Utilities Report PARCO

Submitted To
Engr. Husnain Farid Engineer I
Date: 7 April 2015
Mohammad Yasser Ramzan

Trainee Engineer P # 5738
Email: m_yasser_ramzan@hotmail.com
PAK ARAB REFINERY LTD
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

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.
ii.
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.
98% sulfuric acid handling system: sulfuric acid is stored in a horizontal vessel (900V1) 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
Utility, Boiler Makeup Water System,
Cooling Water System, Spent Caustic
Section
Caustic User
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
Department: U&OM
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
m3/hr
R.P.M.
Power
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
900-P4A/B
Acid Process Pump
Centrifugal
6.47
925P53A/B
Cooling Tower Acid

Injection Pumps
Diaphragm
0.02
Tag No.
Service
Type
2915
29.4
2915
7.5
Min Stock 15 S.P.M, Max 80

S.P.M.
Diameter Height Capacity
MLL
m3
110
3.9
900TK1A/B
Caustic Storage Tank
Fixed
Rood
5.8
4.2
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

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.
ii.
Protecting the instruments and control system from damage.

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
Department: U&OM
Process Description
Plant & instrument air unit consists of following sections
i.
ii.
Air Compressor Package

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.
Department: U&OM
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.
ii.
iii.
iv.
v.
vi.
vii.
Suction Filter: Used to filter any dust particles from air. 22cmH2O pressure drop
across filter generate alarm to clean it.
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.
Unloading Valve: Known as anti-surge valve, PCV installed at outlet of compressor
maintain the outlet pressure and discard excess pressure.
1st & 2nd Stage Intercooler: Plate type heat exchanger installed to cool down
compressed air from each stages by Cooling water.
After Cooler: Counter current heat exchanger installed to cool down compressed air to
required supply temperature by cooling water.
Lube Oil System: The lubrication system supplies oil to compressor bearings and
gears. It is cooled down by cooling water (80oC to 30/40oC).
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.
Department: U&OM
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.
ii.
iii.
Pre-Filter (910-ME1-V2A/B): Used to remove any moisture or oil contamination.

Adsorption Vessels (910-ME1-V1A/B/C/D)
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.
ii.
iii.
iv.
v.
vi.
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.
Depressurization: Depressurizing vessel by closing air inlet valve and outlet valve and
opening valve installed towards silencer vent.
Regeneration: During regeneration air is routed from top to bottom and saturated bed
is regenerated and air is vent through vent.
Pressurize: After regeneration silencer valve is closed and air from top pressurize
vessel.
Parallel Drying: For about 5sec both adsorber starts drying before switching.
Switch over: After regeneration air inlet valve is opened for drying and vent closed.
Department: U&OM
Equipment Data Sheets

Dryer Train 910-ME1
Tag No.
Service
910-ME1
910-ME1V1A/B/C/D
910-ME1V2A/B
910-ME1V3A/B
Dryer Trains
Design
Pressure
kg/cm2
11.25
Air Dryer
Design
Temperature oC
Capacity m3
Weight
kg
120
4790
11.25
5/120
1.8
950
Pre-Filter
11.25
5/120
0.055
150
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
0.014kg/cm2
Maximum Pressure Drop

Cooling Water
Inlet Outlet Temperature
Inlet Outlet Pressure
Flow Rate (LO, After Cooler, Interstage
Cooler)
Compressor
Stages, Impeller Dia, Max. Conti. Speed
34.5 45oC
4.4 3.4kg/cm2
29, 10, 59.7 m3/hr
3, (300+199+149), 2986 r.p.m
Flare System U-915
Department: U&OM
Flare System U-915

Introduction
Flare system are used to destroy corrosive, toxic, and flammable waste products during process startups or during upset plant conditions. This is achieved by converting them into less harmful products
through combustion.
Whenever industrial plant equipment items are overpressured, 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).
ii.
iii.
iv.
v.
vi.
i.
A knockout drum to remove any oil and/or
water from the relieved gases.
A water seal drum to prevent any flashback of the flame from the top of the flare
stack.
An alternative gas recovery system for use during partial plant startups and/or
shutdowns as well as other times when required.
A steam injection system to provide an external momentum force used for efficient
mixing of air with the relieved gas, which promotes smokeless burning.
A pilot flame (with its ignition system) that burns all the time so that it is available to
ignite relieved gases whenever needed.
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.
ii.
Main flare system

: 950 ton/hr (General power failure case)
Acid gas flare system : 48.6 ton/hr (284Unit CV failure open case)
Flare System U-915
Department: U&OM
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.
Flare System U-915
Department: U&OM
Equipment Specifications
Tag No.
915-V1
915-V2
Service
K.O.Durm
Main
Flare
K.O.Drum
Acid
Tag No.
Diameter
Length
5.5
18
1.22
Service
Material
D.P.
D.T.
Weight
kg/cm2
oC
ton
SA516Gr.70
3.5
338/5
97
3.9
316L SS
3.5
210/5
2.5
Type
Capacity
m3/hr
915P1A/B
915P2A/B
Tag No.
915-ME1
LSL Pump Main

Centrifugal
11.4
K.O.D.
Sour Water Pump
Centrifugal
7.5
K.O.D.
Service
Diameter
Length
Capacity
Main
Flare
915-ME2 Acid Flare
inch
Ton/hr
48
112
950
112
48.607
Pressure
S/D
Kg/cm2
R.P.M.
Power
kW
0.27/5.54
7.5
0.29/5.50
7.5
Specifications
Smokeless Flare DP 3.5kg/cm2,
DT 338oC
Elevated Flare DP 3.5kg/cm2,
DT 210oC, Steam Traced,
Insulation
Daily Checkups (Main+Acid)

i.
ii.
iii.
iv.
v.
vi.
Knockout Drum Level

Pumps Status
Pressure, Temperature, Seal Level
Steam Ton/hr
Fuel Gas Flow m3/hr
Pilot Burner Status 1/2/3/4/5/6
10
Fuel Oil & Fuel Gas System U-920
Department: U&OM

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.
ii.
iii.
DieselMax, Visbreaker & Vacuum Residue

Fuel Oil Product (temporary used, such as refinery startup)
Flushing Oil from Tankage (as cutter stock for heavy oil)
Destination (Consumers)
i.
ii.
Crude heater, Vacuum heater, Charge heater in NHT, Product fractionator feed
heater, Thermal cracking heater in Diesel Max Unit , Visbreaker heater
Utility boilers
Priority Of Fuel Oil

i.
ii.
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.
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.
ii.
iii.
iv.
v.
Purge gas from the catalytic section of the DieselMax Process Unit
Treated gas from the Amine Treating Process Unit
Net gas from the Platforming Process Unit
Natural gas from outside of the refinery
On-spec LPG from LPG sphere
11
Department: U&OM
Destination (Consumers)
i.
ii.
iii.
iv.
v.
vi.
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
Utility boilers
Purge gas to flare headers
Dry seal for flare stacks
Incinerator, 820-H3/H4 in the Sulfur Recovery Unit
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
12
Department: U&OM
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
m
920TK1A/B
Fixed
Rood/Steam
13.5
12.2
Traced
Service
Type
Capacity
920P1A/B/C
Tag No.
RFO Supply Pump
920-E2
Service
RFO Heater
Centrifugal
Type
Shell & Tube
1600
Head
m3/hr
32
153
Area
MLL
m3
RFO
Storage
Tag No.
Sp.
Gravity
0.98
11.45
R.P.M.
Power
kW
2950
Shell
75
Tube
m2
DP
DT
DP
DT
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.
13
Water System U-925
Department: U&OM
Water System U-920

Introduction
Unit 925 Water System is composed of the following system
i.
ii.
iii.
iv.
Well Pumps Section

Raw Water and Plant Water Section
Potable Water Section
Cooling Water Section
Design Capacity
U-925s different sections designed on basis of their requirement in refinery.
i.
ii.
iii.
iv.
Well Pumps Section has pumping capacity 100m3/hr per well.

Raw Water & plant storage capacity of 9500m3 of each tank 925-TK1A/B
Portable Water section has storage capacity of 925-TK2 640m3 and filtering capacity
20m3/hr.
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.
ii.
iii.
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.)
Make up of Potable Water
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).
14
Water System U-925
Department: U&OM
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.
15
Water System U-925
Department: U&OM
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.
16
Water System U-925
Department: U&OM
Equipment Data Sheet

Tag No.
925TK1A/B
925-TK2
Service
Type

m
m3
Liquid
MLL
m
Raw Water
Fixed Roof
28.8
14.63
9500
1.0
PortableWater
Cone Roof
9.2
9.8
640
1.0
Capacity
Head
R.P.M.
Power
m3/hr
Tag No.
Service
Well Pumps
Submersible
100
70
2950
RawWaterPump
Centrifugal
400
5.5 P
1500
kW
34.35
B.H.P.
110
PortableWaterPump Centrifugal
45
C.W. Circulation
Centrifugal
6870
Pump
Cooling Tower Data Sheet
5.3 P
2925
13.8
4.5 P
598
1140
925P1/2/3/4/5/6
925-P7A/B/C
925-P9A/B
925P10A/B/C
Type
13.89
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)

[Gravel, Fine, Coarse Sand][Fine Sand,
Anthracite]
Filter Medium
Daily Checkups
i.
ii.
iii.
iv.
Chemical Pit Level & Stocks, H2SO4, Chlorine Pressure & Flow
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)
Cooling Water Turbines (HP & Condenser Vacuum, temp. pressure flow, Lube oil
pressure, temp. CWS to cooler)
Surface condenser Level, temp. CW outlet temp, P12A/B discharge pressure, MP
Steam pressure, C.C. temperature
17
Effluent Treatment Plant U-930
Department: U&OM
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.
ii.
There will be no outside firefighting assistance.

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.
18
Department: U&OM
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
Tag No.
Service
Type

m
926-TK1
Tag No.
926P1A/B/C/D
926-P2A/B
Fire Water
Cone Roof
38.2
14.63
Tank
Service
Type
Capacity
Main Fire Water
Pumps
Jockey Pump
Liquid
m3
16760
Head
m3/hr
Centrifugal
1136
108.5
Centrifugal
24
104
MLL
m
1.0
R.P.M.
Power
kW
1490
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.
19
Department: U&OM
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)
Chromium,
Hexavalent
mg/l
50-100
30
mg/l
0.1
Chromium, Total
mg/l
0.5
Lead
mg/l
< 0.1
0.1
Benzo (a) pyrene
mg/l
0.05
NH3-N
mg/l
10
TDS 3500
Benzene
mg/l
<1
0.05
20
Department: U&OM
Phenol
mg/l
<6
0.3
Sulphide
mg/l
<5
1.0
Oil and Grease
mg/l
30 - 2000
10
200 as CaCO3
Toxic Metals 2
mg/l
Sanitary effluent feed :
Alkalinity
Treated sanitary effluent :
BOD5
TSS
BOD5
TSS
300 mg/l
300 mg/l
20 mg/l
30 mg/l
Chemical Summary
Name
Emulsion Breaking
Polymer
Sulfuric Acid
Caustic Soda
Ferric Chloride
DAF Polymer
DAP
Oily & Bio Sludge
Polymer
Hypochlorite
Specifiaction
NALCO EC ST9302
40% wt H2SO4
18.7% NaOH
40% wt FeCl3
40% wt Polymer
Purpose
Slop Oil emulsion
breaker
pH Control
pH Control
Coagulating Agent
Sludge Accumulator
Nutrient
40% wt Polymer
Sludge Accumulator
12.5% wt as Cl2
Bacteria Killer
Service
930-TK6A/B &
TK7
930-ME22 & V7
930-ME22
930-ME22
930-ME4A/B
930-ME5A/B
930-ME51 &
ME61
930-TK72
21
Department: U&OM
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.
ii.
iii.
iv.
v.
API oil/water separator basins

Equalization tank
DAF basins
Biological aeration basins and Clarifiers
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
22
Department: U&OM
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.
23
Department: U&OM
Tag No.
Service
Type
Liquid
MLL
m3
Open Roof
49.2
14.6
25400
W.W.
13.87
Fixed Roof
19
14.6
4100
W.W.
13.87
Cone Roof
5.8
5.2
130
Spent Caustic Fixed Roof

12.2
12.2
Emulsion
930-TK7
Cone Roof
5.8
5.2
Breaking Tank
Tag No.
Service
Type
Capacity
1425
930-TK1
930-TK2
930TK6A/B
930-TK5
930P1A/B
930P2A/B
930P3A/B
930P15A/B
930P17A/B
930P18A/B
930P19A/B
930P23A/B
930P24A/B
930P28A/B
Tag No.
930-C1A/B
930C2A/B/C/D
930-C4
Diversion
Tank
Equalization
Tank
Slop Oil Tank
130
Head
m3/hr
Slop
0.95
1.05
Slop
0.95
R.P.M.
4.52
11.59
4.52
Power
kW
W.W. to API
Separator
Submersible
4.59
36
1496
45
W.W. to TK1
Submersible
12.7
89
1465
132
Treated Water to
Saim Nala
Submersible
200
72.4
2950
56.3
W.W. Flash Mixer
Centrifugal
192.3
17
1450
Acid Injection to
V-7
Centrifugal
8.8
1.75
1500
1.5
Circulation Pump
Centrifugal
120
3.5
2950
22
Centrifugal
180
23
1470
22
Centrifugal
28.5
2895
3.7
Centrifugal
28.5
2895
3.7
Diaphragm
1.9
3.1
1500
3.6
Spent Caustic
Transfer Pump
Slop Oil Heater
Transfer Pump
TK7 to Heater
Transfer Pump
Spent Caustic To
ETP
Service
Type
Capacity
Pressure
R.P.M.
Equalization Tank
Rotary Gear
4.59NMPH
kPa g
1496
Aeration Basin
Rotary Gear
1950
40.7
1950
930-TK60
Rotary Gear
400
39.2
2791
24
Steam, Feed Water & Condensate Handling System
Department: U&OM
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.
ii.
iii.
iv.
v.
Boiler Makeup Water Treating Section

Steam letdown Section
Condensate Recovery Section
De-Aerator Section
Boiler Section
D.M.W. B.F.W. & Steam Conditions

D.M.W.
85m3/hr Normal Flow
Conductivity < 5S/cm
Silica <0.02ppm as SiO2
Turndown 32m3/hr
B.F.W.
Pressure
Temp.
2
oC
kg/cm
58
121/115
pH=8.5-9.5, Cond. < 5S/cm
O2 <0.005cc/l (0.007mg/l)
Type
HP
MP
LP
Steam
Pressure
kg/cm2
42.2
10.5
3.5
Temp.
oC
390
205
160
Steam Gernerator
High Pressure Steam is mainly generated by HP steam Boilers of utility area and also by Waste Heat
Recovery Steam Generators of 300-V12 & 820-E1.
MP Steam is mainly generated by process waste heat Boilers in the Refinery, and also by exhaust
/extraction of HP Steam turbines. 300-C1.
LP Steam is generated by HP/MP Steam turbine exhaust and extraction from 284-C1.
25
Department: U&OM
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.
10 ppm as CO2 obtained.
And residual
Then water is pumped to anion exchanger by 925-P51A/B/C.
26
Department: U&OM
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

following scheme:
according to the
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.
27
Department: U&OM
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.
28
Department: U&OM
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.
29
Department: U&OM
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
pH
Conductivity @ 25oC
Phosphate
C.B.D.
9.4 - 10.5
< 600 us/cm
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.
30
Department: U&OM
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.
Tag No.
Service
Type
Diameter
Height
Capacity
m3
Liquid
MLL
m
940TK1A/B
DMW Tank
Cone Roof
14.5
13.4
2200
1.0
940-TK5
Blowdown Tank
Pit
42.2
1.3
2200
1.0
Tag No.
Service
12.73
Diameter
Length
Design
Pressure
Design
Temperature
Insulation
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
260/150
75
940-V5
HC.Recovery
1.2
3.6
13
285/186
75
Tag No.
Service
Type
Capacity
Head
m3/hr
R.P.M.
Power
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
940-P5A/B
Neutralization Pump
Submersible
73
Daily Checkups
i.
ii.
iii.
iv.
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
Analyzer (CBD, O2, pH, Conductivity), Phosphate Control, Pump Stocks
F.D. Fan Turbine (Flow, Speed, HS & LS temperature pressure)
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
31
Suggestion/Recommendation
Department: U&OM
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 noncondensable 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
32

Utilities Report PARCO

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Utilities Report PARCO

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Submitted To

Engr. Husnain Farid Engineer I

Date: 7 April 2015

Mohammad Yasser Ramzan

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

Chemical Handling Area U-900

Chemical Handling Area U-900

Design Capacity & Users

Chemical Handling Area U-900

Sulfuric Acid System

Equipments & Data Sheets

Acid Transfer Pump

Acid Process Pump

Cooling Tower Acid

Min Stock 15 S.P.M, Max 80

Diameter Height Capacity

Caustic Storage Tank

Acid Storage Vessel

Plant & Instrument Air System U-910

Plant & Instrument Air System U-910

Protecting the instruments and control system from damage.

Quality of Instrument Air

Design Capacity & Users

Plant & Instrument Air System U-910

Air Compressor Package

Plant & Instrument Air System U-910

Compressor PACKAGE (Elliott USA)

Compressor Trip Conditions

Plant & Instrument Air System U-910

Air Dryer Package

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

Plant & Instrument Air System U-910

Equipment Data Sheets

Compressor Package 910-C1A/B

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

Maximum Pressure Drop

3, (300+199+149), 2986 r.p.m

Flare System U-915

Flare System U-915

Design Capacity & Sources

Main flare system

Flare System U-915

Acid gas flare system

Flare ignition system

Flash back protection

Flare System U-915

LSL Pump Main

915-ME2 Acid Flare

Daily Checkups (Main+Acid)

Knockout Drum Level

Fuel Oil & Fuel Gas System U-920

Fuel Oil & Fuel Gas System U-920

Design Capcity & Users, Sources

DieselMax, Visbreaker & Vacuum Residue

Priority Of Fuel Oil

Refinery Fuel Gas

Fuel Oil & Fuel Gas System U-920

Priority Of Fuel Gas

i. Normal operation : Refinery off gas

Refinery Fuel Oil

Fuel Oil & Fuel Gas System U-920

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

FUEL OIL HEATER (920-E2)

FUEL OIL STRAINER (920-ME1A/B)