Industrial Training Report PDF

INDUSTRIAL TRAINING REPORT
2013/2014
PREFACE
I had my training experience from 12.11.2013 to 09.05.2014 at Ceylon Petroleum
Corporation oil refinery. I am fortunate to have my industrial training experience in such a
place where the chemical and process engineering mostly involve in Sri Lanka.
Here in this report I present the experience, knowledge, skills I had during the training
period. The report contains three chapters. The first chapter contains an introduction to
Ceylon Petroleum Corporation, main products of the refinery, the organizational structure
and SWOT analysis of the refinery. The second chapter contains the training experience,
information on production process and equipment, project work and assignments that I
involved during the training period. The third chapter contains conclusion.
I had a very successful training period and the experience and knowledge I got is very
valuable to my future career.
Abeysekara A.W.A.T.M. (100008H)

Department of Chemical and Process Engineering
Faculty of Engineering
University of Moratuwa
2013/2014
ACKNOWLEDGEMENT
There are lots of people who have helped me towards the successful completion of my
Industrial Training. First of all I would thank to University of Moratuwa and National
Apprentice and Industrial Training Authority (NAITA) for arranging industrial training for
undergraduates. Then I would like to thank Mr. N.A. Wijewikrama, the Director of the
industrial training division, Mr. Roy Sankaranarayana, Mr. P. Gunawardanea, Mr. S.
Amarasinghe and Dr. Jagath Premachandra for arranging me this opportunity to have my
training experience in Ceylon Petroleum Corporation.
I sincerely thank Ms. Nirmala, the Human Resource Manager of Ceylon Petroleum
Corporation, Mr. N.R.R Jayasekara, Refinery manager and Mr. T.A.S.W. Tennakoon,
Training Manager for accommodating me as a trainee. I must greatly appreciate Mr.
E.A.A.K.P. Edirisinghe, Training assistant for giving me advices, sharing his knowledge and
guiding me during the training period.
I also express my gratitude towards Mr. Neel Wickramasinghe, Manager Technical
Services department , Mrs. Anoma Senevirathne, Mrs. Shiwanthi Rajapakshe, Mr. W.
Rajapakshe, Mr. Kodagoda, Mr. Chulaka and Mrs. Wenuja Mihirani Chemical and Process
engineers of the Technical Services Department for suppoting me to success my training
period.
I also thank Mr. Rathnasiri, Deputy Manager Technical Services (Laboratory), Mr. C.
Weerasekara (Inspection), Mr. K.H.E. Peries, Fire and Safety department and Ms. Janakee,
the Librarian of the technical library for helping me during my training period.
I wish to express my gratitude again to all those people who helped me towards the
success of my Industrial Training.
Abeysekara A.W.A.T.M.
100008H
Department of Chemical and Process Engineering
Faculty of Engineering
University of Moratuwa
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TABLE OF CONTENTS
PREFACE .............................................................................................................. i
ACKNOWLEDGEMENT ....................................................................................ii
1
CHAPTER 1 - INTRODUCTION ............................................................... 1

1.1
Introduction to Ceylon Petroleum Corporation ........................................................... 1
1.2
History of Ceylon Petroleum Corporation Refinery ................................................... 1
1.3
Vision and Mission...................................................................................................... 1
1.4
Organizational Structure ............................................................................................. 2
1.4.1
Ceylon Petroleum Corporation ............................................................................ 2
1.4.2
Refinery Division ................................................................................................. 3
1.4.3
Organizational Structure of the Refinery ............................................................. 3
1.4.4
Departments in the Refinery ................................................................................ 4
1.4.5
Product Index of the Refinery .............................................................................. 4
1.4.6
Functions .............................................................................................................. 5
1.4.7
Emergency Preparedness ..................................................................................... 6
1.4.8
SWOT Analysis ................................................................................................... 7
1.4.9
Suggestions to improve ........................................................................................ 7
CHAPTER 2 - TRAINING EXPERIENCE ................................................ 8

2.1
Training Center ........................................................................................................... 8
2.1.1
Training Schedule ................................................................................................ 8
2.1.2
Crude Oil .............................................................................................................. 9
2.2
Refinery Process ........................................................................................................ 10
2.2.1
Crude Distillation Unit (CDU) O1 Unit............................................................. 10
2.2.1.1
Overhead corrosion..................................................................................... 11
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2.2.1.2
Desalting ..................................................................................................... 12
2.2.1.3
Main Distillation Column ........................................................................... 13
2.2.2
Naphtha Unifiner Unit O2 Unit ......................................................................... 14
2.2.3
Platformer Unit O3 Unit .................................................................................... 15
2.2.4
Gas Oil Unifiner Unit and Gas Oil Hydro Treating Unit (O4 and O7 Units) .... 18
2.2.5
Visbreaker Unit (O5 Unit) ................................................................................. 19
2.2.6
LPG Merox Unit (O6 Unit)................................................................................ 19
2.2.7
Vacuum Distillation Unit (O8 Unit) .................................................................. 20
2.2.8
Bitumen Blowing Unit (O9 Unit) ...................................................................... 20
2.2.9
Kerosene Merox Unit (15 Unit) ......................................................................... 20
2.3
Equipment ................................................................................................................. 21
2.3.1
Storage Tanks..................................................................................................... 21
2.3.2
Reactor ............................................................................................................... 22
2.3.3
Furnace ............................................................................................................... 23
2.3.3.1
O1F1 furnace .............................................................................................. 25
2.3.4
Heat Exchanger .................................................................................................. 26
2.3.5
Pumps................................................................................................................. 26
2.3.6
Compressors ....................................................................................................... 27
2.3.7
Boilers ................................................................................................................ 28
2.4
2.3.7.1
Water tube boiler ........................................................................................ 28
2.3.7.2
Demineralizer ............................................................................................. 30
2.3.7.3
Deaerator .................................................................................................... 31
2.3.7.4
Boiler details ............................................................................................... 31
Departments .............................................................................................................. 32
iv
2.4.1
Laboratory .......................................................................................................... 32
2.4.1.1
Oil tests ....................................................................................................... 32
2.4.1.2
Water tests .................................................................................................. 33
2.4.2
Inspection Department ....................................................................................... 34
2.4.3
Pump House ....................................................................................................... 36
2.4.4
Utilities............................................................................................................... 37
2.5
2.4.4.1
Main utilities in the plant ............................................................................ 37
2.4.4.2
Water treatment process at the refinery ...................................................... 37
2.4.4.3
Water treatment process at water intake ..................................................... 38
2.4.4.4
Steam .......................................................................................................... 39
Projects and assignments ........................................................................................... 40
2.5.1
Project: Sulfur recovery Plant Simulation ......................................................... 40
2.5.1.1
Scope: ......................................................................................................... 40
2.5.1.2
Method ........................................................................................................ 40
2.5.1.3
Results ........................................................................................................ 41
2.5.2
2013/2014
Assignment ........................................................................................................ 41
2.5.2.1
Material Balance for CDU .......................................................................... 41
2.5.2.2
Overall Heat Transfer Coefficients of Heat Exchangers ............................ 46
2.5.2.3
Efficiency of O1P1B Pump ........................................................................ 51
2.5.2.4
Heat loss calculation of uninsulated pipe lines ........................................... 53
CHAPTER 3 - CONCLUSION ................................................................. 57

3.1
CONCLUSION ......................................................................................................... 57
ANNEX ............................................................................................................. viii

ABBREVIATIONS ............................................................................................. ix
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LIST OF FIGURES
Figure 1.1 Organizational Structure ......................................................................................... 3
Figure 1.2 Crude oil transportation and product storage ......................................................... 5
Figure 1.3 Product Distribution ................................................................................................ 6
Figure 2.1Refinery overall process flow diagram ................................................................... 10
Figure 2.2 Desalter .................................................................................................................. 12
Figure 2.3 Main Distillation Column ...................................................................................... 13
Figure 2.4 Steam Ejector ......................................................................................................... 20
Figure 2.5 Kerosene Merox Process ....................................................................................... 21
Figure 2.6 Fixed roof tank ....................................................................................................... 22
Figure 2.7 O2R1 Catalyst loading diagram ............................................................................ 23
Figure 2.8 Rectangular ............................................................................................................ 24
Figure 2.9 Cylindrical ............................................................................................................. 24
Figure 2.10 Types of Compressors .......................................................................................... 27
Figure 2.11 Interior of centrifugal compressor ....................................................................... 27
Figure 2.12 Reciprocating compressor - cross section ........................................................... 28
Figure 2.13 Boiler arrangement .............................................................................................. 29
Figure 2.14 Dye penetrant test procedure ............................................................................... 35
Figure 2.15 Utilities of the refinery ......................................................................................... 37
Figure 2.16 Water treatment process at the refinery ............................................................... 37
Figure 2.17 water treatment process at water intake .............................................................. 38
Figure 2.18 Steam Generation and usage ............................................................................... 39
Figure 2.19 Simulation of the Sulfur recovery process ........................................................... 40
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LIST OF TABLES
Table 1.1 Entities under CPC .................................................................................................... 2
Table 2.1 In-Plant training programme..................................................................................... 8
Table 2.2 Crude oil composition................................................................................................ 9
Table 2.3 Fuel parts in crude oil ............................................................................................... 9
Table 2.4 Boiler details ............................................................................................................ 31
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CHAPTER 1 - INTRODUCTION
1.1
Introduction to Ceylon Petroleum Corporation

The Ceylon Petroleum Corporation was established as a state enterprise by Act No. 28
of 1961 in parliament and further amendments carried out subsequently. The main objectives
of Ceylon Petroleum Corporation are To carry on business as an importer, exporter, seller,
supplier and distributor of Petroleum products. To carry on business of exploring for the
exploiting, producing, and refining of Petroleum and to carry on any such business as may be
incidental or conducive to the attainment of the objectives
1.2
History of Ceylon Petroleum Corporation Refinery

The oil refinery at Sapugaskanda was commissioned in August 1969 to process 5200
MT/d of Iranian light crude oil. The unit was capable of processing 5800 MT/d of crude oil.
Crude oils similar to Iranian light such as Upper Zakum, Arabian light were processed in the
plant meeting required specifications. In 1971 LPG production was started and Naphtha
merox unit was modified to process LPG. Then the crude distillation unit was debottlenecked to increase capacity to 6900 MT/d. A Kerosene Merox unit was installed in
1981 to produce Jet A1. In 1992 crude distillation unit was revamped to process eastern
crudes such as Miri light. Naphtha unifiner unit capacity was increased up to 1100 MT/d. In
1999 platformer unit was revamped to increase its capacity to 650 MT/d. Exiting Kerosene
unifiner was revamped to process diesel and gas oil unifiner was repair to meet 0.3% wt. of
sulfur in Diesel. The refinery consists of a utilities section. It supplies electricity, water,
steam, instrument air required for plant operation. There are 65 tanks in the refinery to store
crude oil, intermediate products and finished products.
1.3
Vision and Mission
Vision
To be the premier customer driven, environmental friendly, enterprise in the petroleum and
related industries in the region while contributing towards the prosperity of our nation.
2013/2014
Mission
To achieve excellence in refining, sales and marketing of high quality products and meet the
expectations of the stakeholders through a dedicated team of professionals and a loyal &
efficient dealer network and by providing total solutions and services exceeding customer
expectations, while utilizing a high technology base for growth and development of the
enterprise with total employee participation and innovation, by maintaining high ethical
norms in all its activities and with highest concern for health, safety and environment.
1.4
Organizational Structure
1.4.1
Ceylon Petroleum Corporation
There are separate entities under Ceylon Petroleum Corporation. Most of the activities are
administrated by the head office in Colombo 09.
Table 1.1 Entities under CPC
Entities under CPC
Functionality
No.609, Dr. Danister de Silva Mawatha, Head office,

Colombo 09.
Set of the chairmen
Sapugaskanda oil refinery
Oil refinery
Sapugaskanda terminal
Crude and product storage farm
Kolonnawa Installation
Product storage farm

Distribution terminal
Agro chemical section
Orugodawatta tank farm
Crude tank farm
Bulk depots in Jaffna, Kilinochchiya, Area offices of respective Area and fuel
China
Bay,
Anuradapura,
kurunegale, depots
Peradeniya, sarasaviuyana, Galle, Matara
1.4.2
2013/2014
Refinery Division
Refinery division is situated at P.O. Box 11, Kelaniya. It is 165 acres of land. The head of the
refinery is the refinery manager. There are almost 20 departments in the refinery. The
function of the refinery is to refine crude oil. The crude oil refining process area is operated
under control of the operational department.
1.4.3
Organizational Structure of the Refinery
Refinery Manger
Senior Manager
Manufacturing
& Operation
Senior Manager
Technical
Service
Medical
Officer
Manager
Operations
Deputy Refinery
Manager
Maintenance &
Project
Manager
Technical
Services
Manager
Technical
Services
Administration
Manager
Deputy
Deputy
Manager
Fire &
Safety
Deputy
Operational
Manager
Process
Deputy
Engineering
Manger
Inspection
Manager
Technical
Services
Deputy
Engineering
Manager
(Plant
Equipment)
Medical
Training &
Development
Deputy
Engineering
Manager
(Civil
Maintenance)
Deputy
Engineering
Manager
(Workshop)
Deputy
Manager
Deputy
Manager
Deputy
Manager
Technical
Services
(Project)
Technical
Services
(Process)
Technical
Services
(Laboratory)
Engineering
Manager
Mechanical
Maintenance
Deputy Refinery
Manager
Electrical &
Instrument
Engineering
Manager
Project
Deputy
Engineering
Manager
(Project)
Deputy
Engineering
Manager
(Plan)
Deputy
Engineering
Manager
(Electrical)
Engineering
Manager
Mechanical
Maintenance
Deputy
Engineering
Manager
(Civil Project)
Deputy
Engineering
Manager
(Offsite)
Deputy
Engineering
Manager
(Inspection)
Deputy
Material
Manager
Deputy
Material
Manager
Figure 1.1 Organizational Structure
1.4.4
2013/2014
Departments in the Refinery
Maintenance and project department
Material department
Electrical department
Finance department
Instrument department
Fire and safety department
Economics & scheduling department
Planning department
Civil department
Transport department
Operation department
Mechanical department
Technical service department
Personal department
Security department
Laboratory, Technical Library, Medical Center
Inspection department
and other supporting sections
Training & Development department

1.4.5
Product Index of the Refinery
Petrol Engine Oil
Specialty Oil
Diesel Engine Oil
Brake Fluid
Four Stroke Engine Oil
Greases
Two Stroke Engine Oil

Gas Fuel Engine Oil
Marine Engine Oil
Gear Oil
Transmission Fluid
Tractor Fluid
Industrial Oil
Transformer Oil
4
1.4.6
2013/2014
Functions
Main functions are import crude oil, process petroleum products and deliver the products to
Kolonnawa Terminal for distribution. Refinery sells LPG to LITRO Ltd and Laugh Gas
Lanka Ltd and sells bitumen to RCDC and other road construction companies.
Types of Crude oil,
Iranian Light(IL) crude Oil from Iran
Arabian Light (AL) Crude Oil from Saudi Arabia
Miri Light (ML) Crude Oil from Malaysia
Crude oil is transport to Sri Lanka in ships. They are called tankers. With prevailing demand
usually 2-3 tankers with a maximum capacity of 160MT are arrived per month to the
Colombo port. As the depth is low near the Colombo port, the ships cant reach to the port.
So a buoy is floated off shore to connect tanker pipeline. Crude oil is pump through 36
diameter pipelines underwater to Colombo port. From the Colombo port crude oil is pump to
crude oil tanks in Orugodawatta tank farm and tanks in refinery premises. There are four
storage tanks at Orugodawatta tank farm and five storage tanks at refinery.
Colombo
Port
Crude oil
tanker
Single Point Buoy
9.2 km off shore
Colombo Port
Refining Process
Crude oil
tank
complex
Orugodawa
Refinery
Sapugaskanda
Sapugaskanda
terminal
Refinery
tank farm
Kolonnawa
installation
Figure 1.2 Crude oil transportation and product storage

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2013/2014
The final products are stored in Sapugaskanda refinery tank farm. Every final product is
tested and checked whether they have standard product specifications by taking samples to
the refinery laboratory. According to the demand products are pumped to Kolonnawa through
6, 8 and 12 diameter pipelines. LPG and bitumen are sold directly by the refinery
terminal.
CEB & Asia plant
Fuel oil
Kolonnawa
Petrol
Jet A-1
Sapugaskanda
Terminal
Chemical
Refinery
Fuel oil
Naphtha
Diesel
Diesel
Kerosene
Kerosene
Litro & Laughe
Fuel Oil
LPG
Figure 1.3 Product Distribution
1.4.7
Emergency Preparedness
Refinery is a place where it mainly and always involves with fuel. Fuel is a basic requirement
for a fire and other two is heat and air (oxygen). So there is a high risk of fire. CPC refinery
has a fire and safety department which steadily prepared for emergency accidents. There are
underground water pipes and fire alarms. These alarms are numbered and if pressed, it is
reported to the fire and safety department control room. Fire alarm is checked every Monday
at 9.00 a.m. There is a bomb alarm and it is checked every Wednesday at 9.00 a.m. There is
an all clear alarm also. There are dry powder cylinders and dry ice cylinders for cease fire.
When an accident is occurred people are gathered in assembly points and then sweep and
clear operation is done by the security department army.
6
1.4.8
2013/2014
SWOT Analysis
Strengths:
CPC refinery is the only company that refining crude oil in Sri Lanka.
The staff has expert engineers and operators.
There are operators with a very good practice and knowledge for many years
in the refinery.
Weakness:
Theres a surplus of workers. Its an unnecessary expense for the company.

Management is not utilizing the human resource to the best. There are some
workers that are not willing to work.
Capacity of production is not enough to fulfill the demand. It is because with
the current property the refinery cant increase the production. Equipment
capacities are not enough. Lot of equipment is very old and overdue. Refinery
is needed to modernize with the novel technology.
Opportunities: The staff has expert engineers and other employees. Engineers have prepared
project proposals to improve efficiency and modernization.
There is a high demand for products in Sri Lanka, especially for diesel and
petrol.
Threats:
Politics highly involve in recruitment of staff, especially normal workers, so is

there surplus of workers and unsuitable ones.
CPC has to issue diesel and fuel oil to Ceylon Electricity Board for debt.
Government is unable to bear the cost for modernization.
1.4.9 Suggestions to improve

There are equipments that need to be replaced by new equipments as they have overdue and
some equipments and instruments need to be repaired and modernized to increase the
capacity, minimize the loss and maximize the efficiency. Although it will require very high
cost for these new installments and repairing, it is definitely a valuable investment for the
future. It will be a contribution for the state economy as the demand for the petroleum
products are increasing but not decreasing.
2013/2014
CHAPTER 2 - TRAINING EXPERIENCE
2.1
Training Center
We were assigned to follow the below shown In-Plant training programme by the training
center.
2.1.1
Training Schedule
Table 2.1 In-Plant training programme

Location
Training Contents
Supervisor
Induction, Plant visit,
MTD/ATDT
Fire & Safety and
OFSF/OFSS
Security aspects
DM(S)
Duration
Training
12 Nov 13 Nov
Center
Oil
Familiarization
Movements
Movements
Utilities
Process
Area
02
Process
Area
01
Inspection
Laboratory
Instrument
Workshop
of
Oil
OOM
14 Nov 29 Nov
Familiarization of Utilities
OOU
02 Dec 16 Dec
Familiarization of Process
DM (Ops.)/ MTS
17 Dec 17 Jan
Familiarization of Process
DM (Ops.)/ MTS
20 Jan 28 Feb
EM(Insp)
03 Mar 21 Mar
DMTS (Lab)
24 Mar 11 Apr
Familiarization
of
Inspection
Familiarization
of
Laboratory
Familiarization
of
Instrument works (Control EM(Inst)
16 Apr 25 Apr
Room)
Technological
Familiarization
of
Department
Technological Department
MTS
28 Apr 08 May
Training
Centre
Report submission
MTD
2013/2014
09 May 2014
An introduction about the refinery, history of the refinery, refinery process, crude oil types
and their compositions were learnt at the training center. Also knowledge about fire & safety
rules and regulations and security system of the refinery were gained.
2.1.2
Crude Oil
Crude oil is a mixture of hydrocarbons containing Paraffins, Naphthenes, Olefins and

aromatics. Different crude oils contain different amounts of above mixtures.
Crude oil composition
Table 2.2 Crude oil composition
Component
Percentage %
Carbon
85-86
Hydrogen
11-14
Sulfur
0.06-1.75
Nitrogen & salts
low
Metals
Very low
Fuel parts in crude oil

Table 2.3 Fuel parts in crude oil
Iranian Light
Miri light
Naphtha parts
16%
16.5%
Kerosene parts
13.3%
14.0%
Diesel parts
23.3%
48.9%
Fuel oil parts
43.3%
20.6%
Sulfur
1.35%
0.04%
2.2
2013/2014
Refinery Process
Crude oil is a mixture of hydrocarbon. It is need to be fractionated into useful products
through various chemical engineering techniques to achieve products with acceptable

standards. Sapugaskanda refinery has been divided its process into small processing units call
Unit for production of number of products as shown below.
Figure 2.1Refinery overall process flow diagram
2.2.1
Crude Distillation Unit (CDU) O1 Unit
This is the first unit that crude oil under going on process. Crude oil is stored in storage tanks
01, 02, 03, 04 and 59. Crude oil is pumped to the Crude Distillation Unit (CDU) by pumps
with an average rate of 5000 MT/day. First crude oil is preheated by six heat exchangers
(O1E1 to O1E6) and then sent through the desalter. From desalter, salts in the crude are
removed. Then it is sent through another set of heat exchangers for second preheating and
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2013/2014
next to the furnace (O1F1 and O1F2) for heating. After the furnace it is fed to the main
distillation column O1C1.
2.2.1.1
Overhead corrosion
Overhead corrosion can occur due to water, inorganic salts, amine chlorides, organic acids,
sulfur oxy-acids and carbon dioxide.
Example:
Chloride with water form HCl and that cause for corrosion. Reactions start at 120oC and
accelerate at 125oC 205oC.
CaCl2 + 2H2O Ca(OH)2 + 2HCl
MgCl2 + 2H2O Mg(OH)2 + 2HCl
NaCl is stable up to 425oC. The maximum temperature in column is 360oC. So NaCl will not
cause overhead corrosion.
Corrosion prevention methods
Crude oil desalting
Caustic injection Reduce or stop hydrolysis of remaining MgCl2 and CaCl2 after
desalting. That is by converting MgCl2 and CaCl2 into NaCl.
2NaOH + MgCl2 2NaCl + Mg(OH)2
2NaOH + CaCl2 2NaCl + Ca(OH)2
NH3 injection Should be carefully balanced because NH3 can lead to NH4Cl
deposition and the pitting.
Wash water injection
Corrosion inhibitor injection (Nalco) Provide a protective film between the metal
surface and the corrosive liquids.
11
2.2.1.2
2013/2014
Desalting
Figure 2.2 Desalter

A desalter is a process unit in an oil refinery that removes salt from the crude oil. This step is
needed to control corrosion of downstream processing units. Wash water is mixed to crude
oil through a mixing valve, which brings salts in contact with water droplets making
emulsion. Due to the high voltage field between two electrodes, water droplets in oil is
vibrated and seperated from oil. Eventualy these small droplets get together and make large
water droplets and then settle down. Demusifiers are also added to the incoming crude to
assist in oil water seperation.
12
2.2.1.3
2013/2014
Main Distillation Column
Figure 2.3 Main Distillation Column
13
2013/2014
Number of trays 31
Top temperature and pressure 1350C & 1.6 bar
Feed temperature 3600C
Main fractions
SR Naphtha (from top of the column)
Kerosene (25th stage)
Gas Oil (15th stage)
Long residue (bottom of the column)
Temperature gradient of the column is maintained by reflux, top pump around system and
bottom pump around system.
2.2.2
Naphtha Unifiner Unit O2 Unit
O2 unit gets its feed SR Naphtha from the C.D.U. of area I. The average feed rate is 1100
MT/day. This unit removes S, O, N, halides and metallic compounds that consist in SR
naphtha and produce heavy naphtha to feed to O3 unit.
Naphtha unifining process
First the feed is mixed with hydrogen. Then it is sent through pre heat exchangers and
to the furnace O2F1 for heating before the reactor. Next the combined feed (mixture of
naphtha and H2) is entered to the O2R1 reactor at the top and passed down over a Co/Mo
catalyst bed. Inside the reactor, H2 is consumed to hydrogenation and desulphurization.
S + H2 H2S
2N + 3H2 2NH3
O + H2 H2O
These reactions are exothermic and outlet temperature is very high. So reactor outlet is
passed through heat exchangers to remove heat and then sent through the fin fans and trim
coolers. Inject water to dissolve Cl- ions to avoid problems that can occur in fin fans and trim
coolers. Then the liquid and gasses enter the high pressure separator (HP separator) O2V3.
14
2013/2014
From the high pressure separator, water is drained from the boot and the liquid part or oil is
sent to the low pressure separator. In HP separator, only H2 remain as a gas and this H2 is
separated and sent to compressors and H2 make-up header. The gas from O2V4 is sent to fuel
gas with a bypass to the flare. The liquid is fed to the stripper O2C1. From the C1 column
light fractions (hydrocarbons with C1 C4) are removed and sent to 13 unit. Bottom of C1 is
sent to the splitter O2C2 column. O2V1 separates the top product of O2C1 into light fractions
and fuel gas. From O2C2 column light naphtha (C5 C6) and heavy naphtha (C7-C9) are
separated. Heavy naphtha is taken from bottom and is cooled and sent to storage. O2V2
separates the top product of O2C2 into light naphtha and fuel gas.
2.2.3
Platformer Unit O3 Unit
The name Platforming implies Platinum reforming. The Platforming process can be
described as following conversion.
Catalyst
Low aromatic naphtha
Platinum/ Rhenium
(Low- octane)
High aromatic
(High octane)
Bimetallic catalyst
Platforming reactions
Dehydrogenation
Isomerization
Dehydrocyclization
Hydrocracking
Demethalization
1. Naphthene Dehydrogenation (endothermic)
R
R
S
R Alkyl groups
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2013/2014
2. Isomerization
R1
Naphthenes
C
R - C- C- C- C
Paraffins
R- C- C- C
3. Paraffic dehydrocyclisation (endothermic)

R1
+ H2
R- C- C- C- C
R11
+ H2
4. Hydrocracking (exothermic)
C
RH + C- C- C
R- C- C- C + H2
H
5. Demethylation (methane evolves)
R- C- C-
R- C- C- H
+CH4
C-C +
R-C
+
RH
+ CH4
H2
16
2013/2014
Platforming process description

O3 unit gets unifined heavy naphtha as the feed from the splitter O2C2 or
from the storage tanks. The average feed rate is 450 MT/day. Feed is mixed with recycle H2
in order to supply H2 that needs for Platforming reactions. Then it is sent through heat
exchangers E1 A/B and E2 A/B. In between E1 and E2, TCE solution and condensate or
methanol are injected to the feed line, in order to maintain the catalyst water chloride
balance. Next the feed mixture is heated up by O3F1 and entered the first reactor R1 at the
top. It is sent through three reactors R1, R2, R3. In between the reactors it is heated up by
O3F1. These three reactors contain Re/Pt catalyst beds.
Reactor 1: Temperature drop is observed due to endothermic reactions take place inside the
reactor. That is dehydrogenation of naphthens and dehydrocyclization of paraffins.
Reactor 2: Temperature drop is half of that of the first reactor due to occurrence of secondary
reactions as well with an exothermic effect.
Reactor 3: Combination of paraffin dehydrocyclisation and hydrocracking reactions may take
place and reaction kinetics in the reactor may either exothermic or endothermic depending on
the feed characteristics, process conditions and catalysts.
Pt/Rh catalysts are called as dual function catalyst. The two functions are acid function and
metal function.
After R3 reactor, it is sent through E-4 to O3V1. V1 product separator vessel separates H2
from the feed and H2 is sent to the O2 unifiner and to H2 make-up header. Then liquid is sent
through E-6-A/B/C to O3C1. C1-stabilizer separates vapor and liquid. Bottom product is sent
through E-6-A/B/C tubes to recover heat and then E-8 fin fan cooler and output is the product
platformate. Top product of O3C1 is sent through E-7 to O3V2 receiver. It separates fuel gas
and liquid. A part of the liquid is reflux and another part is sent to the L.P.G. unit.
17
2.2.4
2013/2014
Gas Oil Unifiner Unit and Gas Oil Hydro Treating Unit (O4 and O7 Units)
Main purpose of these units is to hydro treat SR gas oil. In this process S, N, O, halides and
metallic components in SR gas oil are removed. There are three feed lines.
1. SR gas oil or SR kerosene from O1 unit
2. Cracked gas oil from O5 unit
3. Gas oil from storage tanks
Process flow description O4 unit
Feed is sent to O4V1 surge drum. The average feed rate is 350 MT/day. The O4 unit
has a low feed supply. So a reciprocating charge pump O4MP1 is used to pump the feed. The
level in surge drum is controlled by LCV-29. It maintains the required suction head to the
pump O4MP1. Feed is mixed with recycled H2 and heated up by E1-A/B and furnace O4F1.
Outlet of the furnace enters the reactor R1 at the top and passes down through a fixed bed of
N-200 (Co/MoO) catalyst. Inside R1, feed consumes H2 and desulphurization happens and
H2S is formed. As the reaction is exothermic, outlet temperature is very high. So the reactor
outlet is sent through E1 heat exchanger to recover heat. Then it is cooled and condensed in
the air fin fan cooler and trim cooler. Condensate is injected before entering the fin fan cooler
to dissolve any salt deposition in water (e.g. NH4Cl). The liquid and gas enters high pressure
separator O4V2. The water collects in the boot and removes as sour water. Gas is sent to
recycle H2 gas line. The liquid is sent to low pressure separator O4V3. Then it is heated up by
three heat exchangers and sent to O4C1. The purpose of this column is to remove H2S and
light hydrocarbons completely. The top product is sent through heat exchanger E4 and sent to
O4V5 accumulator. The uncondensables from V5 are sent to fuel gas. The accumulated
liquid is pumped as reflux, back to the column and a part is pumped to visbreaker O5C1. Part
of the bottom liquid is circulated by pump P3 through furnace F2. Other part is pumped
through heat exchanger E5 to recover heat and is cooled by fin fan E6 and sent to storage as
unifined gas oil product.
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2.2.5
2013/2014
Visbreaker Unit (O5 Unit)
Visbreaking is conversion of high viscosity fuel to lower viscosity fuel while obtaining
cracked naphtha and cracked gas oil as by-products. Long residue from crude distillation unit
is sent as the feed to visbreaker unit.
Operating Parameters
1. Temperature
When the operating temperature increases, the cracking process is increased. So temperature
should be fixed to get stable residue. High temperatures may lead to high coke deposition in
tubes and salt deposition in tubes.
2. Pressure
When the operating pressure increases, the cracking process is increased.
3. Residence time
When the residence time increases the cracking process is increased. So the temperature has
to be adjusted to get the suitable residence time.
4. Feed quality
We can get a better effectiveness from the unit by having a feed which has a shorter boiling
range.
2.2.6
LPG Merox Unit (O6 Unit)
In LPG sulfur exists as mercaptan (RSH). LPG merox unit is used to remove mercaptan in
LPG using NaOH. Mercaptans are removed as NaSR.
RSH + NaOH NaSR + H2O
NaSR + O2 + H2O NaOH + RSSR
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2.2.7
2013/2014
Vacuum Distillation Unit (O8 Unit)
For bitumen manufacturing the long residue product has to be made heavier. Under
atmospheric conditions, it is hard to reach the desired quality as temperature would then have
to be increased above cracking conditions. To avoid cracking the distillation is carried out
under vacuum. The vapour leaving the top of the column is sucked by the steam ejectors
which keeps necessary vacuum inside the column. The thermal balance of the column is
ensured by two pumps- around.
1. Steam chest
2. Jet nozzle
3. Suction chamber
4. Diffuser inlet
5. Diffuser throat
Figure 2.4 Steam Ejector
6. Diffuser outlet
The pressurized steam is supplied in steam chest and expanded through jet nozzle and suction
fluid is entered into the suction chamber due to pressure difference between the column and
the suction chamber. Then it creates a vacuum in the column.
2.2.8
Bitumen Blowing Unit (O9 Unit)
Bottom product of the O1C1 column is used to obtain asphaltic bitumen. First the bottom
product of O1C1 is sent to vacuum distillation unit. The bottom product of vacuum
distillation (short residue) is the feed of bitumen blowing unit. The short residue is blown
with air to get the desired hardness. The air is blown through nozzles at the bottom of the
column. Penetration and softening point are considered as the quality of the product.
2.2.9
Kerosene Merox Unit (15 Unit)
Straight run kerosene contains considerable amount of sulfur and other impurities. Fuel with
impurities may effect on air planes. Kerosene merox unit is used for remove sulfur and to
process the fuel JET-A1 from SR kerosene. In merox reactor mercapton in kerosene is
converted into disulphide as follow;
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RSH + O2 RSSR + H2O

Merox reactor consists of catalysts impregnated on activated charcoal bed.
Process flow:
SR
Feed
Electrostatic
Kerose
Pump
Precipitator
Merox
Reactor
ne
Storage
Clay
Salt
Water
Caustic
Filter
Filter
Wash
Settler
Figure 2.5 Kerosene Merox Process
2.3 Equipment
This section includes the equipment we observed at the refinery and what we learnt about that
equipment.
2.3.1
Storage Tanks
There are 7 types of storage tanks.

1. Fixed roof tanks
2. External floating roof tanks
3. Internal floating roof tanks
4. Domed external floating roof tanks
5. Horizontal tanks
6. Pressure tanks
7. Variable vapor space tanks
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Among these types there are fixed roof tanks and external floating roof tanks in Ceylon
Petroleum Corporation.
Fixed roof tanks
Figure 2.6 Fixed roof tank
These are mainly used to store final and intermediate products and slops. These are normal
tanks made of metal sheets with a conical roof to avoid rain water. There are gas and pressure
release valves.
External floating roof tanks

External floating roof tank consists of an open-topped cylindrical steel shell with a roof that
floats on the surface of the stored liquid. The roof is rising and falling with the liquid level.
Floating roof tanks are normally used to store crude oil which are having a greater tendency
to vaporization when expose to atmosphere and on atmospheric temperature. Floating roof
helps in vapor suppression and also reduce the liquid loss and air pollution.
2.3.2 Reactor
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One of the most important process units that I learnt was reactors. Figure 2.7 shows the
reactor arrangement in naphtha unifining unit. The feed enters at the top and passed down
over a Co/Mo catalyst bed.
Figure 2.7 O2R1 Catalyst loading diagram
2.3.3
Furnace
Furnace is equipment which generates heat and it is used to heat process fluid. There are two
types of furnaces that use in CPC refinery. They are cylindrical vertical coil furnace and
rectangular horizontal coil furnace.
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2013/2014
Cylindrical vertical coil furnace

The fire box is cylindrical, vertical and made of steel. It is mounted on concrete legs. The
cylindrical fire box is closed at the bottom my steel plates and burners are mounted onto this.
Rectangular horizontal coil furnace
In this type burners are arranged in side at the bottom as shown in figure.
Figure 2.8 Rectangular
Figure 2.9 Cylindrical
horizontal coil furnace
vertical coil furnace
Fire box The main purpose of the fire-box is to house the tubes and burners. It
contains the flames and minimizes the heat loss.
Stack The flue gases are let out to atmosphere through the stack at high elevation to
reduce pollution. The height of the stack is decided according to the heat requirements
as it affects the draft of the furnace.
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2013/2014
Damper The damper is a valve that uses to regulate the opening of the stack in order
to control the draft of the furnace.
Soot-blower There are soot blowers to clean the dirt that collect in between studs in
convection tubes.
Convection section As the figure shows, convection section is the area that hot flue
gas pass on the way to stack. There are sets of tubes in this section and process fluid
inside those tubes is heated by convection.
Radiant section The section where there are tubes directly above, besides or beneath
the flame is called radiant section. As the name implies process fluid inside these
tubes is heated by radiation.
Snuffing steam Snuffing steam is medium pressure steam that use to put out
unwanted fire. Normally snuffing steam is used before start-up of furnace to remove
excess fuel gas in fire-box. Also snuffing steam is injected when the tube carrying the
process fluid develops a leak. It helps to put the fire out, other than simply waiting for
all the fuel to be used up.
Peep holes Peep holes are small windows for inspection of the flare of burners and
inside the fire box.
Explosion door These doors are provided to release excessive pressure to prevent
damage. The door hangs on hinges and stays closed by its own weight. A sudden
increase in the internal pressure occurs in an accidental explosion. In that situation
these doors automatically open to outside and release pressure.
Hip thermocouple Measure the temperature of tubes which carry process fluid.
Access door Doors for entry during shut-down for inspection and maintenance.
Center wall Center wall divide the fire box into two sections. It protects the tubes in
radiation section from the flame. Otherwise flame may directly touch the tubes and
damage them.
2.3.3.1 O1F1 furnace

We studied the O1F1 furnace. We observed the safety checking procedure when we were at
the instrument department and also learnt its tripping conditions.
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2013/2014
Tripping conditions of O1F1
Low pressure fuel oil
Low pressure fuel gas
Atomizing steam
Instrument air low pressure
FD fan low pressure
Knock out drum high level
2.3.4
Heat Exchanger
Heat exchanger is a device in which two fluids flow on either side of a solid boundary wall
which separates them. It transfers heat from the hot fluid to the cold fluid. In the refinery
there are various types of heat exchangers. There are parallel flow exchangers, counter flow
exchangers, single pass exchangers and multi pass exchangers. They can be classified as
follows:
Heaters
Heaters are used primarily to heat process fluids. Steam is used for heating.
Coolers
Coolers are used to cool process fluids. In the refinery there are fin fan coolers, trim
coolers and shell and tube coolers.
Condensers
Condensers are coolers whose purpose is the removal of latent heat instead of sensible
heat and to condense the fluid.
Reboilers
Reboilers are used to supply heat requirements in the distillation process.
2.3.5
Pumps
Pumps are used to give energy to a fluid to move it through pipelines or to raise it to a higher
level. The most common pumps used in the refinery are centrifugal pumps and reciprocating
type pumps.
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2.3.6
2013/2014
Compressors
Compressors
Positive
displacement
Dynamic
Reciprocating
Centrifugal
Rotary
Axial
Figure 2.10 Types of Compressors
Centrifugal compressor
Figure 2.11 Interior of centrifugal compressor

Centrifugal compressors are used to elevate gas pressure. In the CPC refinery the centrifugal
compressors are used for H2 compression. There is a multistage turbo driven centrifugal
compressor in Platformer unit (O3).
Operation
At the inlet, low pressure H2 enters the compressor. The inlet wall and inlet vane
distribute the gas to the first stage impeller. The first stage impeller which is attached to the
shaft rotates at a high speed, accelerating the gas and imparting kinetic energy to the gas in
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2013/2014
the form of velocity and potential energy in the form of pressure. The diffuser continues to
change the kinetic energy of the gas (velocity) into potential energy (pressure).
Reciprocating compressor
Figure 2.12 Reciprocating compressor - cross section
In the CPC refinery the reciprocating compressors are used for H2 compression. The
connecting rod derives motion from the crank shaft as it rotates. The rotary motion of the
connecting rod is converted to linear motion of the piston through the crosshead. As the
piston reciprocates alternate suction and discharge strokes take place at either end of the
cylinder.
2.3.7
Boilers
Boiler is a fired chamber in which heat changes water into steam under pressure. There are
two types of boilers. One is fire tube boilers and other type is water tube boilers. In CPC
refinery there are water tube boilers.
2.3.7.1
Water tube boiler
The water circulates through the tubes and the hot combustion gases flow through the
furnace. The hot gases contact the tubes and transfer heat to the water. Economizer and
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2013/2014
preheater are very important parts of the boiler. Economizer increases the capacity and
efficiency of a boiler by recovering heat from the flue gas.
Upper Drum
Atamparator
D Tube
Burners
Economizer
Risers and Down Commers
V-1
Lower Drum
Boiler feed water from deareator

tank
To Header
Primary Super Heating Coil
Secondry Super Heating Coil
Figure 2.13 Boiler arrangement
Economizer
Economizer is a nest of steel tubes placed at the fuel gas outlet of the boiler. It lower the
steam cost because less fuel is needed to heat feed water to its boiling point.
Preheater
Preheater is a tube which circulates inside the bottom drum. Tube carries boiler feed water
which is a by-pass of main feed water line. It preheats feed water before enter the boiler
using heated water comes from economizer.
Burners
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Fuel is mixed with air and burnt in the burner. Burner consists of an oil gun and source of
ignition. The fuel and air is mixed in proper ratio in the oil gun and ignited.
Boiler Feed water
Natural water contains suspended solids, dissolved minerals and dissolved gases. These can
cause corrosion and weaken boiler tube, drums and piping. So demineralization is done to
remove all hardness ions. After demineralization the boiler feed water is pumped to the
deaerator.
2.3.7.2
Demineralizer
A mixed bed demineralizer is used to produce demineralized water. Mixed bed
demineralizer is a single vessel containing an intimate mixture of cation and anion exchange
materials. Anion resin bed immediately grabs the acid produced by its neighboring cation
bed. Removing acid as it forms allows the reaction to go almost to complete. Thus treatment
in a mixed bed gives about closest approach to pure water.
Cation exchange
RSO3H + NaCl RSO3Na + HCl

2RSO3H + CaSO4 (RSO3)2Ca + H2SO4
Anion exchange
Weakly basic anion exchanger

RNH3OH + HCl RNH3Cl + H2O
Strongly basic anion exchanger
R4N-OH + H2SiO3 R4NHSiO3 + H2O
Regeneration of demineralizer
The first cycle is backwashing to remove any accumulated dirt and will loosen and regrade
the resin to prevent packing.
In regeneration process lighter anion resin rises to top and heavier cation resin settles to
bottom.
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2013/2014
A sharp line of demarcation is visible through a sight glass located on slide of tank.
Cation resin is regenerated with acid. (eg. HCl)
Anion resin is regenerated with a base. (eg. NaOH)
2.3.7.3
Deaerator
The remaining gases in the water are removed by the deaerator. Deaerator is a normal
horizontal vessel. Remaining gases are removed by low pressure steam injection below the
water level. Here it is used as a mixer as well as a preheater before entering the boiler. The
temperature in the vessel is about 2250F and pressure is 4.5 psig.
2.3.7.4 Boiler details
There are three boilers in the refinery utilities section.
Table 2.4 Boiler details
Type
Boiler III
Boiler IV
Boiler V
D type Water tube
D type Water
D type Water tube
tube
Maximum Capacity(MT/h)
27.5
44
35
Operating Pressure(BarG)
36
36
36
Maximum allowable
40
40
40
404
404
404
Pressure
Pressure
Air atomizing
atomizing
atomizing
pressure(BarG)
Superheated steam
o
temperature( C)
Start up
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2.4
2013/2014
Departments
2.4.1
2.4.1.1
Laboratory
Oil tests
Acidity test
Significance and use:
Acids can be present in aviation fuel due to acid treatment during refinery process and
some acids can be naturally present. Trace amount of acid which present in the fuel has
tendency to corrode metals that it contacts and has tendency to impair the water separation
characteristics of the aviation turbine fuel.
Flash point test
Flash point measure the tendency of the specimen to form a flammable mixture with
air under controlled laboratory conditions. Flash point is used in shipping and safety
regulations to define flammable and combustible materials. Test can indicate the possibility
of presence high volatile and flammable materials in a relatively non-volatile or nonflammable material.
Viscosity test
Many petroleum products and non-petroleum materials are used as lubricants. The
correct operation of equipment depends upon the appropriate viscosity of liquid being used.
Viscosity of many petroleum fuels is important for the estimation of optimum storage,
handling and operational conditions. Accurate determination of viscosity is essential to many
product specifications.
Reid vapour pressure test
Vapor pressure is an important physical property of liquid spark-ignition engine fuels.
It provides an idea about how the fuel will perform at engine starts under different operating
32
2013/2014
conditions. Petroleum product specifications generally include vapour pressure limits to

ensure products of suitable volatility performance.
Freezing point test
The freezing point is the lowest temperature at which the fuel remains free of solid
HC crystals that can restrict the flow of fuel through filters if present in the fuel system of
aircraft. The temperature of fuel in the aircraft tank normally falls during flight depending on
its speed, altitude and flight duration. Freezing point should be lower than the minimum
operational tank temperature.
Octane number test Knock characteristics of motor fuels by the research method
Knock characteristics of motor gasoline intended for use in spark-ignition engines.
The research method octane number correlates with full-scale spark-ignited engine antiknock
performance at low speed. This test method is used to ensure proper matching of fuel
antiknock quality and engine requirement.
Distillation test
Distillation characteristics indicate the performance in their (petroleum products)
intended applications. Assure the product in suitable volatility performances.
2.4.1.2
Water tests
pH Test
The determination of pH in water is an indication of its acidity or alkaline tendency. A pH
value less than 7.0 shows a tendency toward acidity and a value greater than 7.0 shows
tendency toward alkalinity. Most natural water has pH between 6.0 and 9.0. pH measurement
is very important for determine the corrosive action of water.
Chloride ion Test
Chloride ion in water is highly detrimental to high pressure boiler systems and to stainless
steel equipment. So this test is very important for prevention of damage due to corrosion.
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Silica Test
Silica concentration is an important fact in steam generation and cooling water system. Silica
and silicate scales make troubles in high pressure steam turbine blades. Silica forms deposits
in cooling water systems when solubility limits are exceeded.
Hardness Test
Calcium and Magnesium salts are the common salts that cause for hardness in water. They
cause scaling in tubes and pipes. This leads for failures and loss of efficiency due to clogging
and heat loss.
2.4.2
Inspection Department
Inspection department do NDT tests and other tests for equipment used in the refinery to
monitor their damages or to improve their quality.
Definition of NDT (Non Destructive Tests)
The definition of NDT is use of non-invasive techniques to determine the integrity of a

material component or structure. Simply it is inspect or measure without doing harm to the
equipment.
NDT methods that use in the CPC refinery
Visual inspection
This is the most common method of inspection. It is inspect using human eye.
Optical equipment such as fiberscopes bore scopes, magnifying glasses and mirrors
can be used to enhance sensitivity.
Ultrasonic test
Ultrasonic is mechanical vibrations of high frequency low energy. It is created
by applying high frequency electrical pulses to a crystal mounted in a transducer.
High frequency sound waves are introduced into a material and they are reflected
back from surfaces or cracks. Reflected sound energy is displayed versus time. By
ultrasonic inspection, thickness of a material can be measured and flaws or cracks in
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2013/2014
a material can be found by scanning. By this test method it can inspect internal and
surface defects in equipment.
Dye penetrant test

This test is done to locate defects that are open to the surface.
Clean the part
Apply penetrant
Clean the surface
Apply developer
Figure 2.14 Dye penetrant test procedure
Properties of liquid penetrant

Viscosity
Surface tension
Angle of contact between liquid and solid
Capillarity
Radiography test
Internal and surface defects in equipment can be inspected using radioisotopes.
Magnetic particle test

This test is used to inspect surface defects and sub-surface defects. The test
can be done only for ferromagnetic materials (iron, nickel, cobalt or alloy). A
magnetic field is induced in the material and small magnetic particles (i.e. iron
fillings) are used in the test.
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Other test methods

Material test
Corrosion test
Tube thickness test using bore gauge
Vacuum test
Hardness test
2.4.3
Pump House
Main operational movements of pump house
Take crude oil to TK 1, 2, 3,4,59 from orugodawatta tank farm or directly from the
tanker.
Continuously feed crude oil to CDU, according to the request of the plant, while
keeping their quality and quantity.
Intermediate products are stored and supply them to other units under maintaining the
overhead level.
Store final products and maintain the ullage and transfer to kolonnawa, CEB,
asiapower, etc. Maintain their main quality range between IBP and FBP, octane
number, flash point, etc.
Continuously supply fresh water to utilities from water intake via main water basin A
and B and control basic specifications.
Fire water handling
Stome water management
Effluent water management and transfer to Kelani river
Effluent gas management (flare system)
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2.4.4
2013/2014
Utilities
2.4.4.1 Main utilities in the plant

Utilities
Electricity
Water
Service
water
Cooling
water
Deminerali
zed water
Drinking
water
Steam
High
pressure
steam
Medium
pressure
steam
Air
Fuel
Instrument
air
Fuel oill
Tool air
Diesel
Low
pressure
steam
Figure 2.15 Utilities of the refinery

2.4.4.2 Water treatment process at the refinery
Figure 2.16 Water treatment process at the refinery
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2.4.4.3
2013/2014
Water treatment process at water intake
Water for utilize in the refinery are taken from Kelaniya river. Before sending water to the
refinery it is treated as shown in figure 2.17.
Chlorine
Water
from
Pump
Kelaniya
Pre-settler 1
Pre-settler 2
river
L
F
pH Test
Clarifier 2
Clarified water basin
Pump
Clarifier 1
Sand Filter
Filtered water
1, 2, 3, 4, & 5
basin
A Alum Al2(SO4)3
L Lime
To Refinery
F - Flocculent
Pump
Figure 2.17 water treatment process at water intake
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2013/2014
2.4.4.4 Steam
Steam is generated using water tube boilers. There are three water tube boilers in the refinery.
Treating process of boiler feed water and capacities of boilers are described in section 2.3.7
under equipment. Figure 2.18 shows how steam is produced, characteristics of steam
(pressure and temperature) and the usage of steam in process.
Figure 2.18 Steam Generation and usage

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2013/2014
2.5 Projects and assignments

2.5.1 Project: Sulfur recovery Plant Simulation
2.5.1.1 Scope:
Sulfur in crude oil is removed in the unifining process by hydro-treating. Reactions take place
with H2 at high temperature and pressure and sulfur is removed as H2S. As H2S is highly
toxic, it is burnt by the flare system and released as SO2 to the environment. But, SO2 also
make severe problems and damage the environment. So if we recover elemental sulfur from
H2S without burning it is good for environmental health. Also recovered sulfur can be
exported or used for another industry as a raw material. Therefore by introducing a sulfur
recovery unit for the CPC oil refinery, SO2 content of the release gas stream can be reduced
and recovered sulfur will bring an additional profit.
2.5.1.2 Method
We used direct oxidation method to recover sulfur from H2S. The process is following three
main unit operations; absorption of H2S from acid gas stream to amine, stripping H2S gas
stream, reaction of H2S with air. We did a simulation using Aspen-plus software and found
optimum temperature, pressure for each unit operation and developed the process model
using compressor, heat exchanger, furnace and condenser. Figure 2.16 shows the simulated
process model.
Figure 2.19 Simulation of the Sulfur recovery process

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2013/2014
2.5.1.3 Results
By the simulation of the sulfur recovery plant it can be observed 95% of H2S can be
absorbed to the amine stream and by the oxidation of H2S, 94% of S can be recovered. The
simulation results are annexed.
2.5.2 Assignment
2.5.2.1 Material Balance for CDU
Stream
Flow
Flow
Recorder
Factor
O1FR19
938.3600
6.90
East O1FRC32
359.4500
7.25
West O1FRC34
359.4500
6.50
Coil O1FRC28
275.0200
7.40
Crude Intake
O1F1
Flow Calibrated
Temperature( )
density
853
360
861.6
Side Coil
O1F1
Side Coil
O1F2
Flow
Gas To Flare
O1FR07
3.0300
0.50
62
Gas To Fuel
O1FR43
3.2300
0.84
LPG
O1FR42
9.1848
7.58
Naphtha
O1FR47
137.3038
7.80
800
50
708.5
Kerosene
O1FR44
228.0000
3.50
750
40
789.3
Gas Oil
O1FR16
357.7700
3.60
666
50
845.9
Long Residue
O1FR26
310.8000
7.80
884
348
941.1
LPG From O3
O1FR113
7.170
6.00
LPG From O2
O2FR122
5.1790
2.50
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2013/2014
Density correction equation
Naphtha
Kerosene
Gas Oil
Long Residue
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2013/2014
Naphtha
Kerosene
Gas Oil
Long Residue
Crude Oil
Corrected Flow Factor (CFF) =
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2013/2014
Naphtha
Kerosene
Gas Oil
Long Residue
Crude Oil
Stream
Flow Corrected Flow Factor(CFF) Flow Rate(MT/D)
Crude Intake
6.90
791.9760
5464.6340
O1F1 East Side Coil
7.25
359.4500
2606.0130
6.50
359.4500
2336.4250
O1F2 Coil Flow
7.40
275.0200
2035.1480
Gas To Flare
0.50
3.0300
1.5150
O1F1 West Side Coil
44
Gas To Fuel
0.84
3.2300
2.7132
LPG
7.58
9.1848
69.6208
Naphtha
7.80
125.8000
981.2400
Kerosene
3.50
231.0710
808.7485
Gas Oil
3.60
397.1247
1429.6490
Long Residue
7.80
277.4820
2164.3600
LPG From O3
6.00
7.1700
43.0200
LPG From O2
2.50
5.1790
12.9475
2013/2014
General material balance equation

Material in + Material generation = Material out + Material accumulation + Material loss
Assume that there are no material generations or material accumulation. Therefore,
Material in = Material out + Material loss

Material in = Crude intake + LPG from 02 unit
= 5464.634 + 12.9475
= 5477.582 MT/D
Material out = Gas to Flare + Gas to Fuel + LPG + Naphtha + Kerosene + Gas Oil
+ Long Residue
= 1.515 + 2.7132 + 69.620784 + 981.24 + 808.7485 + 1429.64892 + 2164.3596
= 5457.846MT/D
Material loss = (5477.582 - 5457.846) MT/D
= 19.73 MT/D
But there are no any material loss occurred practically. Because all unfractionated materials
are in the stream of long residue and no chance for material loss. So the amount that is in as
material loss is balanced by adding to the long residue stream.
45
2013/2014
Products Yield of the Crude
2.5.2.2 Overall Heat Transfer Coefficients of Heat Exchangers

O7E1 Heat Exchanger
Tin =360
Tout =144.2
Tshell in =74.1
Tshell out =304.5
Tube length =3.048
m (U tubes)
Tube outer diameter =19mm

Number of tubes =385
46
2013/2014
Flow rate
Flow of gas oil =7.38MT/day
Flow factor =128.54
Flow rate =
=10.979kg/s
Flow rate per one tube = 10.979/385
= 0.0285kg/s
Flow rate of recycle gas stream = 142MT/day

Gas flow per one tube =
= 4.268
kg/s
Total flow rate per one tube = 0.0285kg/s + 4.268
kg/s
=0.0328 kg/s
LMTD =
= 62.526
Cp of gas oil =1750 J/kg k

Cp value determination of recycle gas stream
Gaseous stream
Recycle
gas
(%
by
volume)
H2
70.17
C1
14.97
C2
13.04
C3
1.22
IC4
0.3
NC4
0.15
IC5
0.12
NC5
0.03
47
2013/2014
Total weight = (70.17*2) + (14.97*16) + (13.04*30) + (44*1.22) + (0.3*58) + (0.15*58) +

(0.12*72) + (0.03*72)
=861.64
Weight fractions
Gaseous stream
Weight fraction (%)
H2
(70.17*2/861.64) =16.29
C1
(14.97*16/861.64) =27.8
C2
(13.04*30/861.64) =45.4
C3
(44*1.22/861.64) =6.23
IC4
(0.3*58/861.64) =2.02
NC4
(0.15*58/861.64) =1
IC5
(0.12*72/861.64) =1
NC5
(0.03*72/861.64) =0.26
Cp = { (14.32*16.29) + (2.22*27.8) + (1.75*45.4) + (1.68*6.23) + (1.67*2.02) + (1.67*1) +

(2.28*1) + (2.28*0.26)}/100
=3.928 kJ/kg K
For gas oil and gas stream
Q = mCT (heat released by one tube)
Q = 0.0328*(1750+3928)*(360-144.2)
Q= 14380.845W
Q = UA(LMTD)
14380.845*385 = U**0.019*3.048*2*62.526*385*4
U=
(For 385 U tubes and four HE)
= 136.03 kcal/m2hr
48
2013/2014
O2E1 Heat Exchanger

Tin =314.4
Tout =102.8
Tshell in =44.1
Tshell out =265.6
Tube length =3.048
m (U tubes)
Tube outer diameter =19mm

Number of tubes =295
Flow rate
Flow rate of naphtha =7.66MT/day
Flow factor =140.374
Flow rate =
=12.445kg/s
Flow rate per one tube = 10.979/295

= 0.042kg/s
Flow rate of recycle gas stream = 23.9 MT/day
Gas flow per one tube =
= 9.376
kg/s
Total flow rate per one tube = 0.042kg/s + 9.376
kg/s
= 0.043 kg/s
LMTD =
= 53.597
Cp of naphtha =2220 J/kg k
49
2013/2014
Cp value determination of recycle gas stream
Gaseous stream
Recycle
gas
(%
by
volume)
H2
87.98
C1
7.75
C2
1.09
C3
0.27
IC4
0.28
NC4
1.5
IC5
0.89
NC5
0.24
Total weight = (87.98*2) + (7.75*16) + (1.09*30) + (44*0.27) + (0.28*58) + (1.5*58) +

(0.89*72) + (0.24*72) = 529.14
Weight fractions
Gaseous stream
Weight fraction (%)
H2
(87.98*2/529.14) =33.25
C1
(7.75*16/529.14) =23.43
C2
(1.09*30/529.14) =6.18
C3
(44*0.27/529.14) =2.24
IC4
(0.28*58/529.14) =3.07
NC4
(1.5*58/529.14) =16.46
IC5
(0.89*72/529.14) =12.11
NC5
(0.24*72/529.14) =3.26
50
Cp
2013/2014
= { (14.32*33.25) + (2.22*23.43) + (1.75*6.18) + (1.68*2.24) + (1.67*3.07) +
(1.67*16.46) + (2.28*12.11) + (2.28*3.26)}/100

= 6.104 kJ/kg K
For naphtha and gas stream
Q = mCT (heat released by one tube)
Q = 0.043*(2220+6104)*(314.4-102.8)
Q= 21028.175W
Q = UA(LMTD)
19817.1649*295 = U**0.019*3.048*2*53.597*295*7
(For 295 tubes and 7HE)
U = 154.033 W/m2K
1J = 0.2389 Cal
U=
U = 132.47 kcal/m2hr
2.5.2.3 Efficiency of O1P1B Pump
V = Volumetric flow rate

Discharge Pressure - Suction Pressure
= (21-10) bar
= 11 bar
V = 5000 MT/D (corrected with flow factor)
Suction temperature =133.9
Discharge temperature =134.6
51
2013/2014
52
2013/2014
2.5.2.4 Heat loss calculation of uninsulated pipe lines

5.94m
7.62 cm
6.1cm
Outside heat transfer coefficient = 10 W/mK

Thermal conductivity of carbon steel = 52 W/m2K
Fluid temperature = 720C
Atmospheric temperature = 300C
R = 0.0704 K/W
1m
7.62 cm
6.1cm

53
2013/2014
R = 0.4184 K/W
30 cm
27 cm
27.3 cm

Atmospheric temperature = 300C
R = 0.3889 K/W
72 cm
27.3 cm
27cm

54
2013/2014

R = 0.1620 K/W
34 cm
27cm
27.3 cm

R = 0.3431 K/W
Total heat loss = 596.59 + 119.50 + 1208.567 + 2827.16 + 1361.119 W

= 6112.94 W
= 6112.94 * 3600 * 24 J/day
= 528157670.4 J/day
55
2013/2014
= 126178.43 kCal/day
Gross Calorific Value of fuel oil (minimum) = 10200 kCal/kg
Amount of fuel oil which will be equal
to the heat loss
= Q/ calorific value
= 12.37 kg/day
Density of fuel oil
= 970 kg/m3
Amount of fuel oil

= 12.75 l/day
Price of 1 l of fuel oil
= Rs. 90 /=
Price for heat loss
= Rs. 90 * 12.75 per day

= Rs. 1147.77 per day
Annual loss
= Rs. 1147.77 * 365

= Rs. 418936.87 /=
56
2013/2014
CHAPTER 3 - CONCLUSION
3.1 CONCLUSION
I selected Ceylon Petroleum Corporation as my Industrial Training place and I applied
for it. I was lucky enough for that I was selected by Ceylon Petroleum Corporation. With me
another four Chemical and Process Engineering undergraduates were trained at Ceylon
Petroleum Corporation for six months (26 weeks) period.
After completing my training experience I realized that Ceylon Petroleum is a very
best place for industrial training, especially for Chemical and Process undergraduates as I
could learn lot of new things that one would never be able to learn at our university academic
environment. Also I was able to practice what I learnt at the university as theory. So I suggest
that it will be a great opportunity if more undergraduates can be selected for industrial
training at Ceylon Petroleum Corporation. The presentation series did by the senior batch
students about training places before our selection of a training place was a very good session
and I suggest for continue that session.
There is a separate department as training center for training undergraduates and
newly recruited operators and engineers in CPC. First we were given a training schedule from
the training center. At the training center we had lectures on safety procedures, fire protection
and security system of the refinery. There is a handbook on safety at the refinery and we were
given that to refer. Also an introduction on 5S and Kyzon methods were given.
During our training period the Visbreaking unit (O5 unit) was not working, because
the viscosity of the bottom product of O1C1 (long residue) was lower enough. So the two
furnaces of Visbreaking unit O5F1 and O5F2 were maintaining. It was a good opportunity for
us and we were able to see the inside and outside configuration of the furnace. There are three
boilers in the utilities section for steam production. One of this three (boiler iii) was
completely under repairing. So we were able to go inside the boiler and to learn all the
configuration of the boiler very well. The demineralizer which use for remove hardness in
boiler feed water is going under regeneration process once in three days and we got the
opportunity to observe the regeneration process. Also we learnt about compressors, reactors
and columns. We could observe safety checking procedure of compressor and furnace. We
57
2013/2014
observed tray types that similar to trays used in the main distillation column at the
mechanical workshop.
Other than these special opportunities we learnt about the whole processes of all
processing units in the refinery. The engineers and operators were very friendly and they
helped us to learn the process.
We were assigned for training at Laboratory, Inspection department and Instrument
department at the final section of the training period, with two weeks for each department. At
the Inspection department we learnt and observed nondestructive testing methods such as
radiography testing, ultrasonic testing, liquid penetrant testing and magnetic particle testing.
This was a great opportunity for us because there are almost no industries in Sri Lanka that
doing some of these test methods. We had a lot to learn that cant finish completely learning
for two weeks, especially in the Instrument department. Another important point is that it is
better that if we had the experience at the Instrument department in the middle of the training
period, because then one can have a better understanding, knowledge about process
controlling while following the process in area I and II.
We got the opportunity to do a project on sulfur recovery. In the refinery, sulfur in crude oil
is removed as H2S and this is sent to flare system and burnt before releasing to the
environment. From burning of H2S, SO2 is produced. It is not congenial for the environment.
Also if we recover sulfur, it can be exported or use as a raw material for other industry like
sulfuric acid production. So we did a project on how to recover sulfur and did a simulation
for a sulfur recovery plant using Aspen plus software. We could optimize the simulation of
the sulfur recovery plant to absorb 95% of H2S to the amine stream and to recover 94% of S
from H2S.
We did a material balance for crude distillation unit, calculated heat transfer
coefficient of a heat exchanger, pump efficiency of O1P1B Pump, heat loss of uninsulated
pipe lines. From this assignment we got a good understanding how to apply the theories we
have learnt in real applications.
Finally I can say that I completed my Industrial training period successfully, I got lots
of experience and guidance for my future career.
58
2013/2014
Sulfur Recovery Project Simulation Results
ANNEX
viii
2013/2014
ABBREVIATIONS
UOP
Universal Oil Products
MTD
Manage Training Division
MTS
Manager Technical Services
DM (Process) Deputy Manager (Process)

OOU
Day Superintendent (Utilities)
OOM
Day Superintendent (Movements)
EM (inst)
Engineering Manager (Instrument)
DTSM (Lab) Deputy Technical Services Manager (Lab)

EM (Insp)
Engineering Manager (Inspection)
Furnace
FRC
Flow Recorder Controller
CDU
Crude Distillation Unit
TPA
Top Pump Around
BPA
Bottom Pump Around
Heat Exchanger
Vessel
Reactor
Compressor
LP
Low Pressure
HP
High Pressure
MP
Medium Pressure
LPG
Liquefied Petroleum Gas
ASTM
American Standard Test Method

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