In-plant Training Report

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  c c We take this opportunity to express our deep sense of gratitude and sincere thanks to all who helped us to complete this training successfully. Our first and foremost thanks go to God almighty that showered his immense blessing on our effort. We are deeply indebted to our guide Mr. g
D Senior Manager(Ú
  D Mr. À   D Deputy Manager(Ú
  and Mr. MÀ   for their excellent guidance and support. We also thank     D Deputy General manager L&D centre and Ms. MÀ   for giving the opportunity to undergo the in -plant training. Finally big thanks to all the staff of Kochi Refinery Limited who directly contributed to completion of this training successfully.

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  c c Kochi RefineryD a unit of Bharat Petroleum Corporation Limited (BPCL)D embarked on its journey in 1966 with a capacity of 50D000 barrels per day. Formerly known as Cochin Refineries Limited and later renamed as Kochi Refineries LimitedD the refinery was originally established as a joint venture in collaboration with Phillips Petroleum CorporationD USA. Today it is a frontline entity as a unit of the Fortune 500 companyD BPCL. Kochi RefineryD located at Ambalmugal near the city of Kochi in KeralaD is one of the two Refineries of BPCLD presently having a crude oil refining capacity of 9.5 Million Metric Tonnes per Annum (MMTPA). The product portfolio of the 190D000 barrels per day refinery today includes petrochemical feedstocks and specialty products in addit ion to its range of quality fuels. Fuel products of this fuel based refinery includes Liquefied Petroleum GasD NaphthaD Motor SpiritD KeroseneD Aviation Turbine FuelD High Speed DieselD Fuel Oils and Asphalt. Specialty products for the domestic markets include BenzeneD TolueneD PropyleneD Special Boiling Point SpiritD Poly Iso Butene and S ulphur. The refinery has implemented world class technology and systems for operations and enterprise resource planning. It is an ISO 14001 Environmental Management Systems (EMS) and ISO 9001:2000 Quality Management System (QMS) accredited company and has also obtained the ISO 17025 (Testing Methods in Quality Control) certification from NABL (National Accreditation Board for testing & Calibration of Laboratories). The refinery has successfully implemented the Occupational Health and Safety Management System (OHSAS) 18001:2007 in the year 2009. With the prestigious Crude Oil receipt facilities consisting of the Single Point Mooring (SPM) and the associated shore tank farm in place since December 2007D the refinery is equipped to receive crude oil in Very Large Crude Carriers (VLCCs). This facility helps Kochi refinery in reducing the freight charges to a great extentD over and above increasing flexibility in crude oil selection. ThisD therebyD is a major infrastructure facility to accelerate the future growth of Kochi Refinery. The refinery has facilities to evacuate products to the consuming centres through roadD railD ships and through pipelines. All the major industries in the area are connected to the refinery for product receipt. The BPCL installation at IrumpanamD to which the refinery is connected by pipelinesD is the major product distribution centre of the refinery. Petronet CCKD a joint venture company of BPCL looks after the 300 km long pipeline that connects the refinery to various consumption point s in Tamil Nadu such as Coimbatore and Karur. Of the two-part Capacity Expansion cum Modernisation Project (Phase±II)D the capacity expansion to 9.5 MMTPA has been successfully completed and refinery modernisation slated for completion in August 2010 would equip the refinery to produce auto-fuels conforming to Euro-III and partly Euro-IV specifications. The refinery¶s foray into direct marketing began since 1993 through marketing of its aromatic products - Benzene and Toluene. The entry into the international petroleum

business stream began with its first parcel of Fuel Oil exported in January 2001. Since then the refineryD has earned the reputation as a reliable player in the international tradeD by virtue of superior product quality and customer service. MoreoverD the Fuel Oil has been benchmarked in the Singapore and Dubai Fuel Oil markets. Kochi Refinery is situated in KochiD the most happening city in Kerala that is rightly called God¶s own country. The refinery has a unique bond with its environment which is evident in the green blanket so carefully nourished right around it. The refinery has been blessed with a fine topography and the entire complexD spreading across over thousand two hundred acres has been so constructed as to blend naturally with it. Upcoming expansions and developments would also adhere to this philosophy of blending with nature. The most recent addition to the refinery architecture is the rainwater harvesting pond and eco-park that has been converted to a must-see spot with sprawling landscaped lawns and thatched canopies for conferences and get-togethers. Year after year the refinery has been bagging accolades for its commitment to the environment; for the all round care for the environmentD the judicious storageD use and reuse of waterD the efficiency in managing solid wastes and effluents and the care taken to keep the atmosphere clean. The recent achievement of 18 million accident free man-hours stands testimony to the fact that the prime focus of Kochi Refinery is on safety in everything we do. From training to retrainingD and adhering to international standards in safety practicesD bothD offsite and onsiteD Kochi Refinery has taken it as a mission to make safe living and working a natural mantra of its employeesD contract workersD customers and the general public. Several awareness programmes have been successfully conducted to this effect with the results for all to see. As a socially responsible corporate citizenD the community welfare initiatives of the refinery concentrate on developing the weaker sections of societyD particularlyD the scheduled castes and scheduled tribes and people below the poverty line in important sectors like healthD educationD housing and women empowerment. Most of the programmes falling under the categories of medical and educational assistance turned out to be poverty alleviation measures also. This is since the programmes like universal health insuranceD scholarship to SC/ST students and medical camps for poor have helped the poor villagers in the refinery vicinity to save money over their medical expenses and educational expenses of children. Various people intensive small-scheme community development programmes have brought new life for many; be it poor villagers in need of medical treatment; poor students in government schools or differently abled children! ThusD apart from maintaining its world class standards in operational excellenceD the singular objective of Kochi Refinery is to uphold the BPCL vision of energizing lives by continued excellence in all round performance with new ideasD added vigour and sustained commitment to its socialD culturalD organizational and natural environment.

  

 g   or   is a naturally occurringD flammable liquid consisting of a complex mixture of hydrocarbons of various molecular weights and other liquid organic compounds that are found in geologic formations beneath the Earth's surface. Petroleum is recovered mostly through oil drilling. This latter stage comes after studies of structural geology (at the reservoir scale)D sedimentary basin analysisD reservoir characterization (mainly in terms of porosity and permeable structures). It is refined and separatedD most easily by boiling pointD into a large number of consumer productsD from gasoline and kerosene to asphalt and chemical reagents used to make plastics and pharmaceuticals Petroleum is often attributed as the "Mother of all Commodities" because of its importance in the manufacture of a wide variety of materials. Petroleum includes only crude oilD but in common usage it includes all liquidD gaseousD and solid hydrocarbons. Under surface pressure and temperature conditionsD lighter hydrocarbons methaneD ethaneD propane and butane occur as gasesD while pentane and heavier ones are in the form of liquids or solids. HoweverD in an underground oil reservoir the proportions of gasD liquidD and solid depend on subsurface conditions and on the phase diagram of the petroleum mixture. An oil well produces predominantly crude oilD with some natural gas dissolved in it. Because the pressure is lower at the surface than undergroundD some of the gas will come out of solution and be recovered (or burned) as a
aa or

a . A gas well produces predominantly natural gas. HoweverD because the underground temperature and pressure are higher than at the surfaceD the gas may contain heavier hydrocarbons such as pentaneD hexaneD and heptane in the gaseous state. At surface conditions these will condense out of the gas to form natural gas condensateD often shortened to 
 a Condensate resembles petrol in appearance and is similar in composition to some volatile light crude oils. The proportion of light hydrocarbons in the petroleum mixture varies greatly among different oil fieldsD ranging from as much as 97% by weight in the lighter oils to as little as 50% in the heavier oils and bitumens. The hydrocarbons in crude oil are mostly alkanesD cycloalkanes and various aromatic hydrocarbons while the other organic compounds contain nitrogenD oxygen and sulfurD and trace amounts of metals such as ironD nickelD copper and vanadium. The exact molecular composition varies widely from formation to formation but the proportion of chemical elements vary over fairly narrow limits as follows:

Carbon

83 to 87%

Hydrogen

10 to 14%

Nitrogen

0.1 to 2%

Oxygen

0.05 to 1.5%

Sulfur

0.05 to 6.0%

Metals

< 0.1%

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c Kochi Refinery is a petroleum based refineryD producing a variety of petroleum-based products such as: ‡ Liquefied Petroleum Gas (LPG) and Superior Kerosene Oil (SKO) for household and industrial uses ‡ Motor Spirit (MS/ Petrol) and Hi-speed Diesel (HSD) for automobiles ‡ NaphthaD the major raw material for fertilizer and petrochemical industries ‡ Furnace Oil (FO)D Light Diesel Oil (LDO) and Low Sulphur Heavy Stock (LSHS) as fuel for industries ‡ Aviation Turbine Fuel (ATF) for aircrafts À g À ‡ Benzene for manufacture of caprolactumD phenolD insecticides and other chemicals ‡ Special Boiling Point Spirit (SBPS) used as solvent in tyre industry ‡ Toluene for manufacture of solvents and insecticidesD pharmaceuticals and paint ‡ Mineral Turpentine Oil (MTO) for use in textile and paint industry ‡ Sulphur for use in fertilizerD sugarD chemicals and tyre industry ‡ Poly Isobutene (PIB) for manufacture of lubricants and cable jelly ‡ Propylene as a feedstock for various petrochemicals  !À"g À Natural Rubber Modified Bitumen or Rubberised Bitumen: Natural Rubber Modified Bitumen (NRMB) is one of Kochi Refinery¶s premium products that revolutionized road development. NRMB has been on a fast track since its introduction in 1999.BitumenD which is derived from petroleumD is a critical component in road building. Polymer added to Bitumen enhances both quality and longevity of roads. Kochi Refinery in association with leading research institutes made an in-depth study on feasibility of using natural rubber available in abundance in KeralaD to develop the premium productD NRMB.NRMB has improved many roads throughout the region. Its success track is evident from the smooth Seaport-Airport road in Cochin.NRMB is a superior mix of bitumen and natural rubber latex. It is superior in quality to ordinary bitumen.

 

 
c Kochi Refinery presently has a crude oil processing capacity of 9.5 MMTPA (Million Tons per Annum) in its two Crude Distillation units (CDU-1 and CDU-2). The refinery currently processes about 30% of Indigenous and 70% Imported crude oils. Crude oil is transported in ships from the point of origin to Kochi and is received through a Single Point Mooring (SPM) facility. Kochi SPMD located approximately 20 kms off the shore of PuthuvypeenD is capable of handling Very large Crude Carriers (VLCC) with crude oil carrying capacities upto 3.0 Lakh Tons. Crude oil from SPM is received in offshore tanks in Puthuvypeen and is then pumped to the refinery. Apart from the Crude Distillation UnitsD major processing facilities in the refinery include a Fluidized Catalytic Cracking (FCC) unitD Diesel Hydro Desulphurization (DHDS) unitD Kerosene Hydro Desulphurization (KHDS) unitD Sulphur Recovery Unit (SRU) and an Aromatics Block consisting of a Naphtha Splitter Unit (NSU)D Naphtha Hydro Desulphurization (NDHS)D Catalytic Reformer Unit (CRU) and Aromatics Recovery Unit (ARU). Crude oil is first processed in the Crude Distillation Unit where it is heated up to around 360 to 380 oC depending on the type of crude oil after removing impurities such as sodium and magnesium saltsD water and other sediments. Crude oil is then fractionated in a distillation column where lighter fractions such as LPGD NaphthaD Kerosene and Diesel are separated. The products are routed to respective storage locations after cooling to atmospheric temperature. LPG is treated using Di-Ethanol Amine (DEA) to remove the impurities before being stored as product LPG. Part of the Naphtha is processed in the Aromatics Block to produce BenzeneD Toluene and a solvent SBPS (Special Boiling Point Spirit). Part of the Kerosene is treated either in a MEROX unit or in KHDS to produce Aviation Turbine Fuel (ATF) and Mineral Turpentine Oil(MTO). Diesel from the CDU is processed in DHDS unit to produce BS-II/ Euro-III grade Diesel. Remaining heavier portion of the crude oil is further distilled under vacuum in a Vacuum Distillation Unit (VDU) to separate Vacuum Gas Oil (VGO) and Vacuum Residue (VR) as major fractions. The VGO is processed in FCC unit where the heavier molecules are broken down to produce LPGD Gasoline (also called Motor Spirit or Petrol) and Diesel. Refinery is currently capable of producing both BS -II and Euro-III grade Petrol. With the commissioning of Continuous Catalyst Regeneration (CCR) Reformer and VGO Hydro Desulphurization Unit (VGO HDS)D the refinery will be capable of producing nearly 70% MS (Motor Spirit) and HSD (High Speed Diesel) meeting Euro -III specifications and 30% MS and HSD meeting Euro-IV specifications. Vacuum Residue (VR) from VDU is routed to a Biturox Unit to produce Bitumen or to a Vis-Breaker Unit (VBU) to produce Furnace Oil (FO). VR can also be directly routed to LSHS (Low Sulphur Heavy Stock ± fuel used in BoilersD Power PlantsD etc.) pool if the crude oil processed in CDU is of low sulphur content (less than 0.5 wt%). A state of the art Sulphur Recovery Unit (SRU) recovers sulphur from the gases produced within the refinery before it is consumed as fuel gas.

Kochi Refinery operates a Gas Turbine (GT) with a rated capacity of 22.0 MWD a Steam Turbine Generator (STG) of 17.8 MW and a Turbo Generator (TG) of 2.5 MW to meet its power requirements. The steam requirement of the refinery is met from 8 boilers and 2 Waste Heat Boilers (HRSG)D apart from small HRSGs installed in process units. A new GT of 34 MW capacity has been commissioned to cater to the additional power requirement of CCR and VGO HDS units and the associated facilities which being installed. Effluent Treatment Plants (ETP) takes care of the liquid effluent from the process units and other off site areas. The treated effluent after meeting the MINAS (Minimum National Standards) is discharged to inland rivers. Other Utilities and Off-site facilities such as tankagesD flare system and connected pipelines are installed in the refinery to match with the requirements of processingD storage and products dispatch.

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c CDU 1 - Crude Distillation Unit 1 FCCU - Fluidized Catalytic Cracking Unit PIB - Poly Iso Butylene unit NHDS - Naftha Hydro Desulphurization unit

ccc CDU 2 ARU AAU RPU VDU

- Crude Distillation Unit 2 - Aromatic Recovery Unit - Amine Absorption Unit - Raffinate Purification Unit - Vaccum Distillation Unit

ccc DHDS - Diesel Hydro HGU - Hydrogen Generation Unit SRU - Sulphur Recovery Unit

ccc Maintenance

 
c c Maintenance is defined as a set of activities performed on plant and machineries to maintain the same prime conditionD in economic ways for smooth running of the plant for achievement of organizational objectives. Prime conditions refer to that the plant and the machinery shall be in good condition for efficient and effective utilization of the same function for which it is designed and installed for. Maintenance is to ensure the maximum availability and reliability of plant and machinery at an optimum cost uninterrupted operation of all unit s for achievement of organizational goals with respect to reaching targets and to meet standard conditions.

There are 4 types of maintenance:jc 

  #$ It refers to the set of activities that are performed periodically to improve any possible failures. They include checking of lubricating oil conditionD seal quenchingD seal cooling system checking operating parameters like suction pressureD temperatureD discharge pressure etc and also checking for any abnormal noises if any observed. If abnormalities is of critical natureD stand by equipment is put into operation and abnormality is attended to.