The document summarizes the expansion of the Panipat Refinery in 2007 which included the addition of new units: AVU-2, DHDT, HCU, HGU, and MSQ. It then discusses various solutions to optimize operations in these units by adjusting factors like stripping steam, overflash, and reflux ratio. Potential issues with flows in the DHDT and HCU units' wash water systems are identified and calculating pipe sizes and material balances in these systems are proposed as solutions.

1. Panipat Refinery Expansion (Completed in
2007)
• AVU – 2
• DHDT
• HCU
• HGU
• MSQ
6 MMTPA
15 MMTPA
0
2
4
6
8
10
12
14
16
Before 2007 After 2007

2. MSQ Penex
Isomerization
Unit

3. Optimization
of Heat
Exchanger

4. Possible Solutions
INCREASING THE STRIPPING STEAM THAT IS BEING SENT AT
BOTTOM.
Disadvantage:
• Increase in the energy consumption.
• Heavies carry over
• Increase in the condensing duty
• Risk of flooding

5. Possible Solutions
INCREASING THE OVERFLASH.
Disadvantage:
1.By increasing COT of Heater resulting Heater
load increases.
2.Might lead to cracking/over cracking causing
coke formation.
3.Lighter formation that cannot be tolerated.
4.Higher Over flash put lot more energy in
furnace.

6. Possible Solutions
DECREASING THE REFLUX RATIO OF
NAPTHA.
Disadvantage:
1.Has advantage of reduction in duty of
condenser.
2.More stages are required to get the
desired purity.
3.Not enough to cause a remarkable change
in kerosene outlet temp.

8. Provisioned Pipeline

9. Some of the calculation done through excel is being done and attached along:
For crude temperature=125
o
C
1.Taking the LVGO inlet temperature=165
O
C
Area=518 m
2 which is
quite less than the
available area.

10. Taking the LVGO inlet temperature=156
O
C.
Area used
=765 m
2

11. Case-2 Increasing the crude inlet temperature to 126 OC
Taking LVGO at 165 OC.
Area used
=709 m
2

12. Taking LVGO at 160OC.

13. Taking LVGO at 156OC.

14. Steam Ejector (AVU-2)

15. Wash/Sour Water Systems
• Wash Water (Pure/Treated Water)
• Stripped Sour Water (SSW) from Sulphur Recovery Unit (SRU)
• De-Mineralized Water
• Boiler Feed Water (BFW)
• RGC MP Steam Condensate from DHDT
• Cooling Water (CW)
• Service Water (SW)
• Sour Water (Untreated Water from the plant) containing Sulphur,
Nitrogen impurities

16. Why do we need Wash Water System?
• Use
Water Remover Level Controller

17. What was our Aim?
• To show material balance among various Wash Water Sources and
Wash water outlets.
• To show the water carrying line sizes (from P&ID).
• To show the various Pumps and Vessels, in use to transport and store
the Water throughout the Panipat Refinery Expansion Project.
• To recommend a solution to flow problem existing in DHDT and HCU
Unit.

18. DHDT (Diesel
Hydrotreating
Unit)
DHD
T
Wash
Water
SSW from
SRU Wash Water
Drum and Air
fin Coolers
28tph
RGC Turbine
as MP
Condensate 4tph
Stripping
Steam/Fe
ed Stripper 5tph
Sour
Water
Cold HP/MP
Separator SRU
(Hydrotreate
d)
32tph
Stripper
Boot MP
Condensate 5tph

24. AVU-2
Desalter
Wash Water
DM Water
Desalter Water Vessel
30 tph
SSW from SRU 30 tph
Water in Crude Dissolved in Crude 10 tph
Brine Desalter Water Vessel ETP 70 tph
Column
CDU
Stripping Steam
32 tph
VDU 7.5 tph
Steam Ejector 37 tph
Sour Water SRU (Un-Hydrotreated) 76.5 tph
HCU
Wash Water
SSW from SRU
Air Fin Coolers 17.7 m3
DM Water
RGC Turbine as MP
Condensate
Fractionator Boot
(Exception)
Stripping
Steam/Feed Stripper 2.2 m3
Sour Water
Cold Flash Drum 17.7 m3
Stripper Boot 2.2 m3
MSQ
NHT Wash Water Cold Condensate Air Fin Coolers 3 m3
Sour Water
NHT Product Separator
Boot SRU 3 m3
FCC GDS Wash Water Cold Condensate
HDS Effluent Air
Condenser 250 kg
Sour Water
HDS Separator Drum
Boot SRU 250 kg
HGU
Wash Water BFW from Header Air Fin Coolers 7 tph
Stripping
Steam/Feed Stripper 0.285 tph
Sour Water SRU 7.285 tph
Summary

25. Solutions

26. References and Acknowledgement
• Mr. Sandeep Mahajan, DGM
• Mr. Sumit Kumar, PNE
• Mr. Shubham Kumar, PNE
• Mr. Satya Prakash Meena, PNE
• IOCL PRE Manuals