1. REPORT ON REFINERY MODERNISATION
PROJECT (RMP)
SUBMITTED FOR: INTERNSHIP FROM DECEMBER 2012-
JANUARY 2013
AT
BHARAT PETROLEUM CORPORATION LTD. REFINERY,
MAHUL,MUMBAI
SUBMITTED BY:
JUL STEFFO
(DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION)
SATHYABAMA UNIVERSITY, CHENNAI

2. REPORT ON REFINERY MODERNISATION PROJECT
INTRODUCTION
BPCL refinery has undergone major changes after implementation of RMP. RMP has
helped in deriving maximum benefit with the integration of RMP facilities with the
existing operating facility. RMP facilities were designed taking into account the overall
operation philosophy and advantages associated with it. With commissioning of RMP
facilities along with the existing facilities the operation flexibility of the refiner has
increased.
RMP utilities and offsites :
POWER- The total power consumption is 33MW. With 3 gas turbines catering to this
demand.
STEAM- The net steam consumption is 1200MT/D.
COOLING WATER SYSTEM- It consist of independent closed loop circulating
system, 5 cooling tower cell (each with the capacity of 3400 M3/Hr), 5 deticated pumps.
FLUSHING OIL SYSTEM- It is centralized system which is operated from PH-3 of
CCU.
PROCESS DESCRIPTION:
*CRUDE PRE HEAT TRAIN 1- Crude is pumped from PH1 to the suction of the 2
crude pumps in NCDU. Crude temperature and pressure are available on the DCS. The
flow element meter’s total crude flow to the unit is located on discharge of pump. It also
acts as spill backs for the safe guarding the pumps in case of low crude flow in
downstream crude circuit.
The crude first exchanges heat with atmospheric column overhead vapours. From here on
crude flows through various trains. Within each train total crude is split into 2 sub
divisions in parallel which exchanges heat with various strem.
*DESALTER- A 2 stage desalter is provided for removal of salt and water from crude to
the outlet. Service water along with brine water is mixed with crude in a mixing valve
upstream desalter to increase water concentration of subsequent coalescing of emulsified

3. salt laden water. Brine water from desalter is sent to effluent treatment plant. Oil phase ie,
crude after approximately 90% salt removal in first stage is sent to 2nd
stage. Brine from
2nd
stage is fresh water for 1st
stage and finally the brine from the 1st
stage leaves the unit
taking out the total salt approximately 95% of incoming crude.
*PRE FLASH DRUM- The crude from 2nd
stage desalter goes to pre flash drum. The
aim of the pre flash drum is to separate lighters from crude at a early stage so as to load
the furnace with additional charge and also helps in designing further down stream pre
heat exchanging for low design pressures. As pre flash drum does not have any relief
valve, it will be floating with atmospheric column flash zone. Further the crude moves on
through pre-heat exchanger trains where upon it reaches the final required temperature.
From here crude moves to F101 heater for further heating.
*F101 HEATER- Pre heated crude is heated and partially vapourised in atmospheric
heater. Furnace has the facility of burning 3 types of fuel namely steam atomized fuel oil,
fuelgas, vapourisednaptha. Following safety interlocks have been provided on process
and firing side to safeguard the furnace in case of any mal-operation or emergency.
*FURNACE AIR AND FLUE GAS CIRCUIT- Furnace is provided with 2 number of
FD and ID fan to cater the total furnace air requirement for combustion and flue gas
evacuation.
*FD AND ID INTERLOCKS- During operation both FD and ID fans will run. In the
event of failure of one of the working fan as sensed by respective low speed setting limit
or respective motor contact, working fan will attain 100% process load & discharge
damper of the tripped fan will close automatically within 10sec.
In case of furnace tripping following action will take place:
1. Stack damper will open
2. FD fans will trip
3. ID fans will tripafter a time delay of 5min.
PRESSURE MEASUREMENT:
1.BOURDON TUBE: The Bourdon pressure gauge uses the principle that a flattened
tube tends to straighten or regain its circular form in cross-section when pressurized.
Although this change in cross-section may be hardly noticeable, and thus involving
moderate stresses within the elastic range of easily workable materials, the strain of the
material of the tube is magnified by forming the tube into a C shape or even a helix, such
that the entire tube tends to straighten out or uncoil, elastically, as it is pressurized.

4. In practice, a flattened thin-wall, closed-end tube is connected at the hollow end to a
fixed pipe containing the fluid pressure to be measured. As the pressure increases, the
closed end moves in an arc, and this motion is converted into the rotation of a (segment
of a) gear by a connecting link that is usually adjustable. A small-diameter pinion gear is
on the pointer shaft, so the motion is magnified further by the gear ratio. The positioning
of the indicator card behind the pointer, the initial pointer shaft position, the linkage
length and initial position, all provide means to calibrate the pointer to indicate the
desired range of pressure for variations in the behaviour of the Bourdon tube itself.
Differential pressure can be measured by gauges containing two different Bourdon tubes,
with connecting linkages.
2.MANOMETER: A manometer could also refer to a pressure measuring instrument,
usually limited to measuring pressures near to atmospheric. The term manometer is often
used to refer specifically to liquid column hydrostatic instruments.
A manometer consist of a vertical column of liquid in a tube that has ends which
are exposed to different pressures. The column will rise or fall until its weight is
in equilibrium with the pressure differential between the two ends of the tube. A
very simple version is a U-shaped tube half-full of liquid, one side of which is
connected to the region of interest while the reference pressure (which might be

5. the atmospheric pressure or a vacuum) is applied to the other. The difference in
liquid level represents the applied pressure. The pressure exerted by a column of
fluid of height h and density ρ is given by the hydrostatic pressure equation, P =
hgρ. Therefore the pressure difference between the applied pressure Pa and the
reference pressure P0 in a U-tube manometer can be found by solving
Pa − P0 = hgρ.
3. MC LEOD GAUGE: A McLeod gauge isolates a sample of gas and compresses it in a
modified mercury manometer until the pressure is a few mmHg. The gas must be well-
behaved during its compression. The technique is slow and unsuited to continual
monitoring, but is capable of good accuracy.
Useful range: above 10-4
torr [4]
(roughly 10-2
Pa) as high as 10−6
Torr (0.1 mPa),
0.1mPa is the lowest direct measurement of pressure that is possible with current
technology. Other vacuum gauges can measure lower pressures, but only indirectly by
measurement of other pressure-controlled properties. These indirect measurements must
be calibrated to SI units via a direct measurement, most commonly a McLeod gauge.
4.DIAPHRAGM: A Diaphragm uses the deflection of a flexible membrane that
separates regions of different pressure. The amount of deflection is repeatable for known

6. pressures so the pressure can be determined by using calibration. The deformation of a
thin diaphragm is dependent on the difference in pressure between its two faces. The
reference face can be open to atmosphere to measure gauge pressure, open to a second
port to measure differential pressure, or can be sealed against a vacuum or other fixed
reference pressure to measure absolute pressure. The deformation can be measured using
mechanical, optical or capacitive techniques. Ceramic and metallic diaphragms are used.
5. BELLOWS: Bellows pressure element works on the principle of Elasticity. In gauges
intended to sense small pressures or pressure differences, or require that an absolute
pressure be measured, the gear train and needle may be driven by an enclosed and sealed
bellows chamber, called an aneroid, which means "without liquid".
(Early barometers used a column of liquid such as water or the liquid
metal mercury suspended by a vacuum.) These devices use the sealed chamber as a
reference pressure and are driven by the external pressure. Other sensitive aircraft
instruments such as air speed indicators and rate of climb indicators (variometers) have
connections both to the internal part of the aneroid chamber and to an external enclosing
chamber.
6. REMOTE SEAL PRESSURE TRANSMITTER: Diaphragm seals are used to
prevent process medium from entering directly into the pressure-sensing assembly of the
differential pressure transmitter.

7. 7. DIFFERENTIAL PRESSURE TRANSMITTER: The most common and useful
industrial pressure measuring instrument is the differential pressure transmitter. This
equipment will sense the difference in pressure between two ports and produce an output
signal with reference to a calibrated pressure range.
The industrial differential pressure transmitters are made of two housings (See Fig-6).
Pressure sensing element is housed in the bottom half, and the electronics are housed at
the top half. It will have two pressure ports marked as “High” and “Low”. It is not
compulsory that the high port will be always at high pressure and the low port always at
low pressure.
TEMPERATURE MEASUREMENT:
1.THERMOCOUPLE: A thermocouple consists of two conductors of different
materials (usually metal alloys) that produce a voltage in the vicinity of the point where
the two conductors are in contact. The voltage produced is dependent on, but not
necessarily proportional to, the difference of temperature of the junction to other parts of
those conductors.
Thermocouples are a widely used type of temperature sensor for measurement and
control[1]
and can also be used to convert a temperature gradient into electricity. It is
based on the principle that when a conductor is subjected to a thermal gradient, it will
generate a voltage. This is now known as the thermoelectric effect or Seebeck effect.
Any attempt to measure this voltage necessarily involves connecting another conductor to
the "hot" end. This additional conductor will then also experience the temperature
gradient, and develop a voltage of its own which will oppose the original. Fortunately,
the magnitude of the effect depends on the metal in use. Using a dissimilar metal to
complete the circuit creates a circuit in which the two legs generate different voltages,
leaving a small difference in voltage available for measurement.
The voltage is not generated at the junction of the two metals of the thermocouple but
rather along that portion of the length of the two dissimilar metals that is subjected to a
temperature gradient. Because both lengths of dissimilar metals experience the same
temperature gradient, the end result is a measurement of the difference in temperature
between the thermocouple junction and the reference junction.
2.RTD: Resistance thermometers, also called resistance temperature
detectors (RTDs), are sensors used to measure temperature by correlating the resistance
of the RTD element with temperature. Most RTD elements consist of a length of fine
coiled wire wrapped around a ceramic or glass core. The element is usually quite fragile,
so it is often placed inside a sheathed probe to protect it. The RTD element is made from
a pure material, platinum, nickel or copper. The material has a predictable change in

8. resistance as the temperature changes; it is this predictable change that is used to
determine temperature.
LEVEL MEASUREMENT:
RADAR: Radar is an object detection system which uses radio waves to determine the
range, altitude, direction, or speed of objects
A radar system has a transmitter that emits radio waves called radar signals in
predetermined directions. When these come into contact with an object they are
usually reflected or scattered in many directions. Radar signals are reflected especially
well by materials of considerable electrical conductivity—especially by most metals,
by seawater and by wet lands. Some of these make the use of radar altimeters possible.
The radar signals that are reflected back towards the transmitter are the desirable ones
that make radar work. If the object is moving either toward or away from the transmitter,
there is a slight equivalent change in the frequency of the radio waves, caused by
the Doppler effect.
FLOW MEASUREMENT:
1.ORIFICE METER: An orifice plate is a device used for measuring the volumetric
flow rate. It uses the same principle as a venture nozzle, namely Bernoullis
principle which states that there is a relationship between the pressure of the fluid and the
velocity of the fluid. When the velocity increases, the pressure decreases and vice versa.
An orifice plate is a thin plate with a hole in the middle. It is usually placed in a pipe in
which fluid flows. When the fluid reaches the orifice plate, the fluid is forced to converge
to go through the small hole; the point of maximum convergence actually occurs shortly
downstream of the physical orifice, at the so-called vena contracta point (see drawing to
the right). As it does so, the velocity and the pressure changes. Beyond the vena
contracta, the fluid expands and the velocity and pressure change once again. By
measuring the difference in fluid pressure between the normal pipe section and at the
vena contracta, the volumetric and mass flow rates can be obtained from Bernoulli's
equation.
Bernoulli’s equation:

9. is the fluid flow speed at a point on a streamline,
is the acceleration due to gravity,
is the elevation of the point above a reference plane, with the positive z-
direction pointing upward – so in the direction opposite to the gravitational
acceleration,
is the pressure at the chosen point, and
is the density of the fluid at all points in the fluid.
The different types of orifice plates are :
• Concentric.
• Segmental.
• Eccentric.
• Quadrant Edge.
Concentric :
The concentric orifice plate is used for ideal liquid as well as gases and steam service.
This orifice plate beta ratio fall between of 0.15 to 0.75 for liquids and 0.20 to 0.70 for
gases, and steam. Best results occur between value of 0.4 and 0.6. beta ratio means ratio
of the orifice bore to the internal pipe diameters.
(45º beveled edges are often used to minimize friction resistance to flowing fluid )
Eccentric :
The eccentric orifice plate has a hole eccentric. Use full for measuring containing solids,
oil containing water and wet steam. Eccentric plates can use either flange or vena
contracta taps, but the tap must be at 180º or 90º to the eccentric opening.

10. Eccentric orifices have the bore offset from center to minimize problems in services of
solids-containing materials.
Segmental :
The segmental orifice place has the hole in the form segment of a circle. This is used for
colloidal and slurry flow measurement. For best accuracy, the tap location should be 180º
from the center of tangency.
Segmental orifices provide another version of plates useful for solids containing
materials.
Quadrant Edge :
It common use in Europe and are particularly useful for pipe sizes less than 2 inchs.

11. Quadrant edge orifices produce a relatively constant coefficient of discharge for
services with low Reynolds numbers in the range from 100,000 down to 5,000.
2.VENTURIMETER: When a venture meter is placed in a pipe carrying the fluid whose
flow rate is to be measured, a pressure drop occurs between the entrance and throat of the
venturimeter. This pressure drop is measured using a differential pressure sensor and
when calibrated this pressure drop becomes a measure of flow rate.
The entry of the venture is cylindrical in shape to match the size of the pipe through
which fluid flows. This enables the venture to be fitted to the pipe. It is used where high
pressure recovery is required. Can be used for measuring flow rates of
water,gases,suspended solids, slurries and dirty liquids.
The following are the main parts and areas of venture meter:

12. 3. MASS FLOW METER: The mass flow meter does not measure the volume per unit
time (e.g., cubic meters per second) passing through the device; it measures the mass per
unit time (e.g., kilograms per second) flowing through the device. In a mass flow meter
the Fluid is being pumped through the mass flow meter. When there is mass flow, the
tube twists slightly. The arm through which fluid flows away from the axis of rotation
must exert a force on the fluid, to increase its angular momentum, so it bends backwards.
The arm through which fluid is pushed back to the axis of rotation must exert a force on
the fluid to decrease the fluid's angular momentum again, hence that arm will bend
forward.
The performance of flowmeters is also influenced by a dimensionless unit called the
Reynolds Number. It is defined as the ratio of the liquid's inertial forces to its drag forces.
The equation is:
R = 3160 x Q x Gt
D x 
where:
R = Reynolds number
Q = liquid's flow rate, gpm
Gt = liquid's specific gravityD = inside pipe diameter, in.
 = liquid's viscosity, cp
4.PITOT TUBE: It is based on the principle that when solid body is the middle of pipe
is steady & flow streaming is lower direction, flow velocity is decrease. Due to pressure
of body this
decreasement is zero at the body. This point is known as stagnation point.Kinetic head is
lossed & static head is gain so difference measured between normal flowline &
stagnation point.
It works on the principle of differential flowmeter.
CONTOROL VALVES:
Control valves are valves used to control conditions such as flow, pressure, temperature,
and liquid level by fully or partially opening or closing in response to signals received
from controllers that compare a "setpoint" to a "process variable" whose value is
provided by sensors that monitor changes in such conditions.
A control valve consists of three main parts in which each part exist in several types and
designs:
• Valve's actuator
• Valve's positioner

13. • Valve's body
*ACTUATOR: An actuator is the device that brings about the mechanical movements
required for any physical process in the factory. Internally, actuators can be broken down
into two separate modules: the signal amplifier and the transducer. The amplifier
converts the (low power) controlsignal into a high power signal that is fed into the
transducer; the transducer converts theenergy of the amplified control signal into work;
this process usually involves converting from one form of energy into another, e.g.
electrical motors convert electrical energy into kinetic energy.
* POSITIONER: Pneumatically operated valves depend on a positioner to take an input
signal from a process controller andconvert it to valve travel.
Types of control valves:
*Globe valve

14. *Butterfly valve
*Ball valve
*Diaphragm valve
PID CONTROLLERS:
PID controllers are a family of controllers. PID controllers are sold in large quantities
and are often the solution of choice when a controller is needed to close the loop. The
reason PID controllers are so popular is that using PID gives the designer a larger number
of options and those options mean that there are more possibilities for changing the
dynamics of the system in a way that helps the designer. If the designer works it right
s/he can get the advantages of several effects.
PID controllers can be viewed as three terms - a proportional term, and integral term and
a derivative term - added together. PID controllers are also known as three-term
controllers and three-mode controllers. Here's a block diagram representation of the PID.

15. ** OPEN AND CLOSED LOOP DIAGRAM:
DESCRIPTION:
Open and closed loop diagram has 3 sections:
1. Field
2. Control room/ Marshalling unit
3. DCS
The branch cable from various transmitters (on field) are connected to a junction box,
where the branch cables are integrated into one single multi core cable. The current value
ranges from 4-20mA. The multi core cable is attached to a barrier. An external supply to
the system is given by a source which is connected to the barrier. Range of the source:
24V . the connection is followed by a FTA ( Field Termination Assembly) where the
current is converted in terms of voltage(Range:1-5VDC). FTA is connected to a i/p card,

16. comprising of an ADC which converts the existing analog value to digital. This value is
processed by the processor and displayed on the DCS present in the operator station.
Further from the processor the signal is converted to analog form (voltage 1-5VDC). The
voltage signal from the DAC is given to FTA which inturn converts the voltage signal to
current(4-20mA). Now this curren is given to the junction box through the multi core
cable and further to the control valve. An external transmitter is connected to the junction
box.
A current to pressure converter is also present before the control valve.
PLC (PROGRAMMABLE LOGIC CONTROLLER)
PLCs are often defined as miniature industrial computers that contain hardware and
software that is used to perform control functions. A PLC consists of two basic sections:
the central processing unit (CPU) and the input/output interface system. The CPU, which
controls all PLC activity, can further be broken down into the processor and memory
system. The input/output system is physically connected to field devices (e.g., switches,
sensors, etc.) and provides the interface between the CPU and the information providers
(inputs) and controllable devices (outputs).
As PLC technology has advanced, so have programming languages and communications
capabilities, along with many other important features. Today's PLCs offer faster scan
times, space efficient high-density input/output systems, and special interfaces to allow
non-traditional devices to be attached directly to the PLC. Not only can they
communicate with other control systems, they can also perform reporting functions and
diagnose their own failures, as well as the failure of a machine or process.

17. DCS (DISTRIBUTED CONTROL SYSTEM)
DCS (Distributed Control System) is a computerized control system used to control the
production line in the industry.
DCS System consists minimum of the following components.
1. Field Control station (FCS): It consists of input/output modules, CPU and
communication bus.
2. Operator station: It is basically human interface machine with monitor, the
operator man can view the process in the plant and check if any alarm is presents
and he can change any setting, print reports..etc.
3. Engineering station: It is used to configure all input & output and drawing and any
things required to be monitored on Operator station monitor.

18. STANDARD SAFETY NOTATIONS FOR INDUSTRIAN BASED
INSTTRUMENTS:
ZONE 0 - highly flammable area
ZONE 1 – maybe flammable but not for continuous period
ZONE 2 – short terem malfunction
TEMPERATURE SPECIFICATION

19. T1
T2
T2A
T2B
T2C
T3
T4
T5
T6
450
300
280
260
230
200
135
100
85
(in terms of degree celcius)
Specific instruments need certain standar specifications based on area, product,
temperature, pressure, etc inorder to prevent any explosion.
Exia – Permitted in zone 0,1&2
Exib – Permitted in zone 1&2
ACKNOWLEDGEMENT:
I thank Mr Libin Ment, Senior officer (Instruments) for his guidance during
my internship. It was indeed a pleasure to work along with him and I learnt a

20. lot about the working of BPCL and gained knowledge about the procces an
various instruments used in petroleum refineries.
I also thank Mr RV Challam, for his patient guidance through the internship.
I would also like to thank Mr Varun Kumar for his help an guidance.
CONCLUSION
RMP is designed to process crude with high sulphur content. RMP consist of
CDU (crude distillation unit), HCU (hydro cracker unit), HGU (hydrogen
generation unit), LOBS (Lube oil base stock).

21. Research was done on various other topic such as: pressure, temperature,
level, flow measuring instruments, various control valves, P/Iconverter,
various safety measures an protections, DCS, PLC.