Offsite Facilities

Paradip Refinery Project
A Sunrise Project For A Sunshine Future

Offsite Facilities
(Intmdt & Finished product handling)
Prepared by:
Production-CG Team
Faculty:
S Bhattacharya
DMPN-CG
South Side
North Side
Paradip Refinery Overall Plot Plan
Product Tanks & Bullets
TT Loading Bay
PRRPL Area
Finished Product area
Crude handling
Intmdt Product handling
Finished Product handling
Product Despatch
Crude & Product Accounting
Offsite Activity
Intermediate
&
Finished Product
Handling
Crude
Intmdt
Product
Finished
Product
Fuel
Slop
Primary Processing Unit
Primary Processing Unit
Crude
Storage & Transfer
Retailing
Despatches

Intmdt Product
Storage & Transfer
Secondary
Processing Units
Primary
Processing Units
Finished Product
Blending
Storage & Despatch
Crude
purchasing
Refining operation

PMC:- M/s Jacobs

Contractor:- M/s Fabtech

Maintenance & Operation : By IOCL
Intermediate Products & Storage tanks

A. Fire Water Tanks

B. Fuel Tanks
IFO
HSFO
FLO
GT Naphtha
GT HSD

C.Unit Feed Tanks
HGU Feed
NHT Feed
CCRU Feed
DHDT Feed
VGO Hdt Feed
Alkylation Feed
DCU Feed
Intermediate Products & Storage
D. Slop Tanks
Wet Slop
Lt Dry slop
Hvy Dry Slop

E. MS Blending
Reformate Tank
Alkylate Tank
Lt Hdt Naphtha Tank
LCN Tank

F. Other Tanks
Amine tanks
Caustic tanks
Sulphuric Acid Tanks
Intermediate Products & Storage
SL No
Service

No. of
Tanks/MB

Type of Tank
Dia
( m)
Height
(m)
Nominal capacity
(m
3
)
1 HYDROGEN BULLET 3 BULLETS 4 20 T/T 284
2 INTERNAL FUEL OIL 2 FR 30 15 10,574
3 NHT FEED 2 DRIF 49.5 15 28,866
4 ALKYLATION BULLET 3 MB 6.4 85 T/T 2870
5 DHDT FEED 2 DRIF 49.5 15 28866
6 VACUUM RESIDUE 2 DRIF 51.1 15 30763
7 VGO HDT FEED 2 DRIF 78.2 15 72,043
8 HGU FEED 1 CRIF 20.2 15 4,807
9 REFORMATE 1 CRIF 35 15 14,432
10 WET SLOP 1 CR 20.2 15 4,808
11 LIGHT DRY SLOP 1 FR 20.2 15 4,808
12 HEAVY DRY SLOP 1 CR 31.9 15 11,988
13 ALKYLATE STORAGE 1 FR 33.5 15 13,222
14 LCN STORAGE TANK 1 DRIF 24.7 15 7,188
15 LT HDT NAPHTHA STORAGE 1 CRIF 20.2 15 4,807
16 CCR FEED 1 CRIF 20.2 15 4,807
Intermediate Storage Tanks
SL No Service No. of Tanks Type of Tank
Dia
( m)
Height
(m)
Capacity
(m
3
)
17 SOUR WATER 1 CR 60 14 39,353
18 SOUR WATER 1 CR 44 14.6 22,112
19 FRESH AMINE 1 CR 5.6 9.8 242
20 AMINE SOLUTION 1 CR 14.8 12.2 2,097
21 AMINE SOLUTION 1 CR 22.3 12.2 4,756
22 DEMIN REJECT TANK 1 CR 18.4 13.7 3,661
23 DEMIN FEED STORAGE TANK 1 CR 28.5 14.7 9,409
24 UF FEED TANK 1 CR 22.2 16 6193
25 SUSPECT COND TANKS 1 CR 28.1 15.8 9236
26 CLEAN COND TANKS 1 CR 28.1 15.8 9,236
27 DEMIN WATER TANKS 2 CR 35 15.7 15057
28 CONC CAUSTIC TANK 1 CR 6 7.5 213
29 DILUTED CAUSTIC TANK 1 CR 6 10.5 298
30 SLOP OIL 2 CR 15.3 12.2 2,243
31 ULTRAFILTERED WATER 1 CR 21 14 4,847
32 FIRE WATER 2 CR 37.5 15 16,511
33 HIGH SULFUR FUEL OIL 3 DR 30 15 10,840
34 GAS TURBINE NAPHTHA 2 CRIF 22.6 15 6,017
35 GAS TURBINE DIESEL TANKS 2 FR 22.6 15 6,017
36 FLUSHING OIL 1 FR 24 15 6,786
37 CPP HSFO 2 CR 11 14.3 1,080
38 CPP NAPHTHA 2 CRIF 12 15 1,080
39 CPP HSD 4 CRIF 12 15 1,080
Intermediate Storage Tanks
Intermediate Storage
Intermediate
Tanks
Nos. of Tanks
Safe filling
Capacity, M3
Stock, in Days
@ Full TPut
Stock, in Days
@ T/D TPut
DHDT FEED 2 46,186
2.5
5
DCU FEED 2 49,221
3.3
6.6
VGO HDT FEED 2 1,15,269
6
12
CCR FEED 1 3,846
0.4
0.8
HGU FEED 1 3,846
3.9
9.8
NHT FEED 2 46,186
3.2
6.4
Refinery Pipe rack
Receiving of product

Monitoring of tank level

Change over of tank

Feed Tank preparation (Water draining / Heating / Circulation)

Feed to unit

Fuel supply to unit

Slop handling
Intermediate Product Handling Activity
SCOPE:- Installation, Operation and Maintenance of Crude
and Finished Products Tankages facility - On BUILD-OWN-
OPERATE-TRANSFER (BOOT) Basis.

PMC :- M/s FACT ENGINEERING AND DESIGN
ORGANISATION (FEDO), KOCHI,KERALA

BOOT CONTRACTOR:- M/s IOT INFRASTRUCTURE
AND ENERGY SERVICES Ltd.

CONTRACT PERIOD:- 15 years for BOOT.

Finished Products Storage facility
LPG

Propylene

Naphtha

MS-EURO-III / IV

SKO
ATF

HSD- Euro-III /IV

Sulphur (Liquid /Solid)

Coke
Finished Products of PDRP
Finished Product Tank
Straight Run Products

Propylene
Naphtha
SKO
ATF
Sulphur
Coke

Blended Products

LPG
MS
HSD

Finished Products of PDRP
SL
No
Service
No. of
Tanks/MB
Dia
( m)
Height
(m)
Type of Tank
Nominal capacity
(m
3
)
1 Propylene 6 6.4 93 T/T MB 3,000
2 LPG 9 6.4 93 T/T MB 3,000
3 Naphtha 4 58 16 FR 38,000
4 MS(REGULAR) 1 40.7 15.5 FR 18,000
5 MS(PREMIUM) 4 50.5 16 FR 29,000
6 DPK 4 49.5 17 CRIF 27,000
7 SKO 1 49.5 15.5 FR 27,000
8
HSD
(DOMESTIC)
1 46.3 16 FR 24,000
9 HSD (EXPORT) 6 52.3 16 FR 31,000
10 Sulphur (Liquid) 3 15.3 13 FR 2,000
11 HDT HSD 1 35 15.3 FR 13,000
15 Mounded bullets,24 product tanks,1 intermediate tanks
Finished Products Tanks
Receiving of product

Blending of product

Chemical dosing

Monitoring of tank level

Tank preparation ( Water draining / Heating / Circulation)

Certification of product

Correction of off grade product

Despatch of product
Finished Product Handling Activity
Chemicals:
LPG
Ethyl Mercaptan

HSD
Lubricity additive
Cetane Improver

MS
Multi functional Additive
Orange Dye

ATF
Anti Static Agent

Chemical Dosing
Product Blending
Why ?

Single stream does not meet specification

To reduce the Quality Give Away ( QGA )

To increase Profitability / GRM
Product Blending

To produce on spec product continuously

To reduce the Quality Give Away ( QGA )

To reduce tank correction time

Online Product Blending
COMPARISON OF PRICES IN SELLING UNITS (May14)

ITEMS
BASIS /
S.U.
P M J Remarks
(MS E-III - NAP FERT)

RTP
6627

6609

6033

MS-Naphtha gap is quite high therefore margin on
production of MS is attractive.
RS/MT
(HSD E-III-SKO)

RTP
1740

1711

1553

HSD prices are Higher as compared to SKO.So HSD to
be maximised after meeting the SKO demand.
RS/KL
(ATF-SKO)

RTP
-522

-536

-197

SKO price are higher as compared to ATF , therefore
ATF to be produced inline with demand & SKO to be
maximised as per ILP.
RS/KL
(HSD E-III-NAP FERT)
RTP,
RS/KL
5484 5459 4944
HSD prices are higher than naphtha, therefore it is
economical to maximize Hy Naphtha ex-CDU to HSD
pool.
Price Difference
A
Online Blending
A
Blending
Software
A
A
Stream-I
Stream-II
Stream-III
Online Product Blending
Final
Product
Blend spillage
Blend spillage
Blend spillage
Primary component
Alkylate ex Alkylation unit
Treated FCC LCN ex FCC LCN treater
CRU Reformate ex CCRU
Lt HDT Naphtha ex NFU
Secondery component
FCC MCN ex FCCU
Hy HDT Naphtha ex NFU
VGO HDT Naphtha ex VGO
SRN ex AVU
CCRU Feed ex CCRU Tank
Untreated FCC LCN ex FCCU
Online MS Blending
Primary Component
Secondary Component
Configuration of MS Blender

FT
FCV
FIC
203TK042
PCV
FT
ALKYLATE R/D
PT
MOV
FT
FCV FIC
203TK048
PCV
FT
Treated LCN
PT
MOV
FT
FCV
FIC
203TK049
PCV
FT
LT HDT
Naphtha R/D
PT
MOV
203PM018 A/B/C
203PM022 A/B/C
203PM023 A/B/C
FT
FCV FIC
203TK020
PCV
FT
Reformate R/D
PT
MOV
203PM09 A/B/C
FCV
NHT Feed Tank
PCV
FT
FCC MCN
PT
FT
FCV
Naphtha Tank
PCV
FT
VGO HDT
Naphtha R/D
PT
FT
FCV
PCV
FT
SR Naphtha R/D
PT
FT
FCV
CCRU Feed
Tank
CCRU Feed
FT
FCV
203PM 29 A/B
FT FCV
CCRU Feed
Tank
PCV
FT
HY HDT Naphtha
PT
FT
FCV
Untreated FCC LCN
Dye
FT FCV
FT FCV
FT FCV
FT FCV
FT FCV
FT FCV
FT FCV
FT
FT
FT
FT
NHT feed Tank
MS R/D Header- I
MS R/D Header- II
NHT Feed Tank
MS / NAPHTHA
Tanks
NIR
Density
NIR
NIR
Density
Sulfur
Sulfur
OBPC EBC
Configuration of MS Blender
LPG component
Propane from AVU
Butane from AVU
LPG from FCC LPG treater
LPG from CCRU
Propane purge from PRU
LPG from Alkyaltion
C
3
+ from PRU
Unsat C4+ from Alkylation bullet

LPG Blending
C3 from AVU
C4 from AVU
CCRU LPG
FCC LPG
Unsat C4
from Bullets
C3+ from
PRU
Alkylation
LPG
Propane
from PRU
Off spec LPG
A
Blend Spillage
LPG Bullets
LPG Blend Header
Product Accounting
Product Accounting
Product Accounting

Custody Transfer

By Volume ..in KL

By weight.in MT

Material Balance

By weight .in MT

By weight
LPG
Propylene
Naphtha
Sulphur
Coke

By Volume
SKO
ATF
MS
HSD

Product Accounting
Product Accounting : Custody Transfer
Product Accounting
Measurement of Product (Transfer or Receive)
By volumetric flow measurement
By measuring mass flow (Mass flow meter)
By Tank Level measurement (Increase or decrease)
Product Accounting
Product accounting from Tank level measurement

Level in Tank or Bullets

Measured Temperature

Water Cut (BS&W for Crude Oil)

Product density at 15
o
C

Calibration Chart

ASTM Table (SAP system)
Mass Flow Meter (MFM)
1. Sprinkler system in tanks
2. Rim seal fire protection system
3. High volume long range monitor (HVLRM)
4. Medium expansion foam generator (MEFG)
5. Flame detection system
6. Manual call point (MCP)
7. Fire hydrant , monitor, extinguisher
8. Remote operated shut off valve (ROSOV)
9. Gas detector
10. Deluge valve system in pumps, loading gantry, LPG bullets area
11. PSVs in mounded bullets
12. TSVs in lines
13. CCTV camera
Safety System
Always follow shift in-charge instruction & report any abnormalities to
shift in-charge immediately.
Do not fill any tank or Bullets more than safe filling height.
Follow SOPs for all the operation.
R/D line valve, first open then close during tank change over.
During pump suction line valve changeover, first close then open.
Draining operation from tank & Bullets should be manned.
Do not leave duty place during duty time without intimating shift in-charge.
LPG bullets draining to be done in daylight only.
Do not operate any electrical switch when there is any leakage in LPG area.
Dos & Don'ts
1. MOV got stuck up.
2. ROSOV closed due to air failure.
3. Power failure during receiving or transfer.
4. Communication failure with Mktg terminal/Jetty control room.
5. Level gauge got stuck up.
6. Tilting of tank roof
7. Tank overflow
8. Oil from roof drain line
9. Product contamination.
10. PSV of mounded bullets passing
11. Leakage from flanges.
What can go wrong.
Queries.
44

Offsite Facilities

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Paradip Refinery Project

A Sunrise Project For A Sunshine Future

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