Utilities Report PARCO

Mohammad Yasser Ramzan

Trainee Engineer P # 5738 Email: [email protected]

PAK ARAB REFINERY LTD

Submitted To

Engr. Husnain Farid Engineer I

Date: 7 April 2015

CONTENTS Chemical Handling Area U-900 .................................................................................................................... 1

Introduction ........................................................................................................................................ 1

Design Capacity & Users ................................................................................................................... 1

Process Discription ............................................................................................................................ 2

Equipments & Data Sheets ............................................................................................................... 2

Daily Checkups ................................................................................................................................... 2

Plant & Instrument Air System U-910 .......................................................................................................... 3

Introduction ........................................................................................................................................ 3

Design Capacity & Users ................................................................................................................... 3

Process Description ........................................................................................................................... 4

Daily Checkups ................................................................................................................................... 4

Compressor PACKAGE (Elliott USA)................................................................................................... 5

Air Dryer Package ............................................................................................................................... 6

Equipment Data Sheets ..................................................................................................................... 7

Flare System U-915 ...................................................................................................................................... 8

Introduction ........................................................................................................................................ 8

Design Capacity & Sources ............................................................................................................... 8

Process Description ........................................................................................................................... 9

Equipment Specifications ............................................................................................................... 10

Daily Checkups (Main+Acid) ........................................................................................................... 10

Fuel Oil & Fuel Gas System U-920 ............................................................................................................. 11

Introduction ..................................................................................................................................... 11

Design Capcity & Users, Sources ................................................................................................... 11

Process Description ........................................................................................................................ 13

Equipment Specifications ............................................................................................................... 13

Dail Cehckups ................................................................................................................................. 13

Water System U-920 ................................................................................................................................... 14

Introduction ..................................................................................................................................... 14

Design Capacity ............................................................................................................................... 14


Cooling Tower Treatment ................................................................................................................ 16

Equipment Data Sheet ................................................................................................................... 17

Daily Checkups ................................................................................................................................ 17

Fire Water System U-926 ........................................................................................................................... 18

Introduction ..................................................................................................................................... 18

Design Capacity ............................................................................................................................... 18

System Description ......................................................................................................................... 18

Cut-in Sequence .............................................................................................................................. 18

Equipment Specification................................................................................................................. 19

Effluent Tratment Plant U-930 ................................................................................................................... 20

Introduction ..................................................................................................................................... 20

Design Capacity ............................................................................................................................... 20

Quality of Effluent ............................................................................................................................ 20

Chemical Summary ......................................................................................................................... 21



Steam, Feed Water & Condensate Handling System U-940 .................................................................... 25

Intoduction ...................................................................................................................................... 25

D.M.W. B.F.W. & Steam Conditions ............................................................................................... 25

Steam Gernerator ........................................................................................................................... 25



Daily Checkups ................................................................................................................................ 31

Suggestions/recommendations................................................................................................................. 32

Chemical Handling Area U-900 Department: U&OM

1

Chemical Handling Area U-900

Introduction

Chemical handling area provide caustic soda and sulphuric acid storage and pumping services to

refinery and utilities operation as per requirement. UOP unit code U-900 is designated to chemical

handling area. The unit consists of following systems:

i. Caustic soda handling system: 50 BeO is received in 900-TK1 A/B through 10 metric

ton tank Lorries and diluted to 25 BeO. Afterwards supplied to various refinery users

and they further diluted to 10o or 3oBe as required.

ii. 98% sulfuric acid handling system: sulfuric acid is stored in a horizontal vessel (900-

V1) and supplied to users as per requirement.

Design Capacity & Users

Design capacity of caustic soda section is based upon its use in different units of refinery. Total

average use of 50% caustic soda is 1.9m3 per day.

Design capacity of sulfuric acid is also based upon its use. Total design capacity of

Acid User Caustic User

Utility, Boiler Makeup Water System, Cooling Water System, Spent Caustic

Section

Utility, ETP K-MX, LPG-MX, CCR

NHTR, AMINE D-MAX, K-MX(ELEC)

50 BeO caustic specific gravity = 1.510, 25 BeO caustic specific gravity = 1.175

Demineralized water specific gravity = 0.998

50 BeO caustic = 50 % concentrated, 25 BeO caustic = 18.68 % concentrated

1% of tank level = 0.9 m3

Chemical Handling Area U-900 Department: U&OM

2

Process Discription

Caustic System

The 50wt% caustic unloading pumps (900-P1A/B) shall transfer the caustic to 25oBe caustic tanks

(900-TK1A/B) which have demineralized water in advance to dilute 50wt% caustic to 25oBe caustic.

The 50wt% caustic unloading pumps shall circulate the caustic solution for mixing.25oBe caustic is

transferred to each user by 25oBe caustic pump (900-P2A/B) which is running normally.

Sulfuric Acid System

The sulfuric acid transfer pumps (900-P3A/B) shall transfer the sulfuric acid (98wt %) to a sulfuric

acid vessel (900-V1). The sizing of the sulfuric acid vessel is based on maximum demands from the

Boiler Makeup Water Treatment System in the Steam, Feed water and Condensate Handling System,

from Cooling Tower and from Spent Caustic Section at ETP. Sulfuric acid injection tank at Cooling

Tower System will be filled the sulfuric acid from the sulfuric acid vessel (900-V1) directory. The

sulfuric acid process pumps (900-P4A/B) shall run intermittently for spent caustic for ETP and Demin

Train regeneration.

Equipments & Data Sheets

Tag No. Service Type Capacity Head R.P.M. Power

m3/hr m kW

900-P1A/B Unloading Pump Centrifugal 24 35.1 2915 11

900-P2A/B Caustic Pump Centrifugal 13.3 44.9 2915 7.5

900-P3A/B Acid Transfer Pump Centrifugal 2915

900-P4A/B Acid Process Pump Centrifugal 6.47 29.4 2915 7.5

925-P53A/B

Cooling Tower Acid Injection Pumps

Diaphragm 0.02 Min Stock 15 S.P.M, Max 80

S.P.M.

Tag No. Service Type Diameter Height Capacity MLL

m m m3 m

900-TK1A/B

Caustic Storage Tank Fixed Rood

5.8 4.2 110 3.9

900-V1 Acid Storage Vessel Horizontal

Vessel 3.45 6.9

Daily Checkups

900-TK1A/B & 900-V1 Level in % mm, Caustic & Acid Pump Discharge Pressure, Caustic & Acid

Exported % or mm.

Plant & Instrument Air System U-910 Department: U&OM

3

Plant & Instrument Air System U-910

Introduction

Plant air also known as service air is basically for machines that require air that does not need to be

extremely clean or dry, and usually require large volumes.

Instrument air is the mixture of nitrogen & oxygen and very small amount of dust (below the required

limit) used in the instrument to operate pneumatic valves, certain types of pumps, fans, some blowing

down hoses. The Instrument air in a plant is used to supply motive force for control valves & that

keeps the plant in control and running. Instrument air is often specially dried to reduce the risk of

condensation freezing-out in the small-bore piping. To maintain the above situation in the plant

Instrument air must be dried to remove any moisture and/or condensate for:

i. Protecting the instruments and control system from damage.

ii. Obtaining exact readings through these instruments and control system.

Quality of Instrument Air

The quality of instrument air is what distinguishes it from a compressed or service air system. The

most important parameters in specifying air quality are:

Dew Point, Oil Content, Particulates, Temperature

The Instrument Society of America sets quality standards for instrument air in ISA S7.3.

Drying Methods

There are three general methods of drying: Chemical drying, Refrigeration, and Adsorption. Selection

of air drying equipment is based upon required dew point, quantity of air to be dried, pressure of the

incoming air, and excess air capacity of compressor station.

Design Capacity & Users

The plant and instrument air system design capacity are 1400Nm3/hr (3020Nm3/hr in case of Diesel

Max Regeneration) and 4168Nm3/hr respectively at max demand rate. Whole demand is met by a

single compressor but in case of DMax regeneration two compressor used and if both are failure due

to any reason then a portable diesel compressor used.

Description Temperature (oC) Pressure (kg/cm2G)

Max Normal Min

Plant Air 42 8.7 7.7 6.5

Instrument Air 50 8.5 7.0 3.5


4

Process Description

Plant & instrument air unit consists of following sections

i. Air Compressor Package

ii. Air Dryer Package

Air from atmosphere passes through pre-filter and enter in compressor through a control valve which

control density of air entering. 910-C1/A/B two compressor package has 1 steam turbine driven and

1 motor driven centrifugal compressors. After 1st stage pressure increase up to 1.5kg/cm2 and inter

stage cooler cool air to 45oC then after 2nd stage pressure raise to 5.2kg/cm2 and again inter stage

cooler cools air to 45oC. After 3rd stage air compress up to 8.7kg/cm2 and temperature to 109oC and

after cool cools air to 48oC. A diesel compressor DIS390SS can also use as backup in case of both

compressor failure.

The compressors discharge pressurized air to a common Main Air Receiver (910-V1). From this point,

instrument air is passed through Air Dryer Package (910-ME1), while plant air is not dried as bypass

the dryer package and distributed to plant air header through PCV control valve which maintain

header pressure. Air to be used for instrument air is dried using two 100% pressure sewing type

instrument air dryers, one operating and one spare and they are switch after 1month. An instrument

air receiver (910-V2) is located downstream of the air dryers.

The Air Receivers provide reservoir of instrument air in the case of the failure of air compressors. The

total holding time of the vessels is approximately 5 minutes with a pressure transition, when this

pressure is reached the standby compressor will start automatically and re-pressurize the receiver to

7.5 kg/cm2G.

Daily Checkups

Air Filter P, Air Density, Pressure, Vibrations LS+HS Side, Seal Air Pressure, Compressor Temp.

Pressure Each Stage, I.A. Header Pressure, Lube Oil pressure, temp., cooled temp., Filter P, Return

Temp., Oil Bearing Temp. Pressure, Steam Turbine Flow + Speed.


5

Compressor PACKAGE (Elliott USA)

Filtered air, controlled by an automatically operated inlet valve/guide vanes enters the compressor's

first stage, where it undergoes initial compression.

From the first stage, air passes through an intercooler

which removes much of the heat of compression and

through a moisture elimination section where

moisture is removed. Air is further compressed to final

discharge pressure and cooled down to required

temperature through after cooler.

Compressor Auxiliries are as follows

i. Suction Filter: Used to filter any dust particles from air. 22cmH2O pressure drop

across filter generate alarm to clean it.

ii. Inlet Valve: Also density control valve, installed to control density of air. Higher density

of air increases compressor load, lower density cause low pressure zone which can

cause surge.

iii. Unloading Valve: Known as anti-surge valve, PCV installed at outlet of compressor

maintain the outlet pressure and discard excess pressure.

iv. 1st & 2nd Stage Intercooler: Plate type heat exchanger installed to cool down

compressed air from each stages by Cooling water.

v. After Cooler: Counter current heat exchanger installed to cool down compressed air to

required supply temperature by cooling water.

vi. Lube Oil System: The lubrication system supplies oil to compressor bearings and

gears. It is cooled down by cooling water (80oC to 30/40oC).

vii. Seal Air System: Installed to separate oil and compressed air in compressor.

Compressor Trip Conditions

Turbine Low speed, Lube oil low pressure, HS pinion high vibration, LS pinion high vibration,

Lube oil high temperature, Air 2nd inter-stage high temperature, Air 1st inter-stage high temperature,

Motor stator high temperature.


6

Air Dryer Package

Air dryer package removes moisture from air on adsorption principle. Adsorption is a process that

occurs when a gas or liquid solute accumulates on the surface of a solid or a liquid (adsorbent),

forming a molecular or atomic film (the adsorbate). It is different from absorption, in which a

substance diffuses into a liquid or solid to form a solution.

Physisorption or physical adsorption is a type of adsorption in which the adsorbate adheres to the

surface only through Van der Waals (weak intermolecular) interactions, which are also responsible for

the non-ideal behaviour of real gases. Chemisorption is a type of adsorption whereby a molecule

adheres to a surface through the formation of a chemical bond, as opposed to the Van der Waals

forces.

Air Dryer Package consists of following parts

i. Pre-Filter (910-ME1-V2A/B): Used to remove any moisture or oil contamination.

ii. Adsorption Vessels (910-ME1-V1A/B/C/D)

iii. After Filter (910-ME1-V3A/B): Used to remove desiccant material.

Pressure swing adsorption processes rely on the fact that under high pressure, gases tend to

be attracted to solid surfaces, or "adsorbed". The higher the pressure, the more gas is adsorbed;

when the pressure is reduced, the gas is released, or desorbed. PSA processes can be used to

separate gases in a mixture because different gases tend to be attracted to different solid surfaces

more or less strongly. Each train comprises of two beds, one in service and other on regeneration.

Service and regeneration sequence is controlled by PLC based automatic timing sequence (5min)

controller which diverts the air flow by changing the valve position. The cycle can be classified into

following steps.

i. Drying: Compressed air passes through bed from bottom while regeneration valves

are closed. Moisture from air is removed by adsorbent and air exit from top and

routed to instrument air receiver 910-V2 through NRVs.

ii. Depressurization: Depressurizing vessel by closing air inlet valve and outlet valve and

opening valve installed towards silencer vent.

iii. Regeneration: During regeneration air is routed from top to bottom and saturated bed

is regenerated and air is vent through vent.

iv. Pressurize: After regeneration silencer valve is closed and air from top pressurize

vessel.

v. Parallel Drying: For about 5sec both adsorber starts drying before switching.

vi. Switch over: After regeneration air inlet valve is opened for drying and vent closed.


7

Equipment Data Sheets

Dryer Train 910-ME1

Tag No. Service Design

Pressure kg/cm2

Design Temperature oC

Capacity m3 Weight

kg

910-ME1 Dryer Trains 11.25 120 4790

910-ME1-V1A/B/C/D

Air Dryer 11.25 5/120 1.8 950

910-ME1-V2A/B

Pre-Filter 11.25 5/120 0.055 150

910-ME1-V3A/B

After-Filter 11.25 5/120 0.055 150

Compressor Package 910-C1A/B

Specification Values

Capacity 3850Nm3/hr, 1.384kg/s (WET)

Inlet Conditions

Pressure 1.019kg/cm2

Temperature 50/5oC

Relative Humidity 85%

Discharge Conditions

Pressure 10.08kg/cm2

SHP 871kW

R.P.M. 2970

Filter

Maximum Pressure Drop 0.014kg/cm2

Cooling Water

Inlet Outlet Temperature 34.5 45oC

Inlet Outlet Pressure 4.4 3.4kg/cm2

Flow Rate (LO, After Cooler, Interstage Cooler)

29, 10, 59.7 m3/hr

Compressor

Stages, Impeller Dia, Max. Conti. Speed 3, (300+199+149), 2986 r.p.m

Flare System U-915 Department: U&OM

8

Flare System U-915

Introduction

Flare system are used to destroy corrosive, toxic, and flammable waste products during process start-

ups or during upset plant conditions. This is achieved by converting them into less harmful products

through combustion.

Whenever industrial plant equipment items are over-

pressured, the pressure relief valves provided as

essential safety devices on the equipment

automatically release gases and sometimes liquids

as well. The released gases and liquids are routed

through large piping systems called flare headers to

a vertical elevated flare. The size and brightness of

the resulting flame depends upon the flammable

material's flow rate in terms of joules per hour

(or btu per hour).

i. A knockout drum to remove any oil and/or

water from the relieved gases.

ii. A water seal drum to prevent any flashback of the flame from the top of the flare

stack.

iii. An alternative gas recovery system for use during partial plant startups and/or

shutdowns as well as other times when required.

iv. A steam injection system to provide an external momentum force used for efficient

mixing of air with the relieved gas, which promotes smokeless burning.

v. A pilot flame (with its ignition system) that burns all the time so that it is available to

ignite relieved gases whenever needed.

vi. The flare stack, including a flashback prevention section at the upper part of the flare

stack.

Design Capacity & Sources

This system consists of the main flare system and the acid gas flare system.

i. Main flare system : 950 ton/hr (General power failure case)

ii. Acid gas flare system : 48.6 ton/hr (284Unit CV failure open case)


9

Process Description

Main flare system

Flaring gas and/or liquid is routed to the main flare knockout drum 915-V1 via main flare header. The

main flare knockout drum pumps 915-P1A/B transfer any slop oil collected in 915-V1 to the light slop

tank 945-TK47. From 915-V1 the vapor passes to main flare (stack) 915-ME1, and passes through

the water seal drum provided at the bottom of the flare stack and the dry gas seal in the flare stack,

then is combusted at the flare tip

Acid gas flare system

The acid gas flare is the disposal route for relief system. The streams are collected in an acid gas flare

header, pass through an acid gas flare knockout drum 915-V2, and discharge to the acid gas flare

(stack) 915-ME2. The condensate from 915-V2 is pumped to the sour water degassing drum 810-V10

provided in the Amine Treating Unit by the sour water knockout drum pump 915-P2 A/B.

Flare ignition system

A flare ignition package is provided at the flare knockout drum area which is outside the sterile area.

The flare ignition package consists of the ignition system, the flare burner gas supply system, the

monitoring system, and the control panel. For igniting the flare pilot burners, instrument air and

natural gas are used.

Flash back protection

To prevent air penetration back into the flare header, a dry gas seal and a water seal system are

provided. As a seal gas, fuel gas is introduced continuously from the inlet of flare knockout drums and

flare header ends. As a water seal, plant water is continuously supplied to both water seal drums via

the bypass of seal drum level control valves.

Smokeless steam

To prevent generation of smoke from the main flare, MP steam is injected into the main flare. The

flare tip is provided with a steam ring to promote smokeless operation.


10

Equipment Specifications

Tag No. Service Diameter Length Material D.P. D.T. Weight

m m kg/cm2 oC ton

915-V1 K.O.Durm

Main Flare

5.5 18 SA516Gr.70 3.5 338/5 97

915-V2 K.O.Drum

Acid 1.22 3.9 316L SS 3.5 210/5 2.5

Tag No. Service Type Capacity Pressure

S/D R.P.M. Power

m3/hr Kg/cm2 kW

915-P1A/B

LSL Pump Main K.O.D.

Centrifugal 11.4 0.27/5.54 7.5

915-P2A/B

Sour Water Pump K.O.D.

Centrifugal 7.5 0.29/5.50 7.5

Tag No. Service Diameter Length Capacity Specifications

inch m Ton/hr

915-ME1 Main Flare

48 112 950 Smokeless Flare DP 3.5kg/cm2,

DT 338oC

915-ME2 Acid Flare 1 112 48.607 Elevated Flare DP 3.5kg/cm2,

DT 210oC, Steam Traced, Insulation

Daily Checkups (Main+Acid)

i. Knockout Drum Level

ii. Pumps Status

iii. Pressure, Temperature, Seal Level

iv. Steam Ton/hr

v. Fuel Gas Flow m3/hr

vi. Pilot Burner Status 1/2/3/4/5/6

Fuel Oil & Fuel Gas System U-920 Department: U&OM

11

Fuel Oil & Fuel Gas System U-920

Introduction

In PARCO fuel oil and fuel gas system installed to cover thermal energy demands in form of liquid and

gaseous fuel. Refinery itself producer of its own fuels. In U-920 fuels are stored from different supplier

units and redistribute them by two system.

Design Capcity & Users, Sources

Refinery Fuel Oil

The purpose of the refinery fuel oil system is to provide a circulating supply of fuel oil at the pressure

and temperature required for good atomizing and combustion. Normally, about 58% of the thermal

energy consumption is provided by fuel oil.

Refinery Fuel Oil Sources (Producers)

i. DieselMax, Visbreaker & Vacuum Residue

ii. Fuel Oil Product (temporary used, such as refinery startup)

iii. Flushing Oil from Tankage (as cutter stock for heavy oil)

Destination (Consumers)

i. Crude heater, Vacuum heater, Charge heater in NHT, Product fractionator feed

heater, Thermal cracking heater in Diesel Max Unit , Visbreaker heater

ii. Utility boilers

Priority Of Fuel Oil

i. Refinery fuel oil is normally make-up by Diesel Max residue, i.e. primary fuel oil, and

Visbreaker residue is used as first alternate fuel oil.

ii. Fuel oil product will be temporary used, i.e. at refinery start-up operation, and

blended fuel is used as other alternate fuel.

Refinery Fuel Gas

The Fuel Gas System is designed to collect process unit off gas, natural gas, and vaporized LPG, and

to distribute them to meet the needs of fired equipment and miscellaneous users. All sources of gas

are routed to a fuel gas knockout drum (920-V1) which provides liquid knockout and mixing.

Refinery Fuel Gas Sources (Producers)

i. Purge gas from the catalytic section of the DieselMax Process Unit

ii. Treated gas from the Amine Treating Process Unit

iii. Net gas from the Platforming Process Unit

iv. Natural gas from outside of the refinery

v. On-spec LPG from LPG sphere


12

Destination (Consumers)

i. Crude heater, Vacuum heater, Visbreaker heater, Charge heater NHT, Reactor charge

heater, Product fractionator feed, Thermal cracker heater in the DieselMax Process

Unit, Charge heater, No.1 Interheater, No.2 Interheater in the CCR-Platforming

Process Unit

ii. Utility boilers

iii. Purge gas to flare headers

iv. Dry seal for flare stacks

v. Incinerator, 820-H3/H4 in the Sulfur Recovery Unit

vi. SCOT line heater, 820-H51/H52

Priority Of Fuel Gas

i. Normal operation : Refinery off gas

ii. Primary makeup : Natural gas

iii. Secondary makeup : On-spec LPG vaporized in LPG vaporizer

Header Conditions

Description Temperature oC Pressure (kg/cm2G)

Refinery Fuel Oil 165-175 12

Fuel Gas 42 5.7


13

Process Description

Make-up oil runs down continuously and maintains refinery fuel oil tanks (920-TK1A/B) level in

almost constant tanks capacity is 1,600m3.

FUEL OIL CIRCULATION PUMPS (920-P1A/B/C)

The two primary pumps (920-P1A/B) are turbine driven, using MP steam at inlet and exhausting the

LP level; the spare pump (920-P1C) is motor driven. Each pump has 32 m3/h rated capacity that is

approximate 60% of the normal circulation rate.

FUEL OIL HEATER (920-E2)

One shell and tube type exchanger is provided to heat up oil to enough viscosity if oil temperature

getting lower. HP steam is used as heating medium to maintain 165oC.

FUEL OIL STRAINER (920-ME1A/B)

Two bucket type strainers are installed on fuel oil supply line. Operation of the strainer shall be turn

over each other when friction loss via the strainer is increased.

Equipment Specifications

Tag No. Service Type Diameter Height Capacity Sp.

Gravity MLL

m m m3 m

920-TK1A/B

RFO Storage

Fixed Rood/Steam

Traced 13.5 12.2 1600 0.98 11.45


m3/hr m kW

920-P1A/B/C

RFO Supply Pump Centrifugal 32 153 2950 75

Tag No. Service Type Area Shell Tube

m2 DP DT DP DT

920-E2 RFO Heater Shell & Tube 88 33 220 47.5 426/252

Dail Cehckups

920-TK1A/B Level, Temp. Status (F/S), Steam Coil, 920-P1A/B/C Discharge Pressure, P Stainer,

920-ME1A/B Pressure, RFO Header Pressure.

Water System U-925 Department: U&OM

14

Water System U-920

Introduction

Unit 925 Water System is composed of the following system

i. Well Pumps Section

ii. Raw Water and Plant Water Section

iii. Potable Water Section

iv. Cooling Water Section

Design Capacity

U-925s different sections designed on basis of their requirement in refinery.

i. Well Pumps Section has pumping capacity 100m3/hr per well.

ii. Raw Water & plant storage capacity of 9500m3 of each tank 925-TK1A/B

iii. Portable Water section has storage capacity of 925-TK2 640m3 and filtering capacity

20m3/hr.

iv. Cooling Water system is designed to supply 10,000m3/hr or ton/hr cooling water

range 5-6oC and pressure 4.3kg/cm2 supply. The design is based on operating with 3

cycles of concentration, although 6 or 7 cycles are likely to be achievable in

operation.

With Effluent system are Cooling Water Blowdown, Side Stream Filter Back Wash Water 27 m3/hr

and Potable Water Filter Back Wash Water 27 m3/hr.

Process Description

Raw Water

A total of six wells is provided, raw water requirements of 100m3/hr each. Water from the wells is

pumped up normally to Raw Water Tanks (925-TK1A/B) and for fire water make-up to Fire Water Tank

(926-TK1) by well pumps (925-P1~P6). Raw Water Tanks serve as a secondary source of firewater.

Raw water stored in a raw water tanks is pumped to the following users by the raw water supply

pumps (925-P7A/B/C).

i. Plant Water Make-up (Plant water is used mainly of Boiler Make-up Water

Treating System feed, Cooling Water Make-up, utility hose stations and other

miscellaneous users.)

ii. Make up of Potable Water

iii. Sulfur Solidification (as cooling medium)

Potable Water

Raw water is treated by the potable water filter system (925-ME1) and potable water chlorination

system (925-ME3). The treated water is stored in a potable water tank (925-TK2) as potable water.

Potable water is pumped to users by a refinery potable water pump (925-P9A/B).


15

Cooling Water

The tower is of the induced draft, cross-flow type and is designed for a capacity of 10,000 ton/hr with

a cooling 45C to 34.5C based on the wet bulb temperature of 29.5C. The tower consists of four

cells and four induced draft fans equipped with motors.

Cooling water is pumped to the various users by the cooling water circulation pumps (925-P10A/B/C)

and returned to the cooling tower from the users. Cooling water circulation system has side stream

filter system (925-ME2), Chemical Feed System (925-ME4) and Chlorination System (925-ME5).

Cooling Water Circulation Pumps (925-P10A/B/C) Two pumps are turbine (condensing turbine) driven

and the other is motor driven.

Side Stream Filter System (925-ME2A/B/C) Used to remove suspended solids from cooling

water. The filters will be backwashed automatically. Side Stream Filter System is sized for 405 m3/h

and it is approximately 4% of the normal circulation cooling water. Type of the system is Valve-less

Self Backwash Gravity.

Condensate Pumps for Surface Condenser (925-P12A/B) Two motor driven pumps are provided.

Surface condenser to keep its liquid level, flow is sent to cold condensate.


16

Cooling Tower Treatment

Cooling Tower Chlorination System

Cooling tower chlorination system (925-ME5) is installed to inject chlorine gas to the cooling tower

basin in order to prevent the growth of algae and other microbial organisms in the cooling water

system. Rate of 8 kg/h, one hour x once-twice/day continuously.

Chemical Feed System

High stress polymer, Corrosion inhibitor and Bio-Dispersant are involved in 925-ME4 and have

independent injection pump(s) and tank. These three chemicals will be transferred to each tank by

air-driven pump

High stress polymer NALCO-73104 (One definition of stress in water is the existence of high levels

of hardness, alkalinity, or solids (those of greatest concern being calcium, iron, phosphate or silica.

When stress is too high, deposition, corrosion, and microbial fouling result. When stress is too low,

water and chemicals are wasted.) is pumped into the cooling tower basin at a constant rate by the

action of the reciprocating pump (925-P54A/B).

Corrosion inhibitor NALCO-3D7129 (Chemical inhibitors reduce corrosion by interfering with the

corrosion mechanism. Inhibitors usually affect the corrosion reactions at either the anode or the

cathode by establish a protective film on the anode/cathode. Mainly anodic Molybdate,

Orthophosphate, Nitrite, Silicate & Mainly cathodic, Phosphino Succinic Oligomer (PSO), Bicarbonate,

Polyphosphate, Zinc) is pumped into the cooling tower basin with batch operation (once /week) by the

action of the reciprocating pump (925-P55A/B).

Bio-Dispersant NACLO 8506 (Bio dispersants do not kill organisms. They loosen microbial deposits,

which upon detachment from a metal surface, are flushed away with the bulk cooling water. They also

expose new layers of microbial slime or algae to the attack of oxidizing biocides. In addition to

removing bio deposits, bio dispersants are also effective in preventing biofilm formation from taking

place.) is pumped into the cooling tower basin by the action of the reciprocating pump (925-P56A/B).

Bromine NALCO-3434 (bromine-based treatment, which is available as a solid or liquid. Bromine

offers several performance and safety advantages over gaseous chlorine and sodium hypochlorite.) is

pumped into the cooling tower basin by the action of the reciprocating pump (925-P57A/B) from ME6.

Sulfuric acid is pumped into the cooling tower basin at a constant rate by the action of the

reciprocating pump (925-P53A/B) for pH control in directly keep salts in suspended position. Injection

rate is 20 litter/hr.


17

Equipment Data Sheet

Tag No. Service Type Diameter Height Capacity Liquid MLL

m m m3 m

925-TK1A/B

Raw Water Fixed Roof 28.8 14.63 9500 1.0 13.89

925-TK2 PortableWater Cone Roof 9.2 9.8 640 1.0


m3/hr m kW

925-P1/2/3/4/5/6

Well Pumps Submersible 100 70 2950 34.35 B.H.P.

925-P7A/B/C RawWaterPump Centrifugal 400 5.5 P 1500 110

925-P9A/B PortableWaterPump Centrifugal 45 5.3 P 2925 13.8

925-P10A/B/C

C.W. Circulation Pump

Centrifugal 6870 4.5 P 598 1140

Cooling Tower Data Sheet

Induced Draft, Cross Flow, Open Circulation, 4 Cell,

Circulation Capacity 10,000 ton/hr

Basin Capacity ME52 3124.44m3

Fan 114 R.P.M. & variable pitch control

C.W.S. & C.W.R. Temp. Pressure 31.9-38.1oC & 4.3-0.8kg/cm2

Portable Water Filter Data Sheet

Design Filtration Rate 10m3/hr

Feed Pressure, Pressure Drop 5.4kg/cm2, 1.4kg/cm2

Backwash Rate, Pressure, Time 50m3/hr, 4kg/cm2, 10min(17 Total)

Filter Medium [Gravel, Fine, Coarse Sand][Fine Sand,

Anthracite]

Daily Checkups

i. Chemical Pit Level & Stocks, H2SO4, Chlorine Pressure & Flow

ii. Cooling Water & Portable Water (Fan In-service/Sump Level, Process/Utilities Flow,

C.W.S & C.W.R Temperature & Pressure, pH, Side Stream Filter Service/C.W. Flow)

iii. Cooling Water Turbines (HP & Condenser Vacuum, temp. pressure flow, Lube oil

pressure, temp. CWS to cooler)

iv. Surface condenser Level, temp. CW outlet temp, P12A/B discharge pressure, MP

Steam pressure, C.C. temperature

Effluent Treatment Plant U-930 Department: U&OM

18

Fire Water System U-926

Introduction

Many hydrocarbon processing plant are located along waterways, so that availability of fire water is

essentially guaranteed. PARCO use ground water as source of fire water and other make up water and

portable water system through six well pumps. Fire water network system provide fire water at design

pressure 10.5kg/cm2 throughout refinery.

Fire protection system consists of fire water distribution system, foam extinguishing system, portable

nozzles, fire extinguishers, tools and accessories, etc.

The fire protection system intends to prevent fires, as well as to minimize, control, or extinguish fires

already burning.

Design Capacity

The fire protection system is designed on basis of the following criteria:

i. There will be no outside firefighting assistance.

ii. There will be only one major fire at a time.

Fire water storage tank (926-TK1) Capacity: 13,626 m3

The capacity is based on requirement of fire water demand at the rate of 2,271 m3/hr for six (6)

hours continuous firefighting operation.

Raw Water Storage (925-TK1A/B) capacity of each tank: 4,542 m3

The capacity is based on requirement of fire water demand at the rate of 2,271 m3/hr for additional

four hours continuous firefighting operation when the fire water tank(926-TK1) is empty.

System Description

The fire water tank (926-TK1) is a fixed roof tank with effective fire water capacity is 13,626 m3. On

the other hand, the raw water tanks (926-TK1A/B) are also fixed roof tanks, with fire water volume

usable, per tank is 4,542 m3).

Four centrifugal fire water pumps, two electric motor driven (926-P1A/B) and two diesel engine driven

(926-P1C/D) are provided for the refinery. The two motor driven pumps are operated in case of the

largest fire water demand, while the two diesel engine driven pumps are as standby.

Two centrifugal electric motor driven jockey pumps, unit operating 926-P2A/B are provided, to

continuously maintain the pressure in fire water distribution piping.

Cut-in Sequence

Pressure difference and time difference for fire water pumps are used as consequent operation of

multi fire water pumps. The following operation sequence is used.


19

The pressure of fire water distribution main piping is maintained at 10.5 kg/cm2G by the jockey pump

(926-P2A). When fire water distribution piping pressure falls to 9.5 kg/cm2G, the first electric motor

driven pump (926-P1A) will be put into operation automatically with no time delay, the second electric

motor driven pump (926-P1B) will be put into operation automatically, with 10 seconds time delay.

Diesel engine driven pump, 926-P1C, shall start automatically on the following condition; on low

pressure on the fire main header, on electric power failure, on time delay after the signal given to P1A.

Equipment Specification


m m m3 m

926-TK1 Fire Water

Tank Cone Roof 38.2 14.63 16760 1.0


m3/hr m kW

926-P1A/B/C/D

Main Fire Water Pumps

Centrifugal 1136 108.5 1490

926-P2A/B Jockey Pump Centrifugal 24 104

Connection with Raw Water System

In case of fire main fire pumps start as programed to operate, pumps takes suction from fire water

tank if fire water tanks goes to its lower limit, a rupture disc is installed in between Raw Water Tanks

common header and suction of fire water. If suction pressure falls due to lower level in fire water tank

then head maintain in raw water tank cause rupture disc to break and water start flow from raw water

tanks.


20

Effluent Tratment Plant U-930

Introduction

Effluent Collection, Treatment and Disposal System (Unit 930) is to collect and to treat the expected

effluent water from the refinery to be within the stipulated effluent limits for the treated water. And

the system is also to collect aromatics waste, slop oils to be recovered to the refinery slop oil tank.

Design Capacity

The system is composed of the following eight major systems:

i. Clean water sewer system

ii. Oily water collection system (The design capacity of the process waste water lift station inlet

is 2,620 m3/hr, tankage waste water lift station inlet is 460 m3/hr each.

iii. Slop oil recovery system (The skimmed oil circulation rate is 8 m3/hr.)

iv. Spent caustic neutralization system (The capacity is 180 m3/hr.)

v. Closed aromatics waste system

vi. Waste water treatment plant(The design capacity of WTP is 170 m3/hr x 2 train)

vii. Oily sludge handling system (The design capacity is 17 m3/hr with 2 % as dry solids

contents as oily sludge thickener feed and 20 % dry solid cake at dehydrator outlet)

viii. Bio-sludge handling system (The design capacity of bio-sludge handling system is 2.2 m3/hr

average with 1 % as dry solids contents as bio-sludge thickener feed and 17 % dry solid

cake at dehydrator outlet.)

ix. Sanitary waste treatment plant (The design capacity of sanitary waste treatment plant is

7.5 m3/hr total which is capable of treating an average daily flow rate of 144 m3.)

Quality of Effluent

Parameter At API Separator Inlet Treated Water (NEQS)

Temperature 39

pH Value 6 - 9 6 - 9

BOD5 at 20C mg/l 300 30

CODcr mg/l 750 150

Suspended Solids (TSS)

mg/l 50-100 30

Chromium, Hexavalent

mg/l 0 0.1

Chromium, Total mg/l 0 0.5

Lead mg/l < 0.1 0.1

Benzo (a) pyrene mg/l 0 0.05

NH3-N mg/l 10 TDS 3500

Benzene mg/l < 1 0.05


21

Phenol mg/l < 6 0.3

Sulphide mg/l < 5 1.0

Oil and Grease mg/l 30 - 2000 10

Alkalinity mg/l 200 as CaCO3 Toxic Metals 2

Sanitary effluent feed : BOD5 300 mg/l

TSS 300 mg/l

Treated sanitary effluent : BOD5 20 mg/l

TSS 30 mg/l

Chemical Summary

Name Specifiaction Purpose Service

Emulsion Breaking Polymer

NALCO EC ST9302 Slop Oil emulsion

breaker 930-TK6A/B &

TK7

Sulfuric Acid 40% wt H2SO4 pH Control 930-ME22 & V7

Caustic Soda 18.7% NaOH pH Control 930-ME22

Ferric Chloride 40% wt FeCl3 Coagulating Agent 930-ME22

DAF Polymer 40% wt Polymer Sludge Accumulator 930-ME4A/B

DAP Nutrient 930-ME5A/B

Oily & Bio Sludge Polymer

40% wt Polymer Sludge Accumulator 930-ME51 &

ME61

Hypochlorite 12.5% wt as Cl2 Bacteria Killer 930-TK72


22

Process Description

Oily water collection system

Process Waste Water Lift Station (930-ME2) (Bar Screen Skimmer for Process & UTY)

Tankage Waste Water Lift Station (930-ME9A/B)

Spent caustic neutralization system

The spent caustic transfers to the neutralizing drum (930-V7) by the spent caustic supply pumps

(930-P19A/B). The spent caustic circulates from the neutralizing drum (930-V7) through the

neutralization heater (930-E3) and/or the neutralizing waste cooler (930-E4) by circulation pumps

(930-P18A/B).

During the circulation, the sulfuric acid injects into the neutralizing drum by the sulfuric acid transfer

pumps (930-P17A/B). During the neutralization, the spent caustic is heating up by the neutralization

heater (930-E3), if necessary, and then is cooled down to the neutralizing waste cooler (930-E4) when

finishing the neutralization. Discharge pumps (930-P28A/B) via the spent caustic discharge cooler

(930-E8).

Water Treatment Plant WTP

This system consists of the following sections:

i. API oil/water separator basins

ii. Equalization tank

iii. DAF basins

iv. Biological aeration basins and Clarifiers

v. Sand filters

API Oil/Water Separator Section

Process/utility effluent water or oily storm water from the process waste water lift station is led to API

oil/water separator. The API oil/water separator basins (930-ME3A/B) are equipped with a chain

driven scraper and an automatic rotary drum skimmer at the basin outlet. The API separate oil and

oily sludge from the effluent. The treated water is fed to DAF unit through an equalization tank By API

effluent pumps. The sludge is, then sent to the oily sludge handling system. Separated oil is sent to

Slop Oil holding tanks.

Equalization tank section

The treated API effluent water, neutralized spent caustic and recycled filter back wash water receives

to the equalization tank, to produce a constant feed quality and quantity to the DAF units. The air

supplies to the equalization tank by an equalization tank air compressor through diffusers at the tank

bottom.

DAF unit section


23

The API effluent water stored in the equalization tank (930-TK2) transfers at constant flow rate to the

flash mixing basin. Then the ferric chloride as coagulant and DAF polymer are injected by a injection

pump to make flocs. The caustic soda or the sulfuric acid is also dosed to adjust pH. The DAF effluent

is recycled to mix plant air in V-11.

Suspended solids in the waste water collected by the fine bubbles and are accumulated at the

surface of DAF basin as scum. The scum removes by the DAF skimmer and then transfers to the oily

sludge handling system. The DAF bottom sludge removes by the DAF scraper and then transfers to

the oily sludge handling system.

Biological aeration/Clarifier section

The treated effluent from the DAF basins flows by gravity to two biological aeration basins, to reduce

the biological oxygen demand (BOD5) to the acceptable limit of effluent.

The air supplies to the biological aeration basins by air blowers through air diffusers to maintain a

dissolved oxygen (DO) level. The clarifiers (930-ME27A/B) separate the biological solids from the

effluent from the aeration basin. The sludge scraper mechanism installed in the clarifier collects

surface scum is also routed to a bio sludge treatment.

Sand filter section

The clarified water flows by gravity to the rapid gravity type dual media filters which are of rectangular

design and of concrete. The filters are normally repeating the service and back washed by automatic

sequence. Four filters are in operation under full plant flow.

Sanitary Waste Treatment plant

Two packaged rotating biological contactors receive sanitary waste water from the office, buildings,

toilets, and kitchen facilities. The sanitary effluent treat at the aeration section and flows to the

clarifier section. The treated sanitary effluent flows by gravity into a hypochlorite contact tank.

Oily Sludge & Bio Sludge Polymer

Oily sludge from API separator is sent to centrifuge with injection of oily sludge polymer which help to

separate oil from water & Biosludge sent to belt press machine with injection of biosludge polymer

which eject water from sludge then both properly dumped.


24



m m m3 m

930-TK1 Diversion

Tank Open Roof 49.2 14.6 25400 W.W. 13.87

930-TK2 Equalization

Tank Fixed Roof 19 14.6 4100 W.W. 13.87

930-TK6A/B

Slop Oil Tank Cone Roof 5.8 5.2 130 Slop 0.95

4.52

930-TK5 Spent Caustic Fixed Roof 12.2 12.2 1425 1.05 11.59

930-TK7 Emulsion

Breaking Tank Cone Roof 5.8 5.2 130

Slop 0.95

4.52


m3/hr m kW

930-P1A/B

W.W. to API Separator

Submersible 4.59 36 1496 45

930-P2A/B

W.W. to TK1 Submersible 12.7 89 1465 132

930-P3A/B

Treated Water to Saim Nala

Submersible 200 72.4 2950 56.3

930-P15A/B

W.W. Flash Mixer Centrifugal 192.3 17 1450

930-P17A/B

Acid Injection to V-7

Centrifugal 8.8 1.75 1500 1.5

930-P18A/B

Circulation Pump Centrifugal 120 3.5 2950 22

930-P19A/B

Spent Caustic Transfer Pump

Centrifugal 180 23 1470 22

930-P23A/B

Slop Oil Heater Transfer Pump

Centrifugal 8 28.5 2895 3.7

930-P24A/B

TK7 to Heater Transfer Pump

Centrifugal 8 28.5 2895 3.7

930-P28A/B

Spent Caustic To ETP

Diaphragm 1.9 3.1 1500 3.6

Tag No. Service Type Capacity Pressure R.P.M.

930-C1A/B Equalization Tank Rotary Gear 4.59NMPH kPa g 1496

930-C2A/B/C/D

Aeration Basin Rotary Gear 1950 40.7 1950

930-C4 930-TK60 Rotary Gear 400 39.2 2791

Steam, Feed Water & Condensate Handling System Department: U&OM

25

Steam, Feed Water & Condensate Handling System U-940

Intoduction

The Steam, Feed Water and Condensate Handling Systems main purpose is to generate and

distribute steam to the plant users. Unit 940 is composed of the following:

i. Boiler Makeup Water Treating Section

ii. Steam letdown Section

iii. Condensate Recovery Section

iv. De-Aerator Section

v. Boiler Section

D.M.W. B.F.W. & Steam Conditions

D.M.W. B.F.W. Steam

85m3/hr Normal Flow Pressure Temp. Type Pressure Temp.

kg/cm2 oC kg/cm2 oC

Conductivity < 5S/cm 58 121/115 HP 42.2 390

Silica


26

Process Description

Boiler Makeup Water Treating Section

The Plant is designed to produce demineralized water from 8.5 kg/cm2g design pressure Plant water

at a flow rate of 94 m3/h, with a shift volume of 1200 m3, at a battery limit pressure of 3.5 Kg/cm2g.

Activated carbon adsorption principles 940-50A/B

The activated carbon explicates its adsorption capability by means of its porous structure obtained

firing vegetable matter, such as coconuts, or mineral coal. Plant water pumped by 940-P7A/B is

transfer to Demin Trains and its flow is controlled by control valve to trains. Water enter from top and

all possible suspended solid are removed and water leaves from bottom to cation exchanger. For

regeneration water flows from bottom to top.

Cation Exchanger 940-V51A/B

It means to remove cations from water, replacing them by hydrogen ions, flowing the water through a

bed of cationic resin in hydrogen cycle.

Weak acid resins When a dissolved strong acid salt, such as Calcium Sulfate, crosses a weak acid

resin

Strong acid resins To exchange a dissolved weak acid salt like Sodium Bicarbonate

During the Regeneration, carried out, in this package, with sulphuric acid (1.5 & 3%), the cations fixed

on the resin are removed.

Decarbonator 940-V52A/B

Instead of treat the weak hydrochloric acid on strong anion resins, it is possible to"decarbonate" the

decationized waters. This process uses the Henry's law with which it is easy to strip away from

decationized water the dissolved excess of carbon dioxide. And residual

10 ppm as CO2 obtained.

Then water is pumped to anion exchanger by 925-P51A/B/C.


27

Anion Exchanger 940-V53A/B

It means to remove anions from decationized water, replacing them by hydroxyl ions OH" The

operation is carried out by percolating the water through a bed of anionic resin in order to remove the

strong acid anions that were produced during the decationization.

Anions of weak acids are removed according to the

following scheme:

Deanionized water (normally coming after an anionic unit) have an excess of OH Ions that normally

links themselves with Na ions that leaked from the cationic resins. The resultant NaOH base will give

the deionizated water a pH above 7.

During the Regeneration, carried out with sodium hydroxide 3%, the anions on the resin are removed

Mixed bed polisher 940-V54A/B

Polishing demineralization process performs what the previous separated resin's beds cannot

achieve. Some leakage will occur and the so treated water contains some traces of cations and

anions, typically sodium hydroxide and even hardness traces.

A mixed bed is constituted of a mixture of strong cation and strong anion special resins. While during

the exchange process the resins must be thoroughly mixed, their regeneration shall be performed

with resins separated that is done by countercurrent.

After mixed bed polisher DMW send towards storage tanks 940-TK1A/B. For B.F.W. make up in

deaerator 940-P2A/B pump it to process diesel cooler 100-E21 and control by spill back controller

and for DMW regeneration 940-P4A/B are used.

Steam Letdown Section

HP-MP letdown system with desperheater (940-DS1) is provided to cover MP steam requirement

made up with HP steam and BFW.

MP-LP letdown A pressure control valve is also provided to letdown MP steam to LP steam when LP

steam header pressure becomes lower or excess MP steam is letdown to LP steam header.


28

Condensate Recovery Section

Steam changes its phase to condensate when it dissipates heat to the process. All the condensate

from Refinery is collected through separate headers.

HP Condensate Flash Drum (940 -V5).

HP Condensate recovered to HP Flash Drum 940-V5, which flashes at MP Steam pressure (i.e. 10.5

Kg/cm2). Flashed vapors are directed to MP steam Header and flashed liquid is sent to MP Flash

Drum. Excess level to discharge water to 940 TK-5 drain pit.

MP Condensate Flash Drum (940 V4).

MP Condensate recovered to MP Flash Drum 940-V4, which flashes at LP Steam pressure (i.e. 3.5

Kg/cm2). Flashed vapors are directed to LS steam Header and flashed liquid is sent to LP Flash Drum

and mixes with LS Condensate before entering in the LP flash drum.

LP Condensate Flash Drum (940 V3).

LP Condensate recovered to LP Flash Drum 940-V3, which flashes at Deaerator pressure (i.e. 1.05

Kg/cm2). Flashed vapors are directed to Deaerator for deaeration and flashed liquid is also pumped

(940 P3 A/B) to the Deaerator.

Cold Condensate.

Cold Condensate from surface condensers of process area (Condensing Steam Turbines C1-300 &

C1-284) and from utility area (Condensing turbines of 925 P10 A/B via 925 P12 A/B) are mixed with

Demineralized make up water at the Deaerator.

Deaerator Section

The Deaerator receives all recovered condensate (Hot condensate & Cold condensate) plus

Demineralized water required to make up of losses for steam stripping, blow down and so on. Hot

condensate is received to the side of Deaerator shell, while Demineralized water and cold condensate

are received from top of the Deaerator shell. The water is heated up with the saturated steam flashed

from the condensate recovery system and from the continuous blow down tank, plus supplementary

make up from the LP steam system through control valve 940 PV 026 A.

B.F.W. System

Boiler Feed Water Pump (940 P1 A/ B/ C) takes water from Deaerator and pumped to the Utility

Boilers (940 B1 A/ B/ C) and steam generators of process area. Boiler Feed Pumps 940 P1 A / B

are steam turbine driven, while 940 P1C is motor driven.

Boiler Section

This D type TITAN M Boiler Plant is supplied by MACCHI, Italy. Each Boiler produces 65 tons/h

Super-heated steam at 43.5 Kg /cm2 pressure and 390 C for Pak Arab Refinery. Boilers are Water

tube, Forced Draft with natural circulation and are suitable for Fuel Gas & Fuel Oil firing.


29

Steam Drum & Mud Drum

Purpose of both drums are To receive feed water, To provide water storage for proper and safe water

circulation, To receive water & steam mixture, To separate the Steam from water through steam

separators, To dry the saturated steam through the dryers, To send the steam to Super-Heater for

super heating purposes.

The Steam Drum is also fitted with Cyclone separators, Wire mesh (demisters) & Chevrons dryers,

Perforated feed pipe, Chemical dosing pipe, Continuous blow down pipe.

Forced Draught Fan

Each Boiler is equipped with a single suction type centrifugal fan. F.D

Fans provided to Boiler 940 B1A & 940 B1B are fitted with two

drivers (Electric Motor & Steam Turbine).

Burner Assembly

Each Boiler is equipped with two Low NOx type two frontal burner

floors. Each floor consists of pilot burner, two fuel oil burner and four

fuel gas burner with UV/IR flame detector in assembly. With atomizing

steam provision.

Furnace

Front Wall Furnace housing the Burners, Rear Wall forming the rear side of the Furnace, Upper and

lower rear Wall header, D Tubes forming the floor, side and roof Furnace Walls, Boiler-Bank side

Wall.

Boiler-Bank

The sidewalls: Consists of Fin Tubes installed side to furnace.

The Evaporator bundle: Bare tube where water converted into steam and installed in front of burner.

The down comers: Bare tube where water flow downward installed after evaporator.

Super-Heater & De-Super Heater

The Super-Heater is divided in two stages (Primary & Secondary S. heater) with an intermediate water

spray de Super-Heater.

The water spray de Super-Heater No.1 is placed between primary and secondary Super-Heater in

order to keep the final Super-Heater temperature steady within the specified control range.

The spray water de Super-Heater No.2 control the steam temperature at the downstream of the

steam turbine outlet. In both cases the spray water is taken upstream the BFW pre - heater.


30

Economizer

The economizer is fully drainable type, equipped with horizontal bare tubes and installed at Boiler

outlet in flue gas path. Economizer possesses double fins tubes.

The flue gas path is directed vertically, from top to bottom, while tubes are placed horizontal.

Soot Blowers

The Boiler and economizer are equipped with steam soot blowing facilities to keep the external

surface of Boiler clean, Super-Heater & economizer during the operation with Fuel Oil. All soot blowers

are driven by electric motors and are arranged to obtain automatic sequence control for routine

operations or to be remotely operated without automatic sequence.

Each Boiler is equipped with: Two rake soot blower on economizer, One retractable soot blower on

Super-Heater section, Two rotary soot blowers on Boiler-Bank.

Boiler Stack.

Each Boiler is equipped with 26 meters high self - standing type stack, and it is composed by several

rolled and flanged shell.

I.B.D. Drum

The steam-generating unit is equipped with one atmospheric intermittent blow down drum (940 V2),

common for three Boilers. It performs following functions: To receive the drain of C.B.D. tank and to

reduces its water temperature before draining to the waste water system, to receive the drain of soot

blower system of all the three Boilers, To receive IBD from all three Boilers, when IBD is applied, and

reduces its water temperature before draining to the waste water system.

C.B.D. Drum

The steam-generating unit is equipped with one continuous blow down drum (940 V1), common

to the three Boilers, in order to the following functions: To receive high temperature & high pressure

continuous blow down from all three Boilers steam drum, To flush this water into steam and water,

steam pressure is level to the Deaerator pressure, to send the flashed steam to Deaerator for

deaeration, To send remaining water to IBD drum.

Parameters C.B.D.

pH 9.4 - 10.5

Conductivity @ 25oC < 600 us/cm

Phosphate 5-15ppm

Chemical Dosing

Elimin-OX can economically remove small amount of dissolved oxygen. Eliminox is dosed by 940 P53

A / B (reciprocating pump) by adjusting its strokes. Dosing solution is prepared in dosing tank 940 ME

3A by adding 6.0 litters Eliminox and remaining portion filled with Demin water.


31

Tri-Sodium Phosphate is dosed by 940 P60 A / B / C & D (reciprocating pumps) by adjusting their

strokes. One pump is for each Boiler and pump P 60 - D is on back up for all three pumps. TSP keep

salts that are prone to settle at high temp. In suspended form.

Cyclohexane Amine maintain the condensate pH in the range of 8.09.5. It is volatile and distils in

steam to dissolve readily in the condensate. Being alkaline, it neutralizes the carbonic acid present in

steam condensate and thus overcome low pH values and corrosion. Amine is dosed by 940 P54 A / B

(reciprocating pump) by adjusting its strokes. Dosing solution is prepared in dosing tank 940 ME 3B,

by adding 4litres amine and remaining portion filled with Demin water.



m m m3 m

940-TK1A/B

DMW Tank Cone Roof 14.5 13.4 2200 1.0 12.73

940-TK5 Blowdown Tank Pit 42.2 1.3 2200 1.0

Tag No. Service Diameter Length Design

Pressure Design

Temperature Insulation

m m Kg/cm2 oC mm

940-V1 CBD

940-V2 IBD

940-V3 LC.Recovery 2.3 6.7 3.5 260/121 75

940-V4 MC.Recovery 1.6 1.8 6 260/150 75

940-V5 HC.Recovery 1.2 3.6 13 285/186 75


m3/hr m kW

940-P1A/B BFW Pump Centrifugal 133 608 2980 360

940-P2A/B DMW to Deaerator Centrifugal 85 203

(10kg/cm2) 2980 100

940-P3A/B Condensate to Deaerator Centrifugal 122 52 2945 34

940-P4A/B DW Regeneration Pump Centrifugal 70 75 73

940-P5A/B Neutralization Pump Submersible

Daily Checkups

i. B.F.W. Flow, Pre-Heater O/L temperature, I/O Economizer temperature & pressure,

Combustion Air temperature & pressure, Fuel Gas, Steam Drum pressure & level,

Super-Heater U/S & D/S temperature

ii. Analyzer (CBD, O2, pH, Conductivity), Phosphate Control, Pump Stocks

iii. F.D. Fan Turbine (Flow, Speed, HS & LS temperature pressure)

iv. B.F.W Condensate Recovery, 940-P1A/B/C Flow, temperature, pressure

Analyzer (pH, Conductivity, HC), Eliminox & Amine Stocks, 940-P2A/B & P3A/B

discharge pressure

Suggestion/Recommendation Department: U&OM

32

Suggestions/recommendations

Proper sitting arrangement must be made for the Trainees, and each trainee should be

assigned a technical or managerial task for better training

Boiler soot blowing method must be changed because in most of times chain stuck and soot

blowing stops. Steam soot blowing must be change with air because steam and soot blower

temperature can cause steam to condense, so water sludge will ejected and after sometime it

can erode tubes of boiler

Overflow line at Equalization Tan (930-TK2) in case of level instrument failure

Cooling Tower I.D. fans must have variable speed drivers or variable pitch fans in order to

improve energy utilization

Health of cooling tower louvers should be inspected as few stones and debris were found

broken on ground probably from the top louver

Installation of air pre-heater in furnace to increase efficiency of combustion

Instead of converting HP steam to MP steam or MP-LP by BFW injection, install a heat

exchanger that would heat up boiler feed water to lower its temp. & pressure

Installation of Flare Gas Recovery System that takes gases from knockout drum and

compress them to liquefy them. After liquefaction pump liquid to CDU and flare non-

condensable gases

Synchronization of Excel based sheet with supervisors cabins to keep interact them with

process, they have to contact with DCS operator to handle any problem

Documents

Utilities Report PARCO