The petroleum industry, also known as the oil industry or the oil patch, includes the global processes of exploration, extraction, refining, transporting (often by oil tankers and pipelines), and marketing of petroleum products. The largest volume products of the industry are fuel oil and gasoline (petrol).

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2. Table of Contents
Acknowledgement..................................................................................................................................3
Introduction ............................................................................................................................................3
Vision.......................................................................................................................................................4
Values......................................................................................................................................................4
Historical Highlights ................................................................................................................................4
Health, Safety and Environment (HSE) department,..............................................................................5
Environment and Quality Management: ................................................................................................5
Laboratory...............................................................................................................................................6
Oil Management and Shipment..............................................................................................................7
• Single Point Moring (SPM) ......................................................................................................7
• Tanks .......................................................................................................................................7
• High performance Pumps .......................................................................................................7
Oil Refining Complex-I.............................................................................................................................8
• Heat Exchangers......................................................................................................................9
• Desalter...................................................................................................................................9
• Pre-flash column ...................................................................................................................10
• Furnace .................................................................................................................................10
• Crude Distillation Unit...........................................................................................................10
• Naphtha Splitter....................................................................................................................10
• Naphtha Stabilizer.................................................................................................................10
• LPG formation.......................................................................................................................10
• Hydro treating Unit...............................................................................................................11
• Catalytic Reformer Unit ........................................................................................................11
• MerOx Unit............................................................................................................................12
Suggestion.............................................................................................................................................12
Conclusion.............................................................................................................................................12

3. Acknowledgement
First of all, I am very Thankful to Almighty Allah who gives me Power and Strength to
complete our Internship and represent it in such a great way. I also want to thank our
parents who supported us Physically, Mentally as well as financially.
I am very Thankful to all the management of the industry, who gives us a chance of
Internship, they also give wonderful exposure, advice, clear and deep criticisms and
encouragement aided the Internship tasks. I also want to pay high regards on behalf of my
institution “Dawood University of Engineering and Technology”, and I was very grateful from
the depths of my hearts to Chairman, Teaching Staff and Lab Engineers that help to
development of theories and soft skills.
Introduction
Byco Petroleum Pakistan Limited was incorporated in Pakistan as a public limited company
on January 09, 1995. The Company is engaged in the business of refining crude oil into
various saleable components. The shares of the company are listed on the Karachi, Lahore
and Islamabad Stock Exchanges. The company takes pride in having the largest capacity
crude oil storage tanks in the country. It will able to produce 150,000 barrels per day. The
Single Point Mooring (SPM) facility being set up for the first time in Pakistan will
revolutionize the handling of petroleum and oil products in the Country.
The company keeps updating its procedures and is currently a mixture of old and latest
technology. Owing to great localization and with trained engineers and working that has
been done in the past few years the company has
become independent and does not require
external helps to solve their problems.
Byco is Pakistan’s emerging energy company
engaged in the businesses of oil refining,
petroleum marketing, chemicals
manufacturing and petroleum logistics.
We are serving our mission to fulfill the
energy demand within and beyond
borders.
Company under Byco umbrella are:
Byco Petroleum Pakistan Limited
(BPPL)
Oil Refining & Petroleum Marketing
Petroleum Infrastructure & Logistics
Chemical Manufacturing

4. Vision
Our vision is to be a leading energy company through delivering the core business, achieve
sustainable productivity and profitability to deliver a superior shareholder return.
Values
Byco values are the guiding principles that define how it conducts its business and what it
stands for as a company. This includes:
Setting high standards of care for environment, health and safety.
Investment in human capital, offer competitive employment terms and provide safe
and congenial working environment and an equal opportunity for all our employees.
Entail human resource development and promotes openness, professionalism,
teamwork and trust.
Enhancing value addition, implementing conservation measures and growth up-
gradation through addition of newer generation technologies.
Credibility, goodwill and reputation earned through ethical practices, honesty,
integrity and respect for people.
Safeguarding of shareholders' interest and providing them with a consumerate
return on equity is an integral part of our business ethics.
These values are the basis of our commitment to operate as a sustainable energy company.
Historical Highlights
1995 ~ Incorporation of Byco Petroleum Pakistan
Limited (BPPL)
2001 ~ Relocation of BPPL Refinery
2004 ~ Commencement of commercial operations
2006 ~ SAP Implementation
2007 ~ First Retail Outlet
2008 ~ Revamp and Debottlenecking
2008 ~ Joint venture with Abraaj Capital
Limited
2008 ~ Relocation of Byco Oil Pakistan
Limited (BOPL) Refinery
2009 ~ Petroleum Marketing Business
2009 ~ Completion of Storage Tanks
2010 ~ Byco Petroleum acquired 100% shares of
Byco Terminals Pakistan Limited
2010 ~ Capacity Enhancement of Byco Petroleum
Pakistan Limited Refinery
2010 ~ Single Point Mooring and Pipeline Project
2012 ~ Long Service Awards & Safety Awards
2012 ~ Byco Commissions First Ever Single Point Mooring in Pakistan
2012 ~ Byco Announces Completion of Country’s Largest Oil Refinery

5. Environment Health, Safety and (EHS) department
It is the very serious and responsible department of Byco,
because Byco handle very flammable and hazards material. So
HSE depart is very big, it is divided into following,
ERT (Emergency Response Team) ~ Two operational
Fire Fighting Tankers with high capacity foam storage
tanks and Fire water Network.
Medical Services ~ 2 bed hospital with advance
equipment and two equipped Ambulance facility.
IMS (Integrated Management Safety) ~ ERT depart
directly connect with ORC-I & ORC-II from wireless
Motorola for any emergency, but MCPs (Manual Call
Points) system is also installed in all over the plant and it
established hotline service.
Environment and Quality Management:
The main component of Quality Management is the IMS and ISO
certification. this system composes of internal and external auditors of the
HSEQ department that periodically analyze the plant to ensure quality,
health, safety and environmental protection. The results of the IMS
analysis results in approval of ISO certifications for the refinery.
BYCO has the following certifications,
ISO 9001: This certification ensures Quality standards of the
refinery. The certification credits the Quality Management
System of the refinery for running in accordance to the
set international standards.
ISO 1401: This certification is given to companies
with Environmental Management Systems set on the
international standards.
OHAS 1801: This certification is given to
companies maintain occupational, health and
safety standards.

6. Laboratory
The lab of Byco play a vital role for the production of standard products. The lab consists of
advanced equipment and the talented Chemist.
Firstly, we see the procedure of pure point test of gasoline. The pour point of a liquid is
the lowest temperature at which it becomes semi solid and loses its flow characteristics.
We also see the Flash point of the Diesel. The flash point of a volatile material is the
lowest temperature at which it can vaporize to form an ignitable mixture in air.
Here Viscosity is also check by Viscosity bath tester. It is oil testing machine which tells
the viscosity of oil at different temperatures. The kerosene and specially Aviation
Turbine Fuel (ATF) is tested in this equipment.
Then I understand the procedure of Octane test in the Corporate Fuel Research (CFR),
that is consist of a controlled engine (adjusting the piston length, changing the death
end of the piston, easily change the variable compression capacity of the piston, Sample
is tested in 20 minutes, 600 rpm).
And we also see and learn all the application of different chemicals for the testing of
Utilities Water.
Ethylene di-amine tetra-acetic acid (EDTA) is used for Chelating agents. Chelating agents
are chemical compounds that react with metal ions to form a water-soluble complex.
Chelating agents have a ring-like center which forms at least two bonds with the metal
ion allowing it to be excreted.
Sodium Thiosulphate is used for the testing dissolved oxygen in the boiler feed water,
boiler feed water must be clean from dissolved oxygen gasses because it reacts with
metal impurities and form salts the cause fouling/scaling.
Another test is the Alkalinity Test of the water of Cooling Tower, that describe the Buffer
Capacity of the water. It also tells about the Hardness/Softness of water.
Iodine test is also performed for the determination of
percentage of hydrogen sulfide and sulfuric acid present
in the Boiler Feed Water (BFW).
Spectrometer is used the finding the impurities in
Water. A spectrometer is a device for measuring
wavelengths of light over a wide range of the
electromagnetic spectrum. It is widely used for
spectroscopic analysis of BFW, Cooling Tower
Water.
We also see the two Gas Chromatography used
for the purity test of light samples (LPG, Fuel Gas,
Gas Oil). Gas Chromatography (GC) is work with the
relative volatility difference, and the thermal
conductivity detector detects the separated elements in
the compounds.

7. Oil Management and Shipment
It is the very critical and the most important department. It controls all the movement of the
oil, from receiving (Single Point Moring) to the Shipping (distribution to the tankers).
Single Point Moring (SPM)
SPM is the receiving Point in the middle of the sea near
Chearna island. It is the small port, here ship is connected with
14.7 km long pipe and the crude is transfer with ship’s
heavy-duty pump from the ship to the zero point. Byco
build a receiving office of crude oil in the zero point, then
the crude is transfer 3 km far (28-inch diameter), to the
plant’s storage tanks.
Tanks
In this department we learn about all the piping system
of the storage tanks. I go on the top of the crude oil tank.
It is the External Flooding Tank with 16m height and
50,000-barrel capacity. I also learn about the working of
Breather valve, Legs, Critical level zone (1.5m-2m) and fire
proof water lining/foam lining in the top of tank. Total six
tanks are operational in the Byco, four are small and each
50,000-barrel capacity and two are 250,000-barrel capacity.
We also experience the internal environment of fixed roof
furnace oil storage tank, because storage tank is empty
for schedule maintenance. Here I see the sump,
Automatic Tank Gauge (ATG).
LPG bullets are cylindrical and horizontal containers
used for storing Liquefied petroleum gas. These types
of LPG bullets are used for storing 2300 MT amounts of
liquefied petroleum gas.
High performance Pumps
I see the over flow pits and booster pump for transformation of
crude from the tanks to the process plant, and Internal Tank
Transfer Pumps (ITT pump).

8. Oil Refining Complex-I
I was also visited the ORC-I, but unfortunately me and the other Interns cannot observe the
plant in right manner, because the turndown is started, interns is not allowed to visit the
ORC-I. Hence, all the internee only learns the PDF of ORC-I plant.
The common thing, I see in the ORC-I is the Desalters, furnaces, Crude Distillation Unit,
Naphtha Stabilizer, Reformer Units, de-ethanizer, etc. The lighter components of crude
(Methane, Ethane) go to the flare. LPG and lighter compound are consumed in the plant
burners and furnaces.

9. But at the next day, we visited the ORC-I and gain the knowledge of troubleshooting of
different units. Trainer also tell give the information about the specifications of plant. It is a
wonderful visit for me because I see the heat exchangers that is opened for clearance, the
tubes were changed in some heat exchangers.
I see the following units in ORC-I,
Heat Exchangers for preheating of crude,
Desalter for Remove the metallic and salt like impurities,
Pre-flash column for separation of vapors from Liquid,
Furnace for increase the temperature of crude,
Crude Distillation Unit for separation of components into its Boiling Point difference,
Naphtha splitter column used for separation of light naphtha into Heavy Naphtha,
Naphtha Stabilizer is used for separation of LPG from Light Naphtha,
Amine Treating Unit is used for the Sweeting of LPG fuel,
Hydro treating Unit is used for removing hydrogen sulfide from heavy naphtha,
Catalytic Reformer Unit is used for formation of High RON products,
MerOx Unit is used for the purification of diesel.
These are the list of Units in ORC-I, now I want to discuss the specification of Units and the
different Reactions in Reactors for the formation of Valuable
Products.
Heat Exchangers
One shell multi-tube pass Shell and Tube heat Exchangers is
used for pre-heating of Crude. Pre-heating of crude is very
essential for two Reasons,
• To recover the heat of hot product of Crude
distillation unit, Hot products is going through the
Shell side and the crude is going into the tube side,
resulting the Crude gain the maximum heat of hot
products.
• Second reason is that the crude is going through the
Desalter in the next step, therefore high temperature crude
will increase the efficiency of Desalter.
Desalter
At 200 C, the crude is entering in the Desalter, mixed with
water and form emulsion. By using Transformers, a high
voltage is supplied in the Desalter, therefore the metallic
compound and salt ions are move fast and these ions travels
into water. Hence water and salts remove in the bottom drain
and pure crude is transfer at the upper section. But Byco does
not used desalter in all type of crude, if salt impurities are greater
than 5ppm then the desalter is used. Mostly less then 1ppm Crude
is used in ORC-I.

10. Pre-flash column
At 200 C, the lighter components are vaporized and must be separated. So, pre-
flash column is used for the separation of methane, ethane and some amount of
Naphtha,
• It increases the efficiency of Furnace and avoid wastage of heat in the
lighter components,
• Here this column is very important because it decrease the load of main
distillation unit.
Furnace
It is used to increase the temperature of crude above 350 C. the advantage
of this furnace is to decrease the energy consumption in re-boiler. If furnace
is used then it is not essential to used Re-boiler at bottom product.
Crude Distillation Unit
Here the separation of crude is performed due to boiling point difference.
Different components are transfer from different side cuts, and
reflux for increase the purity of products. The re-boiler is not
used in this distillation column (super-heated steam is used for
vaporization of heavy components).
I want to discuss the process light components. So, lighter
components and light naphtha is the overhead product of
CDU. Then it sends to the condenser, the light naphtha is
condensed and reflux again, but methane and ethane
can’t condense and go to the flare and burned.
Naphtha Splitter
This tower is used for separation of Light Naphtha from Heavy
Naphtha. Commonly Heavy Naphtha contain Heptane and
octane and light naphtha contain hexane and lighter components.
Naphtha Stabilizer
It is used for the separation of LPG form light Naphtha. Then the
LPG send to the LPG treating unit and the light Naphtha is
send to the Amine Treating Unit for purification. Then Light
Naphtha go to the Gasoline Blanding Pool.
LPG formation
After Naphtha stabilizer, LPG send to the Amine
Sweeting unit send to a series of tower named, de-
ethanizer, de-propanizer and de-Butanizer. Here ethane,
propane and butane are separated. Ethane is not pure, it
is the mixture of ethane, methane and of other corrosive
gases. Hence these gases are flared out.

11. Hydro treating Unit
It is used to remove oxygen, nitrogen, Sulphur and metallic compound form heavy naphtha.
The impurities react with high pressure Hydrogen gas and produced water, amine Hydrogen
Sulfite gas, respectively. After removing these gases, the heavy naphtha is ready for
reformer unit.
The Reactions are following,
Catalytic Reformer Unit
It is used for conservation of heavy naphtha into the high RON
aromatic compounds. The series of reactors and furnaces are
for this Reformer unit.
The reaction is following,
• The cyclic naphthenes doing endothermic de-
hydrogenation reaction and converted into
aromatic compounds.
• The straight chain or paraffins is dehydrogenate
and form olefins,
• Then dehydrocyclization converts the olefins into
Naphthenes,
• Then Naphthenes convert into Aromatic compounds
through dehydrogenation.
At the last, the product of reformer in send to the gasoline blending pool.

12. MerOx Unit
It is used for the purification of diesel. Firstly, Amine or Caustic washing is used for the
removal of sulfide compounds. Then it sends to the MerOx Unit (Mercaptan Oxidation Unit).
Here, the charcoal-based catalyst is used for the removal of sulfur containing hydrocarbons.
Then diesel is transfer in the storage tanks.
Suggestion
More opportunities should be created for the students to do internship in this
company.
The company should increase and ensure more supervision over the interns in order
for the better understanding of any process carrying out there
I suggest the company to control Hydrogen Sulfide emission from their industry.
The Company must install the Sulfur Recovery System, because it is commonly used
in many Refinery.
The company should use Vacuum Distillation Unit for the production of valuable
products.
They can use Delayed Coker Unit for separation of valuable products, it can also
produce precious Carbon Electrodes.
Conclusion
Finally, the internship was both fruitful and fun for us and we would encourage the other
students to apply here for the internship and to avail the opportunity of doing internship in
this company to clear their concepts and knowledge related to their field by observing
things practically, that were taught to them theoretically in the university.
I saw the theories and laws of science are implemented in the large scale. We learn different
skills that is very useful for me, in my future.