AMANRAJ_INTERN2016_REPORT_FINAL

PREPARED BY – AMANRAJ GUPTA REVIEWED BY – Mr. HETALKUMAR JAVIA
RELIANCE INDUSTRIES LIMITED
Study and suggest optimization of operating window of equipment and process
Internship report
16th MAY 2016 TO 15th JULY 2016
To: LC JAMNAGAR

SEZ-Refinery Tank Farm
Jamnagar
Study and suggest
optimization of operating
window of equipment and
process
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Certificate of Approval
This is certified that the project report entitled “Study and suggest optimization of operating
window of equipment and process” has been submitted by Amanraj Gupta and is approved for
the submission.
(Mr. Hetalkumar Javia)
Date: 12 July 2016
Place: Reliance Jamnagar

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ACKNOWLEDGEMENT
I am extremely thankful to have undergone industrial training at Reliance Industries Limited,
Jamnagar Manufacturing Division. The industrial exposure and the quality of Training were
excellent.
I am grateful to my mentor Mr. Hetalkumar Javia for providing me this wonderful opportunity
and his constant guidance and support. I would also like to thank Mr. Raj Mehta, Mr. C. L.
Prasad and Mr. R.C. Mohanta for their constant inputs and help they have extended to me
despite their busy schedule. Without their help it would have been very difficult to pursue this
project.
I thank my family, friends and co-interns who greatly helped in my endeavor.
At last I would like to extent my gratitude to the entire ZRTF department who in any way helped
in making my internship a successful endeavor.
Amanraj Gupta
3rd Year Chemical Engineering
IIT Mumbai

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Disclaimer
This report is only for the academic purpose of the individual which has
undergone summer training at RIL Jamnagar. Any content of this report should
not be copied or displayed at the public domain without the permission of RIL.

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Contents
Study and suggest optimization of operating window of equipment and process......................................0
Certificate of Approval..................................................................................................................................1
ACKNOWLEDGEMENT...................................................................................................................................2
Disclaimer......................................................................................................................................................3
Reliance Jamnagar Refinery:.........................................................................................................................6
Plants in Jamnagar refinery: .....................................................................................................................7
Marine Facility: .........................................................................................................................................8
Refinery Raw Material: .............................................................................................................................8
Products from Refinery:............................................................................................................................8
Significant Contribution to India’s Economic Growth: .............................................................................9
Tank Farms:...............................................................................................................................................9
REFINERY TANK FARM: ...............................................................................................................................10
Refinery Tank Form Storage Areas: ........................................................................................................11
Facilities at RTF: ......................................................................................................................................11
Raw Material Storage in ZRTF:................................................................................................................12
Products in ZRTF: ....................................................................................................................................12
INTRODUCTION TO IOW: ............................................................................................................................13
Levels of Integrity Operating Windows ..................................................................................................13
Fault Levels – High/Low ..........................................................................................................................14
Alert Limits – High/Low...........................................................................................................................14
Time in Exceedance.................................................................................................................................15
Target Range...........................................................................................................................................15
Target Group:..............................................................................................................................................16
Parameters for Temperature Operating Window ......................................................................................17
Design Range...........................................................................................................................................17
Agreed Specs with Upstream and Downstream process........................................................................17
Pour Point of service fluid.......................................................................................................................18
Acceptable viscosity range of pump.......................................................................................................18
Brief Summary of all the tanks....................................................................................................................19

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Service Fluid-RFO ........................................................................................................................................20
Service Fluid-EFO ........................................................................................................................................24
Service Fluid-Heavy Slop.............................................................................................................................27
Service Fluid-Sour VGO...............................................................................................................................30
Service Fluid-Sweet VGO.............................................................................................................................34
Service Fluid-LSWR......................................................................................................................................37
Service Fluid-CBFS.......................................................................................................................................40
SUMMARY...................................................................................................................................................43
Conclusion...................................................................................................................................................46
Scope and Improvement.............................................................................................................................46
Reference....................................................................................................................................................47

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Reliance Jamnagar Refinery:
Jamnagar refining complex is “the world’s largest refinery at a single location”. With crude
processing capacity of 1.24 million Barrels per Stream Day (BPSD), the Jamnagar refinery is a
trendsetter.
In Jamnagar, there are two refineries. One is Domestic Tariff Area (DTA) and other is Special
Economic Zone (SEZ). DTA refinery has a capacity for processing 650 KBPSD and SEZ refinery has
a capacity for processing 590 KBPSD. All products of DTA refinery export to different states of
INDIA while most of the products from SEZ refinery export outside the INDIA.
The refinery complex besides having atmospheric & vacuum crude distillation unit as the
primary processing units includes more complex secondary processing units namely Fluidized
Catalytic Cracker, Coker and other treating units like CFP, Alkylation’s, hydrotreater and Sulphur
Recovery Unit to meet environmental stipulation.
Refinery complex has elaborate offsite arrangements for storage and handling of raw materials
- feed to primary units, intermediate storage - feed to secondary units, intermediate storage for
products along with blending facilities, finished products along with transfer facilities to marine
terminals and dispatch facilities for evacuation of products through various modes of dispatch
like sea and product pipelines.
Refinery Overall Block Diagram:
CDU Diesel U
HNU
Plat former/
Aromatics
Complex
VDU VGOHTU FCC
Coker
PRU / PP
P
R
O
D
U
C
T
B
L
E
N
D
I
N
G
LPG
Naphtha
Gasoline/
Alkylate
ATF
Diesel
PX/OX
Benzene
PP
ATU / SWS /
CBA
KHT
CNHT
ALKY LCOHC/SCANFINER

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Plants in Jamnagar refinery:
Jamnagar
Refinery
DTA
Fuel
Crude
Cracker
FCC
VGOHT
Non-Fuel
CPP
Utilities
Sulfur
Hydrogen
Poly-
Propylene
Aromatics
SEZ
Fuel
Crude
Cracker
FCC
VGOHT
CFP
Non-Fuel
CPP
Utilities
Sulfur
Hydrogen
Poly-
Propylene
Aromatics
Alkylator

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Marine Facility:
Refinery also has marine facility which is common to both DTA and SEZ refinery, which is India’s
largest private port with state of the art facilities and environmental protection system. Marine
operation is conducted in Eco-friendly way, heralding the way the ports are to be operated.
The port facility comprises of:
 Four product berths
 Three crude SPMs
 2 product SPMs.
Total capacity of the terminal is ~ 100 MMTPA and is over 25% of the total capacity of all ports
in India. Seawater intake and sea water outfall is part of Marine facilities.
Refinery Raw Material:
Crude oil is procured from all over the world and transported through very large crude
containers (VLCC). Crude is off loaded via SBM (Single Buoy Mooring) to crude tanks at the
Marine Tank Farm (MTF). After enough settling and water removal / pretreatment, suitable
crude blend is prepared at MTF as per market requirement & refinery operation. Then it is
pumped to the Crude oil day tanks in SEZ – RTF, from there to crude units.
Products from Refinery:
• Euro IV Gasoline
• Euro IV Diesel
• Alkylate
• JET Fuel
• Propane
• LPG
• Petro Chemical Naphtha
• Poly Propylene
• Sulfur
• Petroleum Coke.

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Significant Contribution to India’s Economic Growth:
• 14 % of India’s Total Exports
• 4.8 % of the GOI’s Indirect Tax Revenues
• Turnover of 68.4 billion US$
• Capable to meet 40% of India's Petroleum product demand
Tank Farms:
Main purpose of tank farms are storage and supply of raw material and products. Jamnagar
refinery has total 4 tank farms:
 MTF (Marine Tank Farm)
 RRTF (Rail Road Tank Farm)
 DTA-RTF (DTA – Refinery Tank Farm)
 SEZ-RTF (SEZ – Refinery Tank Farm)

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REFINERY TANK FARM:
SEZ-Refinery Tank Farm (RTF) is bridge between the Refinery and the rest of the world. It is
distributed over an area of around 4 square kilometer. It covers all the facilities for receiving
and handling of the crude oil. It receives the intermediates from the primary and secondary
units and feed it to the downstream units. It is also responsible for flushing oil and fuel oil
supply of entire Refinery. Apart from supply of feed to unit & receipt of the direct finished
product from unit, RTF is involved in blending of the various refinery streams to give value
added finished products like Gasoline & Diesel for the market. From Refinery Tank Farm
products will be pumped Marine terminal located outside refinery premises where storage &
loading / unloading facilities are provided for evacuation of products. It also handles off spec
product for correction.
CDU/VDU/VGO
HTs
AROMATICS
SHP/ TAME
COKER
SULFUR
PP
RTFFCCU
LPG
BZ/ OX/ PX
Gasoline blend
component
Coker Naphtha
Slop oil
Gasoline
Kerosene/Diesel/Naphtha

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Refinery Tank Form Storage Areas:
 Raw material and storage system (Z611) acts as buffer and receives crude from MTF
and sends to Crude distillation units.
 Intermediate Storage system (Z621) acts as surge capacity for the intermediates
products from various units. It handles VR, sour VGO, Sweet VGO, Heavy Naphtha,
DHDS/LCO Feed, Scanfining unit feed.
 Finished product storage (Z631) handles finished products such as Petro Chemical
Naphtha, Diesel Euro – IV, Gasoline Euro IV, Gasoline USEC RFG, Gasoline RBOB and
Export Fuel Oil (CBFS) storage.
 Spheres handle LPG, Propane, Propylene and Iso butane.
 Blending components (Z641) handles various components and blend them
appropriately to make finished products.
 Slop system (Z673) handles the slop oil from the refinery such as Straight Run Slop,
Cracked Slop and Heavy Slop and also Flushing Oil is part of this system.
 Fuel Oil system (Z741) caters the service of fuel oil receipt and supply to refinery
process heaters or boilers.
 Flare (Z671) caters dedicated to ZRTF flaring and is a new system which did not exist in
DTA RTF.
Facilities at RTF:
Facilities Nos.
Tanks and Spheres 70 Tanks & 15 Spheres
Pumps 180
Side entry mixers 80
Vendor packages 4 nos. of Dryers
Substations 6
PIBs 5
Blending stations 3
Pump houses 28
Analyzer house 4
Metering station 2 Metering stations

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Currently Refinery Tank Farm is equipped with total of 85 storage vessels including 70 tanks of
different types (42 floating roof, 22 cone roof, 4 internal floating roof and 4 dome roof tanks)
and 15 spheres. Indian Government regulations limit the size of tanks within a single dyke to
120000 m3 for floating roof tanks and 60000 m3 for cone roof and internal floating roof tanks
and the maximum permissible height of the tank is 20 m.
The entire RTF operations are carried out by means of Distributed Control System (DCS) and
Automation Packages to ensure the most optimized operation as well as safety.
These packages are:
1. Tank Information System (TIS),
2. Oil Movement Information System (OMIS),
3. Digital Blender System (DBS) and
4. Blend Optimization & Supervisory System (BOSS).
In addition to above, the state of the art fire protection measures like Automatic / Semi -
Automatic foam supply, Sprinklers, Fire and Gas detection system as well as extensive fire
water network consisting of fire monitors / Hydrants have been provided.
All these measures coupled with advance control system will ensure the highest standards of
safety and environment protection in normal operations.
Raw Material Storage in ZRTF:
• The primary refinery raw materials (mainly Crude and LSWR) are stored in this area.
• These materials are received from MTF and RRTF for supply to various customer units as
per agreed specifications.
Crude - Crude Unit Feed
LSWR (Low Sulfur Waxy Residue) - FCCU Feed
Products in ZRTF:
1. LPG 5. Gasoline
2. Propane 6. Alkylate
3. Petrochemical Naphtha 7. CBFS
4. Diesel

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INTRODUCTION TO IOW:
Integrity Operating Windows (IOWs) are sets of limits used to determine the different
variables that could affect the integrity and reliability of a process unit. Put simply, IOWs are
the limits under which a machine can operate safely. Working outside of IOWs may cause
otherwise preventable damage or failure. For this reason, it's incredibly important to be
aware of the IOW for each machine that is in operation.
Integrity Operating Window typically falls into 2 categories:
• Physical
- Various limits on pressures and temperatures, including design, operating,
partial pressures, dew points, dry points, heating and cooling rates, delta P, etc.
- Flow rates, injection rates, inhibitor dosage, amperage levels on Alky contactor
motors, slurry content, hydrogen flux, vibration limits, corrosivity probes, etc.
• Chemical
- pH, water content, acid gas loading, sulfur content, salt content in crude, NH4HS
content, NH3 content, TAN, acid strength, amine strength, inhibitor
concentration, chloride contamination levels, oxygen content, etc.
Levels of Integrity Operating Windows
Term Definition
Variable Any measurement that affects equipment integrity and reliability, that
operations wishes to monitor and control
Fault limit That point at which an operator has the last opportunity to respond
before rapid loss of containment may occur
Alert level That point above which sustained operations could cause cumulative
damage possibly resulting in eventful loss of containment or impact
the long-term unit performances and its ability to meet turnaround
run length expectations
Target Range Points that define stable, reliable, and profitable operations

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Fault Levels – High/Low
• A Fault Limit is the value at which the operator has the last opportunity to respond.
Exceedance immediately results in:
- Rapid loss of containment
- A condition that requiring “mitigate or escalate”.
• Exceedances of Fault Limits require immediate action.
• Fault Limits should normally be reported automatically through the plant’s Distributed
Control System (DCS) monitored in real-time by the plant operators, and alarmed.
• Predetermined immediate corrective actions to get the variable within its Fault limit.
• Failure of corrective actions may require unit shutdown, slowdown, depressurizing, etc.
and notification of the appropriate personnel.
Alert Limits – High/Low
• An Alert Level is one that, if exceeded over time, could cause one of the following to
occur:
- A release of hydrocarbons due to loss of containment
- A negative impact to the long-term unit performance and its ability to meet
turnaround run length expectations.
• Alert Levels should encompass the range of variation normally encountered in the
process and allows for maneuvering to adjust conditions to meet operating targets.
• An Alert Level will have a Time in Exceedance (TIE) limit
• An Alert Level will have a predetermined corrective action that should be performed or
set into action immediately
• Exceedances of Alert Levels do not lead to immediate failures.
• It may be economical for the plant to allow exceedances of Alert Limits to occur when
the cost of the damage is offset by the benefit of, for example, maintaining production
rates.
• The cost/benefit tradeoff should be factored into establishment of the Alert Limit and
the Time in Exceedance.

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Time in Exceedance
• Time in Exceedance applies only to Alert Levels.
• Operator response to an Alert Level exceedance should be expeditious even though the
consequences of the exceedance are not imminent.
• Default maximum = 24 hours for dealing with an Alert Level exceedance.
• Example: A heater skin tube temperatures exceeding the Alert Level may not result in a
tube failure for several weeks. However if the tube skin temperature exceeds that Alert
Level for more than the standard TIE (24 hours maximum), the operator will take action
to escalate. This should result in an Alert Level never being exceeded for more than 24
hours without escalation
Target Range
• The Target Range is the operating range for a variable related to economic optimization
or stability & reliability of unit operations.
• Target Range limits do not define Integrity Operating Windows.
• Target Range should fall within the range defined by Fault Levels and Alert Limits.
• We document Target Ranges when establishing IOW’s to ensure this relationship.
Operating Windows

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Target Group:
Following 13 tanks have been included in the research which would be about validating and
expanding temperature operating window
Tank No. Service Fluid Tag No.(Temp) Min (o
C) Max (o
C)
MT-UWZ621-204 CBFS Z621-TI-527 70 90
MT-UWZ621-205 Sour VGO Z621-TI-026 70 90
MT-UWZ621-206 Sour VGO Z621-TI-027 70 90
MT-UWZ621-207 Sweet VGO Z621-TI-618 70 90
MT-UWZ621-262 LSWR Z621-TI-252 70 90
MT-UWZ631-243 EFO Z631-TI-009 50 100
MT-UWZ631-244 EFO Z631-TI-012 50 100
MT-USZ673-205 Heavy Slop Z673-TI-005 70 95
MT-USZ673-206 Heavy Slop Z673-TI-006 70 95
MT-UUZ741-001 RFO Z741-TI-008 80 100
MT-UUZ741-002 RFO Z741-TI-009 80 100

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Parameters for Temperature Operating Window
The operating range of temperature for a service fluid is fixed after factoring the following
parameters
• Design Range ( Minimum and Maximum operating conditions)
 Tank
 Pump
 Mixer
 Coil
 Heater
 Pipe
• Agreed Specs with Upstream and Downstream process.
• Pour Point of service fluid.
• Acceptable viscosity range of pump
Design Range
Due to Material of construction and type of service fluid there is a design limit for any
instrument. Deviation from maximum design temperature may lead to fire while deviation from
minimum design temperature may lead to material congealing.
Agreed Specs with Upstream and Downstream process
Operating range of previous process as well as next process plays a major role in deciding the
operating range of the current process. We have to come on a common ground so that there is
no material damage and all the processes work at maximum efficiency with least utilities load.

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Pour Point of service fluid
Pour point is a temperature at which the oil becomes a gel and cannot flow. This will make it
difficult to transport and will decrease the efficiency of the operation. Hence we should not
operate near the pour point of service fluid.
Acceptable viscosity range of pump
Viscosity of service fluid has a major impact on efficiency of the pump. High viscous fluid is
undesirable as it will increase drag in the fluid and make it difficult to be pumped.
Viscosity and Temperature of service fluid can be expressed as (reference 1)
𝑙𝑜𝑔(𝑙𝑜𝑔(𝜗)) = 𝐴 + 𝐵 × 𝑙𝑜𝑔(𝑇)
(Formulae 1)
Where 𝜗 =kinematic viscosity in centistokes
T= Temperature in Fahrenheit
A, B= constants
These constant can be found out by curve fitting if we know two to three viscosity, temperature
data points.
Maximum Viscosity at which pump can work is related to its discharge nozzle as (reference 2)
𝜇 𝑚𝑎𝑥 = 300 × [𝐷𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑜𝑧𝑧𝑙𝑒 − 1]
(Formulae 2)
Where 𝜇 𝑚𝑎𝑥= Viscosity in SSU
D outlet nozzle =Diameter of outlet nozzle in inches
Using diameter of the pump, the maximum viscosity permissible by the pump by using formulae
2 can be found out. Thereby using the viscosity –temperature expression, the minimum
temperature allowed through the pump can be found out.

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Brief Summary of all the tanks
• Y= Yes available NA= Not available N=Not found
Process fluid Sweet VGO Sour VGO RFO EFO CBFS LSWR Heavy Slop
DCS limit Y Y Y Y Y Y Y
Components
Tank Y Y Y Y Y Y Y
Pump Y Y Y Y Y Y Y
Mixer Y Y Y Y Y Y Y
Coil Y Y Y Y Y Y Y
Heater NA NA Y NA NA NA NA
Design parameter
Tank Y Y Y Y Y Y Y
Pump Y Y Y Y Y Y Y
Mixer Y Y Y Y Y Y Y
Coil N N Y N N N N
Heater NA NA Y NA NA NA NA
Upstream
and
Downstream
Process
Sufficient
data found
Sufficient
data found
Sufficient
data
found
Sufficient
data
found
Sufficient
data
found
Sufficient
data
found
Sufficient
data found
Viscosity
data
Y, Crude
Assay from
ExxonMobil
Y, Crude
Assay from
ExxonMobil
Y, Specs Y, Specs Y, Specs Y, Data
sheet
Y, but
insufficient
Viscosity
data points
4 4 3 3 3 2 1
Pour point Y, Crude
Assay from
ExxonMobil
Y, Crude
Assay from
ExxonMobil
Y, Specs Y, Specs Y, Specs Y,MSDS N
Viscosity
temp
relation
Y Y Y Y Y Y N
Maximum
viscosity
Y Y Y Y Y Y Y
(For datasheet, see Reference 3, 4, 5, 6, 7, 8, 9)
(For pour point and viscosity data, see Reference 10)

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Service Fluid-RFO
Fuel oil is the liquid fuel that is burned in a furnace or boiler for the generation of heat which is
used in the process. Refinery Fuel oil is the fuel oil which is used by refinery itself
Following table shows various components with their equipment number
Component Number
Temperature Tag Z741-TI-008/009
Tank MT-UUZ741-001/002
Pump MP-UUZ741-P001 A/B/C
Mixer MF-UUZ741-A001/A002
Heating Coil ME-UUZ741-Y001/Y002
Heater ME-UUZ741-S001
Design range of pump and tank can be found out by Equipment Datasheet (See Reference 5).
For the source of pour point and viscosity data of RFO check Reference 10
Pump Viscosity limit is the Temperature at which the fluid has maximum viscosity that the
pump can handle.
Temperature(oF) Viscosity(cSt) Source
122 150 Specs
212 11 Specs
131 42.708 Pump
Datasheet

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Using these data points and fitting with the curve
The values of constants are 𝐴 = 7.00877 𝑎𝑛𝑑 𝐵 = −1.14304
Following table summarizes temperature limit set due to various parameter
Parameter Min. Temp (oC) Max. Temp (oC)
DCS Range 80 100
Tank Design Range 3 110
Pump Design Range 55 110
Pump Viscosity limit 41
(Calculated Value)
-
Pour Point 21 -
0
100
200
300
400
500
600
700
800
900
1000
0 50 100 150 200 250
Viscosity(cSt)
Temperature (F)
Viscosity vs Temperature
viscosity (cSt) Datapoints

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Refinery Fuel Oil (RFO) is used for heating purpose in the plant. The operating temperature of
tank and pump is 55⁰C as per Design data sheet which is maintained by heating coil inside the
tank using LP steam in utility side.
The heater, ME-UUZ741-S001 is employed to heat the outgoing fuel oil to 66⁰C as per the
guidelines stated in 25194-3PS-GAB001 (Page 28). LP steam requirement for heater and coil is
worked out at operating temperature, i.e. 55⁰C (25194-G31-UUZ741-101).
Tag no: z741ti009 (RFO), z741ti008 (RFO)

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These trends are of one year and it is pretty clear that the fluid stored is below 80⁰C (The
minimum DCS range) with temperature reaching as low as 62⁰C.
Now factoring everything we can see that the lowest maximum temperature acceptable is
100⁰C. Also we cannot go above 100⁰C as water boils above this temperature at atmospheric
pressure which would increase the tank pressure.
Hence proposed, maximum limit: 100⁰C
The highest minimum temperature acceptable is 55⁰C, which is pump’s minimum design limit.
But the service fluid goes through the heater first, before being pumped, which is design to
heat the fluid from 55⁰C to 66⁰C. Hence, Minimum limit can be set to as low as 60⁰C which is
also larger than any other minimum temperature constraint.
Hence proposed, minimum limit: 60⁰C

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Service Fluid-EFO
Fuel oil is the liquid fuel that is burned in a furnace or boiler for the generation of heat which is
used in the process. Expert Fuel oil is majorly exported but can also be used in refinery.
Component Number
Tank MT-UWZ631-243/244
Pump MP-UWZ631-P210 A/B
Mixer MF-UWZ631-A243/A244
Heating Coil NO NUMBER GIVEN
Heater NOT PRESENT
For the source of pour point and viscosity data of EFO check Reference 10
pump can handle.
122 150 Spec
212 11 Spec
176 44.231 Data sheet

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DCS Range 50 100
Pump Viscosity limit 44.5
(Calculated)
-
Pour Point 21 -
0
500
1000
1500
2000
2500
3000
3500
0 50 100 150 200 250
Viscosity(cSt)
Temperature(F)
Viscosity vs Temperature

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The operating temperature of tanks and pump is 80C as per Design data sheet. This service fluid
is majorly exported but it can also be used as FO for refinery purposes hence it should meet the
specs of FO system as stated in the document 25194-3PS-GAB001 (Page 28), which states that
the minimum temperature of FO should be 55⁰C.
Tag no: z631ti012
The cases when temperature went below 40⁰C were because tank was empty. Otherwise
tank’s temperature is oscillating between 55⁰C to 70⁰C.
100⁰C. Also we cannot go above 100⁰C as water boils above this temperature at atmospheric
Hence proposed, Maximum limit: 100⁰C
The highest minimum temperature acceptable is 44.5⁰C, which correspond to pump’s
maximum viscosity limit. The service fluid might go to FO system, hence it should be kept above
55⁰C (Minimum temperature limit of FO system). The main function of this tank is to export
hence the earlier set limit is also justifiable.
Hence proposed, Minimum limit: 50⁰C

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Service Fluid-Heavy Slop
Slop Oil is reclaimed petroleum waste mixtures of oil, chemicals and water derived from a wide
variety of processes in refineries or oil fields. Slop Oil is formed when tank wagons and oil tanks
are cleaned or during maintenance work at refineries, or in unforeseen oil accidents.
Heavy Slop is collected in E.T.P through various sewer system networks. Oil reclaimed in E.T.P
particularly from API separators needs to be de-watered and de-emulsified prior to being
processed. Heavy slop is also received from other unit like CDU, DCU, VGO, CFP and Aromatic
complex.
Component Number
Tank MT-USZ673-205/206
Pump MP-USZ673-P203 A/B
Mixer MF-USZ673-A205/A206
Heater NOT PRESENT

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DCS Range 70 95
Pump Viscosity limit - -
Pour Point - -
Heavy slop goes to Coker Plant where it get mixed with Tank stored Vacuum Residue (190⁰C)
and Vacuum distillation unit VR (260⁰C) [as per operating manual of coke, which is then raised
to 305⁰C before entering coker].Minimum Temperature fixed for Vacuum residue from ZRTF
unit to Coker is 180⁰C (Z370-OPS-PRS-001 agreed specs).
Some heavy slop goes to Crude tank too if it has suitable specs.
Tag no: z673ti005

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Tag no: z673ti006
First trend shows that the fluid is majorly around 67⁰C while the second trend shows it is in
between 62⁰C to 95⁰C.
108⁰C. We cannot go above 100⁰C as water boils above this temperature at atmospheric
The highest minimum temperature acceptable is 2⁰C, which correspond to design minimum
temperature. Due to insufficient viscosity and pour point data, commenting on minimum
temperature is not possible.
Hence, Minimum limit: Can’t be determined

Jamnagar
Study and suggest
process
Page | 30
Service Fluid-Sour VGO
Vacuum Gas Oil or VGO is part of the petroleum hydrocarbon heavy distillate family. It is the
top product of vacuum distillation. Vacuum Gas Oil also known as cat feed, which is feedstock
for fluid catalytic crackers used to make gasoline, gasoil and many other by-products.
Sour VGO is the one having high sulfur content.
Component Number
Tank MT-UWZ621-205/206
Pump MP-UWZ621-P202/P222
Mixer MF-UWZ621-A205/A206
Heating Coil NOT PRESENT
Heater NOT PRESENT
For the source of pour point and viscosity data of Sour VGO check Reference 10
pump can handle.
68 139.17 assay from exxon
176 27.78 data sheet

Jamnagar
Study and suggest
process
Page | 31
DCS Range 70 90
Tank Design Range 7.5 93
(Calculated)
-
Pour Point 39.74 -
0
50
100
150
200
250
300
350
400
0 50 100 150 200 250
Viscosity(cSt)
Temperature(F)
Viscosity(cSt) vs Temperature( oF)

Jamnagar
Study and suggest
process
Page | 32
Sour VGO is sent to Vacuum Gas Oil Hyrotreating (VGOHT) where its sulfur content is reduced
and made suitable for Fluidized Catalytic Cracking Unit.
Cold feed from tank is preheated by heater ME-RHZ361-S01, which has the capability of heating
equal to 67% of capacity of one unit such that design throughput of both unit will not be
affected in case of one of the crude unit is under shut down. The heater is designed to heat cold
feed from 50⁰C to 226⁰C for flowrate of 363 Mt/hr.
Tag no: z621ti026, z621ti027

Jamnagar
Study and suggest
process
Page | 33
The above trends shows that liquid in both tank is around 70⁰C to 80⁰C except in instances
when tank was empty.
93⁰C. This is the maximum tank design temperature, which in no condition should be violated
The highest minimum temperature acceptable is 39.74⁰C, which is the pour point of service
fluid. Also, the heater ME-RHZ361-S01 in VGOHT unit is designed for liquid entering at 50⁰C.
Considering all the parameter constraints, the minimum limit can be changed to 60⁰C. Extra
10⁰C for safety and accounting for line loss.

Jamnagar
Study and suggest
process
Page | 34
Service Fluid-Sweet VGO
Vacuum Gas Oil or VGO is part of the petroleum hydrocarbon heavy distillate family. It is the
top product of vacuum distillation. Vacuum Gas Oil also known as cat feed, which is feedstock
for fluid catalytic crackers used to make gasoline, gasoil and many other by-products.
Sweet VGO is the one having lower sulfur content as compared to Sour VGO
Component Number
Temperature Tag Z621-TI-618/518/118
Tank MT-UWZ621-207/208/209
Pump MP-UWZ621-P203/P223
Mixer MF-UWZ621-A207/A208/A209
Heater NOT PRESENT
For the source of pour point and viscosity data of Sweet VGO check Reference 10
pump can handle.

Jamnagar
Study and suggest
process
Page | 35
DCS Range 70 90
(Calculated)
-
Pour Point 39.74 -
0
50
100
150
200
250
300
350
400
0 50 100 150 200 250
Viscosity(cSt)
Temperature(F)
Viscosity(cSt) vs Temperature( oF)

Jamnagar
Study and suggest
process
Page | 36
Sweet VGO goes to Fluidized Catalytic Cracking Unit, where it is broken down to lower carbon
chains so that production of gasoline, LPG and other lower carbon product increases.
The feed for FCCU goes to Raw oil feed drum(MV-RF413-V01) where Cold sweet VGO get
mixed(80⁰C as per JMD-Z410-OPS-PRM-002, 84⁰C as per 25194-G32-RFZ411-002 H&M002,
76.9⁰C as per 25194-G31-RFZ413-001) with VGO from VGOHT unit at 194⁰C (as per JMD-Z410-
OPS-PRM-002 Page 26) . Generally the operating condition of this drum is 177⁰C (as per 22960-
G56-RF411-022). The raw oil is heated from 194⁰C to 238⁰C via series of heat exchangers.
The cold VGO from tanks is used for LCO - cold VGO heat exchanger (ME-RFZ413-S109) which
was install to preheat the cold VGO so that the mix feed(cold VGO + hot VGO) temperature is
around 195⁰C.
The highest minimum temperature acceptable is 39.74⁰C, which is the pour point of service
fluid. Preheater ME-RFZ413-S109 is installed to increase the temperature of cold VGO, hence if
the lower limit is changed from 70⁰C to lower value, it will increase the load of this preheater
which would decrease the outlet temperature of LCO, as currently it is designed to be at 160⁰C
when VGO is at 80⁰C.

Jamnagar
Study and suggest
process
Page | 37
Service Fluid-LSWR
Low Sulphur Waxy Residue or LSWR is the bottom product of Crude Distilling Unit. LSWR is
imported and used as feedstock for FCCU.
Component Number
Temperature Tag Z621-TI-252
Tank MT-UWZ621-262
Pump MP-UWZ621-P213A/B
Mixer MF-UWZ621-A262
Heater NOT PRESENT
For the source of pour point and viscosity data of LSWR check Reference 10
pump can handle.
176 61.05263158 Data sheet
140 143.1578947 Data sheet

Jamnagar
Study and suggest
process
Page | 38
DCS Range 70 90
Pump Design Range - 150
(Calculated)
-
Pour Point 40 -
0
200
400
600
800
1000
1200
1400
1600
1800
0 50 100 150 200 250
Viscosity(cSt)
Temperature(F)
Viscosity(cSt) vs Temperature(F)

Jamnagar
Study and suggest
process
Page | 39
LSWR goes to Fluidized Catalytic Cracking Unit, where it is broken down to lower carbon chains
so that production of gasoline, LPG and other lower carbon product increases.
The feed for FCCU goes to Raw oil feed drum(MV-RF413-V01) where Cold sweet VGO get
mixed(80⁰C as per JMD-Z410-OPS-PRM-002, 84⁰C as per 25194-G32-RFZ411-002 H&M002,
76.9⁰C as per 25194-G31-RFZ413-001) with VGO from VGOHT unit at 194⁰C (as per JMD-Z410-
OPS-PRM-002 Page 26) . Generally the operating condition of this drum is 177⁰C (as per 22960-
G56-RF411-022). The raw oil is heated from 194⁰C to 238⁰C via series of heat exchangers.
The cold VGO from tanks is used for LCO - cold VGO heat exchanger (ME-RFZ413-S109) which
was install to preheat the cold VGO so that the mix feed(cold VGO + hot VGO) temperature is
around 195⁰C
Tag no: z621ti252
The highest minimum temperature acceptable is 46.5⁰C, which correspond to pump’s
maximum viscosity limit. Preheater ME-RFZ413-S109 is installed to increase the temperature of
cold VGO and LSWR, hence if the lower limit is changed from 70⁰C to lower value, it will
increase the load of this preheater which would decrease the outlet temperature of LCO, as
currently it is designed to be at 160⁰C when VGO and LSWR is at 80⁰C.

Jamnagar
Study and suggest
process
Page | 40
Service Fluid-CBFS
Carbon Black Feed Stock (CBFS) is also used in fuel oil system for heating purposes inside
refinery. CBFS from jetty is directly connected to FO system hence we accept fluid at 66⁰C at
the jetty. The surplus fluid is passed to this tank.
Component Number
Temperature Tag Z621-TI-527
Tank MT-UWZ621-204
Pump MP-UWZ621-P214 A/B/C
Mixer MF-UWZ621-A204
Heater NOT PRESENT
For the source of pour point and viscosity data of CBFS check Reference 10
pump can handle.
122 150 spec
212 11 spec

Jamnagar
Study and suggest
process
Page | 41
DCS Range 70 90
Pump Design Range - 150
Pump Viscosity limit 41
(Calculated)
-
Pour Point 21 -
0
500
1000
1500
2000
2500
3000
3500
0 50 100 150 200 250
Viscosity(cSt)
Temperature(F)
Viscosity(cSt) vs Temperature

Jamnagar
Study and suggest
process
Page | 42
The storage tank used in case of excess CBFS also stores Sour VGO. The normal operating value
of FO system is at 66C with min at 55C and max at 88C according to 25194-3PS-GAB-001.Pipes
are steam traced at 50C. As this is a multipurpose tank, limit have to be set depending on both
service fluid
Tag no: z621ti527
The highest minimum temperature acceptable is 41⁰C, which correspond to pump’s maximum
viscosity limit. Taking VGO properties into account, as this tank stores Sour VGO too. Sour VGO
has 40⁰C the highest minimum temperature. The heater ME-RHZ361-S01 in VGOHT unit is
designed for liquid entering at 50⁰C. Considering all the parameter constraints, the minimum
limit can be changed to 60⁰C. Extra 10⁰C for safety and accounting for line loss.

Jamnagar
Study and suggest
process
Page | 43
SUMMARY
• Summarizing all the changes which can be applicable
Tank No. Service Fluid Present Parameter’s Constraint
Min (o
C) Max (o
C) Max Min (o
C) Min Max (o
C)
MT-UWZ621-204 CBFS 70 90 41 93
MT-UWZ621-205 Sour VGO 70 90 39.74 93
MT-UWZ621-206 Sour VGO 70 90 39.74 93
MT-UWZ621-207 Sweet VGO 70 90 39.74 93
MT-UWZ621-208 Sweet VGO 70 90 39.74 93
MT-UWZ621-209 Sweet VGO 70 90 39.74 93
MT-UWZ621-262 LSWR 70 90 46.5 93
MT-UWZ631-243 EFO 50 100 44.5 100
MT-UWZ631-244 EFO 50 100 44.5 100
MT-USZ673-205 Heavy Slop 70 95 Can’t say 108
MT-USZ673-206 Heavy Slop 70 95 Can’t say 108
MT-UUZ741-001 RFO 80 100 55 110
MT-UUZ741-002 RFO 80 100 55 110

Jamnagar
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Page | 44
• For Lower Limit
o To find lower limit, we have used empirical relation and some viscosity and pour
point data from internet. These values may not be very accurate and close to the
real value as the crude quality might be different.
o So in order to compensate for these assumption we have added the Max lower
value due to all the constraints with a factor for safety and errors.
• For Upper limit
o To find upper limit, we haven’t used any relation or used internet. We just
referred to data sheet values. Hence we can assume that to be accurate.
o The temperature can’t be above 100⁰C as water will start boiling and this might
result in increase of tank pressure.
o Here we are not multiplying with any safety factor. Also we have seen we can go
as close as 3 degree difference from the design limit, so we have chosen the limit
accordingly.

Jamnagar
Study and suggest
process
Page | 45
Tank No. Service Fluid Present Parameter’s Constraint Proposed
Min(o
C) Max(o
C) Max Min(o
C) Min Max(o
C) Min(o
C) Max(o
C)
MT-UWZ621-204 CBFS 70 90 41 93 60 90
MT-UWZ621-205 Sour VGO 70 90 39.74 93 60 90
MT-UWZ621-206 Sour VGO 70 90 39.74 93 60 90
MT-UWZ621-207 Sweet VGO 70 90 39.74 93 70 90
MT-UWZ621-208 Sweet VGO 70 90 39.74 93 70 90
MT-UWZ621-209 Sweet VGO 70 90 39.74 93 70 90
MT-UWZ621-262 LSWR 70 90 46.5 93 70 90
MT-UWZ631-243 EFO 50 100 44.5 100 50 100
MT-UWZ631-244 EFO 50 100 44.5 100 50 100
MT-USZ673-205 Heavy Slop 70 95 Can’t say 108 70 100
MT-USZ673-206 Heavy Slop 70 95 Can’t say 108 70 100
MT-UUZ741-001 RFO 80 100 55 110 60 100
MT-UUZ741-002 RFO 80 100 55 110 60 100

Jamnagar
Study and suggest
process
Page | 46
Conclusion
 For the service fluid like CBFS, RFO and Sour VGO, reducing the minimum temperature
limit would decrease heat requirement to maintain the tank temperature thereby
reducing the LP steam requirement.
 Also by decreasing the limit would eliminate unnecessary alarms, like in the case of RFO
where it is suitable to keep the service fluid at around 60º C to 70ºC while the limit was
set at 80ºC.
Scope and Improvement
• Here we can see that operating window for temperature can be further expanded which
will help to reduce unwanted alarms.
• Improvement in this study
 We can get the service fluid tested in our lab so we get actual pour point data,
viscosity data at two or more temperature. This would make viscosity –
temperature relation more accurate.
 Better relation to find viscosity limit for a particular pump, as the current relation
is an empirical one.

Jamnagar
Study and suggest
process
Page | 47
Reference
1. Slide 125.(http://inside.mines.edu/~jjechura/Refining/02_Feedstocks_&_Products.pdf)
2. Page 3. (http://www.warrenpumps.com/brochures/Fluid%20Viscosity%20Effects.PDF)
3. Sour VGO
a. Tank (25194-MTD-UWZ621-204)
b. Pump (25194-MPPD-UWZ621-202) (25194-MPPD-UWZ621-222)
c. Mixer (25194-MFAD-UWZ621-204)
4. Sweet VGO
a. Tank(25194-MTD-UWZ621-207)
b. Pump(25194-MPPD-UWZ621-203) (25194-MPPD-UWZ621-223)
c. Mixer(25194-MFAD-UWZ621-207)
5. RFO
a. Tank(25194-MTD-UUZ741-001)
b. Pump(25194-MPPD-UUZ741-001)
c. Mixer(25194-MFAD-UUZ741-001)
d. Coil
e. Heater
6. EFO
a. Tank (25194-MTD-UWZ631-243)
b. Pump(25194-MPPD-UWZ631-210)
7. CBFS
a. Tank (25194-MTD-UWZ621-201)
b. Pump (25194-MPPD-UWZ621-202) (25194-MPPD-UWZ621-222) (25194-MPPD-
UWZ621-214)
8. LSWR
a. Tank (25194-MTD-UWZ621-262)
b. Pump(25194-MPPD-UWZ621-213)

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Page | 48
9. Heavy Slop
a. Tank (25194-MTD-USZ673-205)
b. Pump(25194-MPPD-USZ673-203)
c. Mixer(25194-MFAD-USZ673-205)
10. Pour Point and viscosity data
a. Sour VGO (http://corporate.exxonmobil.com/en/company/worldwide-
operations/crude-oils/crude-by-region)
b. Sweet VGO(http://corporate.exxonmobil.com/en/company/worldwide-
operations/crude-oils/crude-by-region)
c. RFO (Agreed spec sheet provided by mentor)
d. EFO (Agreed spec sheet provided by mentor)
e. CBFS (Agreed spec sheet provided by mentor)
f. LSWR(MSDS and In pump datasheet 25194-MPPD-UWZ621-213 Note 30)

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