M.TEHSEEN

INTERNSHIP REPORT
PREPARED BY MUHAMMAD TEHSEEN
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INTERNSHIP PROGRAM REPORT
(HCU PLANT)
DURATION 4 WEEK (27TH
DEC. 2016 TO 20TH
JAN. 2017)

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ACKNOWLEDGMENT
Success and achievement is possibleonly through hard work, determination and
strong will. I am gratefulto ALMIGHTYALLAH who gaveme the strength to think,
plan and act accordingly which make me possibleto complete my internship.
Though it is a literary tradition to acknowledgethe contribution and help by
differentpeople & organization in the completion of an internship, but as a
matter of fact somewords cannotexpress our gratitudeto the various helping
hands. Itis very difficult to appreciate each and every person for his contribution,
but there is a standing contribution of my following advisors, who werethere
with me at the time I needed them & without there guideline it would be
difficult for me to complete this internship successfully.
NAME DISIGNATION
ENGR. KAMAL UD DIN PLANT INCHARGE
ENGR. ARSALAN REHMAN TRANEE ENGINEER
MUHAMMAD ISMAIL PLANT OPERATOR
MUHAMMAD ALI RAZA PLANT OPERATOR

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HSEQ DEPARTMENT
INTRODUCTION
ARL is committed to provide the best quality products in the market, endeavors to protect the
environment and to ensure health and safety of its employees, contractors, and customers and work
for continual improvements in Health, Safety, Environment and Quality (HSEQ) systems.
ARL is committed to comply with all applicable Health, Safety, Environment and Quality laws and
regulations.
ARL has a fullyfunctional HSEdepartmentthatrunsaround the clock 365 daysa year.The details of
whichare highlightedbelow.
The HSE departmentof ARLcan be brokendowninto:
• ERT (EmergencyResponse Team)
• Medical Services
• ProcessSafety
• ConstructionSafetyandAnalysis
• IMS (IntegratedManagementSafety)
The Policy shall be used to demonstrate this commitment through:
HEALTH:
ARL seeks to conduct its activities in such a way as to promote the health of, and avoid harm to
its employees, contractors, visitors and the community.
SAFETY:
ARL ensures that every employee or contractor works under the safest possible conditions. It is
our firm belief that every effort must be made to avoid accidents, injury to people, damage to
property and the environment.
ARL believesthatpracticallyall accidentsare preventable bycarryingoutriskassessments,andreducing
risksidentified,byappropriate controls.
INDIVIDUALSAFETY:
In ARL,the HSE departmenttheirsafetymonois“Safetystartsfromyou”. Everyindividualthatenters
the refineryisentrustedwiththe responsibilitytoensure hissafetyandthe safetyof the equipment.
There isa strict code on clothinginside the refinery,noone canenterwithoutwearingahelmet,safety
shoesandan overall.Otherthan that, forfurthersafetyPPEs(Personal ProtectiveEquipment) like
googles,soundmufflers,gloves,SCBA (Self ContainingBreathingApparatus) etc.are readilyavailablein
case of need.

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Otherthan that,the HSE alsoarrangesseminarsandtrainingstospreadsafetyskillsand habitsinthe
individualsworkinginthe refinery.
EQUIPMENTSAFETY:
As muchas humansafetyisimportant,the safetyof equipmentisessential too.HSEdepartment
regularlyinspectsequipmenttocheckif itis inproperworkingconditionandestablishesrulesto
operate orworkwiththe equipment.
In case of maintenance of equipmentthereisaproperworkpermitsystem.Theseworkpermitsare
onlyprovidedafterproperclassificationof the type of work,hazardanalysisandinsurance thatthe
workwill notaffectthe otherequipment.
There are seventype of workpermitat ARL.
1. HOT WORK PERMIT. (RED)
2. COLD WORK PERMIT. (GREEN)
3. CONFINED SPACE WORK PERMIT. (YELLOW)
4. EXCAUTIONCIVIL WORK PERMIT. (WHITE)
5. RADIOGRAPHY PERMIT.
6. ROAD BLACK PERMIT.
7. ELECTRICAL ISOLATION PERMIT.
ENVIRONMENT:
ARL is committed to prevent pollution by the efficient use of energy throughout its operations, recycle
and reuse of the effluent wherever possible, and use of cost-effective cleaner production techniques
that lead to preventive approach for sustainable development.
QUALITY:
ARL recognizes employees' input towards quality by emphasizing skills development and
professionalism.
ARL must be customer driven, cost effective and continuously improving services, works and products
to meet requirements of the market.
ARL conducts periodic audits and risk assessment of its activities, processes and products for setting
and reviewing its objectives and targets to provide assurance, to improve HSEQ standards and loss
control. ARL is committed to share all pertinent information related to HSEQ with all concerned
parties.
INTEGRATED MANAGEMENTSYSTEM (IMS)
Standards Year Issue date Valid till
ISO 14001 2004 2/11/2014 1/11/2017
ISO 9001 2008 15/11/2015 14/11/2016
OHSAS 18001 2007 10/11/2014 10/10/2017

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PURPOSE
1. To give a basicunderstandingof qualityenvironmentoccupationhealthandsafety.
2. Implement,maintainandcontinuallyimprove HSEmanagementsystem.
3. Assure itself of itsconformitywithstatedHSEpolicy.
ELEMENTS OF OSHAS 18001:2007 / ISO 14001:2004 / ISO 9001:2008
HSE
POLICY
PLANNING
IMPLEMENTATION
& OPERATION
CHECKING
MANAGEMENT
REVIEW

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HCU PLANT
HEAVYCRUDEUNITINTRODUCTION:
Thisplantis manufacturedbyMITSUIEngineeringin1999 at 0.920 sp. Gravitybutthissp. Gravitycrude
isnot available soitfurtherredesignat0.84 sp.Gravity.Thisplantisalsooperatedonlightcrude or
mix as perrequirement.Inthisplant,there are twotypesof distillationatmosphericdistillationand
vacuumdistillation.Thisplantproductsare:
1. Atmosphericdistillation
a. Low pressure gas
b. Highpressure gas
c. NEPHTA
d. Kerosene
e. Highspeeddiesel
f. Lightdiesel oil
g. Furnace fuel oil
2. Vacuumdistillation
a. Slope oil
b. Wash oil
c. Jude batchingoil
d. Asphalt

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PUMP
1ST
HEAT TREATMENT
From1,2AB,3AB,4AB,5AB
heat exchanger
2ND
HEAT TREATMENT
From 6,7,9th
B,10,11,12,13,9A
heat exchanger
BLOCK DIAGRAM OF CRUDE:
1. CHARGEPUMP
There is double impeller centrifugal pump is used. A centrifugal pump converts input
power to kinetic energy by accelerating liquid in a revolving device (an impeller). Charge pump
send the crude oil to the heat exchanger at the pressure of 25 kgf/cm2.
PUMP DETAIL
Capacity 76 m3/hr.
Total head 2786 M
RPM 2975
HTP 54 kgf/cm2
Voltage 415 volt
Ampere 257 amp.
2.HEATEXCHANGER
A heat exchanger is a device used to transfer heat from one medium to another.
When crude enter in the heat exchanger increase the temperature (25 to 135 0
C). Heating
medium used in the heat exchanger is product oil and then crude oil sent to the desalter.
TYPES OF HEAT EXCHANGER
 FinFan heatexchanger
 Trim Coolerheatexchanger
 Inside Shell &Tube heatexchanger
 Spiral type heatexchanger
DISALTERS
3 IN
SERIES
HEATER
H-001
FRACTIONATING
TOWER
(V-001)

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 Kettle type heatexchanger
3.DE-SALTER
Desalters are originallyusedtocleanupthe feedof distillationunit.Desalting,reducesthe salt
foulingandcorrosioninexchangersand pipelines.Contaminantsof crude oil mayremove byelectrical
or chemical desaltingandbothcan alsobe usedtogether.There islotof processvariablesinvolvedin
crude desalting.
Desalter is simply a steel vessel having different parts as shown in figure. It helpsin removing the salts
and impuritiesfromthe crude oil.We can see inside the desalterfromfigure and functionof each part
is described as flows.
14
10
9
1
`
DESALTER
2
4
11
3
12
6
5
713
8
TRANSFORMER
It is step up transformer provides electrical power (A.C). The system helps in the separation of water
from the crude (breaking emulsion).
OUT LETCOLLECTION HEADER
It is rectangular so that upward coming crude found the maximum contact area and passes through
circular holes easily.
MUD WASH LINE
It is usedto remove sludge insidevessel.Thisline splitupintolinesinside the desalteralongthe length
of desalter on both sides. These lines equipped withnozzles withenhance the velocity head of water,
whenmudwash line isoperated.Whenthiswaterstrikesthe sludge itsvelocityheadbecome zeroand
1. Transformer
2. Float arrangement
3. Outlet collection header
4. Pressure safety valve
5. Electrodes
6. Mud wash line
7. Cuffheader(optional)
8. Circularholes
9. Tri Cock
10. Mixing valves
11. Inlet crude header
12. Effluent header
13. Man hole
14. Level control valve

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pressure head become maximum. A turbo line is created in the settleddown sludge which comes out
through effluent drain.
INLET CRUDEHEADER
Inlet crude header is cylindrical in shape having capes on both ends. It has circular holes on random
position to keep the flow laminar. The caps at the end do not have any hole.
EFFLUENT HEADER (BELOW THE MAIN CRUDE HEADER)
It has also circularholesto drainsaltedwaterand impuritiescontinuously.There isalevel control valve
on its downstream to maintain the required water level inside the desalter.
CUFF HEADER (OPTIONAL)
It isabove the effluentheader.If anyemulsionisobserved,thenthisheaderisoperated.Itisadjustedat
some heightsothatwaterlevel remainswhiledrainingthe emulsion.Asthe processfluidof cuffheader
is emulsion so that it is called cuff (interface) header.
TRICOCKS
These are sample pointsatthe differentpositionof the desalter.Tri cockshelpstocheckthe waterlevel,
interface height and condition of crude.
PROCESS DISCRIPTION
Desalter are not only used for the removal of salts but also used to remove the other impurities from
crude oil.These impuritiesnormallyconsistof varyingamountof solidmaterials,suchasslit,ironoxides,
sand, crystalline salts carbon and sulfur etc.
Basically,saltsare notfoundincrude oil butinthe waterwhichpresentdispersedfrom.Crudeoil ispre-
heated up to specific limit and fresh water is added to contact the dispersed water. Fresh water also
contact with solid impurities in the crude. Small amount of demulsifying chemical is also added. This
stream of crude, fresh water and demulsifier passes through a mixing valve which makes a required
emulsion.Thisstreamentersthe desalterandpassesthrougha highvoltage electrical fieldprovidedby
a metal electrodes connected with step up transformer.
Demulsifier breaks the emulsion and separated the water entrapped in the crude. Electrical forces
combine the smallwaterdropletsandmakethemsolarge thattheysettledownundergravity.The salted
water collected in the bottom is drained continuously from the vessel and desalted crude is collected
from the top of vessel for distillation.
PARAMETERS OF DESULTER
 Chemical (Demulsifier)
 Freshwater
 Electriccurrent
 Temperature
 Pressure
Afterdesaltingcrude sendto2nd
heattreatmentforpre-heatingagain to increase temperature (135-
220 0
C).

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4.FURANCE (HEATER)
A processheaterisa direct-firedheatexchanger that uses the hot gases of combustion to raise
the temperature of a feedflowingthroughcoilsof tubesalignedthroughoutthe heater. Depending
on the use, these are alsocalledfurnacesorfiredheaters.Some heaterssimplydeliverthe feed at a
predetermined temperature to the next stage of the reaction process; others perform reactions
on the feedwhile ittravelsthroughthe tubes.
Process heaters are used throughoutthe hydrocarbonandchemical processingindustriesinplaces
such as refineries,gasplants,petrochemicals,chemicalsandsynthetics,olefins,ammoniaandfertilizer
plants.Some plantsmayhave onlytwoorthree heaterswhile largerplantscanhave more thanfifty.
Most of the unit operations in these plantsrequire firedheatersandfurnaces.Theseoperations
include:
 Distillation
 FluidizedCatalyticCracking
 (FCC)
 Alkylation
 CatalyticReforming
 ContinuousCatalystRegeneration
 (CCR)
 Thermal Cracking
 Coking
 Hydrocracking
Typical processheaterscanbe summarizedasfollows:
 Start-UpHeater— Starts-upa processunitwhere itisrequiredtoheatupa fluidizedbedof
catalystbefore addingthe charge.
 FiredReboiler— Providesheatinputtoadistillationcolumnbyheatingthe columnbottoms
and vaporizingaportionof it.Usedwhere heatrequirementisgreaterthancanbe obtained
fromsteam.
 CrackingFurnace — Convertslargermoleculesintosmallermolecules,usuallywithacatalyst
(pyrolysisfurnace).
 ProcessHeater— Bringsfeedtothe requiredtemperature forthe nextreactionstage.
 ProcessHeaterVaporizer— Usedtoheatand partiallyvaporize acharge priorto distillation.
 Crude Oil Heater— Heatscrude oil priorto distillation.

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 ReformerFurnace — Chemical conversionbyaddingsteamandfeedwithcatalyst.
HEATER PROCESS
ARL use lightends(e.g.refinerygas) fromthe crude unitsandreformersaswell aswaste gasesfor
heaterfuel.Natural gasisoftenblendedwithwaste gasandthe otheroff-gasesasthe primaryfuel for
heaterprocesses.Residual fuelssuchastar,pitch, and BunkerC(heavyoil) are alsowidelyused
The processheatershownbelowisanatural draft unitwithinspiration type burner.Combustionairflow
isregulatedbypositionthe stackdamper.Fuel tothe burnersisregulatedfromexitfeedtemperature
and firingrate isdeterminedbythe level of productiondesired.
RADIANT SECTION
The radianttubes,either
horizontal orvertical,are located
alongthe walls in the radiant
section of the heater and
receive radiantheatdirectfrom
the burners.The radiantzone
withitsrefractoryliningisthe
costliestpartof the heaterand
85% of the heat shouldbe gained
there.Thisisalsocalledthe
firebox.
CONVECTION SECTION
Rather than hit the radiant
section directly, the feed
charge enters the coil inlet in
the convection section where
it is preheated before
transferring to the radiant
tubes. The convection section
removes heat from the flue
gas to preheat the contents
of the tubes and significantly
reduces the temperature of
the flue gas exiting the stack.
Too much heat picked up in
the convection section is a
sign of too much draft. Tube
temperature is measured in both convection and radiant sections.

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SHIELDSECTION
Justbelowthe convectionsectionisthe shield(orshocktube) section,containingrowsof tubingwhich
shieldthe convectiontubesfromthe directradiantheat.Several importantmeasurementsare normally
made justbelowthe shieldsection.The bridgewall orbreakwall temperature isthe temperatureof the
flue gas afterthe radiantheatisremovedbythe radianttubesandbefore ithitsthe convectionsection.
Measurementof the draftat thispointis alsoveryimportantsince thisdetermineshow well the heater
isset up.Excessdraft,eitherpositive pressure ornegative pressure,canleadtoseriousproblems.
Thisis alsothe ideal place forflue gasoxygenandppmcombustiblesmeasurement.
BREECHING SECTIONS ANDSTACK
The transition from the convection section to the stack is called the breeching. By the time the
flue gas exits to the stack, most of the heat should be recovered and the temperature is much
less. From a measurement point of view, this location places fewer demands on the analyzer
but is much less desirable for the ability to control the process. Measurement of stack
emissions for compliance purposes is normally made here.
ENERGY SAVINGS
All processheatersconsumelarge amountsof fuel toproduce the necessaryheatthatmustbe
transferredtothe material broughtintothe furnace.
Energycosts representupto65% of the cost of runninga chemical/petrochemical/refiningcomplex.
Furnace and heaterfuel isthe largestcomponentof thiscost.Inthe past,there waslittle reasontoseek
efficiencyimprovementsaswaste fuel wascheapandthe excesswasoftenflared.Todaymanyof the
refineryprocessesrequirehydrogen,andalot of the hydrogenrichoff-gases,whichwerepreviously
usedas heaterfuel,are nowneededtomeetthisdemand.Naturalgas,whichisveryexpensive,isused
to make upshortfalls.Therefore,the more energythatcanbe squeezedfromexistingplantfuels,the
lesssupplementarynatural gasisrequired.
Correct use of gas analyzers can conserve the amount of fuel used and maximizes heater
efficiency.
NOX REDUCTION
significantfractionof NOx producedannuallycanbe attributedtothe chemical/refiningindustryand
stringentemissionlimitsrequire greatercontrol of NOx andotherstackcomponents.Operatingthe
heaterat optimumefficiency,withlow excessairfiringusingoxygenandppmcombustibles,isthe
simplestandleastexpensive waytoreduce NOx emissions.
PRODUCT QUALITY
Temperature controlof the processtubesandreactionsiscritical in reformingandcrackingoperations.
Since flaringis nolongerpermitted,gaseswithwidelyvaryingcalorificcontentare now usedasfuel
forthe heaters.Thisleadstolarge variationsinheatdeliveredinthe radiantsection,andtherefore,to
greaterdemandsoncontrol of the productor feedtemperature.

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SAFETY
No informationorincorrectinformationfromapoorlyplacedanalyzercanleadtounsafe operationof
heatersfromairleaks,tube leaks,andfuel orburnerproblems.Purge-downandlight-offcyclesrequire
special care andwarrant methane monitoringinadditiontooxygenandppmcombustibles.
HEATER ANDTUBE LIFE
Incorrectoperationleadstopremature failure,structural damage ortube leaksdue toflame
impingement,secondarycombustionandflue gasleaks.
FACTORS AFFECTINGPROCESS HEATER OPERATION
Processheatersofferchallengesformeasurementandcontrol due to:
 Hightemperature inthe radiantzone where measurementisdesired.
 Multiple burners.
 Multiple radiantzones(cells).
 Widelyvaryingfuel calorificvalue.
 Low investmentinheateroptimization.
A reviewof the factorsaffectingprocessheaterperformance will be
useful.Thisincludesdraft,burneroperation,combustionefficiency
and NOx production.
DRAFT
For optimumoperation,excessoxygeninthe flue gasenteringthe
convectionsectionshouldbe minimizedandthere shouldbe avery
small negative pressure atthe convectionsectioninlet.
CORRECT DRAFT
RefertoFigure 3.Stack dampersandsecondaryairregistersaffectthe
draft and bothadjustmentsare related.The hotgaspushessothat
the pressure isalwaysgreatestatthe firewall.The stackdraftpulls
and whencorrectlybalancedthe pressureatthe bridge wall should
be close to zeroor veryslightlynegative.
A processheateroperatingproperlywillalsohave azero,orslightly
negative draft,atthe shieldsection.The fireboxwillbe slightly
positive (+0.5to +2.0“water column(wc)) andthe stackwill have a
range of -0.5 to -1.0” wc.
Excessive draft,eitherpositivepressure ornegative pressure,can
leadto severe problemsinthe convectionsection.

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EXCESSIVE Draft— Positive Pressure
Created
In Figure 4,the airregistersare wide open
and the dampermostlyclosed.This
generatesapositive pressure whichforces
flue gasesoutwardthroughleaksin the
convectionsectionleadingtoserious
structure damage,aswell asheatloss.
EXCESSIVE DRAFT — NEGATIVE
PRESSURE CREATED
In Figure 5,the airregistersare mostly
closedandthe stack damperiswide open
leadingtoa highnegative pressureinthe
convectionsection.Coldambientairis
suckedinthroughleaksinthe convection
sectionleadingtoerroneousoxygen
readings,aswell asheatloss.Inaddition,
the excessive draftcausestall flames
whichcan reachthe tubesresultingin
seriousdamage.
MOSTLY CLOSED
Figure 4. Excessive positive draft Figure 5. Excessive negative draft
BURNER OPERATION
COMBUSTION EFFICIENCY ANDNOX
REDUCTION
The burnerson a processheaterpremix the fuel
withthe primaryair whichisaspiratedintothe
burnerby the fuel gasflow (see Figure 6).The
primaryair flow shouldbe maximizedwithout
liftingthe flame offthe burner. The pressure of
the fuel gassupplyisimportantsince low gas
pressure degradesperformance.Mostof the air
(as primaryair) isdeliveredtothe burneralong
withthe fuel.Secondaryairisintroducedand
adjustedwiththe registers.Toomuchor toolittle
secondaryairgivespoorcombustion.
Figure 6. Burner with correct combustionair.
GAS
PREMIX
CHAMBER
PRIMARY
AIR REGISTER
REFRACTORY
BURNER
TIP
SECONDARY
AIR REGISTER
CARBON DIOXIDE
WATER VAPOR
OXYGEN
NOx
PPM COMBUSTIBLES
(CO + H2)
NITROGEN

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THE IMPORTANCEOF OXYGEN ANDCOMBUSTIBLES
1% 2% 3% 4%
O2
Figure 10. Determining optimum O2 set point
Reducingthe excessairoroxygentothe minimumsafe level isthe mostimportantstepinreducing
energyconsumption.There isnosingle O2 level thatisrightforall heaters.The optimumoxygenlevel
dependsonthe load,the burnerdesign,the type of fuel,andthe burnerperformance.
RefertoFigure 10. Reducingoxygenwhile measuringthe ppmcombustiblesallowsthe correct
operatingpointtobe determined.The actual value willdependonthe variablesmentionedpreviously
and shouldbe determinedforeachindividual analyzerplacementpoint.Withoutcombustibles,itisnot
possible tofindthe optimumsetpoint,since youcannotknow when tostopreducingthe combustion
air. Withthe combustiblesdetector,the oxygencanbe reducedsafelyuntil the combustiblesstartsto
increase.Thisisthe correctvalue forthatheater.
Combustibleshasalwaysbeenanimportantpartof our combustioncontrol strategy.Thermoxused
the term“combustibles”in1975 to refertothe incompleteproductsof combustioninflue gas,
primarilycarbonmonoxideandhydrogen.The detectorisnotdesignedtomeasure unburnedfuel such
as methane.Manyoperatorshave previouslyusedpercentlevel combustibleswhichisgoodfor
detectingseriousprocessupsetsorforprecipitatorprotection,buthasnobenefitforoptimizing
combustionefficiency.Forthis,areliableppmcombustiblesmeasurementisneeded.
The latestgenerationof Thermox ppmcombustiblesdetectors,perfectedduring20 yearsof research
and development,offersexcellentreliabilityandperformance.
It is oftenthoughtthatthe oxygenmeasurementfromazirconiaprobe will alsoindicatewhenthereis
insufficientexcessair.Thisisbecause anycombustiblespresentwill burnonthe cell andreduce the
displayedoxygenaccordingly.While thisiscorrect,the drop-inoxygenonlybecomessignificantwhena
majorupsetoccurs.For example,a2000 ppm(0.2%) level of combustiblesorCOin the flue gas will
reduce the O2 value byonly0.1%. A drop-inoxygenfrom3.0to 2.9% will notbe treatedas significantby
EXCESS
AIR
LOSSES
COMBUSTIBLES
LOSSES
O2 &
COMBUSTIBLES
OPTIMUM
CONTROL
POINT
300 PPM
200 PPM
100 PPM
EFFICIENCY
COMBINED
LOSSES
O2-ONLY
OPERATING
SET POINT

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an operator.A readingof 2000 ppm on the combustiblesdetectoratthe same time wouldcertainlybe
noticed,and actedupon.
METHANE DETECTION DURING START-UP
As an additional precautionduringthe purge-downandlight-offcycle,the methane detectorwill detect
anynatural gas or otherfuelswhichhave leakedintothe firebox andcouldcause anexplosion.If the
heaterisstarteduponlyrarely,the methane detectorwouldhave limiteduse.Whenaheaterorboileris
started-upfrequently,thenthe methanemeasurementgivesadditionalpeace of mind.Thermoxoffersa
combinationO2,combustiblesand methane analyzer.The methane partisusedonlyduringthe purge-
down/light-offcycle withnatural gas-firedheaters.Once lit,the oxygenandcombustibles
measurementsare usedforoptimization.
EXPANDINGHEATER CAPACITY
Notall heatersituationscanbe improvedwiththe abovesuggestions.Otherclassesof problems
include:
HEATRELEASE-LIMITED
The burnercapacity limitsfurnace duty.Anincrease of gaspressure,orpossiblyincreasingthe burner
orifice can increase capacity.Highhydrogencontentinthe fuel gascancause this.
DRAFT-LIMITED
Withthe damperandregisterswide open,thereisstill insufficientair.Airleakage intothe convection
sectionwill notpermitsecondaryairtoenterthe heater.Convectionsectiontubescouldalsobe partially
plugged.Increasingsecondaryairopeningsize mayremedythe situation.
HEATABSORPTION-LIMITED
The product can’tobtainthe targettemperature.Addconvectivetubes,increaseproductmassvelocity
throughtubes,adjustfordense flame.

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CONCLUSIONOF HEATER
Heateroperatorsoftenfeel thattheyneedonlytomaintainthermal objectivesandthiscanbe done by
controllingthe excessairusinganoxygen-onlyanalyzer.Orif there isno automatictrim onthe heater,
that Oxygen-onlyissufficient.Aswe have shown,thisisamisconceptionandeventhe smallestheater
absolutelyneedsOxygenandppmcombustibles.Slugsof waste gaswithpoorBTU value canhitthe
burnersat anytime andcause major and rapidchangestothe combustionparameters.
Measuringoxygenandppmcombustiblesprovidesbenefitsfarinexcessof the analyzer(s) installed
cost.
1. Improves efficiency - typically 3-5% fuel savings.
2. Reduces emissions - 15-20% NOx reduction is possible.
3. Identify problems due to air leaks.
4. Identify problems due to tube leaks.
5. Monitor burner performance.
6. Maintain product quality.
7. Improve heater and tube life.
8. Critical units such as reformers require multiple measuring points to provide sufficient
information for proper process control.
Afterheater(furnace) crude send to fractionating tower by increase temperature (320-340 0
C).

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DISTILLATION COLUMN
Atmospheric Distillation as the name suggests is a distillation process in which distillation of crude is
done. Distillation is a physical separation process in which Crude oil is split into its different
components based on volatility.
The crude oil distillation unit is the first processing unit in virtually all petroleum refineries. The
fractionator column distills the incoming crude oil into various fractions of different boiling ranges,
each of which are then processed further in the other refinery processing units. Crude oil is sent to the
atmospheric distillation unit after desalting and heating.
Sr. No. PRODUCT PLATE NUMBER TEMPERTURE
1 NAPHTHA 1ST
120 0
C
2 KEROSENE 10TH
165 0
C
3 HIGH SPEED DIESEL 24TH
215 0
C
4 LIGHTDIESEL OIL 30TH
280 0
C
5 FURNACE FUEL OIL STRIPPING SEATION 311 0C
DISTILLATIONTOWER HIGHLIGHTS
• Number of Trays: 42 in total
• Type of Tray: 36 Fixed Valve trays, 2 bubble cap trays, 4 Chamni trays
• HCU Capacity: 10,000 barrels per day
• Top Pressure: 1.3 to 1.5 kg/cm2
• Bottom Pressure: 2.5 to 3.5 kg/cm2
• Feed Charge: At the 37th Tray
• Feed Inlet Temperature: 340 0C.
• Reboiler: No reboiler, temperature controlled by the means of direct contact with superheated
steamat 390 0C

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VACUUM DISTILLATION
It is a methodof distillation wherebythe pressure abovethe liquidmixture tobe distilledis
reducedtolessthanits vapor pressure causingevaporationof the most volatile liquid.This
distillationmethodworksonthe principle thatboilingoccurswhenthe vaporpressureof aliquid
exceedsthe ambientpressure.
Furtherdistillsthe residueoil fromthe bottomof the crude oil distillationunit.The vacuumdistillation
isperformedata pressure wellbelowatmosphericpressure as well as65 mmHg.Feedinlet
temperature of vacuumdistillationtoweris310 o
C.
PRODUCTDETAIL
• Slope Oil
• Wash Oil
• Jude Batching Oil (JBO)
• Asphalt/Bitumen
NAPHTHA STABILIZER
A stabilizer is essentially a distillation column intended to remove what is normally a relatively
small amount of "light ends" from a product. The product is then "stabilized". Thus, one might
run the light petroleum fraction known as through a Naphtha Stabilizer.
NAPHTHASTABILIZER HIGHLIGHT
• Number of Trays: 30 in total
• Type of Tray: Fixed Valve trays
• Stabilizer Capacity: 1830 barrels per day
• Top Pressure: 7.78 kg/cm2
• Bottom Pressure: 11 kg/cm2
• Feed Charge: At 21th Tray
• Reid vapor pressure: 11 psi
• Reboiler.

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SELF OBSERVSTIONS
1) Capacityof plantdependsuponthe distillationcolumn
2) Steamtrap,it isa device usedtodischarge condensateandnon-condensate witha
negligible consumptionorlossof live steam.
3) Saturatedsteamitoccurswhenthe rate of watervaporizationisequal torate of the
condensation.
4) Super-heatedsteamiscreatedbyfurtherheatingsaturatedsteambeyondthe
saturatedsteampoint.
5) Lowerexplosivelimit(LOL),the lowestconcentrationof agasor a vaporin aircapable
of producingaflash of fire inpresence of anignitionsource.
6) Higherexplosivelimit(HPL),the higherconcentrationof agasor a vaporin aircapable
of producingaflash of fire inpresence of anignitionsource.
7) Atomizingsteam, Lowpressuresteamwhichisintroducedtothe oil guntohelp
atomize the oil,toassistthe burningprocess,andtokeepthe oil gunfromplugging.
8) Snuffingsteam,itisusedforcreating the draft inheaterstartup.
9) Non-returnvalve(NRV).
10) Globe valve isusedforflow control.
11) Gate valve isusedforisolationof anyequipmentorcontrol valve
12) Centrifugal pumpisusedforthe continuesflow.
13) Positive displacementpumpisusedforhighpressure requirement.
14) Impingementplateisusedforthe safetyof tubesinheatexchanger.
15) Ventvalve,drainvalve,suctionvalveanddischarge valve.
16) Strainery-type andt-type.
17) Brodie meter,rotameterandorifice meter.
18) Pressure safetyvalve(PSV) andpressurerelievevalve(PRV).
19) Specificgravityismeasure byhydrometer.
20) Doctor test,tomeasure the sournessof anyproducts.
21) Excessoxygenrange 2-8%.
22) Sootblower, isadevice forremovingthe sootthatisdepositedonthe furnace tubesof
a boilerduringcombustion.
23) Ejectoris usedforcreatingvacuumin vacuumtower.
24) Netpositive suctionhead(NPSH).
25) Spectacle blindisusedasa seal.
26) Stripper.
---------------------THE END------------------------

M.TEHSEEN

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