENDOR 50 REV DATE DESCRIPTION BY CHKD APPD
20/15
CLIENT:
VENDOR NC
INDIAN OIL
TO CCBD CORPORATION
SERVICE WATER LIMITED
25-WS-231-3092-A2AW-NI
50-PTC-231-1815-A4AN-NI
20-PTC-231-1820-A4AN-NI
188 231-0031
1. 10.500 65 CA01 LSTK:
FROM SW HEADER 25/20 3 WABAG
1. 0.000 120
1. 0.000 120
VA TECH WABAG
REV:
FILE NAME: 10-P2-D0015-047 Z1
PACKAGE VENDOR:
CA01
VADODARA-GUJARAT
A
CAUG
LINDE DWG. NO. REV:

&AG-P-FP 1008B Z1

PROCESS DRAIN
231-0027
1. 0.000 65 CAUG
TITLE:
SPENT CAUSTIC NEUTRALISATION-II
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0018AB Z1
451/4200 37266
NOTES
1. HOSE CONNECTION FOR SERVICE WATER & NITROGEN

TAG NUMBER 231-E-102A /B 2. DELETED.
SERVICE SPENT CAUSTIC COOLER 3. EXCHANGERS ARE DESIGNED FOR 2X50% DUTY
4. INLET & OUTLET PIPING OF 231-E-102A/B TO BE
TYPE PLATE TYPE SYMMETRICAL.
DUTY, RATED, EACH kcal\hr2 549000 5. AT HIGH POINT OF PIPE.
3
DESIGN PRESSURE kg/cm g 10.500/8.000/ / 6. AT LOW POINT OF PIPE.
DESIGN TEMPERATURE °C 120/120/ / 7. UTILITY FOR PROCESS SIDE CLEANING
AND MAINTANCE.
SIZE:20x25
PSET:8.000
TSV
3004A
25-V-231-1908-A2AW-NI SLOP
E
1. 0.000 120
20
NEAREST FUNNEL Z1 LO
20-WCR-231-1915-A2AW-NI
231-E-102A
SPENT CAUSTIC COOLER
5 1. 10.500 120
2. 8.000 120
CA02
AP7E
25
1
100 100 100-WCS-231-1922-A2AW-NI AS BUILT
N03 1. 8.000 120
4 N01 4
25
6
25
N04 N02 GENERAL NOTES
100-WCR-231-1924-A2AW-NI 1. 10.500 120
1. 8.000 120 100 100 - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
100-WCR-231-1901-A2AW-NI
AP7P
4 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
100-PTC-231-1841-A4AN-NI
25 4
100-WCS-231-3002-A2AW-NI
6
40
100-PTC-231-1907-A4AN-NI
PDRP0451-8110-25-231-0008C.
FF EL. + 100.500 TG TW
HOLDS
65
1. 10.500 120
PDI H 3042 3042
65
1. 10.500 80
3031
1. 8.000
1. 8.000
PG
PDT 3032
3031
150/100
20 AP7ES
150/100 DRAIN
COOLING WATER DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
AP7AP
AP7AS
TREATED CAUSTIC SUPPLY SIGNATURE
20
150-PTC-231-1841-A4AN-NI 150-WCS-231-3002-A2AW-NI
199 231-0018B NC 231-0030 201 DATE
1. 10.500 120 CA02 1. 8.000 65 CA02
TO 231-P-102A/B B B FROM HEADER
REFERENCE DRAWINGS
53-21 53-62
150/100
TI H 100-WCS-231-1914-A2AW-NI
3028 1. 8.000 65
CA02
CA02
150/100
25-WCS-231-1917-A2AW-NI
SIZE:20x25
25-PTC-231-1919-A4AN-NI
PSET:8.000 HH
TT TI
100-WCS-231-1905-A2AW-NI
H 195 &AG-P-FP 1008A
3030A 3030A
1. 0.000 120
1. 0.000 120
NC TSV
150/100
TT TO I-1270
25 3004B 20 ENGINEER'S APPROVAL APPROVED FOR CONST
3028 AP7ES
150/100
AP7ES
65
COOLING WATER
AP7AP
DRAIN REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
40
AP7P
AP7P
RETURN TREATED CAUSTIC

40
150-WCR-231-1901-A2AW-NI 25-V-231-1909-A2AW-NI 150-PTC-231-1907-A4AN-NI
1. 8.000
E
231-0030 200 SLOP

197 231-0018A
1. 8.000 65 CA02 1. 0.000 120 1. 10.500 80 CA02
CA02
B B
100-WCS-231-1910-A2AW-NI
TO HEADER 53-63 53-22 TO 231-JS-102 A3 10.12.12

MK MM CU
REVIEW
A 150/100 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU
100-PTC-231-1906-A4AN-NI
20
150/100
CAUG
1. 8.000 120
LO
231-E-102B SS O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
NEAREST FUNNEL Z1
1. 10.500 120

PROCESS DRAIN
100-WCR-231-1903-A2AW-NI
SPENT CAUSTIC COOLER 50-CCBD-231-1911-A4AN-NI O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM

231-0027
1. 0.000 65 CAUG REV DATE DESCRIPTION BY CHKD APPD
5 20-WCR-231-1916-A2AW-NI 1. 10.500 120 TO CCBD
100-PTC-231-1904-A4AN-NI
CLIENT:
2. 8.000 120
INDIAN OIL
65
CA02
25 CORPORATION
1
1. 10.500 80
100 100 LIMITED
1. 8.000
100-WCS-231-1921-A2AW-NI
1. 10.500 120 N03 1. 8.000 120 LSTK:
4 N01 4
WABAG
AP7ES
25
6
25 VA TECH WABAG
N04 N02 VA TECH WABAG LIMITED

100-WCR-231-1923-A2AW-NI 1. 10.500 120 No.11, MURRAY'S GATE ROAD,
1. 8.000 120 100 100 REV:
4 4 FILE NAME: 10-P2-D0015-048
AP7P
25 3 Z1
6
40
PACKAGE VENDOR:
EL. + 100.500 TG TW LINDE ENGINEERING INDIA PVT. LTD.,

NITROGEN 7 VADODARA-GUJARAT
25-IG-231-3166-A1AA-NI 3043 3043
CA02
CA02
25-WCS-231-1918-A2AW-NI
203 231-0031
25-PTC-231-1920-A4AN-NI
1. 10.500 65 CA02
FROM N2 HEADER LINDE DWG. NO. REV:
&AG-P-FP 1009 Z1
1. 0.000 120
1. 0.000 120
SERVICE WATER 7 PARADIP REFINERY PROJECT

25-WS-231-3167-A2AW-NI Paradip, Orissa State, India
202 231-0031
1. 10.500 65 CA02
FROM SW HEADER This Drawing is the Property of
CA02

A indirectly, nor used for any purpose other than that
CAUG
100/50 for which it is specifically furnished. The apparatus

SS information contained in this drawing may be proprietary
PROCESS DRAIN subject to obligations of confidentiality.
50-CCBD-231-1912-A4AN-NI
231-0027 TITLE:
1. 0.000 65 CAUG PIPING AND INSTRUMENT DIAGRAM
TO CCBD
SPENT CAUSTIC COOLER
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0019 Z1
451/4200 36608
TAG NUMBER 231-K-101A NOTES
SERVICE AIR COMPRESSOR
1) INSTRUMENT AIR TO BE USED FOR TEMPERATURE
TYPE SCREW COMPRESSOR CONTROL VALVE AND FLOW CONTROL VALVE
NO. OF STAGES 2
FLOW RATE kg/h 2796
DESIGN PRESSURE kg/cm2g 12.0/ / /
DESIGN TEMPERATURE °C 250 C/ / /
TP
COOLING WATER 02A 231-K-101A
SUPPLY
207 231-0030
80-WCS-231-3004-A2AW-NI AIR COMPRESSOR
1. 8.000 65 CA03
80/40
AP7ES
FROM CW HEADER
REFER VENDOR P&ID NO. M850195CPID
20
TSH TIC TI FIC

&AG-P-FP 1006 298
3035A 3035A 3035A 3014 L
FROM FT-3014
OPEN TO ATM.
TT
AS BUILT
TV 3035A
3035A
COOLING WATER AP7P
RETURN LO LEI GENERAL NOTES
80-WCR-231-2001-A2AW-NI
231-0030 204 - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
1. 8.000 65 CA03
100-PA-231-2009-A2AP-IH
80/40 100/40 100/40
AP7ES
TO CW HEADER SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH

20 TP PDRP0451-8110-25-231-0008C.
1. 12.000 250
FF 04A
HOLDS
TI PI TI PI
3080A 3067A 3031 3033
FV
TT PT 3014
3080A 3067A TT PT
3031 3033
AP7AS
AP7P
LEI SIGNATURE
40-WCR-231-2008-A2AW-NI DATE
LEI
AP7P
1. 8.000 65
AP7AS
40
100/40 100/40 PROCESS AIR
REFERENCE DRAWINGS
20
TP 100-PA-231-2002-A2AP-IH DRAWING NO. REV TITLE
174 231-0016
03A 1. 12.000 250 CA03
53-32 TO 231-JS-101
TP
01A
INSTRUMENT AIR
25-AI-231-3026-A1AA-NI
292 231-0030
1. 10.500 65 CA03 NOTE 1
FROM IA HEADER ENGINEER'S APPROVAL APPROVED FOR CONST
Z2 09.04.16 RE-ISSUED AS BUILT MK MM CU

A3 10.12.12 MK MM CU
REVIEW
VENDOR SCOPE O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
TP TP TP TP O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
05A 06A 08A 07A REV DATE DESCRIPTION BY CHKD APPD

CLIENT:
INDIAN OIL
15-CCBD-231-2005-A4AN-NI
15-CCBD-231-2006-A4AN-NI
20-CCBD-231-2007-A4AN-NI
20-CCBD-231-2004-A4AN-NI
CORPORATION
LIMITED
65
LSTK:
WABAG
1. 0.000
VA TECH WABAG
REV:
FILE NAME: 10-P2-D0015-049 Z1
PACKAGE VENDOR:
CA03
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1010 .
Z1

25/20 Paradip, Orissa State, India
CA03
A
100/50
CAUG

PROCESS DRAIN shown in the drawing is covered by patents
50-CCBD-231-2003-A4AN-NI
231-0027 information contained in this drawing may be proprietary
1. 0.000 65 CAUG
TO CCBD to Indian Oil Corporation Ltd and/or licensors, and is
TITLE:
COMPRESSOR A
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0020 Z1
451/4200 36609
TAG NUMBER 231-K-101B NOTES
SERVICE AIR COMPRESSOR 1) INSTRUMENT AIR TO BE USED FOR TEMPERATURE
TYPE SCREW COMPRESSOR CONTROL VALVE AND FLOW CONTROL VALVE
NO. OF STAGES 2
FLOW RATE kg/h 2796
DESIGN PRESSURE kg/cm2g 12.0/ / /
DESIGN TEMPERATURE °C 250 C/ / /
231-K-101B
AIR COMPRESSOR
TP
COOLING WATER 02B
SUPPLY REFER VENDOR P&ID NO. M850195CPID
80-WCS-231-3010-A2AW-NI
213 231-0030
1. 8.000 65 CA03
80/40
AP7ES
FROM CW HEADER
FIC
&AG-P-FP 1006 299
20 3015 L
FROM FT-3015
TSH TIC TI
3035B 3035B 3035B
OPEN TO ATM.
TT
AS BUILT
TV 3035B
3035B
COOLING WATER
100-PA-231-2105-A2AP-IH
AP7P
RETURN LO 100/40 100/40 LEI GENERAL NOTES
80-WCR-231-2101-A2AW-NI
231-0030 210
1. 12.000 250
1. 8.000 65 CA03 FF - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
80/40
AP7ES
TO CW HEADER SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH

20 TI PI TP TI PI PDRP0451-8110-25-231-0008C.
40-WCR-231-2106-A2AW-NI
3080B 3067B 04B 3032 3034

HOLDS
FV
65
TT PT 3015
1. 8.000
3080B 3067B TT PT
3032 3034
AP7AS
AP7P
LEI
100/40 100/40
LEI DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
AP7AS
AP7P
PROCESS AIR SIGNATURE
40
20
TP 100-PA-231-2102-A2AP-IH
177 231-0016 DATE
03B 1. 12.000 250 CA03 REFERENCE DRAWINGS
53-32 TO 231-JS-101
TP DRAWING NO. REV TITLE
01B
INSTRUMENT AIR
25-AI-231-3027-A1AA-NI NOTE 1
293 231-0030
1. 10.500 65 CA03
FROM IA HEADER

Z2 09.04.16 RE-ISSUED AS BUILT MK MM CU

A3 10.12.12 MK MM CU
REVIEW
VENDOR SCOPE O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK
TP TP TP TP O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
05B 06B 08B 07B REV DATE DESCRIPTION BY CHKD APPD

CLIENT:
INDIAN OIL
15-CCBD-231-2107-A4AN-NI
15-CCBD-231-2108-A4AN-NI
20-CCBD-231-2109-A4AN-NI
20-CCBD-231-2104-A4AN-NI
CORPORATION
LIMITED
65
LSTK:
WABAG
1. 0.000
VA TECH WABAG
REV:
FILE NAME: 10-P2-D0015-050 Z1
PACKAGE VENDOR:
CA03

VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1011 .
Z1

25/20 Paradip, Orissa State, India
CA03
A
100/50
CAUG

PROCESS DRAIN shown in the drawing is covered by patents
50-CCBD-231-2103-A4AN-NI
231-0027 information contained in this drawing may be proprietary
1. 0.000 65 CAUG
TO CCBD to Indian Oil Corporation Ltd and/or licensors, and is
TITLE:
COMPRESSOR B
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0021 Z1
451/4200 36610
DESCRIPTION SPENT CAUSTIC DESCRIPTION OIL SKIMMER
EQUALISATION TANK 1. SIGHT GLASS WITH FLOW DIRECTION
DESIGN TEMPERATURE °C 80/80/ / 4. DELETED.
6. DELETED.
7. AT GRADE LEVEL.
0-47.5% SPLIT RANGE 52.5-100% 8. FLOW SHALL BE VISIBLE WHILE OPERATING VALVE.
9. NOZZLE C01 SHALL BE LOCATED BELOW
11 LLL LIQUID LEVEL
CA02 CA50 10. DELETED.
PV A1AA A4AN PV 11. SPLIT RANGE VALVE :
3039A 3039B SP A
OPEN
2203
NITROGEN 12 12 TO VOC
25-IG-231-3101-A1AA-NI 50-V-231-2204-A4AN-NI
PV-3
039B
219 231-0031 230-0012 VALVE
1. 10.500 65 CA02 FC 50/25 1. 0.100 65 50/25 FO 50/25
LO LO BL POSITION
039A
AP7ES
AP7ES
FROM N2 HEADER
PV-3
AP7E
AP7E
25 25
PRESS VENT
A2AW A4AN 20 20 20 20 CLOSE VALVE VALVE
50-V-231-2206-A4AN-NI
25 7 40 0 47.5 52.5 100
65
NC NC PRESSURE INCREASE
50-V-231-2206-A4AN-NI
SERVICE WATER
50-WS-231-3022-A2AW-NI LDI H LI LI PROVIDED DEAD BAND (ABOUT 5%) DEAD BAND RANGE
1. 0.100
263 231-0030
65
1. 10.500 65 CA02 3014 3014A 3014B SHALL BE FURTHER ADJUSTED BY OPERATOR, IF
FROM SW HEADER NC NC A1AA A4AN
REQUIRED.
50-WS-231-3022-A4AN-NI
1. 0.100
12. LOCATE PV-3039B ASSEMBLY AT TANK ROOF AND
SERVICE WATER PV-3039A AT GRADE.
25-WS-231-3181-A2AW-NI IZ
1. 10.500 80
231-0031 295
1. 10.500 65 0220
HH SIL a
I LI H
L AS BUILT
1290 3015
LI
3015 RADAR RADAR GENERAL NOTES
H LT LZT PIC H
20
XV 7 3014 3016 3039 L
LL SIZE:25x80 - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
2
3015 PSET:0.065 / -0.018 PDRP0451-8110-25-231-0008C.
L SIZE:200
TREATED CAUSTIC PSET:0.090 PVRV HOLDS
50-PTC-231-1802-A4AN-NI SLOP
3006 PG PT
248 231-0018A E
1. 10.500 80 CA50 FC PRV 3038 3039 SP

FROM 231-E-102A/B
AP7E
AP7E
AP7E
53-26 A 50 RADAR 3005
LT 2205
CA50 CA02
20 20 20 3015 20-V-231-2216-A4AN-NI
AV7P
AV7P
40
AV7AP
AV7AP
N1
AV7P
NC
3.5M
25 Z1
N06 N04 50-CCBD-231-2217-A4AN-NI
N03 C03 200 50 N07 N16 DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
C04 50 80 80 50 C02
A02 80
SIGNATURE
C05 610 50 C06 DATE
80 50
REFERENCE DRAWINGS
231-OS-103
50
N10 OIL SKIMMER 150MM N2
50 25 Z1
50 TO CCBD
9
50 N11
50 AV7P TT TI
50
C01
50 N12 50 3033 3033 ENGINEER'S APPROVAL APPROVED FOR CONST
1 8 REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE

8 50 N18
50-OWS-231-2203-A4AN-NI E 50 N13 50
SLOP
SG
1. 3.500 80 CA02 50 Z1 06.05.15 ISSUED AS BUILT MK MM CU
TREATED CAUSTIC REVISED AS PER 90% DESIGN
SP 50 N14 N08 50-PTC-231-2304-A4AN-NI
A3 10.12.12
REVIEW
MK MM CU
231-0023 261 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU

2201 50 50 1. 15.000 80 CA02
231-JS-105 FROM 231-P-104A/B ISSUE FOR DESIGN (HAZOP
N17 MIN. A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
50
CA02
A01 O2 08.07.11 RE-ISSUE FOR COMMENTS SP NJ DK

50 JET MIXER 610 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
TREATED CAUSTIC O1
A N15 100-PTC-231-2202-A4AN-NI
5
100/50 50 N01 262 231-0023
CAUG
1 8 100 1. 15.000 80 CA02 REV DATE DESCRIPTION BY CHKD APPD

8 TO 231-P-104A/B
SLOP OIL N09 53-27 CLIENT:
231-0027 SG 3 INDIAN OIL
1. 0.000 65 CAUG 1. 3.500 80 CA02 50 100
CA02
SP EL. + 100.800 SLOP
E 50 LIMITED
A
2202 LSTK:
231-TK-103 WABAG
CAUG
VA TECH WABAG
SPENT CAUSTIC
EQUALISATION TANK PROCESS DRAIN
231-0027
TO CCBD Z1
PACKAGE VENDOR:
M VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1012
150-SS-231-2213-A4AN-NI
150 150 Z1

PROCESS DRAIN
SS 150-CCBD-231-2212-A4AN-NI INDIAN OIL CORPORATION LTD
231-0027
1. 0.000 65 CAUG and is lent without consideration other than the
TO CCBD Borrower's agreement that it shall not be
TITLE:
SPENT CAUSTIC EQUALIZATION TANK
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0022 Z1
451/4200 36611
NOTES
TAG NUMBER 231-P-104A/B
SERVICE EQUALIZED SPENT CAUSTIC 1. HOSE CONNECTION FOR SERVICE WATER.
CHARGE PUMPS 2. OPENING RESTRICTED TO PUMP MIN.FLOW.
RATED FLOW RATE m3/h 20.3 3. STRAINER MESH SIZE 40.
DIFFERENTIAL PRESSURE bar 10.55 4. DELETED.
SHUT OFF HEAD bar 11.49 5. SEAL FLUSH LINE.
DESIGN PRESSURE kg/cm2g 15.000/ / / 6. SAMPLING POINT HORIZONTAL,
DESIGN TEMPERATURE °C 80/ / / END CONNECTION DOWNWARD WITH NIPPLE.
7. DELETED.
8. DELETED.
9. API SEAL PLANS 11 & 62 ARE APPLICABLE
IZ RUN
0220 AVAILABLE
SIL a START
MS
STOP
3012B
TRIP
MZS LOCAL STOP
3012B FAULT
ML
3012B TREATED SPENT
CAUSTIC
231-PM-104B 50-PTC-231-2304-A4AN-NI
261 231-0022
PG MIN. FLOW / TANK MIXING 1. 15.000 80 CA02
EQUALIZED SPENT CAUSTIC TO 231-TK-103
CHARGE PUMP MOTOR 3041
231-P-104B
1 EQUALIZED SPENT CAUSTIC M
CHARGE PUMP AP7E
AP7AP
40
1. 15.000 80 80/40
20
9
AP7E
CA02 20 2
100/80 300#
AP7E
20 RO
300# AS BUILT
3019
3
AP7E
20 SP
20/15 VENDOR
2302
VENDOR
5
TO CCBD
GENERAL NOTES
TO CCBD 20-PTC-231-2310-A4AN-NI - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
1. 0.000 80 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
PDRP0451-8110-25-231-0008C.
50-PTC-231-2307-A4AN-NI
CA02
1. 0.000 80 HOLDS
CA02
CAUG
PROCESS DRAIN
25-CCBD-231-2305-A4AN-NI
231-0027
1. 0.000 65 CAUG
TO CCBD
53-27
100-PTC-231-2301-A4AN-NI
20-WS-231-2314-A2AW-NI

IZ
SIGNATURE
80-PTC-231-2302-A4AN-NI
0220 RUN DATE
SIL a
1. 15.000 80
AVAILABLE REFERENCE DRAWINGS

START
MS
1. 15.000 80
STOP
3012A
TRIP
CA02
MZS
53-28
FF
3012A LOCAL STOP
SERVICE WATER PI
25/20 FAULT
25-WS-231-3198-A2AW-NI ML 3043
267 231-0031
1. 10.500 65 CA02 3012A
FROM SW HEADER 231-PM-104A ENGINEER'S APPROVAL APPROVED FOR CONST
EQUALIZED SPENT CAUSTIC PG REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
CHARGE PUMP MOTOR PT
3042 3043
231-P-104A
1 M Z1 06.05.15 ISSUED AS BUILT
MK MM CU
EQUALIZED SPENT CAUSTIC A3 10.12.12

REVIEW
MK MM CU
40 CHARGE PUMPS TREATED SPENT

AP7AP
AP7AP
80/40 CAUSTIC
1. 15.000 80
9
AP7E
20
80-PTC-231-2303-A4AN-NI 50-PTC-231-2303-A4AN-NI ISSUE FOR DESIGN (HAZOP
20
TREATED CAUSTIC CA02 269 231-0024 A 03.08.11 COMMENTS INCORPORATED) SP NJ DK
100/80 300# 53-28 80/50 1. 15.000 80 CA01

100-PTC-231-2202-A4AN-NI TO 231-F-101
AP7E
262 231-0022 20 53-28

1. 15.000 80 CA02 A A O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
FROM 231-TK-103 3 300#

AP7E
53-27 20 SP
CA02 CA50 CA50 CA01 O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
SC-1 20/15 VENDOR REV DATE DESCRIPTION BY CHKD APPD

2301 VENDOR
6
CLIENT:
5
TO CCBD INDIAN OIL

TO CCBD CORPORATION
LIMITED
50-PTC-231-2308-A4AN-NI
20-PTC-231-2311-A4AN-NI
LSTK:
WABAG
20-WS-231-2313-A2AW-NI
VA TECH WABAG
80
80
1. 10.500 65 VA TECH WABAG LIMITED

1. 0.000
1. 0.000

REV:
FILE NAME: 10-P2-D0015-052 Z1
PACKAGE VENDOR:
VADODARA-GUJARAT
CA02
LINDE DWG. NO. REV:

&AG-P-FP 1013 Z1
A
CAUG

PROCESS DRAIN
231-0027
1. 0.000 65 CAUG
TITLE:
EQUALIZATION SPENT CAUSTIC CHARGE PUMPS
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0023 Z1
451/4200 36612
TAG NUMBER 231-F-101 NOTES
SERVICE COALESCER 1. AT GRADE LEVEL.
DIMENSION (ID x TT) mm 300X2800 2. 231-LI-3017 AND ISOLATION VALVE SHALL BE FACING
SIZE:25D50
DESIGN PRESSURE kg/cm2g 15.000/ / / EACH OTHER.
PSET:15.000
DESIGN TEMPERATURE °C 80 C/ / / 3. SIGHT GLASS WITH FLOW DIRECTION AT
PSV GRADE LEVEL, SPECIAL PART.
3005 4. INTERPHASE MEASUREMENT.
5.DELETED
6. TO SAFE LOCATION.
50-PTC-231-2403-A4AN-NI Z1 7. SAMPLING POINT HORIZONTAL,
1. 0.000 80 CA01 END CONNECTION DOWNWARD WITH NIPPLE.
8. DELETED.
20 9. FLANGE END A03 SHALL BE USED FOR MAINTANCE.
LO
25-PTC-231-2402-A4AN-NI
25-PTC-231-2401-A4AN-NI
1. 15.000 80 CA01
AP7E
FF
LI LI
2
H
3017B 3017A L 50/25
1
AS BUILT
C01 N03 C03
AV7AP 50 50
AV7AP
PG LT LG
GENERAL NOTES
4
3060 3017 3018
AV7AP 50 50 AV7AP - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
C02 C04 PDRP0451-8110-25-231-0008C.
AV7E
NC
HOLDS
A02 C05 RO
20 50 50 3026
231-F-101
AP7E
TREATED SPENT
CAUSTIC A03 COALESCER
50-PTC-231-2303-A4AN-NI
269 231-0023 N01 1. 15.000 80
9
1. 15.000 80 CA01 50
FROM 231-P-104A/B CA01
AP7E
53-28
1
NC
50 50
2
20 N04 A01 N02 EL. + 101.140
AP7AP

SP SIGNATURE
SG
AV7E
50/ NC
3
DATE
2401
NC
20 50 REFERENCE DRAWINGS
CA01
A
CA01
CAUG
A
CAUG
PROCESS DRAIN
50-CCBD-231-2407-A4AN-NI FIC H
231-0027 L
1. 0.000 65 CAUG 3020
TO CCBD
SLOP OIL ENGINEER'S APPROVAL APPROVED FOR CONST
40-OWS-231-2406-A2AQ-NI
231-0027
53-29
FF 1. 0.000 65 CAUG REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
TO 231-TK-108
HH
PDI H FT
3057 3020 PG Z1 06.05.15 ISSUED AS BUILT MK MM CU
3059 A3 10.12.12
REVIEW
MK MM CU

FV
CA01
CA50
A 03.08.11 SP NJ DK
PDT AP7AP 3020 COMMENTS INCORPORATED)
AP33
3057 A TREATED SPENT
AP7AP
20 O1 20.06.11 RE-ISSUE FOR COMMENTS SP NJ / DK SM
CAUSTIC
50-PTC-231-2404-A4AN-NI SCT B/L O 18.05.11 ISSUE FOR COMMENTS SP MS / DK SM
M 230-0005
FC 1. 15.000 80 CA50 REV DATE DESCRIPTION BY CHKD APPD
CA02
TO BL
AP7E
AP7E
AP7E
50 B 53-30 TP 06 CLIENT:
INDIAN OIL
20 20 20 SC-1 CORPORATION
7
50-PTC-231-2405-A4AN-NI BYPASS LINE 40 40 LIMITED
1. 15.000 80 CA01 NC NC NC LSTK:
B WABAG
TO CCBD VA TECH WABAG

REV:
FILE NAME: 10-P2-D0015-053 Z1
PACKAGE VENDOR:
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1014 .
Z1

TITLE:
COALESCER
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0024 Z1
451/4200 36613
NOTES
1. DELETED.
2. DELETED.
20 3. SAFTY SHOWER, SPECIAL PART.
AP7ES
COOLING WATER 4. DELETED.
RETURN 5. DELETED.
80-WCR-231-2001-A2AW-NI
231-0020 204 6. NEAR 231-E-101A/B
1. 8.000 65 CA03
7. NEAR TANK 231-TK-104A/B
AP7ES
FROM 231-K-101A
COOLING WATER 8. NEAR TANK 231-TK-111
RETURN
20 150-WCR-231-1901-A2AW-NI
231-0019 200
1. 8.000 65 CA02
53-63 FROM 231-E-102A/B
COOLING WATER RETURN A
250-WCR-231-3005-A2AW-NI
231-0028
1. 8.000 65 CA03 CA03 CA50 A
FROM 231-CP-100A/B
AP7ES
A COOLING WATER
25
RETURN
DRAIN 200-WCR-231-1701-A2AW-NI
231-0017 184
1. 8.000 65 CA01
53-65 FROM 231-E-103
COOLING WATER
RETURN
80-WCR-231-2101-A2AW-NI
231-0021 210
20 1. 8.000 65 CA03
FROM 231-K-101B
AP7ES
NC COOLING WATER
SUPPLY
80-WCS-231-3004-A2AW-NI
207 231-0020
1. 8.000 65 CA03
AP7ES
TO 231-K-101A
20
150-WCR-231-3099-A2AW-NI
COOLING WATER SUPPLY

250-WCS-231-3001-A2AW-NI
231-0028 AS BUILT
1. 8.000 65 CA03 CA03 CA50
FROM 231-P-113A/B A A
AP7ES
A 25 COOLING WATER
SUPPLY
DRAIN 150-WCS-231-3002-A2AW-NI
201 231-0019 GENERAL NOTES
1. 8.000 65 CA02
53-62 TO 231-E-102A/B - ALL INSTRUMENTS TO HAVE PREFIX AS UNIT NO. i.e.231
COOLING WATER - FOR STANDARD SYMBOL DETAILS AND LEGEND SHEETS
SUPPLY SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
200-WCS-231-3003-A2AW-NI PDRP0451-8110-25-231-0008C.
182 231-0017
1. 8.000 65 CA01
53-64 TO 231-E-103 HOLDS
COOLING WATER
SUPPLY
80-WCS-231-3010-A2AW-NI
213 231-0021
1. 8.000 65 CA03
TO 231-K-101B
A INSTRUMENT AIR
50/25 25-AI-231-3026-A1AA-NI
292 231-0020 DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
CA50 CA03 1. 10.500 65 CA03
TO 231-K-101A SIGNATURE
25-AI-231-3035-A1AA-NI DATE
DRAIN REFERENCE DRAWINGS
25 INSTRUMENT AIR
25-AI-231-3027-A1AA-NI DRAWING NO. REV TITLE
293 231-0021
IAM-06 1. 10.500 65 CA03
TO 231-K-101B
INSTRUMENT AIR A
50-AI-231-3008-A1AA-NI
230-0022
1. 10.500 65 CA50
FROM INSTRUMENT AIR HEADER
25-AI-231-3039-A1AA-NI 25-AI-231-3038-A1AA-NI 25-AI-231-3036-A1AA-NI REV DATE SIGNATURE OE* AE* REV DATE SIGNATURE
25 25 25
IAM-01 IAM-02 IAM-03

25-AI-231-3034-A1AA-NI REVISED AS PER 90% DESIGN
POTABLE WATER IAM-04 A3 10.12.12
REVIEW
MK MM CU
50-WDK-231-3009-S1RW-IH 25 A2 15.02.12 REVISED AS PER COMMENTS VP BT CU

230-0022
1. 12.500 65 CA50 ISSUE FOR DESIGN (HAZOP
FROM POTABLE WATER HEADER
CA02 CA50
25-AI-231-3033-A1AA-NI O 08.07.11 ISSUE FOR COMMENTS SP NJ DK

A IAM-05
25 REV DATE DESCRIPTION BY CHKD APPD
25-WDK-231-3062-S1RW-IH
25-WDK-231-3007-S1RW-IH
25-WDK-231-3025-S1RW-IH
50-WDK-231-3014-S1RW-IH
CLIENT:
INDIAN OIL
CORPORATION
LIMITED
SP SP SP SP
LSTK:
3004 3001 3002 3003 SERVICE WATER WABAG
50-WS-231-3052-A2AW-NI
146 231-0011 VA TECH WABAG
1. 10.500 65 CA50
CA03 CA50

TO 231-TK-101 No.11, MURRAY'S GATE ROAD,
3

A REV:
FILE NAME: 10-P2-D0015-059
6
SERVICE WATER Z1
50-WS-231-3022-A2AW-NI PACKAGE VENDOR:
263 231-0022
DRAIN 1. 10.500 65 CA02 LINDE ENGINEERING INDIA PVT. LTD.,
TO 231-TK-103 VADODARA-GUJARAT
25
SERVICE WATER LINDE DWG. NO. REV:

LEI LEI LEI LEI 25-WS-231-3061-A2AW-NI &AG-P-FP 1015 .
Z1
167 231-0015
RO RO RO RO 1. 10.500 65 CA02
TO 231-E-101A/B PARADIP REFINERY PROJECT
3024 3023 3021 3022
SERVICE WATER This Drawing is the Property of
25-WS-231-3098-A2AW-NI INDIAN OIL CORPORATION LTD
165 231-0012
1. 10.500 65 CA02 and is lent without consideration other than the
TO PUMP 231-P-101A/B Borrower's agreement that it shall not be
SERVICE WATER A A A SERVICE WATER shown in the drawing is covered by patents
50-WS-231-3012-A2AW-NI 50-WS-231-3012-A2AW-NI
230-0021 211 231-0031 information contained in this drawing may be proprietary
1. 10.500 65 CA50 1. 10.500 65 CA50
FROM SW HEADER TO SW HEADER
TITLE:
SERVICE WATER PIPING AND INSTRUMENT DIAGRAM
25-WS-231-3023-A2AW-NI SPENT CAUSTIC TREATMENT PLANT
251 231-0013
1. 10.500 65 CA50
TO 231-TK-102 UTILITIES-I
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0030 Z1
451/4200 37263
NOTES
NITROGEN 1. HOSE CONNECTION.
25-IG-231-3109-A1AA-NI
149 231-0011 2. STEAM TRAP, SPECIAL PART.
1. 10.500 65 CA02
TO 231-TK-101 3. IBR LINE LP STEAM HEADER.
4. DELETED.
5. DELETED.
NITROGEN 6. REFER P&ID NO. PDRP0451-8110-25-231-0032
25-IG-231-3102-A1AA-NI
254 231-0013 REV. A FOR STEAM TRAP DETAILS.
1. 10.500 65 CA02
TO 231-TK-102
NITROGEN
25-IG-231-3162-A1AA-NI
168 231-0015
1. 10.500 65 CA02
TO 231-E-101A/B
NITROGEN
25-IG-231-3166-A1AA-NI
203 231-0019
1. 10.500 65 CA02
TO 231-E-102A/B
NITROGEN
25-IG-231-3101-A1AA-NI
219 231-0022
1. 10.500 65 CA02
231-TK-103
AP7ES
20
NITROGEN A A A A
50-IG-231-3107-A1AA-NI
230-0022
1. 10.500 65 CA50
FROM NITROGEN HEADER
40-AP-231-3152-A1AA-NI 25-AP-231-3158-A1AA-NI
AS BUILT
40-AP-231-3149-A1AA-NI
1. 10.500 65 CA01
GENERAL NOTES
40-SL-231-3151-A1AS-IH 25-SL-231-3157-A1AS-IH
3 3 SEE DRAWINGS PDRP0451-8110-25-231-0004 THROUGH
40-SL-231-3148-A1AS-IH PDRP0451-8110-25-231-0008C.
1. 7.000 240 CA01
2. -1.000 240 3 HOLDS
40-WS-231-3147-A2AW-NI
1. 10.500 65 CA01
A
25-AP-231-3155-A1AA-NI
25-SL-231-3154-A1AS-IH
40/25
40/25
40/25
40-WS-231-3150-A2AW-NI DISCIPLINE PROC EQUIP INSTR PIPING COMM THSE
25-WS-231-3153-A2AW-NI
SIGNATURE
3
DATE
40/25
40/25
40/25
REFERENCE DRAWINGS
25-WS-231-3156-A2AW-NI
CA01
CA01
CA01
UTILITY STATION 5 UTILITY STATION 6 UTILITY STATION 7 UTILITY STATION 8

T.S. T.S. REACTOR REACTOR
1 1 1 1 ENGINEER'S APPROVAL APPROVED FOR CONST

SERVICE WATER
25-WS-231-3092-A2AW-NI
188 231-0018B
1. 10.500 65 CA01
TO PUMP 231-P-102A/B
CA50 CA03
A3 10.12.12 MK MM CU
REVIEW
A
25-AP-231-3161-A1AA-NI
PLANT AIR A
50-AP-231-3113-A1AA-NI O 08.07.11 ISSUE FOR COMMENTS SP NJ DK
230-0022
1. 10.500 65 CA50 REV DATE DESCRIPTION BY CHKD APPD
FROM PLANT AIR HEADER
AP7ES
20 CLIENT:
INDIAN OIL
CORPORATION
SP LIMITED
3103 LSTK:
LP STEAM WABAG
25-SL-231-3193-A1AS-IH
ST 181 231-0017 VA TECH WABAG
1. 7.000 240 CA01
CA03

SP 3 3 3 3 3 SP 2. -1.000 240 TO 231-RO-3012/VENT No.11, MURRAY'S GATE ROAD,
A
3101 3102 FILE NAME: 10-P2-D0015-060 REV:
CA50
Z1
LP-STEAM A A
50-SL-231-3111-A1AS-IH PACKAGE VENDOR:
230-0021 ST ST
1. 7.000 240 CA50 CA50 LINDE ENGINEERING INDIA PVT. LTD.,
FROM LP STEAM HEADER
6
6
2. -1.000 240 3 VADODARA-GUJARAT
25-SL-231-3160-A1AS-IH
25-AP-231-3165-A1AA-NI
25-AP-231-3183-A1AA-NI
25-AP-231-3142-A1AA-NI
40-AP-231-3146-A1AA-NI
25-SL-231-3164-A1AS-IH
25-SL-231-3182-A1AS-IH
40-SL-231-3145-A1AS-IH
25-SL-231-3141-A1AS-IH
LINDE DWG. NO. REV:

&AG-P-FP 1016 .
Z1
25-WS-231-3163-A2AW-NI
SERVICE WATER This Drawing is the Property of
A
50-WS-231-3012-A2AW-NI INDIAN OIL CORPORATION LTD
211 231-0030
1. 10.500 65 CA50 and is lent without consideration other than the
40/25
40/25
AP7ES
FROM SW HEADER 25-WS-231-3140-A2AW-NI A A
25-WS-231-3144-A2AW-NI
25-WS-231-3159-A2AW-NI
25 reproduced, copied lent or disposed of directly or

SERVICE WATER shown in the drawing is covered by patents
25-WS-231-3167-A2AW-NI
202 231-0019 information contained in this drawing may be proprietary
1. 10.500 65 CA02 to Indian Oil Corporation Ltd and/or licensors, and is
UTILITY STATION 1 UTILITY STATION 2 UTILITY STATION 3 UTILITY STATION 9 UTILITY STATION 4 TO 231-E-102A/B subject to obligations of confidentiality.
PIPE RACK OIL REMOVAL SYSTEM PIPE RACK NEAR TO H2SO4 TANK NEAR TO COOLING TOWER
TITLE:
1 1 1 1 SERVICE WATER PIPING AND INSTRUMENT DIAGRAM
1
25-WS-231-3181-A2AW-NI 25-WS-231-3198-A2AW-NI SPENT CAUSTIC TREATMENT PLANT
295 231-0022 231-0028 267 231-0023
1. 10.500 65 CA02 1. 10.500 65 CA02
TO 231-P-104A/B UTILITIES-II
231-0028 SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0031 Z1
451/4200 37264
NOTES
1. LOCATE TRAP ISOLATION VALVES MINIMUM DISTANCE
FROM TRAP AND AT GRID.
2. INLET LINE SHALL BE FREE DRAINING TO TRAPS.
OUTLET LINE TO BE SUPPORTED FOR SLUG FLOWS.
3. THE ROOT VALVE AT DRIP LEGS IS NOT REQUIRED IF
DRIP LEG IS AT GRADE AND THE TRAP IS WITHIN 5M
OF DRIP LEG.
MP STEAM TRAP ASSEMBLY LP STEAM TRAP ASSEMBLY
4. FOR STEAM BOOT DETAILS REFER 3210-8230-54-0030.
5. STEAM TRAP WITH INTEGRAL SCREEN.
6. DISCHARGE TO PEBBLE POT (FRENCH DRAIN) OR
SIMILAR.
MP STEAM HEADER LP STEAM HEADER

LINE NO. (A) LINE NO. (A)
STEAM SUPPLY STEAM SUPPLY

LINE NO. (B) LINE NO. (B)
3 STEAM SUPPLY LINE CONDENSATE LINE 3 STEAM SUPPLY LINE CONDENSATE LINE
1 CONDENSATE 1 CONDENSATE
LINE NO. (C) LINE NO. (C)
ST ST
AP7ES
AP7ES
AP7ES
AP7ES
20 20
5 5
4 4
AS BUILT
2 2 GENERAL NOTES
GRADE GRADE PDRP0451-8110-25-231-0008C.
HOLDS
6 6

SIGNATURE
DATE
REFERENCE DRAWINGS
STEAM STEAM HEADER STEAM SUPPLY CONDENSATE STEAM STEAM HEADER STEAM SUPPLY CONDENSATE
SP ITEM NO. SP ITEM NO.
HEADER P&ID NO. LINE NO. (A) LINE NO. (B) LINE NO. (C) HEADER P&ID NO. LINE NO. (A) LINE NO. (B) LINE NO. (C) ENGINEER'S APPROVAL APPROVED FOR CONST
PDRP0451-8110-25-231-0016 SP-1601 80-SM-231-1604-B1AS-IH 20-SM-231-1624-B1AS-IH 20-CL-231-1626-A1AS-PP PDRP0451-8110-25-231-0031 SP-3101 50-SL-231-3111-A1AS-IH 20-SL-231-3103-A1AS-IH 20-CL-231-3105-A1AS-PP
PDRP0451-8110-25-231-0016 SP-1602 80-SM-231-1604-B1AS-IH 20-SM-231-1625-B1AS-IH 20-CL-231-1627-A1AS-PP PDRP0451-8110-25-231-0031 SP-3102 50-SL-231-3111-A1AS-IH 20-SL-231-3104-A1AS-IH 20-CL-231-3106-A1AS-PP
PDRP0451-8110-25-231-0016 SP-1603 80-SM-231-1604-B1AS-IH 20-SM-231-1628-B1AS-IH 20-CL-231-1630-A1AS-PP
PDRP0451-8110-25-231-0016 SP-1604 80-SM-231-1604-B1AS-IH 20-SM-231-1629-B1AS-IH 20-CL-231-1631-A1AS-PP Z2 09.04.16 RE-ISSUED AS BUILT MK MM CU
Z1` 06.05.15 ISSUED AS BUILT MK MM CU

A3 10.12.12 MK MM CU
REVIEW

CLIENT:
INDIAN OIL
CORPORATION
LIMITED
LSTK:
WABAG
VA TECH WABAG
REV:
FILE NAME: 10-P2-D0015-061 Z1
PACKAGE VENDOR:
VADODARA-GUJARAT
LINDE DWG. NO. REV:

&AG-P-FP 1017 Z1

TITLE:
STEAM TRAP DETAIL
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0032 Z1
451/4200 39170
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


O0 17.09.10 FOR REVIEW VPK MTK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME:
10P2-D0015-015 ( SH 1 OF 2) REV: 5

TITLE:
FOR LANDFILL LEACHATE TREATMENT SYSTEM
NTS PDRP0451-8110-25-231-0001 1 OF 2 B1
451/4200 20468
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME:
10P2-D0015-015 ( SH 2 OF 2) REV: 5

TITLE:
FOR LANDFILL LEACHATE TREATMENT SYSTEM
NTS PDRP0451-8110-25-231-0001 2 OF 2 B1
451/4200 20468
NOTES
HOLD

SIGNATURE
DATE
REFERENCE DRAWINGS


H1 02.05.11 ISSUED FOR HAZOP VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-016 5
TITLE:
FOR HARD COD MANAGEMENT
SCALE: DWG NO: REV:

NTS PDRP0451-8110-25-231-0002 B1
451/4200 20469
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H1 04.05.11 ISSUED FOR HAZOP VPK RR PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-021 6
TITLE:
FOR CHEMICAL DOSING SYSTEM FOR
LANDFILL LEACHATE & HCOD TREATMENT
SCALE: DWG NO: REV:
NTS PDRP0451-8110-25-231-0007 B1
451/4200 20470
DOCUMENT CODING BOX
PROJECT
PROJECT TITLE:
PROJECTTITLE:
TITLE: IOCL
IOCL
IOCL PARADIP
PARADIP
PARADIP EPCM-1
EPCM-1
CLIENT
CLIENTNAME:
CLIENT NAME:
NAME:INDIAN
INDIANOILOIL
INDIAN CORPORATION
OIL CORP LTDLIMITED (IOCL)
CORP LTD
SUPPLIER
SUPPLIER NAME:
NAME: VAVA TECH
TECH WABAG
WABAG LTD
LTD
PROJECT
PROJECT NO:
NO: 1-14-4200/399
1-14-4200/399 PROJECT
PROJECTLOCATION:
LOCATION:PARADIP,ORISSA
PARADIP,ORISSA
PO
PO NO: 4200/451
NO:ORDER
CLIENT 4200/451
NO: CLIENT
CLIENTORDER
ORDERNO:
NO:
TAG
REQNOS:
REQ NO:
NO: 4200-4305A003
4200-4305A003
TAG
TAG NOS:
NOS:

SUPPDOCNO:
SUPPDOCNO: PDRP0451-8110-20-231-0001
PDRP0451-8110-20-231-0001
DOC. TYPE: SUPPLIER REV: 04
CLDOCNO:
CLDOCNO:
DSN: 18913 FW REV:
DOC
DOC TYPE:
TYPE: F50
STATUS:
F50 SUPPLIER
SUPPLIERREV:
REV:04
04
DSN: SIGNED:
DSN: 18913
18913 FW
FWREV:
REV:55
DEPARTMENT:
Status:
Status: Code 4
DATE:
COMMENT STATUS
Signed:
Signed:
CODE:MohanRao Ramarao
Dept:
Engi
Date:
Date: 13/Jan/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-InfoOnly
Only
VA TECH WABAG LTD.
COMPLIANCE STATEMENT

India.
Drg. / Doc. Title PROCESS FLOW DIAGRAM FOR LANDFILL LEACHATE
PRETREATMENT PACKAGE.
Commented drg./doc. No. PDRP0451-8110-20-231-0001_Rev 03
Revised drg. PDRP0451-8110-20-231-0001_Rev O4
1. 231-P-005 - Spec calls for stand by for all pumps. Noted and provided.
231-P-005 - check service- as per process design

Noted and corrected in design
2. calculations it is indicated as brine recirculation
calculations.
pump.
231-P-008A/B- Filter Press feed pumps.- check
3. service.As per process design calculation it is Noted and corrected in the drawing.
indicated as Leachate sludge transfer pumps.
231-SU-001- check volume (18m3/hr as per design

4. Noted and corrected.
calcs).
231-P-006A/B - Head-? ,
5. Noted and included.
Capacity - as per P&ID and design calculations.
6. 231-M-005- type? Noted and corrected.
7. 231-P-015A/B, 231-P-016A/B- head - ? Noted and included.
8. Ensure suitable area classification for tank. Noted.
Preferred option (on providing pH analyzer). See

9. Agreed and provided pH analyzer.
comments to compliance statement 2. 1,9&14.

VA TECH WABAG LTD.
Cycle timers are not necessary for the valves.

VTW to consider the following: one easy way to get
this to desludge the max velocity is as follows:
when 231-P-008 has pumped 231-SU-002 to level
L then system has the max head available to give
10. max flow rate from 231-SU-005. The LC can then Agreed and corrected as such.
open one of the sludge valves for a preset time (as
per run timer). The run timer does not need to
cause 231-SU-002 to fill completely. When 231-
SU-002 is pumped down to level L again, open the
next sludge valve and so on.
11. Check Cell Basis - over flow from Clarifier. Noted and corrected.
12. Design flow rate- landfill leachate- 50m3/hr. Noted and corrected.
The plate clarifier is designed for 20%

additional margin on the max.
Check design Flow rate (of column 7). As per
sustained flow of leachate stream.
13. Process Design calcs design hydraulic flow per
The mentioned value in design
clarifier is 60 m3/hr.
calculation is typographical error and
will be corrected.
Ensure Consistency with Process Design

14. Noted and corrected.
calculation and Pump Hydraulic Calculations.
LLPP drainage pumps Tag No. should be changed

15. The provided Tag No. is correct.
as per P&ID and hydraulics.
231-M-004- hydraulics to consider 20% design

16. Refer reply for Point No. 13
margin over the plate clarifier design flow.
CLIENT / CONSULTANT COMMENTS (In

Sl.No. VA TECH WABAG REPLY
compliance statement)
The selected material will be suitable
17. Is HDPE material OK for Sludge line? for the sludge application. It has been
discussed and concluded.
Operation without pH feedback limits the flexibility
to adjust the pH. Also there is no feed back to the
pH analyzer will be provided in the pH
Operator in case the acid dosing fails full open.
18. adjustment tank-2 with feed back as
This will probably fail to get past HAZOP unless
required.
VTW can demonstrate that the respiration
monitoring system will reliably detect such events.
************

NOTES
Down
SIGNATURE
DATE
REFERENCE DRAWINGS


02 11.10.10 FW COMMENTS UPDATED JAI MTK/RR PSK
01 17.09.10 FW COMMENTS UPDATED JAI MTK PSK
00 20.08.10 FOR APPROVAL SS YP GSS
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-B0003-002 4
TITLE:
PROCESS FLOW DIAGRAM
LANDFILL LEACHATE TREATMENT

NTS PDRP0451-8110-20-231-0001 1 0F 1 04
451/4200 2 18913
DOCUMENT CODING BOX
PROJECT
PROJECTTITLE: IOCL
TITLE: PARADIP
IOCL REFINERY
EPCM-1
CLIENT NAME: INDIAN OIL CORPORATION LIMITED (IOCL)
PROJ NO: 1-14-4200/399 PROJ. LOCN.: PARADIP, ORISSA STATE, INDIA
PROJECT
PO PROJECT
NO: 1-14-4200/399 CLIENT DOC.
NO: 4200/0451 NO: LOCATION: PARADIP,ORISSA
PO NO:ORDER
CLIENT 4200/451
TAG
REQNOS:
NO: 4200-4305A003
REQ NO: 4200-4305A003
TAG NOS:

SUPPLIER DOC. NO.:PDRP0451- 8110-20-231-0003
SUPPDOCNO:
DOC. TYPE: F50 PDRP0451-8110-20-231-0003 SUPPLIER REV:2
CLDOCNO:
DSN: 35955 FW REV:
STATUS:
DOC TYPE: F50 SUPPLIER REV: 2
SIGNED:
DSN: 35955 DEPARTMENT: FW REV: 3
Status: Code 4
DATE:
Signed:
COMMENT STATUS CODE: MohanRao
1- REJECTED; 2- COMMENTS
Ramarao AS NOTED;
(J1983) 3-MINOR
COMMENTS ACCEPTABLE; 4-NO COMMENTS; 5-INFO ONLY
Dept:
Department: Engi
Date: 17/Feb/2012
COMMENT STATUS CODE: 1-Rejected; 2-Comments as Noted;
VA TECH WABAG
PROJECT : 10P2M-IOCL Paradip Refinery Project
PLANT : Effluent Treatment Plant

for IOCL Paradip Refinery Project
At Paradip,Orissa,India
DOCUMENT TITLE:
Process Flow Diagram for Sulphidic Caustic Storage
CLIENT DOC. NO. : PDRP0451- 8110-20-231-0003 REV. : 2

STAMPING AREA
2 08.02.2012 Resubmitted As per FW comments VNU PSK PSK

1 04.07.2011 Resubmitted As per FW comments VNU PSK PSK
0 03.06.2011 Submitted for Review / Approval VNU PSK PSK

Project IOCL PARADIP REFINERY , ORISSA
VA TECH Project No. 10P2M
Client's Project No. 1-14-4200/399
Consultant M/s. FOSTER WHEELER ENERGY LTD.
LEI Doc. No. &AG-P-FF-1001
TITLE PFD- SULPHIDIC CAUSTIC STORAGE
VA TECH Drg. No. (commented) 10P2-B0003-004
Client Drg. No. (commented) PDRP0451-8110-20-231-0003
Sr. No. Client / Consultant Comments LINDE / VA TECH WABAG Clarification
Please review requirement of including reference Note; H & MB reference is added. Other reference need not required.
1 documentation - HMB, design basis etc as required. Refer Rev O3
As discussed and agreed during the ERM, please note

that the SCTP shall have provision to process design System is designed for approved design basis documents received from
2 flow (11.9 m3/h) in full refinery case (deferred units). Vatech
This shall be accordingly reflected in the PFD.
Reactor and plant is designed based on the approved design basis

WS: Please ensure that this capacity includes an which is 10.3 m3/hr (120% of normal flow). Moreever upstream tanks
3 allowance for drainage & contaminated stormwater. and process sumps are designed for sufficient capacity to handle work -
offs.
08.02.12
DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECTTITLE: IOCL
TITLE:
TITLE: PARADIP
IOCL
IOCL REFINERY
PARADIP
EPCM-1
EPCM-1
CLIENT
CLIENT NAME:
NAME: INDIAN
INDIAN OIL
OIL CORP
CORP LTD
LTD
SUPPLIER
SUPPLIER NAME:
NAME: VAVA TECH
TECH WABAG
WABAG LTD
LTD PARADIP, ORISSA STATE, INDIA
PROJ NO: 1-14-4200/399 PROJ. LOCN.:
PROJECT
PROJECT
PO NO:
NO: 1-14-4200/399
NO: 4200/0451 PROJECT
PROJECT
1-14-4200/399CLIENT DOC. NO: LOCATION:
PARADIP,ORISSA
PO
PO NO:
CLIENT 4200/451
NO:ORDER NO:
4200/451 CLIENT
CLIENT ORDER
ORDERNO:
NO:
TAG
REQNOS:
NO: 4200-4305A003
REQ NO: 4200-4305A003
TAG
TAG NOS:
NOS:

SUPPLIER DOC. NO.:PDRP0451-8110-20-231-0004
SUPPDOCNO:
DOC. TYPE: F50 PDRP0451-8110-20-231-0004
SUPPDOCNO: PDRP0451-8110-20-231-0004 SUPPLIER REV:2
CLDOCNO:
DSN: 35956
CLDOCNO: FW REV:
DOC STATUS:
DOC TYPE:
TYPE: F50
F50 SUPPLIER
SUPPLIER REV:REV:22
SIGNED:
DSN:
DSN: 35956
35956 DEPARTMENT: FW
FW REV:
REV: 33
Status:
DATE:
Status: Code 4
Signed:
Signed: 1- REJECTED; 2- COMMENTS
Ramarao AS NOTED;
(J1983) 3-MINOR
Dept:
Department: Engi
Date:
Date: 17/Feb/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-Comments as
as Noted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-InfoOnly
Only
VA TECH WABAG

DOCUMENT TITLE:
Process Flow Diagram for Oxidation,Neutralisation
CLIENT DOC. NO. : PDRP0451- 8110-20-231-0004 REV. : 2

STAMPING AREA
2 08.02.2012 Resubmitted as per FW comments VNU PSK PSK


TITLE PFD - OXIDATION, NEUTRALISATION
08.02.12
DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECTTITLE: IOCL
TITLE:
TITLE: PARADIP
IOCL
IOCL REFINERY
PARADIP
EPCM-1
EPCM-1
CLIENT
CLIENT NAME:
NAME: INDIAN
INDIAN OIL
OIL CORP
CORP LTD
LTD
SUPPLIER
SUPPLIER NAME:
NAME: VAVA TECH
TECH WABAG
WABAG LTD
LTD PARADIP, ORISSA STATE, INDIA
PROJ NO: 1-14-4200/399 PROJ. LOCN.:
PROJECT
PROJECT
PO NO:
NO: 1-14-4200/399
PROJECT
1-14-4200/399CLIENT DOC. NO: LOCATION:
PARADIP,ORISSA
PO
PO NO:
CLIENT 4200/451
NO:ORDER NO:
4200/451 CLIENT
CLIENT ORDER
ORDER NO:
NO:
TAG NOS:
REQ
REQ NO:
NO: 4200-4305A003
4200-4305A003
TAG
TAG NOS:
NOS:

SUPPLIER DOC. NO.:PDRP0451-8110-20-231-0005
SUPPDOCNO:
DOC. TYPE: F50 PDRP0451-8110-20-231-0005
SUPPDOCNO: PDRP0451-8110-20-231-0005 SUPPLIER REV:2
DSN:
CLDOCNO:
35957
CLDOCNO: FW REV:
STATUS:
DOC
DOC TYPE:
TYPE: F50
F50 SUPPLIER
SUPPLIER REV:
REV: 22
SIGNED:
DSN:
DSN: 35957
35957 DEPARTMENT: FW
FW REV:
REV: 33
DATE:
Status:
Status: Code 4
Signed:
Ramarao AS NOTED;
(J1983) 3-MINOR
Dept:
Department: Engi
Date:
Date: 17/Feb/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-Comments as
as Noted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-Info Only
Only
VA TECH WABAG

DOCUMENT TITLE:
Process Flow Diagram for Naphthenic Caustic storage
CLIENT DOC. NO. : PDRP0451-8110-20-231-0005 REV. : 2

STAMPING AREA


TITLE PFD - NAPHTHENIC CAUSTIC STORAGE
Please review requirement of including reference Note; H & MB reference is added. Other reference need not
1 documentation - HMB, design basis etc as required. required. Refer Rev O3
2 WS: Show filling and drain connections. Noted; It is shown in the P & ID.
Please ensure provision of appropriate controls and safety

3 devices.
Noted; It is shown in the VOC system P & IDs.
08.02.12
DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECTTITLE:
TITLE:
TITLE: IOCL
IOCL PARADIP
PARADIP
IOCL EPCM-1
REFINERY
EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN OIL OIL
INDIAN CORPORATION
SUPPLIER
SUPPLIER NAME:
NAME: VA
VA TECH
TECH WABAG
WABAG LTD
LTD
PROJECT
PROJECT
PO NO:
NO: 1-14-4200/399
PROJECT
1-14-4200/399 CLIENT DOC. NO: LOCATION:
PARADIP,ORISSA
PO
PO NO:
CLIENT 4200/451
NO:ORDER NO:
4200/451 CLIENT
CLIENT ORDER
ORDERNO:
NO:
TAG
REQNOS:
NO: 4200-4305A003
REQ NO: 4200-4305A003
TAG
TAG NOS:
NOS:

SUPPLIER DOC. NO.:PDRPDRP0451-8110-20-231-0006
SUPPDOCNO:
SUPPDOCNO: PDRP0451-8110-20-231-0006
DOC. TYPE: F50 PDRP0451-8110-20-231-0006 SUPPLIER REV:2
CLDOCNO:
DSN:
CLDOCNO:
35959 FW REV:
DOC STATUS:
DOC TYPE:
TYPE: F50
F50 SUPPLIER
SUPPLIER REV:
REV:22
SIGNED:
DSN: 35959
DSN: 35959 DEPARTMENT: FW
FW REV:
REV: 33
Status:
DATE:
Status: Code 4
Signed:
Ramarao AS NOTED;
(J1983) 3-MINOR
COMMENTS ACCEPTABLE;
Dept: 4-NO COMMENTS; 5-INFO ONLY
Department: Engi
Date:
Date: 17/Feb/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-Comments as
asNoted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-InfoOnly
Only
VA TECH WABAG

DOCUMENT TITLE:
Process Flow Diagram for Equalisation

STAMPING AREA
2 08.02.2012 Resubmitted as per FW Comments VNU PSK PSK

1 04.07.2011 Resubmitted as per FW Comments VNU PSK PSK

TITLE PFD - EQUALISATION
08.02.12
DOCUMENT CODING BOX
PROJECT TITLE: IOCL PARADIP EPCM-1
PROJECT
PROJECTTITLE:
TITLE:IOCL PARADIP
IOCL REFINERY
EPCM-1
CLIENTNAME:
CLIENT NAME: INDIAN
INDIAN
OIL CORP LTD
OILOIL
CORPORATION
CLIENT NAME: INDIAN CORP LTDLIMITED (IOCL)
SUPPLIERNAME:
SUPPLIER NAME: VAVA TECH
TECH WABAG
WABAG LTD
LIMITED, CHENNAI.
PROJ NO: 1-14-4200/399
PROJECT NO: 1-14-4200/399PROJ. LOCN.: PARADIP,LOCATION:
PROJECT ORISSA STATE, INDIA
PARADIP,ORISSA
PO NO: 4200/451 CLIENT ORDER NO:
PO NO: 4200/451
CLIENT ORDER NO: CLIENT ORDER NO:
REQNOS:
TAG NO: 4200-4305A003
REQ NO: 4200-4305A003
TAG
TAG NOS:
NOS:

SUPPLIER
SUPPDOCNO:DOC. PDRP0451-8110-20-231-0007
NO.: PDRP0451-8110-20-231-0007
SUPPDOCNO: PDRP0451-8110-20-231-0007
DOC. TYPE: SUPPLIER REV:2
CLDOCNO:
CLDOCNO:
DSN: FW REV:
DOC
DOC TYPE: F50
F50
STATUS: SUPPLIERREV:
SUPPLIER REV:
22
DSN: 37130 SIGNED:
DSN: FWREV:
FW REV:4 4
DEPARTMENT:
Status: Code 4
Status:
DATE:
Signed:
Dept:
Department:
MINOR COMMENTS ACCEPTABLE;D153
4-NO COMMENTS; 5-INFO ONLY
Date:
Date: 12/Jul/2012
COMMENT STATUS
CODE: 1-Rejected;
1-Rejected;2-Comments
Noted;
3-Minor Comments
3-Minor CommentsAcceptable;
Acceptable;4-No
4-NoComments;
Comments;5-Info Only
5-Info Only
VA TECH WABAG
DOCUMENT TITLE:
Process Flow Diagram for Naphthenic Oil Removal System

STAMPING AREA
2 21.06.2012 Revised as per FW Comment SS PSK PSK

1 01.02.2012 Resubmitted as per FW Comment VNU PSK PSK
Discipline : Process

Sheet 1 of 1
An ISO 9001:2000 Company

VA TECH WABAG LTD
Project : IOCL PARADIP REFINERY PROJECT, PARADIP, ORISSA STATE-INDIA.

VA Tech Project No. : 10P2M
Client’s Project No. : 1-14-4200/399 Job No: 451/4200
Consultant : M/s. FOSTER WHEELER ENERGY LIMITED
TITLE : Process Flow Diagram for Naphthenic Oil Removal System
VA Tech Drg. No. : 10P2-B0003-010 (Sheet 2 of 3) Rev.2
(Commented)
Client Drg. No. : PDRP0451-8110-20-231-0007 Rev.2 (Sheet 2 of 3)
(Commented)

No COMPLIANCE
List of Changes after Rev.1 - PDRP0451-8110-20-231-0007 Rev.2 (Sheet 2 of 3)
In the corresponding P & ID there is a valve

between stream no 1 and the line taken
Sample waste can not flow up here before JS-106 as well as the line taken after
1 unless there is a back pressure due to JS-106.In regular operation the bypass line
an orifice here. will be closed, which will enable to build up
sufficient back pressure for the up flow of the
sample waste.
Based upon the experimental data the
2 Check for heat release / temperature rise. maximum rise of the temperature is 10 to 15 0
C. Which is insignificant.
Please show how the caustic split is
3 controlled. Caustic flow control will be done manually.
Based upon the experimental data the

4 Check for Heat release / temperature rise. maximum rise of the temperature is 10 to 15 0
C. Which is insignificant.
21/06/2012 SS RVK PSK
DATE PREPARED BY CHECKED BY APPROVED BY

DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECT TITLE:
TITLE:
TITLE: IOCL
IOCL
IOCL PARADIP
PARADIP
PARADIP EPCM-1
EPCM-1
CLIENT
CLIENT
CLIENTNAME:
NAME:
NAME:INDIAN OILOIL
INDIAN
INDIAN CORPORATION
OILCORP
CORPLTD
LTDLIMITED (IOCL)
SUPPLIER
SUPPLIERNAME: VA VA
NAME: TECH WABAG
TECH LIMITED,
WABAG LTDCHENNAI.
PROJECTNO:
PROJECT NO:1-14-4200/399
1-14-4200/399 PROJECTLOCATION:
PROJECT LOCATION:PARADIP,ORISSA
PARADIP,ORISSA
PO NO: 4200/451
PO NO:ORDER
CLIENT 4200/451
NO:
CLIENTORDER
CLIENT ORDERNO:
NO:
REQNOS:
TAG
REQ NO:4200-4305A003
NO: 4200-4305A003
TAGNOS:
TAG NOS:

SUPPLIER
SUPPDOCNO:DOC. NO.: PDRP0451-8110-20-231-0008
PDRP0451-8110-20-231-0008
SUPPDOCNO: PDRP0451-8110-20-231-0008
DOC. TYPE:F50 SUPPLIER REV: 1
CLDOCNO:
CLDOCNO:
DSN: 37131 FW REV:
DOCTYPE:
DOC TYPE:F50
F50
STATUS: SUPPLIERREV:
SUPPLIER REV:11
DSN: 37131 SIGNED:
DSN:37131 FWREV:
FW REV:33
DEPARTMENT:
Status:
Status: Code 4
DATE:
Signed:
Dept:
Department:
MINOR COMMENTS ACCEPTABLE;Engi
4-NO COMMENTS; 5-INFO ONLY
Date:
Date: 09/Feb/2012
COMMENT
COMMENTSTATUS
STATUSCODE:
CODE: 1-Rejected;
2-Commentsas
asNoted;
Noted;
3-Minor
3-MinorComments
CommentsAcceptable;
Acceptable;4-No
4-NoComments;
Comments; 5-Info
5-InfoOnly
Only
VA TECH WABAG
DOCUMENT TITLE:
Process Flow Diagram for

Chemical Storage & Dosing System

STAMPING AREA
1 01.02.2012 Revised as per FW Comments VNU PSK PSK


Sheet 1 of 1

VA TECH WABAG LTD

TITLE : Process flow diagram for Chemical storage and Dosing facility
VA Tech Drg. No. : 10P2-B0003-009 Rev.0
(Commented)
Client Drg. No. : PDRP0451-8110-20-231-0008 Rev.0
(Commented)
Sl.
CLIENT / CONSULTANT COMMENTS VA TECH WABAG CLARIFICATION / COMPLIANCE
No
1 Please furnish the stream data Noted & Incorporated.
Please furnish calculation for tank/Pump &

2 Line sizing. Sizing calculation provided.
PFD shall be inline with …….Client & Noted .We have incorporated all the comments,
3 Consultant. including Hazop & as per comments on P & ID
Rev.A & update the PFDs..
Noted .We have incorporated all the comments,
Please show system to safely mange…..,at
4 including Hazop & as per comments on P & ID
end of delivery.
Rev.A & update the PFDs.
Please indicate location of Neutralization

5 We have shown this arrangement in the Layout.
pit………..effluent to be indicated.
6 How are the drains disposed? Drains will be taken via closed drain.
01/02/2012 VNU PSK PSK

DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECTTITLE: IOCL
TITLE:
TITLE: PARADIP
IOCL
IOCL REFINERY
PARADIP
EPCM-1
EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN OIL OIL
INDIAN CORPORATION
SUPPLIER
SUPPLIER NAME:
NAME: VA
VA TECH
TECH WABAG
WABAG LTD
LTD
PROJECT
PROJECT NO:
NO: 1-14-4200/399 PROJECT
PROJECT
1-14-4200/399CLIENT DOC. LOCATION:
PARADIP,ORISSA
PO NO: 4200/0451 NO:
PO
PO NO:
NO:
CLIENT 4200/451
4200/451
ORDER NO: CLIENT
CLIENT ORDER
ORDER NO:
NO:
TAG
REQNOS:
REQ NO:
NO: 4200-4305A003
4200-4305A003
TAG
TAG NOS:
NOS:

SUPPDOCNO:
SUPPDOCNO: PDRP0451-8110-20-231-0009
PDRP0451-8110-20-231-0009
CLDOCNO:
CLDOCNO:
DSN: 37132 FW REV:
DOC
DOC TYPE:
TYPE: F50
STATUS:
F50 SUPPLIER
SUPPLIER REV:
REV: 11
DSN: 37132 SIGNED:
DSN: 37132 FW
FW REV:
REV: 33
DEPARTMENT:
Status:
Status: Code 4
DATE:
Signed:
Signed:
COMMENT STATUS CODE: MohanRao Ramarao
Dept:
Department:
MINOR COMMENTS Engi
Date:
Date: 09/Feb/2012
COMMENT
COMMENT STATUS
STATUS CODE:
CODE: 1-Rejected;
2-Comments as
as Noted;
Noted;
3-Minor
3-Minor Comments
Acceptable; 4-No
4-No Comments;
Comments; 5-Info
5-Info Only
Only
VA TECH WABAG
DOCUMENT TITLE:

Process Drain & Slop Oil Collection System

STAMPING AREA


Sheet 1 of 1

VA TECH WABAG LTD

TITLE : Process flow diagram for Process drain and Slop oil collection system
(Commented)
(Commented)
Sl.
No
DOCUMENT CODING BOX COMMENTS:

1 Please furnish the stream data including Hazop & as per comments on P & ID
Sizing basis for equipment to be provided. Noted .We have incorporated all the comments,
2 including Hazop & as per comments on P & ID
3 PFD shall be inline with …….during the ERM. including Hazop & as per comments on P & ID
4 Shouldn’t these be valve controlled? including Hazop & as per comments on P & ID

DOCUMENT CODING BOX
PROJECT
PROJECT
PROJECTTITLE:
TITLE:IOCL
TITLE: PARADIP
IOCL
IOCL REFINERY
PARADIP
EPCM-1
EPCM-1
CLIENT
CLIENTNAME:
NAME:INDIAN OILOIL
INDIAN CORPORATION
SUPPLIER
SUPPLIERNAME:
NAME:VAVATECH
TECHWABAG
WABAGLTDLTD
PROJECT
PROJECTNO:
NO:1-14-4200/399
1-14-4200/399 PROJECT
PROJECTLOCATION:
PARADIP,ORISSA
PO
PONO:
NO:
CLIENT 4200/451
4200/451
ORDER NO: CLIENT
CLIENTORDER
ORDERNO:
NO:
TAG
REQNOS:
REQ NO:
NO:4200-4305A003
4200-4305A003
TAG
TAGNOS:
NOS:

SUPPLIER
SUPPDOCNO: DOC. NO.: PDRP0451-8110-20-231-0011
SUPPDOCNO:PDRP0451-8110-20-231-0011
PDRP0451-8110-20-231-0011
CLDOCNO:
CLDOCNO:
DSN: 37321 FW REV:
DOC
DOCTYPE:
TYPE:F50STATUS:
F50 SUPPLIER
SUPPLIERREV:
REV:11
DSN: SIGNED:
DSN:37321
37321 FW
FWREV:
REV:22
DEPARTMENT:
Status:
Status: Code 4
DATE:
Signed:
Signed:
COMMENT STATUS CODE: MohanRao Ramarao
Dept:
Department:
MINOR COMMENTS Engi
Date:
Date: 09/Feb/2012
COMMENT
COMMENTSTATUS
STATUSCODE:
CODE: 1-Rejected;
2-Commentsas
asNoted;
Noted;
VA TECH WABAG
DOCUMENT TITLE:

Cooling Tower Utility System

STAMPING AREA


Sheet 1 of 1

VA TECH WABAG LTD

TITLE : Process flow diagram for Cooling water Utility system
(Commented)
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DOCUMENT CODING BOX COMMENTS:

1 Not required. including Hazop & as per comments on P & ID

Document No: PDR/PN/WRP/OM
Indian Oil Water Recovery Plant August, 2012 7 Jan, 2022
Paradip Refinery
Operating Manual
Water Recovery Plant

(Unit 235)

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INDEX
TABLE OF CONTENTS PAGE NO.
Chapter 1: Introduction………………………………………………………………………………………04
Chapter 2: Description of the Plant…………………………………………………………………….05
2.1: Basic Water Chemistry…………………………………………………………………………………05
2.2: Glossary of Terms………………………………………………………………………………………...06
2.3: Process Description……………………………………………………………………………………..11
2.4: Desalinization Process …………………………………………………………………………………13
2.5: Monitoring of Instruments …………………………………………………………………………32
2.6: Summary of foulants and likely performance effects…………………………………..35
Chapter 3: Design & Details of RGSF –UF-Ro Plant ……………………………………………37
3.1: Design Parameters UF ……………………………………………………………………………….38
3.2: Design Parameters RO ………………………………………………………………………………39
3.3: Water Analysis …………………………………………………………………………………………40
3.4: List of Chemical Consumption ………………………………………………………………….42
3.5: Equipment List & Technical Notes …………………………………………………………...42

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CHAPTER 1: INTRODUCTION

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INTRODUCTION
GENERAL:
This manual furnishes the procedures to be followed during commissioning, Operation & Maintenance of
the Water Recycle Plant for Phase I – Stage I, Phase I – Stage II. Any actions that deviate from these methods
of procedures have to be avoided.
All troubles with in the plant must be reported to the responsible Supervisor and necessary action to be
taken with the Supervisor instruction.
CHAPTER 2: DESCRIPTION OF PLANT

2.1: Basic Water Chemistry
RAW WATER AND IMPURITIES
Water as it occurs in nature “pure” and whatever be the source, always contains impurities either in
solution or in suspension. The determination of these impurities makes analysis of water necessary and
removal and control of these impurities make water treatment essential.
SOURCES
The various sources of water can be broadly classified as:
a) Rain water
b) Surface eater (Rivers, Streams, Ponds, Lakes and Reservoirs)
c) Ground water (Spring, Shallow Wells and Deep Wells)
Of the above, logically, rain water is the purest but even this collects and dissolves atmospheric Gases.
Further, once in contact with the earth’s crust, the rain water will gradually dissolve various materials.
IMPURITIES
The major impurities of waters can be classified in three main groups:
1) Non-ionic and Undissolved
2) Ionic and Dissolved

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3) Gaseous
1) NON-IONIC IMPURITIES
These are mainly turbidity, salt, mud, dirt and other suspended matter, microorganism, bacteria and other
organic matter, oil and corrosion products. It goes without saying that drinking water and most industrial
water supplies should be clear and organic-free.
2) IONIC AND DISSOLVED IMPURITIES
Any salt which dissolved in water solids into positively charged Cations and negatively charged Anions and
since these permit the water to conduct electricity, these salts are called electrolytes. Some of the most
common cations in water are Calcium, Magnesium and Iron rarely.
Ammonium manganese. These cations are associated with anions like Bicarbonates. Carbonates.
Hydroxides (the sum of which is termed as Alkalinity). Sulphates and chlorides. Presence of Nitrates and
Phosphates is normally not very common. In water treatment field.
The preferred method of expression of these dissolved impurities is in terms of Equivalent Calcium
Carbonate, abbreviated to as “CaCO3”. This is because Calcium Carbonate is a good common denominator
as it has a molecular weight of 100, which facilitates calculations. Temperatures and Pressure. Even in lower
pressure boilers, it could form a very hard type of scale by acting as a binding agent.
3) GASEOUS IMPURITIES
Of the atmospheric gases found in naturally occurring waters. Only two. Carbon Dioxide and Oxygen are
the main causes of many Corrosion problems.
REMOVAL OF IMPURITIES
Our major concern is industrial water treatment, where by, water used directly or indirectly in an industrial
process is made suitable for particular application. The use of water in boilers for steam generation is an
Obvious industrial us. Depending on the process. Varying degrees of purity of treated water are required.
For Example. A textile processing unit will require soft and clear water for process uses; a chemical plant or
electronic components manufacturing until will require ultrapure water containing total dissolved
impurities not exceeding 0.5mg/litre or less
2.2: Glossary of Terms
ADSORPTION:

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Physical adhesion of molecules or colloids to the surface of solids without chemical reaction.
ALGAE:
A variety of one-celled, conical or filamentous organisms containing chlorophyll and other pigments
necessary for photosynthesis and producing oxygen in the presence of sunlight . Though frequently placed
in the plant kingdom. They have no true roots, stems or leaves. Algae use of oxygen as the terminal electron
acceptor for their respiratory process.
ALKALINITY:
A quantitative measure of an aqueous solution’s capacity to react with Hydrogen ions. Expressed as parts
per million (ppm) or milligrams per litre (mg/litre) of calcium carbonate. In water analyses,
Alkalinity generally represents the bicarbonate. Carbonate and hydroxide ions.
ALUM:
Sulphate salt of aluminum. The chemical compound Al2 (SO4)3. 18 H2O, commonly used in water
clarification applications as a coagulant aid.
BACTERIA:
A wide variety of microorganisms, usually one called, frequently rod shaped but may also be spherical or
spiral shaped. Members of this group may perform bacterial photosynthesis or use a Variety of Organic and
inorganic compounds as terminal electron acceptors.
AEROBIC BACTERIA:
Bacteria that require molecular oxygen for respiration.
ANAEROBIC BACTERIA:
Bacteria that can thrive in absence of molecular oxygen by using organic compounds, oxides by using
organic compounds, oxides of nitrogen or Sulphur, or carbon dioxide as terminal electron Acceptors.
BIOCHEMICAL OXYGEN DEMAND (BOD):

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The quantity of oxygen required for the biological oxidation of water-borne substances. Under standard
conditions. The test is usually run for 5 days.
CHEMICAL OXYGEN DEMAND (COD):

The quantity of oxygen required for the chemical oxidation of water-borne substances. Under standard test
conditions.
CHLORINATION:
The addition of chlorine gas or a chlorine-releasing agent to water.
COAGULATION:
A chemical and physical process in which the electrical charge of colloidal particles is neutralized by the
chemicals of opposite charge. Allowing them to coalesce and eventually settle.
COAGULANT AID:
See Polymer flocculent
COLLOIDS:
Particulate matter of very fine size, usually in the range of 10-5 to 107 centimeters in a diameter and not
prone to settling by subsidence.
ELECTROLYTE:
A chemical components, which dissociates or ionizes in water to produce a solution which will conduct an
electric current; an acid, base or salt.
EMULSION:
A relatively stable suspension of small but not colloidal particles of a substance in a liquid, the suspended
particles being un-dissolved.
FLOCCULATION:
The entrapment of neutralized coagulated particles in to larger particles. Flocculation is largely a
mechanical or physical process.

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HARDNESS, CALSIUM:
The Calcium concentration in water, generally expressed as calcium carbonate.
HARDNESS, MAGNESIUM:
The magnesium concentration in water, generally expressed as magnesium carbonate.
HARDNESS, TOTAL:
The sum off total divalent cations, predominantly calcium and magnesium ions, expressed as calcium
carbonate.
U.S. Geology Survey hardness criteria for potable water are:

Soft water: 0-60 ppm.
Moderately water: 61-120 ppm.
Hard water: 121-180 ppm.
Very hard water: > 180 ppm.
POLYELECTROLYTE:
A substance which, when dissolved in water or other ionizing solvents, dissociates to give a multi-charged,
large molecular weight ion. See also Polymer Flocculent.
POLYMER:
Polyelectrolyte composed of repeating organic monomers. Charge characteristic may be cationic, anionic
or essentially non-ionic with varying charge densities.
POLYMER DISPERSANT:
Polyelectrolytes having molecular weights ranging from 1000 to 10000. Low molecular weights make them
incapable of flocculation, but do allow for impartation of ionic charges making them effective as dispersing
or fluidizing agents for boiler or cooling water suspended solids.
POLYMER FLOCCULANT:
Long chain polymeric electrolytes having molecular typically greater than 1 million. High molecular weights
make them particularly effective in flocculation of coagulated particles by farming molecular bridges.

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POTABLE WATER:
Water approved and used for domestic purposes, especially human consumption.
PRECIPITATION (WATER CHEMISTRY):

Formation of an insoluble compound by the reaction of two or more soluble ions.
RAW WATER:
Water to which mechanical and/or chemical pre-treatment is applied in order to produce make up water.
SEDIMENTATION:
Gravitational settling of solid particles in a liquid system. See subsidence.
SUSPENDED SOLIDS:
See Total Suspended Solids.
SYNERGISM:
A condition where the effects of a combination of two or more materials is greater than the sum of their
individual effects.
TOTAL DISSOLVED SOLIDS (TDS):

The sum of the inorganic and organic materials dissolved in water.
TOTAL SUSPENDED SOLIDS (TDS):

The sum of all insoluble particles suspended in water.
TURBIDITY:
The interference of light transmission caused by suspended or colloidal material in water.
2.3.1: The water Recycle System is provided for:
* Receive and filter bio treated water;

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* Recover and upgrade sufficient bio treated water for re-use within Paradip Refinery Project in order to
ensure compliance with the flow limit for the discharge to sea;
* Produce and distribute water of a suitable grade which is required within the ETP & WRP for the make-
up of chemicals and clean in place systems;
* Balance recovered and upgraded water flows against demand from the users of upgraded Water and
deliver the upgraded water into a header for distribution to users(primary in the demineralization plant) in
the Paradip Refinery Project;
* Collect and manage internal recycles within the WRP;
* Upgrade the saline reject (RO reject) from the water recovery stage to the quality which is required for
discharge to sea;
* Deliver the upgraded saline reject into a header which connects into the sea outfall pipeline.
2.3.2. PROCESS AND UTILITY LINES

2.3.3.0 PROCESS LINES ENTERING B/L
1. Brine from crude tank farm
2. FGD effluents
3. Desalter effluent line
4. Oil water sewer
5. Settled coke pile runoff
6. CRWS
7. Cooling Tower Blowdown, 4 separate header
8. Stripped Sour Water
9. Steam Systems Blowdown
10. Landfill Leachate
11. Raw water from U-100
12. Demin Regn. Effluent
13. Sulphidic Spent Caustic
14. Naphthenic Spent Caustic
15. Sanitary line from Township
16. Sanitary line from Refinery

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17. Off-spec from storm water reservoir
2.3.2.1 UTILITY LINE ENTERING B/L FROM GATE-055

1. Instrument Air
2. Plant Air
3. Service Water
4. Potable Water
5. LP Steam
6. Nitrogen
7. Caustic solution
2.3.2.2 UTILITY LINES LEAVING B/L AT GATE-056

1. Instrument Air
2. Plant Air
3. Service Water
4. Potable Water
5. LP Steam
6. Nitrogen
2.3.2.3 PROCESS LINE LEAVING B/L

1. Off-spec to Storm water reservoir
2. Dry Slop oil to Refinery
3. Oily Sludge to DCU
4. CRWS to DCU
5. Sea (Long Outfall Package)
6. RO Permeate to DM Plant
7. RO reject for Dust Suppression

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2.4: Desalinization Process

PROCESS DESCRIPTION FOR WRP (Gravity Filter’s, UF & RO SECTION)
The non-ionic impurities such as turbidity, suspended solids, colloidal particles etc., are removed in pre-
treatment depends on the type and quantity of constituents.
The pre-treatment consists of the following
1. Filtration (Gravity & Sand)
(A) RAPID GRAVITY FILTRATION PROCESS:
Filtration is the process by which water is separated from the suspended and colloidal impurities it contains.
The number of bacteria is materially reduced and passing it through a porous substance brings about
changes in the chemical characteristics of water.
In the field of drinking water or process water purification sand is used almost exclusively as Filtering
material because of its availability, it’s relatively low cost and satisfactory experience it has given. Even
when other granular filtering materials (like anthracite coal are applied, this is mostly done in combination
with sand to obtain multi-layer beds with a higher sill storage capacity. During the process of filtration the
impurities are removed from water. They precipitate in the voids between the grains of the filter bed,
reducing the defective pore space and increasing the resistance (head loss or pressure drop) becomes so
high, that the filter bed requires cleaning. In rapid sand gravity filters the water flows through a bed of
medium to coarse sand at high velocities (filtration rates). The specific grain size varies from 0.5mm to
2mm, while the rate of filtration is between 5000 to 7500 lit/sq.m/hr (5 to 7.5 m/hr). This rate is high
enough to cause a rapid clogging of the filter bed, which necessitates it’s cleaning at the interval of every
few hours. Normally a rapid sand gravity filter is required to be backwashed at the interval of 16hr to 48hr
or more depending on the physical and chemical characteristic of water.
GENERAL DESCRIPTION OF FILTER BED
The filter bed essentially consists of a box, normally of reinforced concrete. It is rectangular in shape and
varying in area having depth of 0.50m up to 1.0m. The depth of water over the top of filter box varies from
3.0m up to 5.0m. The filtration medial at many a times is placed over a supporting media. The supporting
medial is normally graded layers of gravel.

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The supporting gravel ensures that the sand does not pass into the filter underdrain or outlet Piping. It also
dissipates the velocity of water injected during the backwash through the under Drain system, provides a
cushion and ensures that disruption of sand media does not take place. The supporting media is placed
over a filter under drain system. The under drain systems are provided to support and retain filtration
media, distribute the wash water uniformly and to collect the filtered water.
The under drain system may be of three types:
a. Manifold and laterals type
b. Nozzle type with a false bottom
c. Blocks type
Sufficient advances have taken place in the design of both b and c type of the systems to eliminate the need
of supporting gravel. A well designed under drain system ensures uniform distribution of wash water below
the filter media.
During a conventional backwash with water (hard wash) the water is forced into the filter bed, through the
under drain system in a reverse (upward) direction. The rate of backwash should be sufficient to cause
expansion of media to 20 to 50% its original depth during the backwashing to ensure reasonably good
removal of suspended solids and impurities. The rate of backwash varies from 36m/hr to 80m/hr depending
on the design parameter and temp of the water. In cold Climate the rate of backwash is normally low as it
is sufficient to achieve the desired expansion. The backwash is operated for the duration of 5 to 10min.
until the entire bed is clean. In order to clean the top most portion of sand thoroughly and to increase the
effectiveness of Backwash, auxiliary backwash in the form of surface wash or air-scour is many a time
supplemented in addition to the hard wash. The wash water is normally provided from an elevated tank
with a sufficient storage capacity and head. At some places requisite rate and head is generated by low
head backwash pumps. During the high rate backwash, stratification of san takes place and the media
gradation becomes fine to course in the direction of backwash. This is countered by adopting dual media
or multimedia filtration.
The spent up or dirty wash water is collected by a series of uniformly spaced cross-troughs placed above
the top of filter media. The wash water is then led to a central gutter (gullet) or a side gutter provided in
the bed. From the gutter the wash water is deposed of through a sluice/butterfly valve outside the filer box

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to the plant drainage system. The cross-troughs may provide in reinforced concrete or clued be of
composite plastic and fibre glass.
The filter beds may be arranged in a single row with the piping provided on one side of it. In case four or
more number of beds, the beds may arranged in two rows a space provided in between to house the control
piping. The space in which filter piping is provided is known as pipe Gallery. Normally it is enclosed inside a
structure with a roof, while the beds may be provided as open to sky or enclosed under a roof. The walkway
and platform are provided inside the pipe gallery to facilitate the operation of valves.
In a manually operated plan the valves are operated from the “upper level walkway” which is designed and
provided to watch the filter beds during operation of the backwash cycle. In the automated plants, the
valves are operated with pneumatic actuated with a set of toggle switches located on a console.
RAPID GRAVITY FILTER CONTROL:
The rapid gravity filters can be designed and operated on one of the following principles:
a. Constant rate filtration with manual control
b. Constant rate, constant level filtration with rate controller
c. Constant rate filtration with influent splitting
d. Variable declining rate filtration
a. Constant rate filtration with manual control:
In order to achieve the desired water quality consistently and to ensure the filter bed does not develop any
problem, it is important that the rate of filtration is uniform and the fluctuating in the rate of flow should
be gradual. A positive control over rate of filtration is therefore necessary. The operation technique is one
of the most popular and wide-spread practices in the operation output from the filter bed.
A variable resistance in the form of a valve is placed in the outlet pipe from filter bed. This valve can be
controlled manually or with the help of mechanical devices to ensure constant output from gravity filter
bed.
The filter outlet pipe is then connected to a “rate control chamber”. The rate control chamber has a weir
for measurement of the output quantity. The level of this weir is normally above the level of gravel placed
in the filter bed to ensure that negative head loss does not built up. During the service cycle the inlet to

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filter is opened and the filter bed is filled up to the FSL (Full Supply Level or total water level). The outlet
valve to the filter is then opened in a controlled manner to ensure that only desired quantity of water
passes through the filter bed. This is checked by measuring flow over the outlet weir in the rate control
chamber. As the service cycle progresses, the filter media starts clogging which increase the resistance to
the down ward flowing water. As a result the water level in the filter gradually starts increasing. The water
level is then controlled by gradually opening the filter outlet valve. In the manual operation the filter outlet
valve is opened form time to time to ensure that water level over the rate control weir remains same.
In this operation the primary importance is given to control the rate of filtration. The water level in the
filter is not actually regulated (except for limits on extreme levels) and may fluctuate within a short range.
Thus this controls system also features some characteristics of constant level filtration.
When the filter is put into service cycle after a backwash, it will register a minimum headless at the
beginning. As the filter run progresses, the headless starts increasing and at the end of the run the headless
is maximum. The filter is taken out for backwash when either of the two conditions mentioned below occur
earlier.
At the large installations it is not practical to control a number filters by manual operation. In such cases
mechanical rate controllers are deployed to regulate the filter operation. Generally a flow controller is a
control valve operated by a lever mechanism connected to a float placed in the filter control chamber. The
flow control valve is designed on the principle of hydraulics. The float and control valve are isolated by a
partition wall.
The filtered water outlet is connected to this flow control valve. Prior to the control valve isolation valves
are provided on the outlet pipe. The filtered water is discharged through the control valve and flows over
a measuring weir (rectangular). From measuring weir the water flows into the pure water channel with an
adequate freefall. The height of water over weir indicates the rate of flow. A rate setter device consists of
a telescopic tube with a circular weir at the top. This telescopic tube is located on the upstream side of the
measuring weir. The height of circular weir is so adjusted that when the water flows over the measuring
weir, a portion of water spills over the circular weir and falls into the telescopic tube. From the telescopic
tube the water trickles down to the float chamber as the telescopic tube is connected to the float chamber
by means of a bend. In the float chamber a submerged orifice is provided (orifice gear) which continuously
discharges the water to the drain. When there is a balance of water coming in and going out of the float
chamber, the level of the float gets set. The slightest difference in the rate of inflow and outflow upsets

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this balance which causes changes in the float level which automatically adjusts opening of control valve
through the connecting lever until the balance is restored. The telescopic pipe can be raised or lowered to
give the desired discharge. A calibrated scale is given over the rate setter to operate the desired discharge.
The flow control valve is also controlled by a second float located in the filter bed. This float closes down
the control valve when the level of water in the filter drops down below present desired level. This helps
to avoid the dewatering of filter bed also. This this mechanism incorporates the control over rate of
filtration as well on the level of water in the filter.
c. Constant rate filtration with influent flow splitting:
As against the control over the filter effluent described in the earlier Para’s, this system exercises control
over the filter influent. The entire flow of influent is split equally at the inlet of filter beds by means of
simple weirs. The rectangular weirs with equal dimensions are located at the same elevation in the concrete
weir boxes. The influent channel is connected to the inlet of weir boxes by means of an isolation gates. The
influent enters into weir boxes flows over the weirs and then is conveyed into the bed by a vertical pipe
reaching the top of the gullet. In the process the influent is split equally over all the beds and each bed
receives equal and desired amount of water. The filtered water flows over a measuring weir located in the
outlet chamber. The filter outlet pipe is connected to the inlet of the chamber by means of an isolation
valve. The level of the measuring weir is provided above the top of sand media to avoid accidental
dewatering of the Bed. During the service cycle the filter inlet and filter outlet is opened completely. If the
filter is Backwashed prior to the service cycle, media will offer the least resistance and there will be
Minimum water level over the bed. As the service run progresses the media will offer greater Resistance.
The eater level over the media will gradually increase to counter this resistance, till it reaches the level of
influent weir. Thus the entire head loss in terms of water head will be accumulated over the top of the
media. These beds require standing water depth of 2.25m to 3.0m over the filter media and hence are deep
bed filters. From operation and control point of view these are very simple filters. The filter bed is taken
out of the service cycle for backwash once the water level in that bed reaches up to the influent weir level.
d. Variable declining rate filtration:
When there are three or more filter beds in an installation, this system could be employed to control the
filter battery. The general arrangement of beds is similar to the filter beds with influent splitting weirs with
the following changes.

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1. The influent splitting weirs are not provided

2. Influent header channel is deep and large enough so that all the beds in the battery have same water
level all the time during service cycle.
Flow is distributed through the beds on the basis of the relative condition (state of clogging) of the beds.
The influent launder losses being roughly equal, of a uniform operating level over all filter is achieved. The
filtration rate will decrease as the solids accumulate. The rate of flow from the filter can be checked over
the measuring weir in the outlet chamber. To determine which bed is in the immediate need of
backwashing, only the water level over the outlet measuring weir has to be checked. The filter giving the
least output is then backwashed. Otherwise the backwash sequence is decided at the fixed time interval.
The bed which has served the longest service cycle is taken up for backwash.
As this clean filter bed is put into operation or service cycle, it will draw the maximum water from the
battery. As a result the water level over entire battery will drop down. This will cause the proportionate
declining of flow rates over the other beds. The changes in the water level in the battery are very gradual.
As the bed that is the cleanest will draw the maximum water, the effluent quality from the battery is least
affected. In a “controlled or restricted head” declining rate operation, a resistance in the form of an orifice
plate or a valve is incorporated on the filtered water outlet piping to control the excess rate that may
generate after putting into service a newly backwashed bed.
MEASUREMENT OF FLOWS
From operation and control point of view, the measurement of inlet flow to a treatment plant with a fair
degree of accuracy is an important operation. Not only one has to keep the account of water supplied but
coagulant dosing and overall functioning of the plant is directly related to the rate of flow. For a water
treatment plant the fluctuations in the flow rate should be minimum and if at all should be very gradual.
To achieve the stability for the various unit processes. Though a lot of development has taken on the
instrumentation side with the help pf mechanical and electronic devices, the basic principle of
measurement of flow has remained same. The discharge or the rate of flow is a function of depth of water
established by theoretical or empirical formulae. In a gravity flow water treatment plant, the rate of flow
at inlet is measured over either notches, weirs or over flumes. To get an accurate reading the water should
be sufficiently “stilled” to dampen the turbulence in the approach path to these devices. The depth of water
is measured on the upstream of these devices. The notches and weirs are normally used to measure the

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small flows. While flumes are used for large flows. The notches and weirs could be located either in a open
channel or on the outlet side of inlet chamber to the plant. Flumes are normally located in the open
channel. The “head” or “depth” of water is measured on the upstream side of these devices and then
converted into “rate of flow”. The simplest and the most reliable way is to place or fix a scale of non-
corrodible material near the tapping point (for measurement of depth of water) given in the design and
drawing. This will enable the operator to instantly know the depth of water from which he can correlate
the flow. It is better if a calibrated scale showing the readings directly in terms of quantity of flow (lit/hr,
cum/hr) is provided instead of a linear scale for the operator’s convenience. At many places, a tapping in
the form of a diam. Pipe is provided to transfer the water level to a convenient position, which is normally
a small chamber. The changes in the water level in this chamber are corresponding to changes in the depth
of water over a measuring device. The scale, which is mentioned earlier, can also be located in this chamber.
There is wide variety of instruments available for measurement of flow. One of the popular instrument is a
float operated dial gauge. The circular dial is calibrated according to the device provided for the
measurement of flow (weir, flame etc.) A float provided in the chamber transfers the changes in the water
depth with the help of a pulley to the pointer on the graduated dial. The motion of the float is controlled
by a counter – weight located on the other side of pulley. The them into electronic signals and through a
microprocessor calibrate these signals for direct readings in terms of ratter of flow over a digital display. It
is always wise to cross check the ratter flow display over instrument or derived with a formula against the
ever a reliable “Volume Vs Time” method during commissioning of the plant. In case of failure of the
instrument or non-availability of a correct formula one can easily fall back on this fir’s principle for
calibration. At the end of this booklet calibration chants for notches, weirs and flumes showing various
dimensions and locations for measurement of depth of water are the guidance.
(B) ULTRAFILTRATION
The UF section comprises of:
 Basket Strainers
 Ultrafiltration Skid
 RO Feed tank
 UF backwash pump
 Cartridge Filter Feed pump
 CEB dosing system

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 Cleaning in place tank
1. Basket Strainers (Tag. No. 235-STR-107A/B/C/D/E/F/G/H)
After filtration system, basket strainers are provided for trapping any sand particles that ma leak out and go into
ultra-filtration thus permanently chocking of ultra-filtration fibres. These strainers are guard filter for ultra-filtration
system. Since the frequency of leakage of sand is very low, manual backwashing is done once in a month or two. The
necessary valves are provided for backwashing of basket strainers.
For phase-I stage-I, four no (3 working + 1 standby) of basket strainer are to be installed.
For phase-I stage-II, 1 additional basket strainer is to be provided in the parallel to stage-I basket strainers (By others)
For additional case with CRWS routed to WRP, separate stream of three nos. (2 Working + 1 Standby) basket strainers
are to be added (By others).
2. Ultrafiltration Skid (Tag. No. 235-A-002 A/B/C/D/E/F/G/H/I)
Ultrafiltration is a membrane process in which a porous membrane is used to separate or reject Colloidal and
particulate matter. Similar to other membrane processes, Ultrafiltration is a Pressure driven process. High
permeability of Ultra-filtration membrane and negligible osmotic effects allow the ultra-filtration process to operate
at relatively low pressures. Ultra-filtration modules incorporate capillary or hollow fibre as the membrane when
filtrate or product flow has decreased due to accumulation of material on membrane surface. The ultra-
filtration process is operated on “dead-end” or “cross flow”. The fibre composition is PVDF, hydrophilic
material that resists organic fouling and is tolerant to chlorine exposure fibres and filtrate passes radially
inward through the membrane “tube”. Water is pressurized through the membrane and particulates are
left at membrane surface. Due to small pore size of the membrane, effectively all suspended solids are
removed from the filtrate. These particulate build up in concentration at membrane surface, thus the water
flow direction is periodically reversed to remove particulate matter (backwash).
The modes of operation of Ultra-filtration are: Processing, Backwash and Chemical enhance backwash.
System is automated to switch between these modes. However, cleaning mode is semi-automatic.
Processing:
Processing is the mode in which filtration takes place. In dead end filtration, all water fed to the ultra-
filtration module passes through the membrane and is filtered. During processing step the dirty material is
accumulated on outside membrane surface.

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Backwash:
During processing, solids accumulate on the membrane surface and short cleaning or Backwash with filtrate
water is necessary to restore the membrane performance. The system is programmed to backwash
individual blocks at fixed periodical interval. During the backwash the water flow will be reversed. Clean
permeate water will be forced from inside of the capillary and will transport the foulant out. The duration
of the backwash is sufficient to remove all dirt from the membrane surface and drive it out from modules
and membrane system. Set of backwash pumps shall be provided to carry out the UF backwash operation
(Tag. No. 235-PM-110A/B). If the backwash is insufficient to remove all the foul ants, the backwash
efficiency can be enhanced by adding chemicals into the backwash (Chemically enhanced backwash) during
CEB.
It is important that first backwash without chemicals will remove most of the foulants prior to backwash
with added chemicals. In this way chemicals are exposed only to the hard to remove problems. It is also
important that all fibres are filled with chemicals, in the correct amount, concentration and with correct
soaking time. After soaking it is important to flush all the chemicals out with a backwash.
Depending on foulant NaOH, CaOCl and H2SO4 will be dosed in the backwash inlet water. Three different
system each comprising of a dosing tank, dosing pumps and agitator (if required) are provided.
CEB-I dosing is for dosing 20% NaOH in backwash water during chemically enhanced backwash. A tank (Tag.
No. 235-TK-111) is provided with dosing pumps (Tag. No. 235-PM-116A/B).
CEB-II dosing is for dosing 10% NaOCl in backwash water during chemically enhanced backwash. A tank
(235-TK-112) is provided with dosing pumps (235-PM-111A/B/C).
CEB-III dosing is 98% H2SO4 in backwash water during chemically enhanced backwash. A tank 235-TK-125)
is provided with dosing pumps (235-PM-112A/B).
Cleaning:
A key measure of ultra-filtration membrane is the TMP (Trans Membrane Pressure). This is the difference
between average feed pressure and the permeate pressure. It gives an indication that amount of fouling
on the membrane surface. As the solids accumulate on the membrane surface, the TMP increase. Backwash

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help to reduce the TMP, but backwash is not 100% efficient. When TMP increase to pre-set limit it is the
time for chemical cleaning of membrane. Cleaning is typically performed by taking the system offline and
subsequently recirculating chemical solutions. The chemicals used for cleaning are NaOCl, Sodium
Hydroxide and Citric acid. Other cleaning solutions can be used depending upon fouling. A tank (235-TK-
124) along with agitator (235-M-124) is provided for preparing cleaning solution. Set of pumps (235-PM-
125A/B) are provided for pumping and circulating chemicals in UF membranes.
For Phase-I Stage-I, Five no. (4 working + 1 Standby) of UF skids are to be installed.
For Phase-I Stage-II, 1 additional UF skid is to be provided in the parallel to phase-I stage-I UF skid (by
others).
For additional case with CRWS routed to WRP, separate stream of three (2 Working + 1 Standby) UF skids
are to be added.
Backwash, CEB facility & CIP will be same for Phase-I Stage-I, Phase-I Stage-II & CRWS routed to WRP. UF
permeate tank/RO feed tank is common for Phase-I Stage-I, Phase-I Stage-II & CRWS, routed to WRP.
Reverse Osmosis, as a water treatment process has been gaining in importance ever since the pioneering
work on a suitable membrane for the process was developed by an Indian Scientist, Dr. S. Sourirajan at the
University of California, Los Angeles in 1958. Commercialization of the process began in the last sixties and
within 20 years from the time initial work was done by Dr. S Sourirajan, the process has come to stay as
one of the established processes, for not only treating brackish and sea waters but also for the production
of ultrapure water for the electronic industries, boiler feed water and a host of other critical applications.
In order to understand the process of reverse osmosis, it is necessary t know the natural process of
‘Osmosis’, which is a biological process. When a semi permeable membrane, such as a living cell wall
separates two solutions with diffusing concentration of dissolved solids, pure water flows from the solution
containing the lower concentration of solute through the membrane into the solution containing the higher
concentration of solute. This movement of water can be explained as follows: As the solution containing
lesser solute is at higher energy state compared to the concentrated solution, the water keeps moving till
equilibrium is attained. The pressure developing due to this movement of water to the more concentrated
solution is the Osmotic pressure. The movement of water from the soil to the roots of plants or trees is an
example of Osmosis in nature.

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If pressure is applied gradually to the more concentrated solution, the normal osmotic flow get Reversed
until a stage when there is no flow at all. A pressure in excess of the osmotic pressure results in pure water
passing from the more concentrated solution through the membrane. This process of separating the pure
water / solvent from a concentrated solution is termed ‘Reverse Osmosis’.
The osmotic pressure is a function of the specific solute and its concentration in water, and in Practical
terms, it is the minimum pressure required producing the first drop of pure water from a Solution of solute
at a specific concentration. Reverse Osmosis must be differentiated from ultra-filtration as the membranes
used in Reverse Osmosis processes have pores in the order of 5-angstrom units as compared to 20 to 1000
angstrom multivalent salts like calcium sulphate. The molecular weight cut-off lies in the range of 100-
1000MW for the Reverse Osmosis membranes. Optimization of pure water flux through the membrane is
very important in the process of Desalination by Reverse Osmosis. The flow of water through the
membrane is governed by the Equation.
When Q= Water flux through the membrane units in the case of ultra-filtration.
The exact mechanism of the separation is still not clearly understood and different theories have been put
forward. However, it is well established that the higher the ionic charge (valence) of an ion, the better its
rejection by the membrane. Thus, monovalent salts like sodium chloride will pass through the membrane
at a rate higher than the
K= Membrane constant
A = Membrane Area
P = Applied pressure differential
Delta P = Osmotic Pressure Differential
T = Membrane thickness
OPERATION AND MAINTENANCE MANUAL
In order to increase the flux through the membrane ‘A’ & ‘P’ should be increased and ‘T’ should be
decreased. Increasing P beyond a certain limit will be uneconomical and this leaves us the choice of
increasing area of the membrane and reducing its thickness. Commercially available membranes have
thickness in the range of 100 microns and less.

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MEMBRANE MATERIAL AND CONFIGURATIONS

The earliest developed membrane material is cellulose acetate and it continues to be one of the most
widely used material. Later, polyamides have been employed and have established themselves as good
membrane materials. The advent of thin film composite membranes has reduced the operating pressures
of RO systems considerably, making the process cheaper. The original membrane developed by Dr. S.
Sourirajan was asymmetric in nature, meaning that they had a tight and thin surface layer with a dense
substrate.
The rejection of the solutes takes place at the tight surface layer and the substrate merely acts as a support
base and carrier. The thin film composite is membranes in which a thin film, similar to the tight layer of the
asymmetric membrane, is placed over a highly porous substrate material. This type of membrane has less
pressure drop across it, thus enabling operation at reduced pressure. As a thumb rule, the osmotic pressure
of a solution having 1000ppm of dissolved mineral salts can be taken as 10psi. Thus, seawater having
35000ppm TDS will have an osmotic pressure of 350psi.
Basically, there was three membrane configurations in common use today: tabular, spiral wound, and
hollow fibre. The ideal membrane configuration is the one that packs maximum are in the minimum volume
and provides resistance of fouling from suspended solids.
FIGURE ILLUSTRATING MEMBRANE POROUS STRUCTURE:
TABULAR: In this configuration, the membrane is either coated on the inside of a Porous material, and the
fee water enters from one end of the tube under pressure. The products water or permeate passes through
the membrane and exists as product, while the concentrate leaves from the other end. A number of such
tunes are placed in series/parallel arrangement to increase the flow from the system. Because of the very
low area to volume ratio, this configuration is not widely used for water desalination but it offers the
greatest tolerance to suspended matter.
SPIRAL WOUND: In this design, two layers of membrane are sandwiched around a product water carrier,
with one end of this ‘sandwich’ bonded to a plastic permeate tube. The tube is perforated and the
membrane sandwich is attached to it such that the permeate enters the tube through the perforations and
exists through either or both ends. The sandwich sheet is rolled around the tube in a spiral fashion along
with a plastic netting spacer which provides a finite separation between the sandwich layers. The tree free
ends of the sandwich sheets are sealed before rolling around the central product tube. The entire assembly

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is now placed in a pressure vessel of FRP or SS construction. The feed water flows, from one end of the
pressure vessel, parallel to the central tube. Under pressure, the permeate passes through the membrane
in a spiral fashion down to the permit tube, while the concentrated stream or ‘reject’ passes out of the
vessel at the other end. The spiral wound configuration offers a good ratio of surface area to volume, can
be operated under turbulent conditions, and is resistant to fouling by suspended material.
HOLLOW TUBE: In this configuration, the membranes are in the form of tiny hollow fibres (having a
diameter smaller than even human hair), packed in a cylindrical pressure vessel in a ‘U’ shape and the free
ends are potted in an epoxy matrix which forms the product water side. Feed water under pressure enters
the fibres from around them, and the permeate enters the hollow fibres making their way out of the vessel
on the product side. This configuration offers the greatest ratio of surface area-to-volume, but susceptible
to fouling by suspended solids and prone to breakage when offered under turbulent conditions.
DESIGN OF RO SYSTEM AND FACTORS AFFECTING ITS PERFORMANCE
For designing a R.O. system the following information is needed:
1. Feed water analysis and source
2. Capacity of plant
3. Treated water analysis and end-use.
The feed water analysis should include such information as TDS, concentration of each significant ion, iron,
manganese, silica concentration, pH, turbidity and temperature. Pre-treatment of the feed water to RO
system is very important to get long trouble free service. The membranes tend to get fouled by suspended
matter, salts of calcium, iron and biological matter. Hence each of these impurities must be either removed
or rendered ineffective by proper treatment. Coagulation and filtration in sand or dual media filters remove
suspended matter. However, small particles cannot be removed in these filters and hence 5 micron
cartridge filters are used for the final filtration. The cartridge filters are the last step in the pre-treatment
of feed water to the RO unit.
Soluble manganese and iron in the feed water get oxidized and precipitate on the membrane thus fouling
it. It is preferable to remove these impurities prior to feeding the water to a RO plant. Alternatively,
oxidation of the impurities can be prevented by pH adjustment to keep iron in ferrous state itself. Calcium

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is high. PH adjustment of feed water is done to keep the Langelier index negative, thus preventing
precipitation of calcium carbonate. Alternatively, a Base Exchange softener softens the feed water.
Calcium sulphate is another constituent, which can precipitate on the membrane surface due to the
concentration of the dissolved salts. Recoveries of the order of 75% - 80% are common in Brackish water
treatment by R.O. due to which the feed gets concentrated four times on passage through the RO system,
resulting in concentration of CaSO4 exceedingly its solubility limits. Dosing of sodium hexa-meta-phosphate
in the feed water can prevent CaSO4 precipitation. Biological fouling is caused by the growth of micro-
organisms on Reverse Osmosis membranes. Chlorine dosing in the feed water kills bacteria preventing
biological fouling. However, free chlorine must be removed either on an activated carbon filter, or by dosing
sodium sulphite, prior to the feed water entering into the cartridge filters. Cellulose acetate membranes
tolerate free chlorine residuals up to 1 ppm below a pH of 8, but polyamide membranes cannot tolerate
free chlorine residuals.
Cellulose acetate membranes are prone to hydrolysis at higher pH values and hence acid is essential in the
case of cellulose acetate membranes.
RO membranes are sensitive to temperature. At lower temperature, the viscosity of water increases
reducing the efficiency of the membranes. At higher temperatures, the flux is better but membranes
Detroit faster. The ideal temperature for RO membranes is 250 C.
Reverse Osmosis plant capacities can be increased by adding more number of membrane modules. Spirally
wound membrane modules are available in 4” and 8” diameter and in lengths of 40” for each element. In
a pressure vessel, six such elements can be placed to increase the yield from a module. A number of such
modules are placed in series/parallel combinations to suit the requirement of capacity, recovery and final
treated water quality.
Seawater can be treated by Reverse Osmosis to produce water to WHO standard of drinking water in a
single stage RO system. However, if the TDS in the treated water has to be further reduced, a second stage
RO can be used; the reject from the second stage is recirculated by mixing with the feed to the first stage
RO system.
The RO system normally includes the following:
* Feed Inlet valve

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* Cartridge filter to remove large particle matter

* High pressure pump to pressurize the feed water
* High pressure switch or pressure relief device is given in the feed line to protect RO modules from over
pressurization
* Low-pressure shutdown switch on high pressure pumps suction to protect the high-pressure pump and
to prevent operation of RO system at inadequate flows
* Flow control valve on the reject to control conversion/recovery
* Flow meters to measure product and reject flows
* Pressure gauge to determine pressure drop across cartridge filter and the pressure drop across the RO
modules
* Sample ports on feed, reject and product to evaluate system performance
* Conductivity meter to monitor product quality
* pH meter to monitor pH of feed water
There are two types of pumps employed in R.O. systems – centrifugal and positive Displacement. For a
centrifugal pump, a throttling valve on the pump discharge controls the feed pressure to R.O. A
backpressure valve for recirculation of some of the flow can be used when the pump capacity is greater
than that needed to supply to the RO system.
For a positive displacement pump, a pressure relief valve is required on pump discharge. Flow restrictions
must never be used on the pump discharge between the pump and the relief valve. To smoothen out the
fluctuations in flow, pulsation dampers are used on the pump delivery and also if possible, on suction. A
backpressure valve to control the system pressure and allow for recirculation of part of the flow can be
used when the pump capacity is greater than that needed for the system. Fig.4 depicts the two pumping
systems. The modular design concept is used to expand the single device system when the desired product.
Flow is greater than the output of an individual device. A single valve in the brine manifold controls the
system conversion. It is possible to obtain conversions higher than 50% if two or three stages are employed.
The reject from the first stage is fed to the second stage and the product from both the stages collected in

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a single header. Normally sea water systems operate in a single stage with conversion in the range 20 to
40% to produce product water in the range of 500 – 700 ppm TDS.
APPLICATIONS
Reverse Osmosis is being increasingly employed to desalinate brackish/sea water for potable purposes. In
combination with ion exchange demineralization, R.O. is being used to produce water for industries
requiring ultra pure water such as boilers, chemical processes, electronic industries etc.
Reverse Osmosis has been successfully used for reclaiming large quantities of municipal and industrial
wastewater.
Food processing represents a great potential for reverse osmosis. Not only is evaporation of water by heat
expensive, but also in food processing the application of heat usually causes undesirable changes in the
flavor or appearance of the product.
Typical schemes for brackish water desalination is shown in Fig. 4
(C) REVERSE OSMOSIS (RO) SYSTEM (Tag. No. 235-SK-101 A/B/C/D/E/F/G/H/I):
Osmosis is a natural involving fluid flow across a membrane, which is said to be ‘semipermeable’. A
semipermeable membrane is selective in that certain components of a solution, usually the solvent can
pass through, while others, the dissolved solids cannot pass through it.
The direction of solvent flow is determined by its chemical potential, which is a function of Pressure,
temperature and concentration of dissolved solids. In case pure water is available on both sides of a semi-
permeable membrane at equal pressure and temperature, no resultant flow can occur across the
membrane, as the chemical potential is equal on both the sides. However, if any soluble salt is added on
one side of the membrane, the chemical potential of the water on that side is reduced. The osmotic flow
from the pure water on one side to the salt solution on the other side will occur across the membrane until
equilibrium of solvent chemical potential is restored.
The thermodynamic requirement for osmotic equilibrium is that the chemical potential of the solvent
should be the same on both sides of the membrane. No such condition is imposed on the solute, since the
membrane prevents its passage. The equilibrium state occurs when the pressure differential on the two
sides is equal to the osmotic pressure, a solution property that is independent of the membrane.

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The application of external pressure to the solution side, which equals the osmotic pressure, will also
accomplish equilibrium. A further increase in pressure will increase the chemical potential of the water in
the solution and will cause a reversal of the osmotic flow towards the pure water side which is at a lower
solvent chemical potential relative to the solution. This phenomenon is termed as Reverse Osmosis and is
the basis for a process to desalinate water without phase change.
In order to prevent the precipitation of the hardness salts and silica during cases when the concentration
exceeds the solubility limit, an Antiscalent is added at the inlet of the reverse Osmosis system, which will
result in inhibition of scales. Antiscalent dosing tank (235-TK-117A/B/C) with agitators (235-M-117 A/B/C)
and set of pumps (235-PM-117 A/B/C/D) are provided for this purpose.
For phase- I Stage-I & Phase-I Stage-II only two dosing tanks for Antiscalent are to be provided. However
for CRWS added to WRP one more tank is to be added (By others). However dosing pumps for Phase-I
Stage-I & Phase-I Stage-II two (1 working & 1 standby) dosing pumps are to be provided. For CRWS routed
to WRP two (1 working & 1 Standby) additional pumps are to be provided (By others).
Furthermore free chlorine present in the filtered water may result in chemical oxidation of the Membrane.
Hence sodium bi-sulphite (NaHSO3) is injected at the inlet of the reverse osmosis system to eliminate any
oxidizing elements being present in the raw water and to protect the membranes which are the most vital
part of the plant. SBS dosing tank (235-TK-118A/B/C) with agitators (235-M-118A/B/C) and set of pumps
(235-PM-118A/B/C/D) are provided for this purpose. Sodium Meta Bisulphite (NaHSO3) is a reducing agent
capable of dechlorinating the feed water to a reverse osmosis system as per the following reactions:
2NaHSO3 + 2HOCl H2SO4 + 2HCl + 2Na2SO4
In theory, 1.34 mg of sodium metabisulfite will remove 1.0 mg of free chlorine. In practice, however, 3.0
gm of sodium metabisulphite is normally used to remove 1.0 mg of chlorine.
For phase-I stage-I & phase-I stage-II only two dosing tanks for SMBS are to be provided. However for CRWS
added to WRP one more tank is to be added (By others).
However dosing pumps for phase-I stage-I & phase-I stage-II two (1 working & 1 standby) dosing pumps are
to be provided. For CRWS routed to WRP two ( 1 working & 1 standby) additional pumps are to be provided
(By others). 98% H2SO4 acid is also continuously dosed inlet of the reverse osmosis system to adjust the pH
of the filtered water. Acid dosing tank (235-TK-119A/B/C) and set of pumps (235-PM-119A/B/C/D) are
provided for this purpose. 98% H2SO4 transfer pumps (235-PM-121A/B) will be provided to transfer acid in

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acid day / dosing tanks. Metallic pipe with PTFE lining shall be used to take care of heat of dilution of H 2SO4
inline dosing.
For phase-I stage-I & phase-I stage-II only two dosing tanks for H2SO4 are to be provided. However for
phase-I stage-I & phase-I stage-II two (1 working & 1 standby) dosing pumps are to be provided. For CRWS
routed to WRP two (1 working & 1 standby) additional pumps are to be provided. (By CRWS added to WRP
one more tank is to be added (By others). However dosing pumps for others).
(C).1. Micron Cartridge Filter Tag. No. 235-GN-101 A/B/C/D/E/F/G/H)
Micron cartridge filters are provided in order to remove up to 5 micron size particles, which are not
removed by the sand filter. These cartridge are disposable type and would be replaced if differential
pressure across cartridge approaches pre-specified level.
For phase-I stage-II, 1 additional micron cartridge to be provided in the parallel to stage-I micron cartridge
filters (by others).
For additional case with CRWS routed to WRP, separate stream of three (2W+1S) micron cartridge filters
are added (by others).
Water is then pumped using high-pressure pumps (Tag. No. 235-PM-114 A/B/C/D/E/F/G/H/I/J/K) through
RO membranes for removal of total dissolved solids (TDS).
For phase-I stage-I six nos. (5W+1S) of High pressure pumps are to be installed. For phase-I stage-II, 1
additional High pressure pump is to be provided in the parallel to stage-I high pressure pumps are to be
added (by others).
For additional case with CRWS routed to WRP, separate stream of 4 nos. (3working & 1standby) High
pressure pumps are to be added (by others).
Reverse Osmosis module consists of thin film composite polyamide membranes. Two stage RO system is
used to get the desired recovery. Inter turbo booster (Tag. No. 235-PM-115 A/B/C/D/E/F/G/H/I) are
provided to achieve feed pressure requirement of second stage. On continuous running the RO membrane
get fouled with fine colloids, bacterial debris or sometimes scales of salts. These need to be removed and
cleaned from the surface of the membrane. For each type of foulant, there is a recommended chemical
cleaning procedure, which is convenient to perform with cleaning in place (CIP) system.

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2.5 MONITORING OF THE INSTRUMENTS

The following instruments will be installed in the common header downstream of the cartridge filter to
monitor respective parameters:
1. Oxidization Reduction Potential (ORP) Analyser.
The absence of chlorine would be monitor using an oxidation-reduction potential (ORP) Electrode
downstream of the mixing line. The ORP Electrode is placed in the feed line of the Membrane modules. The
electrode indicates the free Chlorine in terms of mille volts, and Activates the opening of the feed drain
valve and ensures that chlorinated water in the feed Pipeline is drained off immediately. The ORP
electrodes also gives signal to activate an alarm Which can use to Shut down the HP pump when chlorine
is detected.
2. PH monitoring: pH will be monitored using pH analyser on the main header Downstream of the cartridge
filter, the permeate water outlet header.
3. Conductivity analyser: the TDS of influent to the RO plant will monitored using Conductivity analyser
located on the main header downstream of the cartridge filter. Also, Conductivity of RO permeate water is
monitored to know the quality of product water.
For phase-I stage-I, Five (5 Working) of RO skids are to be installed.
For phase-I stage-II, 1 additional RO skid to be provided in the parallel to phase-I stage-I RO skids
(By others)
For additional case with CRWS routed to WRP, Separate stream of three (3 Working) RO skids are to be
added (by others).
Degasser System:
RO permeate water is then fed to degasser tower (tag no. 235-c-109A/B/C/D/E) to reduce the CO2 gas.
Degasser tower is filled with PP pall rings. Air is forced from the bottom of the Tower by centrifugal blowers
(tag no. 235-k-104A/B/C/D/E/F/G), while the water flows down through the packed bed of PP rings. The
packing are provided to ensure proper contact of water with air so that all the dissolved carbon dioxide in
the permeate water is stripped off thereby increasing the pH and decreasing the ionic load on the

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Demineralization plant. The carbonic acid present in the water splits up into carbon dioxide gas and water.
This carbon Dioxide gas is stripped off and escaped from the top of the Tower. The degassed water is
collected in the RO permeate storage tank (235-TK-110) and further pump (tag no. 235-pm-
124A/B/C/D/E/F/G/H) to RO permeate storage tank (tag no. 235-tk-121A/B). The product water is then
pumped to battery limit header feeding to DM plant by set of pumps (235-pm-126A/B/C/D/E/F/G/H).
H2CO3 H2O + CO2
For phase-I stage-I, 3 nos. (3 working) degasser towers, 4 Nos. (3 Working+ 1 Standby) blowers, 4 Nos. (3
Working+ 1 Standby) permeate tanks feed pumps & 4 Nos. (3 Working+ 1 Standby) permeates transfer
pumps are to be installed.
For phase-I stage-II, 1 No. additional degasser tower, Degasser air blower, RO permeate tank feed pump,
RO permeate tank transfer pump are to be provided in the parallel to stage-I respective Equipments. (By
others).
For additional case with CRWS routed to WRP, Separate stream of 1 No. Degasser tower, 2 Nos. (1 working
+ 1 Standby) degasser blower, 3 Nos. (2 working + 1 Standby) RO permeate tank Feed pump & 3 Nos. (2
working + 1 Standby) RO permeate transfer pumps are to be added. (By others).
RO intermediate & RO permeate storage tank is common for phase-I stage-I, phase-I stage-II & CRWS route
to WRP.
RO Bypass: - in case of off specs effluent condition & problem in upstream of UF. Raw water from U-100 is
taken through basket strainers & UF. RO is bypassed only when UF permeate will comply with RO permeate
specification.
Cleaning In Place System for RO:
Cleaning In Place (CIP) system is provided for cleaning of fouled RO membranes, an alarm is sounded in the
PLC and the cleaning cycle is initiated by the operator. The system is provided for cleaning of one train of
RO system at a time. The cleaning system consists of cleaning Tank (tag no. 235-TK-128), Cleaning pumps
(tag no. 235-pm-122A/B) AND MICRON FILTER (235-gn-102A) of 5 micron size along with agitator (235-M-
121). When there is a high pressure drop across the RO membrane, an alarm is sounded in the PLC and the

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cleaning cycle is initiated Manually by the operator. Cleaning system For phase-I stage-I, For phase-I stage-
II & CRWS routed to WRP will be same.
REJECT STAGE RO: - There is limitation on RO reject disposal to sea RO reject flow not exceed 324 m 3/hr
(i.e. 7776 m3/day) For phase-I stage-I & 350 m3/hr (i.e. 8400 m3/hr for For phase-I stage-II. During phage-I
stage-I reject from 5 working skids shall be 323.5 m3/hr. However during phase-I stage-II
Reject from 6 working skids will exceed limit of 8400 m3/day. To restrict the reject Outfall one no:
Reject RO to be installed during phase-I stage-II erection. The feed to reject RO shall be 121.8 m3/hr. The
reject stage RO is having the two passes. RO permeate from pass-I is pass through RO pass-II by RO high
pressure pump for pass-II. Reject of pass-I is directly taken from from there to the carbon contact tank. RO
pass-II is having two stages. RO reject from pass-II stage-I will feed to pass-II stage-II @ final reject from
pass-II stage-II is recirculated back to the inlet of pass-I. permeate from the reject stage RO is balanced in
the RO intermediate & then to RO permeate tank. Antiscalent dosing & cleaning for reject stage is separate
for Reject stage RO.

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Chapter 2.6 Summary of foulants and likely performance effects on RO
Foulants Description Effects on RO Method of

Performance Control/Cleaning
Scale Precipitation of  Major loss of salt  Lower power
sparingly soluble salts rejection recovery
(minerals) caused by  Moderate increase  Adjust PH
concentration of salts in in differenctial  Clean with citric
the feed solution during pressure acid or EDTA
passage across the  Sight loss of BASED SOLUTION
membrane production  Clean silicate
Example;  The effects usually based foulants
CaCO3,CaSO4,BaSO4, occur in the final with ammonium
SrSO4,SiO2 stage biflouride based
solutions
Colloidal clays /silt Agglomeration of  Rapid increase in  Filtration
suspended matter on differential  Charge
the membrane surface pressure stabilisation
Example ; SiO2, Fe(OH)3,  Moderate loss of  Higher feed-brine
Al(OH)3, FeSiO3 production flows Clean with
 Moderate loss of EDTA, STP or
rejection detergent at high
 The effects usually PH(-11)
occur in the first  Clean silicate
stage based foulants
with ammonium
biflouride based
solutions
 Lower recovery

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Bilogical Formation of bio  Major loss of  Sodium bisulfite

growth on membrane production addition along
surface  Moderate loss of with chlorination
Example; iron reducing salt passage with or without
bactria , sulfur reducing  Possible moderate activated carbon
bacteria , increase in filtration
mycobacterium, differential  Clean with
pseudomonas pressure detergent or EDTA
 The above effects solutions at high
occur slowly pH(-11)
steadily  Clean with enzyme
solutions
 Shock disinfection
program with
formaldehyde,
hydrogen
peroxide,
Organic Attachment of organic  Rapid and major  Filtration with GAC

species to the loss in production  Cleaning is rarely
membrane surface  Stable or moderate successful but
Example; poly- increase in salt isopropanol or
electrolytes, oil grease rejection proprietary
 Stable or moderate solutions have
increase in been effective
differential
pressure

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CHAPTER 3; DESIGN BASIS

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3.1 DESIGN BASIS –UF SKIDS {TAG NO.:235-A-002A/B C/D/E/F/G/H/I}
Sr. no. Description Units Phase-I stage-I Phase-I CRWS

stage-II Routedto
WRP
1. Tag no. 235-A-002 A/B C/D/E 235-A-002 A/B 235-A-002
C/D/E/F G/H/I
2. Max sustained flow m3/hr 1367.5 1617.4 606.3
3. Total design flow m3/hr 1640.95 1940.85 727.6
4. No. of working streams Nos. 4 5 2
5. No. of stand by streams Nos. 1 1 1
6. Design flow per stream m3/hr 410.3 388.2 363.8
7. Recovery % 90.00% 90.00% 90.00%
8. Design permeate flow m3/hr 369.2 349.4 327.4

per stream
9. Total suspended solids Mg/L 5 5 5

in feed

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10. Total oil & grease in Mg/L 0 0 0

feed
11. Feed SDI <5 <5 <5
3.2: Design Parameters RO

1.1 – Specifications of Modules *1)
Module type HFU-202N

Membrane Surface Area, Outer Surface 72m2
Dimensions Diameter 216mm

Length 2,160mm
Weight Full of water 110 kg
After draining 67kg
Materials Housing Polyvinylchloride or equivalent
potting Epoxy Resin or equivalent
Connections Top Victaulic joints 80A
Bottom Victaulic joints 80A
Side Victaulic joints 65A
Max. Feed Water Flow 12 m3/h(167 lmh)
Max. Backwash Flow 13.5 m3/h(167 lmh)
Max, Air Flow 9 Nm3/h
Filtration Method Pressurized type Outside to inside , dead end
Backwash Type Backwash followed by air-scrubbing
Max. Feed Water Pressure 300 kPa
Max. Backwash Pressure 300 kPa
Air Pressure Lower than 200 kPa
Maximum Temperature 40 degree C {104 degree F).

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1). Please note that the specifications are subject to changes from time to time.
3.3: Water Analysis

Feed water conditions for UF membrane Module
Category of UF Feed water: Effluent from Refinery (treated by AS unit / Bio DAF unit
Effluent Check Basin / Granular Media Filter)
Sr. Parameter Unit UF feed Water Quality UF Feed water Quality

No Indicated by customer required by Toray
1 TDS ppm 4.777 <4.777
2 TSS ppm <5 <5
3 Oil ppm <2 <2(100% Time)
<1(90%time)
4 BOD ppm <15 <15
5 pH 6-9 6-9
6 Turbidity NTU <6 <5
7 COD ppm <80 <80
8 Soluble COD ppm <69 <89
9 Maximum Temperature Degree C - 40
10 Minimum Temperature Degree C - 20
Note
1. Assumed that the raw water is treated with the screen having less than 200 micron meter of net size
2. 2. Toray assumes stable raw water for with above quarties entering the hollow fiber UF membrane
modules.

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2.2 – Permeate Water Quality and Design expected
Sr. No Parameter Unit Expected by Toray

1 Turbidity NTU <0.3 (100 % time)
2 Silt density Index (SDI (15) <3 (90 % time)
Note
1. We explicitly exclude any costs associated with sampling or analysis
2. 2. Regarding permeate water quality. Toray request to discuss with a customer after a definition of UF
feed water quality.
2. Outline of Design OF UF Membrane

Filtration Process 1 /3
2.1- Feed water condition for UF membrane Module
Category of UF Feed water: Effluent from Refinery (treated by As unit /Bio DAF Unit
/Effuluent Check Basin /Granular media filter).
Sr. Parameter Unit UF feed Water Quality UF Feed water Quality
No Indicated by customer required by Toray
1 TDS ppm 4.777 <4.777
2 TSS ppm <5 <5
3 Oil ppm <2 <2(100% Time)
<1(90%time)
4 BOD ppm <15 <15
5 pH 6-9 6-9
6 Turbidity NTU <6 <5
7 COD ppm <80 <80
8 Soluble COD ppm <69 <89

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9 Maximum Temperature Degree C - 40

10 Minimum Temperature Degree C - 20
Note
1. Assumed that the raw water is treated with the screen having less than 200 micron meter of net size
2. 2. Toray assumes stable raw water for with above quarties entering the hollow fiber UF membrane
modules.

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Sr. no. Description Units Phase-I stage-I Phase-I CRWS

stage-II Routed
to WRP
1. Tag no. 235-A-002 A/B C/D/E 235-A-002 A/B 235-A-101
C/D/E/F G/H/I
2. Max sustained flow m3/hr 1230.8 1455.7 564.1
3. Total design feed flow m3/hr 1476.9 1746.8 655.3
4. No. of working streams Nos. 5 6 3
5. No. of stand by streams Nos. 0 0 0
6. Design flow per stream m3/hr 295.4 291.1 218.4
7. Recovery % 78.10% 78.10% 78.10%
8. Design permeate flow m3/hr 230.7 227.4 170.6

per stream
9. Total dissolved solids in Mg/L 4789.9 4680.3 3648.0

feed

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3.4. List of Chemicals used in WRP:

 Sodium Hypochlorite
 Sodium meta bisulphite
 Sulfuric Acid
 RO-Antiscalent
 Citric Acid
 Sodium Hydroxide
 Sodium Lauryl Sulphate
 Di ammonium Phosphate
 Cationic Poly-electrolyte
 Poly Aluminium Chlorite
3.5: Equipment List & Technical Notes
U-235
SR.no Equipment Tag No. Name of equipment
1 STR-107A-E UF BASKET STRAINER
2 TK-124 UF CLEANING SOLUTION TANK
3 A-001A-E UF KIDS
4 P-110A-B UF BACKWASH PUMP
5 P-125A-B UF CLEANING SOLUTION PUMP
6 TK-125 CEB-3 SULPHURIC ACID DOSING PUMP
7 P-112 CEB-3 SULPHURIC ACID DOSING TANK
8 TK-112 CEB-3 10% NAOCL DOSING TANK
9 P-111A-C CEB-3 10% NAOCL DOSING PUMP
10 TK-111 CEB-3 20% NAOCL DOSING TANK
11 P-116A-B CEB-3 20% NAOCL DOSING PUMP
12 TK-108 UF PERMEATE/RO FEED TANK
13 GN-101 A-1 RO CATRIDGE FILTERS
14 P-113A-H RO CATRIDGE FEED PUMP
15 P-114A-K RO HIGH PRESSURE PUMP
16 A-101 A-I RO SKIDS

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17 P-115 A-I RO SECOND STAGE BOOSTER PUMP

18 P-124A-G RO PERMEATE TANK FEED PUMP
19 P-126 A-G RO TREATED WATER TRANSFER PUMP
20 P-123A-B DM REGENERATION WASTE TARANSFER PUMP
21 P-121 A-B 98% H2SO4 TRANSFER PUMP
22 TK 126 A-C H2SO4 STORAGE TANKS
23 TK-128 RO CLEANING SOLUTION TANK
24 P-122A-B RO CLEANING SOLUTION PUMP
25 GN-102 RO CLEANING CARIDGE FILTERS
26 TK-119 ACID DOSING TANK FOR RO
27 TK-118 A-B SMBS DOSING TANK FOR RO
28 P-118A-D SMBS DOSING PUMP
29 M-117A-B ANTISCALANT DOSING TANK AGITATOR
30 P-117A-D ANTISCALANT DOSING PUMP
31 C-109A-E DEGASSER TOWER
32 K-104A-G DEGASSER AIT BLOWER
33 TK-110 RO INTERMEDIATE STORAGE TANK
34 TK-121A-B RO PERMEATE TANK
35 TK-122 DM REGENERATION WASTE COLLECTION SUMP
36 M-118A-B SMBS TANK AGITATOR
37 M-121 RO CLEANING SOLUTION TANK AGITATOR
38 M-124 UF CLEANING SOLUTION TANK AGITRATOR
39 K-105A-B UF AIR SCOURING BLOWER
40 P-127A-B COLD DUST SUPPRESSION PUMP
41 P-128 DRUM PUMP FOR SMBS
42 P-129 DRUM PUMP ANTISCALANT
43 P-130A-B REJECT STAGE RO HP PUMP
44 P-136A-B REJECT STAGE RO HPSTAGE 2 PUMP
45 GN-103A-B CATRIGE FILTER FOR RO
46 P-131A-B CATRIGE FILTER FEED PUMP FOR RO REJECT
47 TK-127 CIP TANK FOR RO REJECT
48 P-132A-B RO CLEANING PUMP FOR REJECT STAGE
49 GN-104 CLEANING CATRIGE FILTER FOR REJECT STAGE RO
50 M-127 CIP TANK AGITRATOR FOR REJECT STAGE RO
51 P-119A-D CID (98%H2SO4) DISING PUMP ROR RO
52 TK-117A-B ANTISCALANT DOSING TANK
53 A-102 REJECT STAGE RO
54 P-133 DRUM UMP FOR CITRIC ACID FOR UF CLEANNING &RO CLEANING
55 TK-130A-B ANTISCALANT TANK FOR REJECT STAGE RO
56 P-135A-B ANTISCALANT DOSING PUMP FOR REJECT STAGE RO

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57 M-130A-B ANTISCALANT AGITATOR FOR REJECT STAGE RO
PROCESS DESCRIPTION
PROCESS DESCRIPTION FOR WRP (UF & RO SECTION)
(A) ULTRAFILTRATION
The UF section comprises of:
 Basket strainers
 Ultra filtration skid
 RO Feed tank
 UF backwash pump
 Cartridge filter feed pump
 Dosing system
 Cleaning in place tank
Basket Strainers (Tag. No. 235-STR-107 A/B/C/D/E/F/G/H)
After filtration system, basket strainers are provided for trapping any sand particles that may leak out and
go into ultra-filtration thus permanently chocking of ultra-filtration fibers. These strainers are guard filter
for ultra-filtration system. Since the frequency of leakage of sand is very low, manual backwashing is done
once in a month or two. The necessary valves are provided for backwashing of basket strainers.
For phase-I stage-I four no (3 working + 1 Standby) of basket strainers are to be installed.
For phase-I stage-II, 1 additional basket strainer is to be provided in the parallel to stage-I basket Strainers
(By others).
For additional case with CRWS routed to WRP, Separate stream of three nos. (2 Working +1 Standby)
Basket strainers are to be added (By others).

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Ultra filtration Skid (Tag. No. 235-A-002 A/B/C/D/E/F/G/H/I)

Ultra filtration is a membrane process in which a porous membrane is used to separate or reject colloidal
and particulate matter. Similar to other membrane processes, Ultra filtration is a pressure driven process.
High permeability of ultra-filtration membrane and negligible osmotic effects allow the ultra-Filtration
process to operate at relatively low pressures.
Ultra filtration modules incorporate capillary or hollow fibre as the membrane structure. The benefit of this
type of construction is that it allows for backwashing of the membrane when filtrate or product flow has
decreased due to accumulation of material on membrane surface.
The ultra-filtration process is operated on “dead-end” or “cross flow”. The fibre composition is PVDF,
hydrophilic material that resists organic fouling and is tolerant to chlorine exposure. The flow pattern
Is outside to inside, meaning the feed water flows through the outside of the fibers and filtrate passes
radially inward through the membrane “tube”. Water is pressurized through the membrane and
particulates are left at membrane surface. Due to small pore size of the membrane, effectively all
suspended solids are removed from the filtrate. These particulates build up in concentration at membrane
surface, thus the water flow direction is periodically reversed to remove particulate matter (Backwash).
The modes of operation of Ultra filtration are: Processing, Backwash and Chemical enhance backwash
System is automated to switch between these modes. However, cleaning mode is semi-automatic.
Processing:
Processing is the mode in which filtration takes place. In dead end filtration, all water fed to the ultra-
Filtration module passes through the membrane and is filtered. During processing step, the dirt material
Is accumulated on outside membrane surface.
Backwash:
During processing, solids accumulate on the membrane surface and short cleaning or backwash with
Filtrate water is necessary to restore the membrane performance. The system is programmed to backwash
individual blocks at fixed periodical interval. During the backwash the water flow will be reversed. Clean
permeate water will be forced from inside of the capillary and will transport the foulants out. The duration
of the backwash is sufficient to remove all dirt from the membrane surface and drive it out from modules

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and membrane system. Set of backwash pumps shall be provided to carry out the UF backwash operation
(Tag. No. 235-P-110 A/B).
If the backwash is insufficient to remove all the foul ants, the backwash efficiency can be enhanced by
adding chemicals into the backwash (Chemically enhanced backwash). During CEB it is important that first
backwash without chemicals will remove most of the foulants prior to backwash with added chemicals. In
this way chemicals are exposed only to the hard to remove problems. It is also important that all fibers are
filled with chemicals, in the correct amount, concentration and with correct soaking time. After soaking it
is important to flush all the chemicals out with a backwash.
Depending on foulant NaOH, NaOCI and H2SO4 shall be dosed in the backwash inlet water. Three different
systems each comprising of a dosing tank, dosing pumps and agitator (if required) shall be provided.
CEB-I dosing is for dosing 20% NaOH in backwash water during chemically enhanced backwash. A tank (Tag
no. 235-TK-111) is provided with dosing pumps (tag no. 235-P-116 A/B).
CEB-II dosing is for dosing 10% NaCl in backwash water during chemically enhanced backwash. A tank (Tag
no. 235-TK-112) is provided with dosing pumps (tag no. 235-P-111 A/B/C).
CEB-III dosing is for dosing 98% H2SO4 in backwash water during chemically enhanced backwash. A tank
(Tag no. 235-TK-125) is provided with dosing pumps (tag no. 235-P-112 A/B).
Cleaning:
A key measure of ultra-filtration membrane performance is the TMP (Trans Membrane Pressure). This is
the difference between average feed pressure and the permeate pressure. It gives an indication that
amount of fouling on the membrane surface. As the solids accumulate on the membrane surface, the TMP
increases. Backwash help to reduce the TMP, but backwashing is not 100% efficient. When TMP increases
to present limit it is the time for chemical cleaning of membranes. Cleaning is typically performed by taking
the system offline and subsequently recirculating chemical solutions. The chemicals used for cleaning are
typically NaOCI, sodium hydroxide and Citric acid. Other cleaning solutions can be used depending upon
fouling. A tank (235-TK-124) along with agitator (235-M-124) is provided for preparing cleaning solution.
Set of pumps (235-P-125 A/B) are provided for pumping and circulating chemicals in UF membranes.
For phase-I stage-I Five no. (4 Working +1 Standby) of UF skids are to be installed.

Paradip Refinery
For phase-I stage-II, 1 additional UF Skid is to be provided in the parallel to phase-I stage-I UF Skid (by
others).
For additional case with CRWS routed to WRP, Separate stream of three (2 Working +1 Stand by) UF Skids
are to be added.
Back wash, CEB facility & CIP will be same for Phase-I stage-1, Phase-I stage-II & CRWS Routed to WRP.
UF permeate tank/RO feed tank is common for Phase-I stage-I, Phase-I stage-II & CRWS Routed to WRP.
(B) REVERSE OSMOSIS (RO) SYSTEM (Tag. No. 235-SK-101 A/B/C/D/E/F/G/H/I):
Osmosis is a natural process involving fluid flow across a membrane, which is said to be 'semi-permeable'.
A semi-permeable membrane is selective in that certain components of a solution, usually the solvent can
pass through, while others, the dissolved solids cannot pass through it. The direction of solvent flow is
determined by its chemical potential, which is a function of pressure, temperature and concentration of
dissolved solids. In case pure water is available on both sides of a semi-permeable membrane at equal
pressure and temperature, no resultant flow can occur across the membrane, as the chemical potential is
equal on both the sides. However, if any soluble salt is added on one side of the membrane, the chemical
potential of the water on that side is reduced. The osmotic flow from the pure water on one side to the salt
solution on the other side will occur across the membrane until equilibrium of solvent chemical potential
is restored.
The thermodynamic requirement for osmotic equilibrium is that the chemical potential of the solvent
should be the same on both sides of the membrane. No such condition is imposed on the solute, since the
membrane prevents its passage. The equilibrium state occurs when the pressure differential on the two
sides is equal to the osmotic pressure, a solution property that is independent of the membrane.
The application of external pressure to the solution side, which equals the osmotic pressure, will also
accomplish equilibrium. A further increase in pressure will increase the chemical potential of the Water in
the solution and will cause a reversal of the osmotic flow towards the pure water side which is at a lower
solvent chemical potential relative to the solution. This phenomenon is termed as Reverse Osmosis and is
the basis for a process to desalinate water without phase change.
In order to prevent the precipitation of the hardness salts and silica during cases when the Concentration
exceeds the solubility limit, an Antiscalent is added at the inlet of the reverse Osmosis System, which will

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result in inhibition of scales. Antiscalent dosing tank (235-TK-117 A/B/C) with Agitators (235-M-117A/B/C)
and set of pumps (235-P-117A/B/C/D) are provided for this purpose.
For phase-I Stage-I & phase-I stage- II only two dosing tanks for Antiscalent are to be provided. However
for CRWS added to WRP one more tank is to be added (By others). However dosing pumps For Phase-I
stage-I & phase-I stage- II two (1 working & 1 Standby) dosing pumps are to be provided. For CRWS routed
to WRP two (1 working & 1 Standby) additional pumps are to be provided. (By Others)
Furthermore free chlorine present in the filtered water may result in chemical oxidation of the Membranes.
Hence sodium bi-sulphite (NaHSO3) is injected at the inlet of the reverse osmosis system to eliminate any
oxidizing elements being present in the raw water and to protect the membranes Which are the most vital
part of the plant. SBS dosing tank (235-TK-118 A/B/C) with agitators (235-M-118A/B/C) and set of pumps
(235-P-118A/B/C/D) are provided for this purpose. Sodium Meta Bisulphite (NaHSO3) is a reducing agent
capable of de chlorinating the feed water to a reverse osmosis system as per the following reactions:
2 NaHSO3 + 2HOCI - H2SO4 + 2HCl + 2Na2SO4
In theory, 1.34 mg of sodium metabisulfite will remove 1.0 mg of free chlorine. In practice, however, 3.0
mg of sodium metabisulfite is normally used to remove 1.0 mg of chlorine.
For phase-I Stage-I & phase-I stage-II only two dosing tanks for SMBS are to be provided however For CRWS
added to WRP one more tank is to be added (By others). However dosing pumps for Phase-I stage-I & phase-
I stage-II two (1 working & 1 Standby) dosing pumps are to be provided.
For CRWS routed to WRP two (1 working & 1 Standby) additional pumps are to be provided. (By others)
98% H2SO4 acid is also continuously dosed inlet of the reverse osmosis system to adjust the pH of the
filtered water. Acid dosing tank (235-TK-119 A/B/C) and set of pumps (235-P-119A/B/C/D) are provided for
this purpose. 98% H2SO4 transfer pumps (235-P-121 A/B) shall be provided to transfer Acid in acid day /
dosing tanks. Metallic pipe pieces with PTFE lining shall be used to take care of Heat of dilution of H2SO4
inline dosing.
For phase-I Stage-I & phase-I stage-II only two dosing tanks for H2SO4 are to be provided however For
CRWS added to WRP one more tank is to be added (By others). However dosing pumps for Phase-I stage-I
& phase-I stage-II two (1 working & 1 Standby) dosing pumps are to be provided. For CRWS routed to WRP
two (1 working & 1 Standby) additional pumps are to be provided.(By Others)

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Micron Cartridge Filter (tag no. 235-GN-101 A/B/C/D/E/F/G/H)

Micron cartridge filters are provided in order to remove micron size particles, which are not removed by
the sand filter. These cartridges are disposable type and should be replaced if differential pressure across
cartridges approaches pre-specified level.
For phase-I stage-I Five nos. (4 Working & 1 Stand by) of micron cartridge are to be installed. For phase-I
stage-II, 1 additional micron cartridge to be provided in the parallel to stage-I micron Cartridge filters (by
others).
For additional case with CRWS routed to WRP, Separate stream of three (2W+15) Micron cartridge Filters
are added by others).
Water is then pumped using high-pressure pumps (tag no. 235-P-114 A/B/C/D/E/F/G/H/I/J/K) through RO
membranes for removal of total dissolved solids (TDS).
For phase-I stage-I Six nos. (5W+1Standby) of High pressure pumps are to be installed.
For phase-I stage-II, 1 additional High pressure pump is to be provided in the parallel to stage-I high Pressure
pumps (by others).
For additional case with CRWS routed to WRP, Separate stream of 4 nos. (3 working & 1 Standby) High
Pressure pumps (By Others)
Reverse Osmosis module consists of thin film composite polyamide membranes. Two stage RO system is
used to get the desired recovery. Inter stage turbo booster (tag no. 235-P-115 A/B/C/D/E/F/G/H/I) are
provided to achieve feed pressure requirement of second stage. On continuous running the RO Membranes
get fouled with fine colloids, bacterial debris or sometimes scales of salts. These need to be removed and
cleaned from the surface of the membrane. For each type of foulant, there is a recommended chemical
cleaning procedure, which is convenient to perform with cleaning in place (CIP) System.
Monitoring
The following instruments shall be installed in the common header downstream of the cartridge filters
To monitor respective parameters:
1. Oxidization Reduction Potential (ORP) Analyser.

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The absence of chlorine should be monitored using an oxidation-reduction potential (ORP)

Electrode downstream of the mixing line. The ORP Electrode is placed in the feed line of the
Membrane modules. The electrode indicates the Free Chlorine in terms of mille volts, and
Activates the opening of the feed drain valve and ensures that chlorinated water in the feed
Pipeline is drained off immediately. The ORP electrode also gives signal to activate an alarm
Which can use to shut down the HP pump when chlorine is detected.
2. PH monitoring: pH shall be monitored using pH analyser on the main header downstream of the
cartridge filter, the permeate water outlet header.
3. Conductivity analyser: The TDS of influent to the RO plant shall monitored using a conductivity
analyser located on the main header downstream of the cartridge filter. Also, conductivity of the
RO permeate water is monitored to know the quality of product water.
For phase-I stage-I Five (5 Working) of RO skids are to be installed.
For phase-I stage-II, 1 additional RO Skid is to be provided in the parallel to phase-I stage-I RO Skids (By
others)
For additional case with CRWS routed to WRP, Separate stream of three (3 Working) RO skids are to be
added (by others).
Degasser System:
RO permeate water is then fed to degasser tower (tag no. 235-C-109 A/B/C/D/E) to reduce the CO2 Gas.
Degasser tower is filled with PP pall rings. Air is forced from the bottom of the tower by centrifugal Blowers
(tag no. 235-K-104 A/B/C/D/E/F/G), while the water flows down through the packed bed of PP rings. The
packing are provided to ensure proper contact of water with air so that all the dissolved Carbon dioxide in
the permeate water is stripped off thereby increasing the pH and decreasing the ionic Load on the
Demineralization Plant.
The carbonic acid present in the water splits up into carbon dioxide gas and water. This carbon dioxide Gas
is stripped off and escapes from the top of the tower. The degassed water is collected in the RO

Paradip Refinery
Permeate intermediate storage tank (235-TK-110) and further pump (tag no. 235-P-124A/B/C/D/E/F/G/H)
to RO permeate storage tank (tag no. 235-TK-121 A/B). The product water is then pumped to battery limit
header feeding to DM plant by set of pumps (235-P-126 A/B/C/D/E/F/G/H).
H2CO3 + H2O + CO2
For phase-I stage-1 3 nos. (3 working) degasser towers, 4 Nos. (3 Working+ 1Standby) blowers, 4 Nos. (3
Working+ 1Standby) permeate tank feed pumps & 4 Nos. (3 Working+ 1Standby) Nos. permeate Transfer
pumps are to be installed.
For phase-I stage-II, 1 no. additional Degasser tower, Degasser air blower, RO permeate tank feed Pump,
RO permeate transfer pump are to be provided in the parallel to stage-I respective Equipments. (By Others)
For additional case with CRWS routed to WRP, Separate stream of 1no. Degasser tower, 2 Nos. (1 Working
+1Standby) degasser blowers, 3 Nos. (2 Working +1 Standby) Ro permeate tank feed Pump & 3 Nos. (2
Working +1 Standby) RO permeate transfer pumps are to be added (by others).
RO intermediate & RO permeate storage tank is common for Phase-I stage-I, Phase-I stage-II & CRWS
Routed to WRP.
RO Bypass: - in case of off specs effluent condition & problem in upstream of UF. Raw water from U-100 is
taken through basket strainers & UF. RO is bypassed only when UF permeate will comply with RO permeate
specification.
Cleaning In place System for RO:
Cleaning in place (CIP) system is provided for cleaning of fouled RO membranes, an alarm is sounded in the
PLC and the cleaning cycle is initiated by the operator. The system is provided for cleaning of one train of
RO system at a time. The cleaning system consists of cleaning tank (tag no 235-TK-128), Cleaning pumps
(tag no. 235-P-122 A/B) and micron filter (235-GN-102 A) of 5-microns size along with Agitator (235-M-
121). When there is a high-pressure drop across the RO membrane, an alarm is sounded in the PLC and the
cleaning cycle is initiated manually by the operator. Cleaning system for Phase-I Stage-1, Phase-I Stage-II &
CRWS routed to WRP will be same.
REJECT STAGE RO: - There is limitation on RO reject disposal to sea RO reject flow should not exceed 324
m3/hr (i.e. 7776 mº/day) for Phase-I Stage-I & 350 m3/hr (i.e. 8400 m3/day) for phase-I Stage-II. During

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phase-I stage-I reject from 5 working skids shall be 323.5 m3/hr. However During phase I Stage-II reject
from 6 working skids shall exceed limit of 8400 m3/day. To restrict the reject outfall one no Reject RO to
be installed during phase-I Stage- II erection. The feed to reject RO shall be 121.8 m3/hr. The reject stage
RO is having the two passes. RO permeate from Pass- I is pass through RO Pass-II by RO high pressure pump
for Pass-II. Reject of Pass-I is directly taken from there to the Carbon contact Tank. RO pass-II is having two
stages. RO reject from pass- II stage-I will fed to Pass-II stage- II & final Reject from Pass-II stage- II is
recirculated back to the inlet of Pass-I. Permeate from the reject stage RO is balanced in the RO
intermediate & then to RO permeate tank. Antiscalent dosing & cleaning for Reject stage is separate for
Reject stage RO.

i

SIGNATURE
DATE
REFERENCE DRAWINGS

A1 18.10.11 AJ/SS RH SMD.

05 25.08.11 REVISED AS PER COMMENTS AJ/SS RH SMD.
04 03.08.11 REVISED AS PER COMMENTS AJ/AG RH SMD.
O3 02.02.11 REVISED AS PER COMMENTS AJ/TR RH SMD.
O1 17.09.10 ORIGINAL DRAWING AJ/TR RH SMD.
INDIAN OIL
CORPORATION
LIMITED
VA TECH WABAG LIMITED WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-023 A1
i

i
TITLE:
& DM REGENERATION WASTE)
DWG NO:

451/4200 2 20454
i
CRWS SUMP CRWS SUMP CRWS SUMP

SIGNATURE
DATE
REFERENCE DRAWINGS


O5 25.08.11 REVISED AS PER COMMENTS AJ/SS RH SMD.
O4 03.08.11 REVISED AS PER COMMENTS AJ/AG RH SMD.
INDIAN OIL
CORPORATION
LIMITED
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-023 A1
TITLE:
& DM REGENERATION WASTE)
DWG NO:

451/4200 2 20454
SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-024 A1
TITLE:

FOR ULTRAFILTRATION UNITS
DWG NO:

451/4200 2 20455
SIGNATURE
DATE
REFERENCE DRAWINGS

PHASE - I STAGE - II

INDIAN OIL
CORPORATION
LIMITED
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-024 A1
TITLE:

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451/4200 2 20455
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10P2-D0015-024 A1
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05 25.08.11 ISSUED FOR HAZOP AJ/SS RH SMD.
04 03.08.11 ISSUED FOR HAZOP AJ/AG RH SMD.
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10P2-D0015-025 A1
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235-JS-102


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FILE NAME: REV:

10P2-D0015-025 A1
04 03.08.11
for ISSUED
which it isFOR HAZOPfurnished. TheAJ/AG
specifically RH
apparatus SMD.
TITLE:

DWG NO:

451/4200 2 20456
SIGNATURE
DATE
REFERENCE DRAWINGS

235-JS-101 A1 18.10.11 AJ/SS RH SMD.

05 25.08.11 REVISED AS PER COMMENTS AJ/SS RH SMD.
i

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PHASE - I STAGE - II Paradip, Orissa State, India
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DEGASSER TOWER DEGASSER TOWER DEGASSER TOWER DEGASSER TOWER

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Document No: PDR/PN/VOC/OM
Indian Oil VOC August, 2012 7 Jan, 2022
Paradip Refinery
OPERATING MANUAL
VOC COLLECTION AND REMOVAL SYSTEM

Paradip Refinery
PREFACE
This manual gives detailed operating and specific guidelines for VOC Collection & Removal System for
Effluent Treatment & water recovery Plant for IOCL- Paradip Refinery. It consist of detailed process
description & operating procedures.
The instructions have been prepared for the purpose of facilitating the Start-up and subsequent
operations. Modifications may be necessary in Actual operation as a result of experience gained in
operating the unit.
Detailed operating and maintenance instructions of the Vendor’s Equipment are not included in this
manual, which can be found in the Manufacturers’ data book. In the event of any discrepancy between
this Manual and manufacturers’ recommendations the latter shall be deemed Final.

Paradip Refinery
TABLE OF CONTENTS
SL No Topics Page No
1 INTRODUCTION 4
2 DESIGN BASIS & BATTERY LIMIT 6
3 EQUIPMENT LIST 7
4 TREATMENT PHILOSOPHY 8
5 PROCESS DESCRIPTION 10
6 CONTROL PHILOSOPHY 12
7 PRE-COMMISSIONING 22
8 START-UP PROCEDURES 32
9 SHUT DOWN 33
10 RE-START UP 35

Paradip Refinery
1. INTRODUCTION
The Project which is known as ‘Paradip Refinery Project' is to install an integrated Grassroots 15 MMTPA
(300,000 BPSD) refinery and petrochemical complex, as ‘Phase 1’ of the development at a site located
5 km south of the Port of Paradip in the state of Orissa, on the northern part of the east coast of India.
The Paradip Refinery Project facilities process imported crude oil and produces refined products and
polymers for domestic use and export.
The Storage facilities include crude, intermediate and final product storage and Product transfer
pipelines. Other facilities include Flare System, Effluent Treatment Plant facilities, Warehouse and
bagging facilities for Polypropylene and dispatch Facilities for finished products (solid and liquid).
The process units to be part of the Refinery Complex include the following:
1) AVU – Atmospheric Vacuum Unit (CDU/ VDU / NSU)
2) Kerosene Treater
3) Diesel Hydro treater
5) Delayed Coker
6) Naphtha Hydrometer
7) Catalytic Reformer (CCR Plat former)
8) Sulfone Extraction
9) Benzene / Toluene Fractionation
10) Xylene Fractionation
11) Para xylene Separation (‘Parex’)
12) Trans-alkylation (‘Tatoray’ Unit)
13) Xylene Isomerization
14) VGO Hydro treater
14) Fluid Catalytic Cracker
15) FCC Naphtha Splitter

Paradip Refinery
16) Propylene Recovery

17) Polypropylene
18) SR LPG Treater
19) FCC LPG Treater
20) Coker LPG Treater
21) FCC Lt. Naphtha Treater
22) Ethyl Benzene / Styrene Monomer
23) Butane Isomerization (‘Butamer’)
24) Alkylation
25) Hydrogen Production and Purification
26) Amine Regeneration (Train #1)
27) Sour Water Stripper (Train #1)
28) Amine Regeneration (Train #2)
29) Sour Water Stripper (Train #2)
30) Sulphur Recovery
31) Tail Gas Treating
This package is to Capture Volatile Organic Compound for the Paradip Refinery Project (PDRP) and
dealing with emissions from the following Effluent Treatment
Plant equipment:
1) Sulphidic Spent caustic equalization tank (221-TK-101)
2) Spent caustic equalization tank (221-TK-102)
3) Equalization Tank A/B (230-TK-006A/B)
4) Oily DAF (230-TK-110,210,210,410,510)
5) De salter equalization tank (220-TK-001)

Paradip Refinery
6) Slop Oil tank (230-TK-010-A/B)

7) Intermediate drain sump (220-SU-118)
8) API+TPI Oil Separator (230-TK-105,205,205,405)
9) API sump (220-TK-004)
10) Common Oily Sludge Sump (220-SU-010)
11) Wet slop Oil sump (230-SU-007)
2. DESIGN BASIS AND BATTERY LIMIT
. Inlet Parameters of VOC gas
Flow Unit Capacity
Parameter MW/hr 8500
Normal
Working MW/hr 8500
Design MW/hr 8500
.Outlate Parameters of effluent gas :

Parameter Units Max limit
Benzene Mg/Nm2 0.5
Phenol Mg/Nm3 20
Ethylbenzene , Styrene,tolune < Xylene, aromatics Mg/Nm2 100
Non –methane HC , acetone,olifines Mg/Nm2 150
Battery limits:-
The inlet and out let Battery Limits indicating scope of supply of major items is shown as bellow.
Parameter Condition
Vent Gas Vent gas is extracted from the API oil separator at a pressure of between -
0.001 and – 0.005 kg/cm2
Exhaust Gas Exhaust gas is to be exhausted to atmosphere at a height of to m
Flared Gas Flared gas is to be exahausted to atmosphere at a height of 10 m ( the stack
may be shared with the inert exhaust gas)

Paradip Refinery
Condensed Condensed hydrocarbons are to be discharged into the nitrogen purged

Hydrocarbon slop oil tank at a height of 15 m. this is located at a distance of
approximately 100 m from the VOC Package.
3. Equipment list:
Sr, TAG NO EQUIPMENT Quality nos SPECIFICATION MOC

no DESCRIPTION QTY W S
1 230-K- ID Fan 3 2 1 8500m3/hr. Casing –IS
104/204/304 /Blower (Normal) 2062Gr.A
8500m3/hr. Shaft-EN8
(working)
8500m3/hr.
(design)
2 230-V- Primary 3 2 1 5n08md Carbon steel
103/203/303 Carbon Bed (Normal) With Epoxy
Vessels 6166m3/hr. coating
(working)
8492m3/hr.
(design)
3 220-V- Secondary 2 2 1 5n08md Carbon steel

104/204/204 Carbon Bed (Normal) with EPOXY
Vessels 6166m3/hr. COATING
(working)
8492m3/hr.
(design)
4 Flame 28 Housing -CS

Arresters Element-SS
5 Conservation 5 CS
Vent for
5Itemes /unit

Paradip Refinery
4. TREATMENT PHILOSOPHY
Volatile organic compounds (VOCs) are among the most common pollutants emitted by chemical
process industries (CPI) dealing with manufacture and processing of Chemicals such as solvents,
thinners, degreasers, cleaners, lubricants, and also liquid Fuels. During handling, storage, and
distribution of these chemicals, a significant Amount of VOCs are also emitted.
Common examples of VOCs emitted are toluene, xylene, di-methyl chloride (DMC), Methanol, and
isopropyl alcohol. VOCs adversely affect the ground air quality, which In turn poses detrimental effects
on human health, plants and vegetation. VOCs are Also precursor to the formation of ozone, an irritant
at low concentration levels and a
Primary component of smog. The formation of ozone in the troposphere as a Consequence of the
photochemical reactions of VOCs with atmospheric nitrogen Oxides (NOx) is well- understood.
Due to the adverse effects of VOCs emissions in the environment, the gaseous Streams from vents and
emission stacks are subjected to suitable abatement Techniques, essentially to bring down the VOCs
concentrations below the permissible Levels before their release into atmosphere. As the emission
tolerance gets lower (ppm and ppb concentration levels) with increasing stringent environmental
regulation, the Control strategies for VOCs require a fresh and systematic approach.
As there are number of technologies & process for VOC emission, however, based on the concentration
& type of hydrocarbon an adsorption process via activated carbon Is recommended and put in place. In
adsorption process, the gas stream passes through the bed, the organic compounds adsorb weakly onto
the surfaces of the Activated carbon, zeolite, or organic polymer used as the adsorbent. Essentially all
of the commercially used adsorbents have a very high surface area per gram of material. When the
adsorbent is approaching saturation with organic vapor, a bed is isolated from the gas stream and
desorbed.
Adsorption systems can be used for a wide range of VOC concentrations from less than 10 ppm to
approximately 10,000 ppm. The adsorption removal efficiency usually exceeds 95% and is often in the
98% to 99% range.
For this project we have provided VOC adsorption technique via two stage activated Carbon bed. First
of all the sources of VOC emission are identified which are listed below.
1. Sulphidic Spent caustic equalization tank (231-TK-101)
2. Oily supernatant Sump (230-SU-011)

Paradip Refinery
3. Spent caustic equalization tank (231-TK-103)

4. Equalization Tank A/B (230-TK-006A/B)
5. Oily DAF (230-TK-110,210,310,410,510)
6. Dilution chamber for oily DAF (230-SU-113A)
7. De salter equalization tank (230-TK-001)
8. Slop Oil tank (230-TK-010-A/B)
9. Intermediate drain sump (230-SU-118)
10. API+TPI Oil Separator (230-TK-105,205,305,405)
11. API sump (230-TK-004)
12. Common Oily Sludge Sump (230-SU-010)
13. Wet slop Oil sump (230-SU-007)
14. Caustic sealed chamber (231-TK-112)
The VOC from individual tank/equipment is collected in main header from which it is routed to Induced
draft fan suction. There are two different headers on the basis of location of different sources routed
to ID fan suction and from where it is blown to Activated carbon filter.
There are three streams of activated carbon beds are provided in which two are working and another
is stand by. Each stream consists of two stages (primary and secondary) to Adsorb VOC gases and to
meet output guarantee and an ID fan. The activated carbon is placed in carbon canisters.
The treated gases from carbon canisters are routed to vent stack and released to Atmosphere. After
some time the breakthrough of activated carbon occurs at that time it is exhausted. The carbon bed is
replaced by new one and the exhausted carbon sent for Regeneration. (Desorption).
The necessary instrumentation and safety measures are provided at each stage to Control whole
process and to check the activeness of carbon bed in use. The details of the same are provided in
subsequent chapter of this manual. (Control philosophy and Process description).

Paradip Refinery
4. PROCESS DESCRIPTION
Process description
Thee treatment of VOC gas consists of following steps…
1. Collection of VOC from all the sources.
2. Treatment of VOC gas with Activated Carbon.
The sources of VOC are from oily waste water. The VOC gases generated from each source is connected
with main header where it is routed to carbon bed system. The sources have been grouped based on
the locations and hazard potential. Two set (with in line spare) of carbon beds are used to serve all
spumes, each with a primary carbon Canister and secondary carbon canisters.
The VOC from the sources contains organic vapors including volatile and semi-volatile organic
Compounds, referred to in general here as VOCs. The VOC spumes are bifurcated in two sections on the
basis of location and VOC discharge is merged in two different headers. The equalization tanks are major
source of emission is stored known as header-A. The Slop oil tank has the highest concentration of VOC
and it forms the separate header-B.
Sources of Header-A :- (Eastern side)
Sulphidic spent caustic equalization tank
Caustic sealed chamber
1. Spent caustic storage tank.
2. Naphthenic oil storage tank
3. Naphthenic spent caustic tank
Oily Supernatant sump
Equalization tank
Spent caustic equalization tank
Oily DAF tank
Distribution chamber of oily DAF

0

Paradip Refinery
 Sources of Header-B:- (Western side)

De salter equalization tank
Slop Oil tanks (2 nos.)
API & TPI – Oil water separator (4 nos.)
API sump
Common oily sludge sump
Wet slop oil sump
The VOC discharge line of each source consists of pressure gauge to measure pressure locally with a
temperature & pressure transmitter. Both these headers are provided with dilution air intake facility
for reducing the hydrocarbon content. Both the headers consist of LEL detectors which measures
presence of hydrocarbon (primarily Methane). The oil vapors sources are connected by duct to the ID
fans (220-K-104,204, and 204). The entire system is designed for slightly-be pressure. The piping
arrangement at suction of ID fan is made such a way that each header parallel have dedicated ID fan
and respective carbon canisters (primary & secondary).
The flame absorber is provided on discharge line of each fan for safety against back flash with manual
dampener valve. The drip trap arrangement is also provided at each Riser to collect moisture from the
header. The differential pressure transmitter is provided across each Flame arrester to measure the
pressure drop across the flame
Arrester. The Temperature transmitter is provided on discharge line of each ID fan to measure
temperature. In case of rise in temperature leads to tripping of fan. Pressure Gauges are provided before
& after flame arrester for local indication of discharge line Pressure of fan.
The flow transmitter is provided in each discharge line for measurement of flow of VOC gas. The
nitrogen and fire water line is provided in each canister (primary & Secondary) with solenoid valve. In
case of temperature rise inside the canister tends to open these valves with drain valve and the
temperature i9 controlled via water (deluge system) & nitrogen blanketing. The inlet valve is also
solenoid type which will be closed in case of temperature rise. The flow of VDC is also stopped via
tripping of ID fan in case of temperature rise to avoid fire hazard.
The differential pressure transmitters are provided across each canister (primary & Secondary) to
measure pressure drop across the carbon bed. It is for indication purpose only. The discharge line of

1

Paradip Refinery
canister (Primary & secondary) is provided with Temperature transmitter to measure temperature of
leaving VOC gas from it. The Secondary canister has also the same facility for the same purpose.
The carbon bed adsorbs these VOCs as they pass through the bed. The gas that exits the bed is moist
air, with small amounts of VOC, CO, and non-absorbable organics such as methane. With long term use,
the bed becomes saturated with organics and can no longer adsorb VOCs. This is when VOC
“breakthrough” occurs. At that time the carbon bed is exhausted and the stand by stream will be taken
in line.
This life of the carbon depends on the amount of VOCs (the VOC loading) in the gas stream, the
molecular weight of the VOCs, amount (and type) of carbon in the bed, and the bed temperature. The
capture rate is to be 90% minimum and with two beds in series, the adsorption is near 100% of VOCs
that have 5 or more carbon atoms per Molecule. CO, methane and other small molecules are not
adsorbed well by carbon.
Simple tests with such instruments as a portable PID (photo ion detector) can be used periodically to
determine the carbon effectiveness via the test ports provided.
The LEL (Hydrocarbon) & CO detectors are provided in outlet main header of secondary canister. It
detects the hydrocarbon (primarily methane) & CO present in the outlet stream. The CO present above
limit (0-20 ppm) shows the combustion of carbon. Once the saturated carbon bed is isolated by
dampener closing and locked, with proof of closure switched being made, the carbon is to be removed
for regeneration. Carbon bed is removed through bottom man hole. Fresh carbon is then introduced
through the top hatch. 3500 kgs. (7700 lbs) of carbon are loaded into each canister. When reinserted
into the canisters as during initial installation, the carbon bed is to be wetted so to inhibit overheating
at the outset of operation.
In summary, the safety aspects of the design are temperature monitoring of the carbon beds, a deluge
system for the carbon beds, LEL monitors on each duct run, a flame arrestor at the inlet to the primary
carbon bed, dilution air, and N2 purge, fan shutdown triggered by high temperature and CO analyzer
after the secondary carbon bed, and a fail closed damper.
6. Control Philosophy:
INTRODUCTION
The Paradip Refinery will be executed in three stages namely,

2

Paradip Refinery
a. Phase 1 Stage I
b. Phase I Stage II
c. Future Phase 11
The ETP & WRP package for the above plant for the Phase-l stage I classified as LSTK-9 will be executed
by VA Tech WABAG Limited. For Phase-I Stage II only design will be carried out. The aim of this document
is to explain the control philosophy of the VOC package only. This Document is to be read in conjunction
with P&ID’s, alarm trip schedule and cause and affect Charts.
ABBREVIATIONS
API- American Petroleum Institute
AT- Analysis transmitter
CRWS- Contaminated Rain Water Sewer
CWBD-Cooling Water Blow Down
DAF- Dissolved Air Floatation
DCS- Distributed Control System
DLT- Differential Level Transmitter
DOPE- de Oiling Poly Electrolyte
DWPE- De Watering Poly Electrolyte
ETP-Effluent Treatment Plant
ESD- Emergency Shut Down
FT- Flow Transmitter
FIC- Flow Indicating Controller
HMI- Human Machine Interface
LPBS- Local Push Button Station

3

Paradip Refinery
MCC- Motor Control Centre

OWS- Oily Water Sewer
PAC- Powdered Activated Carbon
PID- Proportional Integral Differential
PT- Pressure Transmitter
TIC- Temperature Indicating Controller
TPI- Tilted Plate Interceptor
TT- Temperature Transmitter
VFD- Variable Frequency Drive
WRP-Water Recovery Plant
TS- Torque Switch
GENERAL OPERATION OF PLANT:

Refer control philosophy for ETP are (Doc no. PDRP0451-8551-PH-230-0001) for general Operations of
the plant.
INSTRUMENT PHILOSOPHY:
1. The transmitters connected to the DCS are either foundation field bus based instruments or
conventional analog (4-20 mA) type with HART instruments depending upon the Criticality
2. All the transmitters connected to the ESD are conventional analog (4-20 mA) type with HART
3. All the analyzers in this plant are of conventional analog (4-20 mA).
4. All control valves in this plant are provided with conventional analog (4-20 mA) positioners.
6.1 VOC SOURCE POINTS:
The VOC Abatement package is provided to remove the VOC from the tanks and treat the same before
allowing it to the atmosphere. The system consist of relief vents, conservation vents, Ducting, balancing
valves, ID fans, dilution air dampers, flame arresters, carbon canisters, valves and exhaust stack.

4

Paradip Refinery
P&ID Ref: PDRP0451-8110-25-230-0012, SH 1 OF 6 & 2 OF 6:

The VOC system has various sources of collection system.
1. The various sources includes VOCs from,
a. Sulphidic spent caustic equalization tank 231-TK-101.
b. Caustic sealed chamber 231-TK-112.
i. Naphthenic spent caustic storage tank 231-TK-105
ii. Naphthenic Oil storage tank 231-TK-107
iii. Naphthenic spent caustic tank 231-TK-102
c. Oily supernatant sump 230-SU-011
d. Equalization tank 230-TK-006A/B
e. Spent caustic equalization tank 231-TK-103
f. Slop oil collection tank 231-TK-108
g. Oily DAF tank 230-TK-110/210/310/410/510
h. Distribution chamber for Oily DAF 230-SU-113A
The VOCs from the above sources are collected together and considered as Header, an input to the ID
Fans.
2. VOCs from the below sources are collected together and considered as Header B input to the ID Fans.
a. De salter equalization tank 230-TK-001
b. Slop oil tank 230-TK-010A/B
C. API & TPI oil water separator 230-TK 105/205/305/405
d. API sump 230-TK-004
e. Common Oily sludge sump 230-SU-010
f. Wet slop oil Sump 230-SU-007
A. Equipment and Function:

5

Paradip Refinery
1. Each VOC sources has a vent that is used to allow VOC air to exit the source Tank and be induced into
the exhaust.
2. equalization tank 230-TK-006A/B and spent caustic equalization tank 231-TK-103 includes a
conservation vent (pressure relief vacuum relief) PVRV 6001/6002 and PVRV 3005 to control exhaust
flow into the VOC control system and vacuum relief whenever necessary.
3. A pressure gauge is provided at the individual VOC vent line of each tank to monitor the pressure
locally. They are as follows,
a) PG 6007-Sulphidic spent caustic equalization tank 231-TK-101
b) PG 6037 caustic sealed chamber 231-TK-112
c) PG 6005- Oily supernatant sump 230-SU-011
d) PG 6003/6002- Equalization tank 230-TK-006A/B
e) PG 6040- Spent caustic equalization tank 231-TK-103
f) PG 6038- Slop oil collection tank 231-TK-108
g) PG 6006A/B/C/D/E- Oily DAF tank 230-TK-110/210/310/410/510
h) PG 6010 - Distribution chamber for oily DAF 230-SU-113A
4. Another pressure gauge PG-6004 is provided at the common inlet of VOC header line A to monitor
the pressure locally.
5. A temperature transmitter TT-6014 is provided at the VOC common outlet line of header A to monitor
the temperature and to generate high alarm set points as defined in 5.1.B.(1).
6. A temperature transmitter TT-6004A is provided at the VOC common outlet line of equalization tank
230-TK-006 A&B to monitor the temperature and to generate high alarm set points as defined in as
defined in 5.1.B.(3).
7. Another Temperature transmitter TZT-6004B is provided at the VOC common outlet line of
equalization tank 230-TK-006A/B to generate high temperature alarm set point as defined in 5.1.B.(2).
This transmitter is directly connected to the ESD system. From the ESD system, hardwired interlock is
provided in the MCC for tripping the ID Fan.

6

Paradip Refinery
8. A pressure transmitter PT-6001 is provided at the VOC common outlet header A to generate high and
low alarm set points as defined in 5.1.B.(4).
9. A pressure gauge is provided at the individual VOC vent line of each tank feeding Header B to monitor
the pressure locally. They are as follows,
a) PG-6008 -De salter equalization tank 230-TK-001
b) PG-6013/6014 - Slop oil tank 230-TK-010A/B
c) PG-6018A/B/C/D and PG-6019A/B/C/D-API & TPI oil separator 230-
105/2015/305/405
d) PG-6017-API sump 230-TK-004
e) PG-6015- Common oily sludge sump 230-SU-010
f) PG-6016-Wet slop oil sump 230-TK-007
10. Another pressure gauge PG-6001 is provided at the common inlet of VOC header line B to monitor
the pressure locally.
11. A temperature transmitter TT-6015 is provided at the VOC common outlet line of header B to
monitor the temperature and to generate high alarm set points as defined in 5.1.B.(5).
12. A pressure transmitter PT-6002 is provided at the VOC common outlet line of header A to generate
high and low alarm set points as defined in 5.10B.(6).
13. Dilution air inlet dampers, BV- modify the fresh air inlet flow rate that serves to dilute the level of
VOC concentration. Manually set at startup to assure draft
Induced on sources and dilute to total flow rate of 5000 cfm.
B. Interlock Alarm and Control descriptions:
1) 230-1-3010:
High temperature - Generate alarm in DCS HMI and stop the duty ID Fan/Blower
2) 230-IZ-0300:
High High temperature - Trip the duty ID Fan/blower

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3) 230-1-3000
High tem temperature – Generate alarm in DCS HMI and stop the duty ID Fan/Blower
4) 230-P-6001:
High pressure (Set point1) – Generate alarm in DCS and further action to be taken by the operator.
Low pressure (Set point 1) – Generate alarm in DCS and further action to be taken By the operator.
5) 230-1-3020
High temperature – Generate alarm in DCS HMI and stop the duty ID Fan/Blower.
6) 230-P-6002
High pressure (Set point1) – Generate alarm in DCS and further action to be taken by the operator.
Low pressure (Set point 1) – Generate alarm in DCS and further action to be taken by the operator.
6.2. ID FAN/BLOWER:
P&ID Ref: PDRP0451-8110-25-230-0012, SH 3 OF 6:

The ID Fans VOC collected VOC in the two headers A & B. The VOC fans induce dilution Air to help
minimize the VOC concentration. The air/VOC mix enters the ID fan and are then passed to the flame
arresters. The detonation flame arresters are provided to protect the fan and upstream equipment from
canister ignition source. The VOC reaches the individual carbon bed from their respective flame
arrestors.
A) Equipment and function:
1) Three streams of ld. Fan/Blowers each with individual Flame arresters are provided. These blowers
normally operate on two working and one standby philosophy. In the upstream of each of the ID fan a
manual damper is provided for isolation. This damper consists of open and close position proximity
switches.
2) A pressure gauge PG-6021/6022/6023 is provided at the individual ID fan/blower Discharge to
monitor the pressure locally.

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3) Another pressure gauge PG-6025/6026/6027 is provided at the individual flame Arrestor outlet line
to monitor the pressure locally.
4) A temperature transmitter TT-6001A/6002A/6003A is provided on the individual Flame arrestors 230-
DFA-101/201/301 to monitor the temperature and to Generate high alarm set points as defined in
5.2.B.(1).
5) Another temperature transmitter TZT-6001B/6002B/6003B is provided on the Individual flame
arrestors 230-DFA-101/201/301 to monitor the temperature and to generate high high alarm set points
as defined in 5.2.B.(2).
6) Differential pressure transmitter DPT-6001A/6001B/6001C is provided across the individual flame
arrestors 230-DFA-101/201/301 to monitor the differential pressure and also to generate high and high
high alarm set points as defined in 5.1.B.(3)
7) LEL detectors AGDT-6003/6004 is provided at the individual headers A & B inlet line to ID fan/blower
to monitor the concentration of hydrocarbon entering the ID Fan/blowers and to generate high high
and high set points as defined in 5.1.B.(4).
1) 230-1-3030/3040/3050: High temperature (Set point 1) – Generate alarm in DCS HMI and stop the
duty ID Fan/Blower.
2) 230-1-0310/0320/0330: High high temperature – Trip the duty ID Fan/Blower.
3) 230-1-3120/3130/3140: High DP (Set point 1) – Generate alarm in DCS and further action to be taken
by the operator. High high DP (set point 2) – Generate alarm in DCS and stop the duty ID Fan/blower.
4) 230-AGDT-6003/6004: High high VOC (set point 1) – Generate alarm in DCS and further operation to
be taken by the operator High VOC (Set point 2) – Generate Alarm in DCS and further operation to be
taken by the operator.
C) Operation:
1) Soft selector switches are provided in the DCS HMI for online or offline selection of Blower.
2) The start and stop of the ID fan/blower is done manually based on the online or offline Selection of
the respective blowers.

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3) The ID fan/blowers are alternated as duty and standby manually after a preset run Time se by the
operator in DCS HMI.
4) ID fan will start only if the upstream dampers and the downstream on/off valve are in open condition.
5) Flame arrestors will work for the corresponding I.D. fan/blower which is on duty.
6.3. PRIMARY AND SECONDARY CARBON BED VESSELS:-
The primary and secondary carbon beds are provided in series to adsorb the VOC before Releasing
gas/air to the atmosphere through vent stack.
1) Three streams of primary and secondary carbon beds are provided for VOC removal. These streams
work on two working and one standby philosophy.
2) A pressure gauge PG-6028/6029/6030 is provided at the individual inlet line of primary carbon bed
to monitor the pressure locally,
3) Another pressure gauge PG-6031/6032/6033 is provided at the individual inlet line of secondary
carbon bed to monitor the pressure locally.
4) An online type flow indicator F1-6001/6002/6003 is line of primary carbon bed to monitor the flow
locally.
5) differential pressure transmitter DPT-6002/6004/6006 is provided across the Individual inlet and
outlet line of primary carbon vessel 230-V-103/203/303 to Generate various alarm set points as defined
in 5.3.B.(4).
6) Differential pressure transmitter DPT-6003/6005/6007 is provided across the Individual inlet and
outlet line of secondary carbon vessel 230-V-104/204/304 as
Defined in 5.3.B. (4).
7) temperature transmitter TT-6005/6008/6011 is provided on the individual outlet line of primary
carbon bed 230-V-103/203/303 to monitor the temperature and to generate high alarm set points as
defined in 5.3.B.(1).
8) Another temperature transmitter TZT-6016/6017/6018 is provided on the individual Outlet line of
primary carbon bed 230-V-103/203/303 to generate high high level alarm Set points as defined in
5.3.B.(2) and is directly connected to the ESD system.

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9) In case of secondary carbon bed, a temperature transmitter TT-6006/6009/6012 is provided on the

individual outlet line 230-V-104/204/304 to monitor the temperature and to generate high alarm set
points as defined in 5.3.B.(1).
10) Three temperature transmitters TZT-6013-A,B,C 16014A,B,C 16015A,B,C are provided on the
individual outlet line of secondary carbon bed 230-V104/204/304 to generate high high alarm set point
as defined in 5.3.B.(2) and is directly connected to the ESD system. These transmitters work on 2003
voting principle.
11) Each of the primary carbon beds is provided with a pneumatic on-off valve XV-6001/3002/6003 to
allow the VOC at the inlet line into primary carbon bed. These Valves are used to isolate a bed that is
out of service. Only one of three valves is to be closed at one time (unless temp or CO excursion is
sensed in multiple beds.
12) Nitrogen service inlet valves are provided at the inlet of primary and secondary Carbon beds XV-
6004/6005/6006 and XV-6013/6014/6015 to enable nitrogen purging in case of high temperature
sensed at the individual outlet of primary or secondary carbon bed.
13) A fire water deluge valve XZV-6007/6008/6009 and XZV-6010/6011/6012 are provided at the
individual inlet of primary and secondary canisters to spray water into the canister in case the
temperature reaches high high set point.
14) Each primary and secondary carbon bed is provided with individual drain valve XV-6017/6018/6019
and XV-6020/6021/6022 to drain the canister of quench water if high Temperature set point is triggered.
15) Gas detector AGDT-6001A/B/C are provided at the common outlet header of Secondary carbon bed
to monitor the concentration of CO and to generate high High level alarm set points as defined in
5.3.B.(5).
16) Another gas detector with LEL sensors AGDT-6002A/B/C are provided at the Common outlet header
of secondary carbon bed to monitor the concentration of Hydrocarbon and to generate high and High
High level alarm set points as defined in5.3.B.(6)
1) 230-1-3060/3080/3100/3070/3090/3110: H1 temperature (Set point 1) – Generate Alarm in DCS HMI
and operator to take further action H2 temperature(Set point 2) –Generate alarm in DCS HMI, open
Nitrogen inlet valve, close VOC inlet valve and Stop the ID Fan/blower.

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2) 230-IZ-0370/0380/0390/0340/0350/0360: High high temperature – Generate Alarm, open the fire

water deluge valve and trip the ID Fan/blower.
3)230-1-3150/3160/3170/3180/3190/3200: Whenever a fire water deluge valve is opened, the
respective drain valve will open.
4)230-DP-6002/6004/6006/6003/6005/6007: High DP-Generate alarm in DCS HMI and Operator to
check for plugging, VOC buildup etc.
5)230-AGDT-6001A/B/C: High High level (Set point 1)-Generate alarm in DCS and further operation to
be taken by the operator High level(Set point 2)-Generate alarm in DCS and further operation to be
taken by the operator.
6)230-AGDT-6002A /B/C : High High level (Set point 1 )-Generate alarm in DCS and further operation to
be taken by the operator to changeover to backup bed and Cleanout/desorb/replenish this bed. Use
portable analyzer to determine which bed is spent High level (Set point 2}-Generate alarm in DCS and
further operation to be taken by the Operator.
C) Operation: Soft selector switches are provided in the DCS HMI for online or offline Selection of carbon
bed streams.
7. Pre Commissioning
This section of the operating discusses the period of time between the end of construction and the
initial startup of the VOC collection and control system. These activities must be completed before the
initial startup of the system is attempted. Instructions are intended to supplement manufactures’
information for individual equipment and must never replace or supersede that information. The
procedures provided are intended only as a guide actual procedure may vary.
Successful startup of the system will depend upon the results of careful checkout work performed prior
to startup to ensure that all equipment and systems are in proper working order and that the complete
system is ready for operation. A log book should be started at this time to record daily completion of
checkout and pre commissioning steps.
The entire system must be cleaned, inspected and tested and the inspections logged or recorded. Many
of the activities described in this section are performed only during the initial startup while selected
items must also be performed when the system is down for major overhaul or inspection

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DANGER
To prevent death or injury to personnel, never commission any system unless it has been completely
checked and deemed safe to commission.
CAUTION
Ensure that the fire water system is fully in service and that all personnel safety apparatus is in its
designated location. Check all fire extinguishers, safety showers, eye wash stations etc. to ensure they
are charged properly.
7.1 CLEANUP
Before attempting to startup the plant, all scaffolding, construction equipment and refuse must be
removed from the equipment and lines. Foreign materials can damage equipment or foul process
controls and valves. Grease and oil can act as foam promoters. Cleaning procedures in the following
sections must be observed in removing these materials.
7.2 WORK PERMITS AND SAFETY CONDIDERATIONS
A work permit control system must be initiated at this stage. Gas analysis must be conducted to insure
work areas are safe and hot work permits must be issued for each work site before work is stated. This
system provide two safeguards. It protects constructions personnel still engaged in constructions
activities and informs operating personnel of construction work still in progress. As an additional safety
precaution, a fence or rope barrier should isolate any construction work in the operating area at this
stage.
Before systems can be flushed and operated, all fire protection and safety equipment must be in place
and operable. All personnel must be completely familiar with location and operation of the equipment.
If construction is still in progress signs must be installed on equipment that is operating to protect
construction personnel. “No Smoking” signs must be installed in the process areas where flammable
materials can be present.
7.3 TRAINNING OF PERSONNEL
Prior to initial startup of new facilities, all operators must be thoroughly familiar with the process,
process equipment, instrumentation and procedures. Maintenance personnel must be thoroughly
familiar with mechanical equipment and instrumentation utilized in the new facilities. This manual
should be read in its entirety as well as the site walked and inspected.

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Particular attention must be given to the instruction governing the operation, lubrication, and
maintenance of the various equipment items, as outlined in the manufacturer’s manuals.
Each operator must thoroughly review and understand the proper operating procedures for each piece
of equipment before operating it. This promotes a safe and efficient startup by reducing hazards and
equipment failures.
7.4 START-UP MATERIALS
Sufficient filter media (Activated carbon) and lubricants must be on site and in place for use during
commissioning and in the initial startup. Care must be taken to assure that materials stored on site are
not subject to atmospheric deterioration.
It is necessary to ensure that Activated Carbon is strictly as per the recommended Data sheet and valid
quality assurance certificate for the same is available.
7.5 INSPECTION OF EQUIPMENT
Each piece of equipment and associated piping must be thoroughly inspected by the operators before
it is tested and placed in operation. This ensures that everything is in proper order to operate and
familiarizes the operators with the equipment and the plant. Any deficiencies found must be reported
and then corrected prior to use of the equipment.
1. Check list for Vessels
2. Whether the hydraulic test is taken before erection.
DANGER
Practice safe vessel entry procedures during execution of internal inspections and final preparation
for startup. Ensure that a proper vessel entry permit system is in place.
2. Check vessel internals are not damaged.
3. Check that adequate operating space is provided for safe operation and maintenance.
4. Check the safety valves and see that they are at proper settings.
5. Check for installation and approachability of all instruments.
6. Check the vessels against P&IDs, data sheets and G.A. drawings
7. Check any expansion provision as per drawings.

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8. Check grounding of vessels.

9. Check blinding of all spare nozzles with proper rated blinds.
10. Box up manholes with permanent gaskets after clearance.
11. Check supports (e.g. spring supports) for cold & hot setting at appropriate time.
12. Check the insulation as per the specification.
13. Check that all valves specially instrument drain valves and root valves are approachable.
14. Check all gauges are visible from grade.
2. Check List for I.D. Fans
1. Check installed ID Fans and motors are suitable and meet the operating requirements.
Check the test certificate if in doubt.
2. The earthen of motor. Check for specification and enclosure of electrical motor and check direction
of rotation.
3. Check the tightness of foundation bolts.
4. Check the no load current of the motor. Ensure the alignment of coupling is within tolerance. Check
for alignment record.
5. Suction & discharge piping and ensure no piping strain is transmitted to fan nozzles. This will be done
by either visual observation of unconnected pipes for small fans or by checking alignment with and
without piping connection for bigger fans.
6. Check all the accessories, instruments and control.
7. Ensure the fans surroundings are cleared up and easy approach provided to the valves, start/stop
push buttons etc.
8. Ensure the availability of spares and consumables.
9. Ensure availability of lifting arrangements.
10. Read carefully the operating manual for any special instructions/precautions.
11. Check that piping layout is not fouling from fans maintenance point of view.

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12. Check completion of cooling system/lube system/seal flushing system/seal quench system as per
data sheets specifications.
13. Check drains of foundation are properly routed.
3. Check List for Piping
1. Provision of branch lines, vents, slip fits, drains, supports anchors, guides, valves, blinds, etc. as per
P&IDs.
2. To obtain clearance from construction with regard to
- Mechanical completion with exception, if any
- Blinds/caps/welded plates provided for testing are removed
- Support including spring supports
- testing correct installation of gasket, bolts etc.
- Position of blinds (if any)
- Instrumentation
3. Ensure all instruments tapping are provided.
4. Flange joints with gaskets and bolts.
5. Sliding support is free to slide (Visual).
6. Expansion joints/loops/spring supports are provided.
7. Low point drains are provided to drain out water from the collection header. Proper slope is given
towards drain points.
8. All bolts are of correct size and uniform length.
9. Access to drains and isolation valves.
10. During flushing, no slip blind to be inserted without tail and no blind gasket is left off. While flushing
the system, instruments are to be removed.
11. Check all foundations of supports have been laid.
12. Check respective hydro testing is complete before flushing of lines is done.

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13. All the drain isolation valves are provided with end blinds.
Check List for Valves

1. Check whether Globe & NRVs are mounted in proper direction.
2. Check whether valves can be properly operated. Valve wheels should be in position properly locked.
3. Check whether gland are properly packed and bolted.
4. Check whether valves are properly accessible. Turning of the valve may be necessary in few cases. In
case of valves in cold service, valves should be mounted with stem in upright position
5. Check whether proper arrow indication for valve operation is provided. If not provided this should be
done by paint/or by punch and torque.
6. Whether limit switches, are properly working for motor operated valves, ROV’s etc.
7. Ensure proper greasing of spindle, gear box etc.
8. Valves having locking arrangement should be properly checked for this facility.
9. Check the greasing of the valve. Vent/breather on the top of the valve diaphragm should be checked.
10. For most of the valves before installing protective plastic valve caps are to be removed.
7.6 CLEANIND AND FLUSHING OF EQUIPMENT AND PIPING

Considering the type of fluid handled, pipe material and internal wall conditions, pipe cleaning method
shall be selected from following alternatives:
1. Water Flushing
2. Air Flushing
This degree of cleaning can be done in conjunction with hydraulic testing of lines and equipment. The
flushing shall be done as follows:
1. Water Flushing
1. Low point drains should be opened.

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2. Low point flanges should be opened during initial flushing, wherever possible.
3. All instrument connections should be isolated, orifice plates removed, control valves dropped or
isolated and by passed. In case there is no bypass facility provided, remove control valves, provide spool
piece and flush the line. Orifice plate and control valves can be installed only after the total flushing of
the loop is over.
4. Flushing should be done up to inlet of flame arrestor and it should be ensured that dirty water from
initial flushing does not get into the flame arrestor.
5. At each opening of the flanged joint, a thin metallic sheet should be inserted to prevent dirty water
from entering the equipment or piping.
6. Flushing should be carried out with maximum possible flow of water till clear water starts coming
out.
7. Vertical lines which are long and rather big (say over 100 mm dia) should preferably be flushed from
top to bottom. This will ensure better flushing. Filling the lines and releasing from bottom is also helpful.
Temporary water connection at suitable points can be made to carry out flushing operation. The run
down lines should be flushed from the unit to the respective tanks or tanks to unit.
8. It should be ensured in all flushing operations that design pressure of lines and equipment are never
exceeded. After flushing of lines and equipment, water should be thoroughly drained from all low
points. Lines and equipment containing pockets of water should not be left idle for a long time, it is
preferable to dry these lines and equipment with air after water flushing. During water flushing
wherever applicable for the equipment having demisters, the demisters are to be removed and shall be
installed only after flushing and subsequent drying with air is completed.
9. In case the piping which is used in gas service is being cleaned by water, temporary pipe supports
may have to be installed. Engineering design should be checked regarding weight carrying capability of
these lines, prior to introducing water.
2. Air Flushing:
Air flushing with plant air shall be done for gas lines, plant air lines and for drying lines after water
flushing. For Instrument air lines flushing shall be done with Instrument air. If sufficient air is not
available, pipes can be cleaned by pressurizing and depressurizing by bursting disc of cardboard or
gasket material. Pressure should not increase beyond design pressure. The instruments and control

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valves shall be isolated / removed from the system before flushing. Equipment shall be disconnected to
prevent entry of flushed material.
Safety valves and rupture discs are to be isolated or removed during the flushing. Strainer elements to
be kept removed during the flushing operation. Surrounding area where air blowing is taking place
should be cordoned off to stop entry of personnel and avoid any injury.
7.7 TIGHTNESS TEST
The purpose of this test is to check the tightness of flanges, joints, manholes etc. for Systems that
operate under pressure. Testing is done with air using soap solution for leak detection. The following
steps are recommended:
1. Ensure that the system that is to be tested is isolated from the rest of the system.
2. Take the system gradually to a pressure of 1-1.5 kg/cm2g or the operating pressure, whichever is
lower. Check all flanges, joints, manholes etc. for any leakage with soap solution.
3. If the system operates under vacuum no further pressurization of the system is necessary beyond 1.5
kg/cm2g.
4. If the operating pressure of the system is more than 1.5 kg/cm2g, slowly raise the pressure of the
system in the stage of 1.0 kg/cm2g at a time to 3.5-5.0 kg/cm2g. After each stage check for leaks using
soap solution. Attend the leaks if any.
5. Further testing for pressure higher than 7.0 kg/cm2g for gas systems is done when feed gas is taken
into the system; keeping in mind that pressurization is at a slow rate and in steps of 5.0 kg/cm2g. The
leak test is satisfactory when the pressure decrease is lower than 0.05 bar/hr over a period of 4
consecutive hours.
NOTE: For liquid lines additional tightness test can be carried out when the pumps are tested with
water. Alternatively, LP steam can also be used for leak checking if design conditions of the system
permit.
7.8 INSTRUMENTATION CHECKS
1. Open main instrument air block valve and purge air through the valve at the far end of the header
2. Blow all pneumatic tubing completely clear by bypassing filters.
3. Check all pneumatic tubing for proper routing and test for leaks.

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4. Label spare pneumatic tubing as to origin and destination.

5. Check electronic transmission circuits and thermocouple lead wires for continuity, shorts and
grounds.
6. Check electronic circuit and thermocouple lead wires for proper routing.
7. Check that all screwed connections are clean and tight.
8. Check proper location and depth of all thermocouple wells in lines and vessels.
9. Check all thermocouples for proper location and insertion depth in wells.
10. Check fuses and breakers for proper rating.
11. Set and test all safety valves.
12. Install control valves with final gaskets after cleaning operations have been completed.
13. Remove paint on control valve stems (to prevent valve stem damage) before stroking or operating
the control valve.
14. Test instrument air header at pressure up to the first block valve. (When a union is provided
downstream of the block valve, it must be loosened and separated for Blow down through the valve to
remove dirt that can cause instruments to malfunctions)
15. Verify that valve nameplate information is in accordance with that provided in instrument
requisition documents.
16. Check the action of the control valves to see that they fail in the right direction and that the output
of the controller changes in the correct direction following a measurement changes.
17. Test the instrument air header at operating pressure to the first block valve. Each lateral up to the
instrument being supplied must be blown clean until no sign of moisture of dirt is exhausted during the
blow.
18. Connect all transmitters and unblock pressure gauges after cleaning operations have been
completed.
19. Check all transmitters, controllers, control loops, and shutdown logic for proper action. Check span
calibration and zero on all instruments for accuracy. Adjust alarm switches and verify that alarms work
properly.

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20. Verify that thermocouple leads are correctly connected to their indicating, Recording, and control
instruments. If any measurement point is suspected of an incorrect reading, the polarity should be
checked at the recorder, controller and at the thermocouple.
21. Check that orifice plates have been installed correctly, with the sharp edge upstream and that in gas
service the vent hole is on the bottom and in liquid service the vent hole is on the top.
22. Check that control valves, flow elements, and check valves are installed in proper direction.
23. The shutdown system must be first simulated then functionally tested by pressing shutdown buttons
and breaking the wire connections at pressure switches. When the connection to the pressure switches
is broken the annunciator should alarm.
24. Complete any specific commissioning checks identified by vendors or suppliers of instruments such
as PLC’s, Analyzers, vibration monitoring equipment, etc.
ELECTRICAL CHECKS
1. Clean up all equipment areas, cubicles, interiors, etc., to eliminate combustible materials,
surplus construction material, tools, unneeded drawings, moisture, and other unsafe and
unsightly materials.
2. Check tightness of screwed terminal block connections and pressure connectors, soundness of
crimped lugs, and adequacy of wire supports.
3. Check for consistency of duty, voltage, and environmental conditions.
4. Check continuity of circuits to verify that circuits are complete from source to load, except where
circuits are disconnected for high voltage testing.
5. During the early stages of checkouts and start up, maintain barriers, DANGER signs, lockout practices,
and the like to increase safety for personnel and to prevent damage to equipment.
6. Remove blocking from relay and contactor armatures.
7. Verify conformance of physical installation to working drawings, specifications, codes, standards,
regulations and other contract documents.
8. Check conformances of safe and secure mounting and installation of units and systems and general
workmanship.
9. Check circuits to insure the completion of wire and terminal identifications.

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10. Check the conformance of purchased equipment and materials with specifications and standing.
11. Perform all specific tests for individual equipment and systems.
12. Log all tests on equipment for future reference.
13. Check all motors for proper rotation directions. Check that motor shafts turn freely by hand.
14. Check all equipment for grounding connections.
15. Ensure that there is sufficient illumination around the unit and at all control points.
16. Perform all inspec8ons and testing of specialized equipment such as HV Switchgear, relays, UPS
Systems etc. as identified in manufacturer’s instructions.
7.9 UTILITY SYSTEMS START-UP
1. General
Utilities such as instrument air, service water and fire water shall be required for pre commissioning
activities. Hence they shall be commissioned first before plant start-Up.
2. Stepwise Commissioning of Utilities
Service water system can be commissioned after flushing the header with service water itself. All low
point drains should be opened at some interval to ensure that dirty water is no more coming through
it. When visual checking of drained water appearance deems to be satisfactory, then it may be
considered that the system is clean and all consumer points are then fed with service water.
Instrument air header and individual supply lines to instruments should be purged with plant air to make
the system clean, followed by purging with instrument air prior to putting instruments in service. The
system should be checked for instrument air quality and then be deemed as commissioned when air
quality is found acceptable.
8. START UP PROCEDURES
Before starting the VOC Collection & Removal system, a rotating equipment run-in shall be conducted
as per manufacturer’s catalogues/recommendations so that I.D. Fans are in ready to use condition
during the startup of the unit. The various steps to start up the VOC Collection & Removal system are
as follows:

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1. Open the service water inlet gate valve so that the service water header for emergency water
sprinkling is fully charged. Solenoid Controlled ON-OFF valves on service water lines at ACF inlet
& outlet shall be in closed condition. Select the stream of Primary & Secondary activated carbon
filters. The third stream shall be under standby conditions. Valves on main VOC collection header
at ACF inlet & outlet shall accordingly be in opened or closed condition depending on respective
ACF service (Primary/Secondary/Standby filter).
2. Open the following valves:

► Suction & discharge line valves of I.D. Fans.
► Suction & discharge line valves of Detonation Flame Arrestors.
► Instruments Isolation Valves
→ Valves at downstream of Flame Arrestor.
3. Close the following valves:
→ Bypass line valves of Detonation Flame Arrestors
> Drain Valves
4. Start the working I.D. Fan. This will allow flow of air in the VOC collection headers.
5. Open Wafer valves on vent lines of various oil handling units connected to the VOC collection
network. This will allow flow of VOC from the oil handling units and its dilution with air in the VOC
collection headers.
1. Adjust the I.D. Fans. Discharge flow with Damper limit switches so that the temperature in the
ACFs shall be maintained below 50 C.
2. Monitor the temperature in the ACFs from safety point of view. Also, monitor the readings at
hydrocarbon detectors & CO Detectors with the help of Port provided and portable Gas Monitor
from plant performance point of view.
9. SHUT DOWN
9.1 NORMAL SHUT DOWN:
Various steps during normal shutdown of the VOC Collection & Control system are as follows:

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1. Close valves on vent lines of various oil handling units connected to the VOC collection network.
This will stop flow of VOC from the oil handling units into the VOC collection headers.
2. Stop the working I.D. Fan. This will stop flow of air into the VOC collection headers.
Bypass line valves of Detonation Flame Arrestors.
Drain Valves
Suction & discharge line valves of I.D. Fans.
Suction & discharge line valves of Flame
Arrestors.
5. Instruments Isolation Valves
› Valves on main VOC collection header at ACF inlet & outlet
6. Close the service water inlet gate valve
9.2 EMERGENCY SHUT-DOWN
Emergencies should be recognized and acted upon immediately. In advance, the operators must
carefully study the steps that are required in such situations. Hard and fast rules are not applicable
to cover all situations, which might arise. The following are the situations which might arise and
require shutdown of the complete system:
Power failure
Instrument Air failure
Service Water failure Equipment failure
Steps as specified above under ‘Normal Shut-Down’ condition shall be followed for emergency Shut
Down conditions also.

4

Paradip Refinery
10. RESTART-UP
Before Re starting the VOC Collection & Removal system, it is important to monitor concentration of
accumulated oil in major VOC Emitting units like API & TPI Separators. In case, the oil concentration is
more than the designed oil concentration, it is recommended to isolate these units initially and start
the system after connecting the balanced VOC Emitting units. Monitor the Temperature in ACF carefully
and then connect the TPI followed by API sequentially.
Before re starting the VOC Collection & Removal system, a rotating equipment run-in shall be conducted
as per manufacturer’s catalogues/recommendations so that I.D. Fans are in ready to use condition
during the startup of the unit. The various steps to start up the VOC Collection & Removal system are
as follows:
1. Start the Belt Oil Skimmers provided on API Separator and run for sufficient time so that the oil
ppm level in the API separator will be lower than the designed capacity.
2. Open the service water inlet gate valve so that the service water head for emergency water
sprinkling is fully charged. Solenoid Controlled ON-OFF valves on service water lines at ACF inlet
& outlet shall be in closed condition. Select the Primary & Secondary activated carbon filters.
The third filter shall be under standby conditions. Valves on main VOC collection header at ACF
inlet & outlet shall accordingly be in opened or closed condition depending on respective ACF
service (Primary/Secondary/Standby filter).
► Suction & discharge line valves of I.D. Fans
► Suction & discharge line valves of Detonation Flame Arrestors
► Instrument Isolation Valves
> Water valves at downstream of Flame Arrestor
5. Bypass line valves of Detonation Flame Arrestors.
6. Drain Valves
7. Start the working I.D. Fan. This will allow flow of air in the VOC collection headers.

5

Paradip Refinery
8. Open Wafer valves on vent lines of various oil handling unit except for API & TIP, connected to
the VOC collection network. This will allow flow of VOC from the oil handling units and its dilution
with air in the VOC collection headers.
3. Adjust the I.D. Fans. Discharge flow with Damper limit switches so that the temperature in the
ACFs shall be maintained below 50 C. It is recommended adjusting the flow to Normal Flow
values as indicated in Flow Instrument Data sheet.
11. Open the wafer valves on TPI Oil Separator.
13. Open the wafer valves on API Separator.
hydrocarbon detectors & CO Detectors with the help of Port provided and Portable Gas Monitor

6

NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS

A2 30.01.12 FOR REVIEW & APPROVAL VNU PSK PSK

A 14.10.11 UPDATED AS PER HAZOP COMMENTS VNU PSK PSK
H 20.03.11 ISSUED FOR HAZOP VNU PSK PSK
02 17.06.11 UPDATED AS PER FW COMMENTS VNU PSK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-012 (SHEET 3 OF 6) 05
TITLE:

NTS PDRP0451-8110-25-230-0012 3 OF 6 A2
451/4200 34388
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


H 20.06.11 ISSUED FOR HAZAP VNU PSK PSK
INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-012 (SHEET 4 OF 6) 05
TITLE:

NTS PDRP0451-8110-25-230-0012 4 OF 6 A2
451/4200 34388
PIPING COMPONENTS INSTRUMENT SYMBOLS MECHANICAL EQUIPMENT ABBREVIATION

SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-012 (SHEET 5 OF 6) 05
TITLE:
LEGEND AND SYMBOLOGY SHEET
NTS PDRP0451-8110-25-230-0012 5 OF 6 A2
451/4200 34388
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-012 (SHEET 1 OF 6) 05
TITLE:
SCALE: DWG NO: SHT NO. REV:

NTS PDRP0451-8110-25-230-0012 1 OF 6 A2
451/4200 34388
NOTES

SIGNATURE
DATE
REFERENCE DRAWINGS


INDIAN OIL
CORPORATION
LIMITED
WABAG
VA TECH WABAG
FILE NAME: REV:

10P2-D0015-012 (SHEET 2 OF 6) 05
TITLE:
SCALE: DWG NO: SHT NO. REV:

NTS PDRP0451-8110-25-230-0012 2 OF 6 A2
451/4200 34388

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Document No: PDR/PN/ETP/OM

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

INDIAN OIL CORPORATION LTD.

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

Effluent Treatment Plant

The Energy Gateway to Eastern India...

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

Operating Manual Distribution List

Copy No. Distributed To Department

2/5 Unit In-Charge ETP

3/5 Shift Officer ETP

4/5 Disaster Control Room

5/5 PDR Intranet PN Website

Prepared by Reviewed By Approved By

T Bhattacharjee, SPNM Bharat Bhushan, CPNM Sandeep Mahajan, DGM-PN

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

Amendment Revision Brief Description Of

Emergency SOP and

Prepared by Reviewed By Approved By

T Bhattacharjee, SPNM Bharat Bhushan, CPNM Sandeep Mahajan, DGM-PN

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

CHAPTER 2: PROCESS DESCRIPTION

CHAPTER 3: OPERATING VARIABLES

Chapter 4: UTILITIES, CHEMICALS & EFFLUENTS

Chapter 5: PREPARATIONS FOR START UP

CHAPTER 6: COMMISSIONING AND START UP PROCEDURES

CHAPTER 7: NORMAL SHUTDOWN

7.1 Normal shutdown 87

Prepared by Reviewed By Approved By

T Bhattacharjee, SPNM Bharat Bhushan, CPNM Sandeep Mahajan, DGM-PN

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

CHAPTER 8: EMERGENCY SHUTDOWN AND HANDLING

Chapter 9: PROCESS INTERLOCKS

Chapter 10: HAZARDS & SAFETY

Chapter 11: EQUIPMENT LIST 185

Chapter 12: MAJOR EQUIPMENTS AND THEIR OPERATION 194

Chapter 13: MATERIAL SAFETY DATA SHEETS 198

Chapter 14: FIRE FIGHTING AND COMMUNICATION FACILITIES 199

Chapter 15: Consequences due to UPSETS IN OUTGOING B/L STREAMS 202

CHAPTER 16: EQUIPMENT DATA SHEETS 214

CHAPTER 17: EQUIPMENT HANDOVER PROCEDURES 216

CHAPTER 18: SAMPLING, LABORATORY ANALYSIS AND QUALITY CONTROL

Prepared by Reviewed By Approved By

T Bhattacharjee, SPNM Bharat Bhushan, CPNM Sandeep Mahajan, DGM-PN

Operating Manual for Issue Date Rev. No. Rev. Date

Indian Oil ETP August, 2012 7 Jan, 2022

18.1 Sampling schedule 220

CHAPTER 19: PLANT PERFORMANCE MONITORING

19.5 Landfill leachate Treatment section 254

CHAPTER 20: INSPECTION REQUIREMENTS

CHAPTER 21: DCS, PLC AND ONLINE ANALYZERS

CHAPTER 22: UTILITY AND AUXILIARY NETWORKS

CHAPTER 23: STANDING INSTRUCTIONS FOR SAFER OPERATION

Prepared by Reviewed By Approved By