inplant training report.pdf

7/28/2019 inplant training report.pdf

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INPLANT TRAINING

REPORT

BHARAT PETROLEUM CORPORATION

LIMITED KOCHI REFINERY

SUBMITTED BY

HEMALATHA MARDI

P:504

ELECTRONICS AND COMMUNICATION ENGINEERING

NIT CALICUT

TENURE: 23

RD

MAY- 3

RD

JUNE


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AKNOWLEDGEMENT

Firstly I would like to thank god almighty for giving me this opportunity. I

express my sincere gratitude to Mr Sabu Jose and Mr Ramesh K. for their

invaluable assistance and support.

I would like to thank Mr Anish P.V, Mr Rajeev M.C, Mr Raveendran Pillai, Mr

Jacob C.V, and Mr Prathish K Babu for their time and effort.

I also appreciate the effort and risk BPCL KR has taken in including us in the

daily busy schedule of its working hours.

I whole heartedly thank all the engineers and technicians who regardless of

their busy routine have found enough time to educate us and exposingourselves in the real working of an industry. BPCL KR has done a great role in

integrating our theoretical knowledge with work experience.


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INDEX

Company profile Introduction Process description CDU I CDU II FCCU DHDS Analyzers Control systems HART management systems TFMC Truck loading unit Wagon loading Conclusion


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COMPANY PROFILE

Kochi Refinery was incorporated as a public limited company in

September 1963, with technical collaboration and financial participation

from Phillips petroleum company, USA. The refinery was commissioned

on 23rd

September 1966, with a crude processing capacity of 2.5 MMTPA

.In addition to the crude distillation unit (presently CDU1), the units

commissioned initially included a Vacuum Distillation, Visbreaker,

Bitumen, Naphtha and Kerosene Hydro de-Sulfurisation and reformer

units .Many new process units were added including secondary

processing facilities, Aromatics Recovery and Diesel De-Sulfurisation

units. Many of the processing units and associated facilities have

undergone several modifications, including expansion and

modernization projects.

The capacity was first expanded from 2.5 to 3.0 MMTPA in September

1973.The production of liquefied petroleum gas(LPG) and aviation

turbine fuel (ATF) were commenced after this expansion. Bombay high

crude was first processed in CDU1 in 1975.

Crude processing capacity of KR was further enhanced to 4.5 MMTPA by

revamping the crude unit in 1984, along with the addition of secondary

processing facilities including a 1.0 MMTPA Fluid catalytic cracking unit

(FCCU).Installation of the FCC unit was necessitated due to the ever-

increasing price of crude oil and increased demand for middle distillates

and lighter products. The FCC unit facilitates conversion of heavier

hydrocarbon streams with lower demand to high value products like

LPG, Gasoline and Diesel.


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The crude processing capacity of the refinery was further increased to

7.5 MMTPA in the year 1994 with the addition of a new 3.0 MMTPA

Crude Distillation Unit (CDU-2). The FCC Unit capacity was also increased

to 1.4 MMTPA along with this, to match the crude capacity. A Vacuum

Distillation Unit (VDU-2), Naphtha Stabiliser, Sour Water stripping unit

and LPG treatment facilities were also included as a part of the

installation of CDU-2. Subsequently a Sulphur Recovery Unit (SRU) for

desulfurisation of refinery fuel gas was commissioned in 1995 as a part

of the capacity expansion project.

All the process units of the refinery are currently monitored and

controlled using state-of-the-art Distributed Control System

(DCS), with associated instrumentation and other facilities. The earlier

Pneumatic control system used in some of the process units and utilities

were changed over to DCS in stages. DCS was first commissioned in CDU-

1 block in November 1988 by changing over from pneumatic system.

Older DCSs of CDU-1 and FCCU blocks and ARU along with CPP-1 were

upgraded in June 2001.A plant wide network connecting DCSs of all the

process units and other areas of the refinery, was commissioned along

with the up gradation. A real time database system for storage,

distribution and displaying of process data and other information was

also commissioned with this .

Raw Material Linkages

Indigenous CrudeBH Crude

LS CrudeLabuan- Malaysia

Bonny light - Nigeria


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Marib Light Yemen

MS CrudeMasila YemenMurban UAE

Essider- Libya

HS CrudesArab Mix- Saudi

Iran Mix- Iran

Dubai- UAE

Important Milestones in Growth:

Formed in joint sector with the financial & technical participationbetween Phillips Petroleum Company, USA and Duncan Brothers,

Calcutta.

Construction completed in 29months at a cost of Rs. 27 crores Commissioned on September 23, 1966 as a 2.5 MMTPA refinery. Crude oil refining capacity expanded to :

o 2.5 MMTPA to 3.3 MMTPA in 1973o 3.3 MMTPA to 4.5 MMTPA in 1984o 4.5 MMTPA to 7.5 MMTPA in 1994

Installation of secondary processing facilities (1MMTPA FCCU) in1984.

Capacity augmented to 1.4 in 1994 & 1.75 with oxygen plant facilityin 2005.


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INTRODUCTION

Instrumentation Engineering has found major application in all sectors of

the plant with it playing a vital role in optimization of labour, resource and

time. The advent of electronic hardware, that replaced mechanical

hardware, has led to greater accuracy, reduced response times and lesser

maintenance. This in turn has augmented margins because of reduced cost

of production and better product quality with very little production and

quality analytic delay.

The purpose of the industrial visit was to acquaint the apprentice with all

the major manifestations of instrumentation engineering on the premises

of the refinery. I met Mr Sabu Jose who briefly described the role of the

instrumentation engineering in the field of refinery. Then I was asked to

report to Mr Ramesh K, who scheduled our tenure at the refinery for the

remaining 10days at the refinery. He assigned us to different people for the

allotted time slot, as per their expertise in the refinery, to augment our

understanding of concepts imbibed within the confines of the classroom.

We visited the following places:

Captive power plant (control room) CDU I Stack and blending analyzers TFMC and offset

However I realised that two weeks would not suffice to see entire plant in

detail, let alone indulge in its intricacies. As such I have attempted to put my

best foot forward and tried to garner as much knowledge and experience from

our guides and instructors. This is a brief report of what I learnt over the

course of the two week I was here at the refinery.


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PROCESS DESCRIPTION

CDU- crude distillation unit

FCCU- fluid catalytic cracking unit

ARU- aromatic recovery unit

DHDS- diesel hydro desulphurisation unit

CRUDE OIL

TANK

CDU I

4.5 MMTPA

CDU II

3 MMTPA

FCCU

1.75 MMTPA

DHDS

2.54 MMTPA

ARUREFORMATE FROM CDU I

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PRODUCTS


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CDU-1 BLOCK

CDU-1 consists of crude distillation unit, LPG recover unit, Naphtha splitter unit(NSU), Naphtha Hydro desulphurization unit (NHDS), Reform unit, kerosene

hydro desulphurization unit (KHDS), visbreaker unit.

I. Crude Distillation Unit (CDU-1)


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temperature, converts sulphur compounds into H2S, which can be easily

removed from the system.

V. Reformer unitThe reformer unit was originally designed to boost the octane number of

straight run naphtha to be sold as gasoline. The main function of the

reformer unit is to produce benzene & other aromatic products from the

C60C90 cut of desulphurized naphtha. Toluene is another major

constituent of the reformate. Hydrogen formed is separated and

recycled in the reactors. The main chemical reactions within this unit

are:

o Dehydrogenation of naphtha into aromaticso Isomerization of paraffin and naphtheneso Dehydro-cyclisation of paraffin into aromaticso Hydro cracking

Reformer unit is semi regenerative unit.

VI. Kerosene hydro desulphurization unitThe unit produces aviation turbine fuel (ATF) or jet fuel (JP5). This unit is

also used for producing mineral turpentine oil (MTO) desulphurization of

kerosene2 stream from CD for blending in diesel pool is another function

of the KHDS unit.

VII. Visbreaker unitVacuum residue obtained from imported crude in the FPU has high

viscosity. The visbreaker unit is used specifically to reduce this viscosity.

Visbreaker, basically is a thermal cracking process wherein long chain

hydrocarbon molecules in heavy feed stock are broken into smaller

molecules having lower viscosity, thereby leading to a reduction in the

velocity. This results in conserving valuable distillate products.


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There are two alternate products for visbreaking:

o Coil visbreaking- feed stock is cracked at high temperature (480-500

OC) in a furnace with sorter residence times to achieve this

conversion.

o Soaker technology- the feed stock is heated to relatively lowertemperature (440-460

OC) and holding the charge in a soaker drum

for larger residence times (20-25min) to achieve the required

conversion.


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CDU II BLOCK

Crude from storage is preheated, mixed with stripped water desalted againpreheated and split into two for preheating. Its finally heated and flashed into

the atmospheric column

Atmospheric column overhead vapours pass through accumulator and

overhead steam is sent to naphtha stabilizer, HGO, LGO, kerosene, HN are

withdrawn with side streams.

HN is routed to gas oil stream, kerosene to storage after stream stripping; gas

oil steam is also routed to storage RCO from crude column bottom is sent to

VDU. Cooling and condensation of vapours is then performed.

I. Naphtha stabilizer:In this unstabilized naphtha is sent to CDU or to LAN/HAN storage.

II.

Naphtha caustic wash:It removes H2S and mercaptan from stabilized naphtha. It is done by

separating hydrocarbons and cautic phases from a mixture of naphtha

and caustics.

III. LPG amine treatment unit:It was designed to remove H2S from LPG. This is done passing feed

through amine absorption column and then processing in a regenerating

boiler. LPG from absorption column is sent to wash drum, then to

storage through a sand filter.

IV. Vacuum distillation unit (VDU):In this unit VGO feed from FCCU is produced, hot RCO is heated, fed to

fractionating column. Slope oil is collected in hot well, vacuum diesel

along with CDUs gas oil is sent to combined diesel pool. VGO obtained is

stored in VGO storage of the FCCU. Slope distillation is partly recycle rest

is routes with VR which is routed to LSHS storage.


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V. Sulphur recovery unit (LOCAT SRU):It removes H2S from refinery fuel gas by converting it into elemental

sulphur. LOCAT is an oxidation process. Unit is an oxidation process. Unit

can process fuel gas from HP & LP source.

VI. Amine absorption unit (AAU):It was installed as an alternative to LOCAT SUR. Centralized facility for

regeneration for DEA in the DHDS block is made use of H2S is absorbed

which is sent to DHDS amine unit.

VII. Aromatic refinery unit (ARU):Aromatic viz. benzene & toluene are extracted from reformate using

salfolane as solvent. Utility system for the supply of plant air, instrument

air, cooling air is a part of ARU.


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FLUIDIZED CATALYSED CRACKING UNIT (FCCU)

The FCCU was commissioned in 1985. It converts the atmospheric residue from

CDU I into additional middle distillates, motor spirit and LPG. There are many

process units under FCCU. A substantial portion of the atmospheric residue

(RCO) which varies from 30 to 45% of the crude throughout depending on the

type of crude, was converted to FO by visbreaking or yielded as low sulphur

heavy stock during earlier periods.

Feed to the unit is the VGO (Vacuum gas oil) generated from FPU (feed

preparation unit) and vacuum distillation unit in CDU II.The functionality of the

FCCU can be divided into:


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1. Feed preparation unit (FPU)The purpose of the feed preparation unit is to make feed of required

quality to be processed in FCCU. In this unit, RCO is distilled undervacuum into four different units mainly vacuum diesel oil (VDO),Light

Vacuum gas oil (LPGO), Heavy vacuum gas oil (HVGO) & Vacuum residue

(VR).

2. Bitumen unitIn this unit, bitumen is produced from VR from vacuum column during

asphalt bearing crude run. Normally VR from BH run is not used for

bitumen make due to its low asphaltene content. VR from FPU is cooled

to around 220oC and charged to which air from an air compressor is

supplied through a distributer.

3. Fluidized catalytic cracking unit (FCCU)FCCU converts VGO in to higher value products such as LPG, Gasoline

and diesel by cracking of heavier hydrocarbon molecules of VGO to

lighter components. Silica-alumina catalyst in powder is used forpromoting the cracking reactions. The reaction takes place at a high

temperature and at a pressure above atmospheric pressure.

4. Gas concentration unit (GCU)In the GCU, LPG is recovered from both the overhead gas an liquid

streams and in the process, gasoline is stabilized. The unit consists of a

primary absorber and a sponge absorber for recovering LPG from fuel

gas, a stripper for removing H2S from the liquid stream to fuel gas, and a

debutanizer for separating LPG and gasoline. Sponge absorber uses LCO

circulating reflux stream as the absorption medium. Fuel gas is routed to

the refinery fuel gas system after removing H2S.


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DIESEL HYDRO-DESULPHURIZATION PLANT (DHDS)

Diesel is currently, the most highly consumed petroleum product in India.Sulphur in diesel results in SO2 and other particulate matter that pollute the

atmosphere. DHDS remedies this and it consists of:

I. Hydrogen generation unit:The HGU is designed to produce hydrogen of 99.99% purity. Hydrogen is

produced from naphtha using steam reforming. Naphtha having a

sulphur content of 1000ppm is desulphurized in a pre-desulphurization

section is to reduce the sulphur level in the feedstock. This is achieved

by the reaction of sulphur compounds in naphtha with hydrogen in a

catalytic reactor.

II. Diesel hydro desulphurization unit:The DHDS unit is designed to desulphurize diesel/VGO in blocked out

mode operation. It is designed to reduce the sulphur content of dieselblend stock.

III. Sulphur recovery unit:The SRU converts and separates H2S contained in the sour gas and acid

gas streams from sour water stripping unit and amine regeneration unit

in the form of elemental solid sulphur.

IV. Amine regeneration unit:Di ethanol amine is the primary feed to this unit, which rich in H2S.

V. Sour stripping unit:The main function of the sour water stripping unit is to treat sour water

generation unit is to treat sour water generated from the DHDS/

hydrogen unit.


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ANALYZER

The industry standards today demand very high standards both for the sake ofhigh quality products and for environmental safety. Analyzer is that

component of the refinery that achieves this. An analyzer is a device that

performs chemical analysis on samples or sample streams. Its purpose of

commission is to ensure the quality of end products. It reduces the

inadequacies in quality control methods prevalent in earlier industrial practices

which cause heavy delay in the delivery of products and losses due to sub

standard quality. The BPCL refinery relies mainly on online analyzer.

The main characteristics of an online analyzer are:

1. Continuous operation for long periods with minimal skilled attention andmaintenance.

2. It must withstand the hostile environment in which the product isformed/treated.

3. It should not pose a threat to the safety to the chemical process.4.

It must have very efficient sampling system.

NIR analyzer

NIR analyzers are used for measuring properties of MS & HSD work on the

same principle. PROSPEC III is the model used. A representative sample from

the blend header is taken and introduced to the flow cell of the analyzer. Near

the infrared rays of wavelength 800nm-1700nm are transmitted through the

sample to obtain the absorption spectrum. The monochrometer consists of the

lamp assembly, the filter wheel assembly and the grating wheel assembly.

White light from a Tungsten-halogen bulb travels through the lenses, through

the slit, through a fibre wheel and is incident upon holographic diffraction

grating. The filter wheel houses several filters that are used for wavelength

calibration. The concave holographic diffraction grating has equally spaced

lines per mm on its surface and dispenses the light into continuum of

wavelengths.


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Oxygen analyzer

1. Paramagnetic oxygen analyzer:It consist of a thin pipe called bypass pipe at the center, a heating

resistance wire is wound around it. There is a tap in the center which is a

Wheatstone bridge together with fixed resistors R1 & R2. Also strong

magnetic field is provided to the left half by means of a permanent

magnet. Thus if a measuring gas which is on the left side of the bypass

pipe contains O2 molecules which are highly paramagnetic are sucked

into the central part of the magnet which has the largest field strength

and it flows from left to right in the bypass pipe.

However, O2 molecules which have reached the center of the magnetic

field are heated by the resistance wire. Thus their paramagnetism is

reduced and their proclivity to being sucked into the magnetic field is

reduced. Therefore they are gradually pushed to the right from the gas

flowing in from the left. The strength of this magnetic wind is

proportional to the O2 content. The magnetic wind cools down in both

the halves at different rates. The difference is directly proportional to

the O2 content and is measured using the electric bridge circuit.

2. Zirconia probe oxygen analyzer:Zirconia sensor works on the principle of Nernst equation which states

that the voltage developed across the zirconia cell is

E=0.0496T log10 [P1 (O2)/P2 (O2)]

Where,

E= sensor output (V)T=absolute temperature (K)

P1 (O2)=ref partial pressure

P2 (O2) =sample gas partial pressure

From this it is clear that as O2 concentration in the sample gas decreases

the emf developed in the sensor increases.


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CONTROL SYSTEMS

I. Programmable logic controller (PLC)A programmable logic controller (PLC) or programmable controller is a

digital computer used for automation of electromechanical processes,

such as control of machinery on factory assembly lines, amusement

rides or lighting fixtures. PLCs are used in many industries and machines.

Unlike general-purpose computers, the PLC is designed for multiple

inputs and output arrangements, extended temperature ranges,

immunity to electrical noise, and resistance to vibration and impact.

Programs to control machine operation are typically stored in battery-

backed or non-volatile memory. A PLC is an example of a hard real time

system since output results must be produced in response to input

conditions within a bounded time, otherwise unintended operation will

result

Programmable logic controllers are microcomputers developed to

handle Boolean operations. A PLC produces ON/OFF voltage output andcan actuate elements such as electric motors, solenoids, fans etc. The

basic operation of a PLC can also execute operations such as counting,

delays and timers. PLC initiates relay actions through software

Features:

The main difference from other computers is that the PLCs are armoured

for several conditions (such as dust, moisture, heat, cold) and have the

facility for extensive input/output (I/O) arrangements. These connect

the PLC to sensors and actuators. PLCs read limit switches, analog

process variables (such as temperature and pressure), and the positions

of complex positioning systems. Some use machine vision. On the

actuator side, PLCs operate electric motors, pneumatic or hydraulic

cylinders, magnetic relays, solenoids or analog outputs.


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The input/output arrangements may be built into a simple PLC, or the

PLC may have external i/o modules attached to a computer network that

plugs into the PLC.

System scale:

A small PLC will have a fixed number of connections built in for inputs

and outputs. Typically, expansions are available if the base model has

insufficient I/O. Modular PLCs have a chassis(also called a rack) into

which are placed modules with different functions. The processor and

selection of I/O modules is customized for the particular application.

Several racks can be administered by a single processor, and may have

thousands of inputs and outputs. A special high speed serial I/O link isused so that racks can be distributed away from the processor, reducing

the wiring costs for large plants.

User interface:

PLCs may need to interact with people for the purpose of configuration,

alarm reporting or everyday control. A human machine interface (HMI) is

employed for this purpose. HMIs are also referred to as MMIs (man

machine interface) and GUIs (graphical user interface).

A simple system may use buttons and lights to interact with the user.

Text displays are available as well as graphical touch screens. More

complex systems use programming and monitoring software installed on

a computer, with the PLC connected via a communication interface.

Communications:PLCs have built in communication ports, usually 9-pin RS-232, but

optionally EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually

included as one of the communication protocols. Other options include

various field buses such as DeviceNet or Profibus. Other communications

protocols that may be used are listed in the list of automation protocols.


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II. Distributed control systems (DCS)It refers to a control system usually of a manufacturing system, process

or any kind of dynamic system, in which the controller elements are not

central in location (like the brain) but are distributed throughout the

system with each component sub-system controlled by one or more

controllers. The entire system of controllers is connected by networks

for communication and monitoring.

DCS is a microprocessor/computer based digital system used for basic

control of various process parameters like flow, pressure, level,

temperature etc. the system gathers process data from various sensors

in the field, operate on these data such as a scale compare, calculate etc.as per preconfigured algorithms and send signals back to final control

elements in field for achieving process control.


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HART MANAGEMENT SYSTEMS

HART is an acronym for highway addressable remote transducer. The HARTprotocol makes use of the Bell 202 frequency shift key (FSK) standard to

superimpose digital signals at a low level on top of the 4-20 mA. This enables

two way communications to take place and makes it possible for additional

information beyond just the normal process variable to be communicated

to/from a smart field instrument. The HART protocol communicates without

interrupting the 4-20mA signal and allows a host application (master) to get

two or more digital updates per second from a field device. HART has been

adopted by most of the major manufacturers of process control field

equipment. It is an open standard that is administered by the HART communications foundation. As the digital FSK signal is phase continuous,

there is no interference with the 4-20mA signal. The relative simplicity of the

HART protocol makes it easy for both end users and suppliers to gain

experience and benefits from the enhanced two-way communication

capability of smart field instruments using this technology. The digital signal is

made up of two frequencies 1200 Hz and 2200 Hz representing bits 1 and 0

respectively. Sine waves of these two frequencies are superimposed on the

direct current (dc) analog signal cables to provide simultaneous analog and

digital communications.

HART devices can operate in one of two network configurations-

Point to point Multidrop

Point to point

In point-to-point mode, the traditional 4-20mA signal is used to communicate

one process variable, while additional process variables, configurationparameters, and other device data are transferred digitally using the HART

protocol. The 4-20mA analog signal is not affected by the HART signal and can

be used for control in the normal way. The HART communication digital signal

gives access to secondary variables ad other data that can be used for

operations, commissioning, maintenance and diagnostic purposes.


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Multidrop

The multidrop mode of operation requires only a single pair of wires and if

applicable, safety barriers and an auxiliary power supply for upto 15 field

devices. All process values are transmitted digitally. In multidrop mode, all field

device polling addresses are >0, and the current through each device is fixed to

a minimum value (typically 4mA).


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TANK FARM MANAGEMENT CENTRE (TFMC)

The major equipments consist of storage tanks, LPG spheres, pumps,pipelines, automatic and manual valves and blending systems. Instrumentation

system includes:

Tank gauging systemsFor monitoring level temperature and water level of products in tanks.

Tank gauging systems are provided by 3companies. The Honeywell

ENRAF (radar and servo types), Emerson SAAB (radar type) and SBEM

(servo and mechanical types). The radar systems use a 10GHz signal.This signal will be transmitted into the tank and gets reflected back from

the top level. The time difference will give the current level. In the servo

type a dispenser is used. The weight of the dispenser, according to the

Archimedes principle, will give a measure of the level of the tank.

Blending instrumentation which includes flow meters using orifice platesensors, differential pressure transmitters, coriolis mass flow meter,

pressure transmitters and control valves with I/P converter and

blending analyser.

LPG sphere safety system utilizing thermal fuses, pressure switches,solenoid valves etc.

Gas monitoring system, LPG sphere deluge valve/sprinkler control paneletc.

Major control systems in TFMC control room are:

Foxboro (Invesys) DCS -It integrates the tank gauging systems, blending systems etc.

GE- Fanuc PLC-For achieving safety interlocks.

Console interlocks switches-To trip the sphere interlocks manually.

Console bypass switches-For the purpose of checking and calibration of level instruments.

Console hardware annunciator-


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Digital indicators such as ROP positions, safety circuit pressure

low, sphere level high is provided with hardware annunciation

with hooter in addition to the DCS indicator.

ENRAF/ENTIS ATG system terminal-for maintenance and operational functions. Also for gauge

operations such as rising and lowering displacers, checking

alarms, configuring of ATGs etc.

SBEM ATG system terminal ENRAF/ENTIS ATG system terminal Gas monitoring systems-

For detecting gas leaks. There are three systems used in KRL:

o Detection instruments systems-installed at pump housearea and truck loading area

o Dil udyog system-installed at LPG spheres,benzene/toluene area

o Pentax system-installed at all other areas controlled byTFMC

It monitors sphere safety and controls the actuation of delugevalves.


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TRUCK LOADING UNIT

All the petroleum products produced from BPCL Kochi refinery are distributedvia truck loading units. The petroleum products are classified as white oil and

black oil. These products include LPG, diesel, motor spirit, LSFO, HSD etc. the

truck loading unit is divided into two areas with gantry in each area. In one

area all white oil are handled and it is known as white oil loading area, whereas

in the second area all the black oils are handled and it is known as black oil

loading area. There are 12bays at white oil loading area. Each bay has a

platform with 3loading arms. In some cases only 2loading arms are provided.

Black oil loading area consists of 8bays. Each bay is provided with one or two

loading arms. Each loading arm is provided with a mass flow meter, digital

control valve (DCV) and local controller. Each bay is provided with a card

reader. Control valves are provided for controlling flow and they are operated

through batch controller. All lines are provided with strainers and deaeraters

to remove foreign materials and air or gas residue. Batch controllers are locally

located in the gantry and have display and keyboard for user interphase. Each

batch controller gets flow data from mass flow meter, temperature data fromRTD and truck earthing status from earthing relay. DCV is controlled by batch

controller through two solenoid valves (one NO and one NC). Mass flow meter

is connected to pressure transmitter which gives pressure reading for mass

flow meter pressure compensation. As mentioned above, each bay is provided

with a card reader. When the card issued to truck driver from the control room

is shown to the correct bay, the data from the control room will be

downloaded to the batch controller to start the loading. During and after

loading the field operation like flow, temperature, total quantity loaded etc

will be sent back to the control room for report generation and billing purpose.

LPG bottling plant: It has a capacity of 9800 cylinders per shift. The plant is

designed for producing 14.2 kg domestic LPG cylinders and 19kg industrial LPG

cylinders with center valves. This is one of the busiest and most profitable

stations in the facility. There are four sections in the bottling plant filling


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section, hot air sealing section, evacuation section and evacuation & purging

section.

Truck loading computer system

Entire operation is controlled by a computer system in the control room and a

microprocessor based batch controller in field. The control room provides the

following:

Indication of all parameters Status of all loading points Stopping of loading Alarm displays and annunciation Graphic displays and indications Logging and reporting Self-diagnostic measurements Configuration displays


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CONCLUSION

An overall brief study of the functioning of the various units of the BPCL KochiRefinery was carried out. The ease in successful execution of analysis, control

and error correction with the advent of electronic hardware and competent

software over the erstwhile mechanical hardware, was demonstrated to us by

our guides.

The tenure, though very short, helped us realize the implications of real time

analysis and apt responses to various issues that arise in the various stages of

the functioning of the plant. It is only through such an exposure, that we

realize the significance of accuracy in measuring and controlling a parameter

and the magnitude of the aftereffects of minor deviations.

The flaws within the prevalent system of education were accentuated by the

training, which is dogmatic in nature and rendering is ill-equipped to solveproblems, thus serving little purpose in the world extraneous to the college.

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