AN INDUSTRIAL INTERNSHIP REPORT ON

HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY

TECHNICAL DEPARTMENT
SPECIFICATIONS OF INDUSTRIAL PRODUCTS
HPCL – VR

Submitted in partial fulfilment of requirements

Under Apprenticeship for the award of
BTECH IN CHEMICAL ENGINEERING
Submitted by
J SAINADHA REDDY
(12302391)

LOVELY PROFESSIONAL UNIVERSITY

PHAGWARA,PUNJAB -144001
 CERTIFICATE

This is to certify that JEERU SAINADHA REDDY Reg. No.

12302391 a bonafied student of LOVELY PROFESSIONAL
UNIVERSITY, PHAGWARA, PUNJAB has undergone Summer
Internship for 6 weeks in HINDUSTAN PETROLEUM
CORPORATION LIMITED VISAKH REFINERY
From 01-06-2024 to 14-07-2024 During the period of
internship he involved in all activities carried out in Technical
department and acquired good knowledge about the
specification on industrial products.

During the period of training his conduct was found to be …………….

Mr. SHAILESH S KULKARNI

Chief Manager- (Technical)
HPCL - VR
VISAKHAPATNAM
 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any

task would be incomplete without mentioning the people who made it
possible and whose constant guidance and encouragement grown all
the efforts with success.

This acknowledgement transcend the reality of formality when I would

like to express deep gratitude and respect to all those people behind
the screen who guided, inspired and helped me for the completion of
the report.

I am thankful to the Human Resource (HR) Department especially to

Mr. RAVI KUMAR (SENIOR MANAGER HR DEPARTMENT) and
Mr. K NITHISH BHARADWAJA (HR-OFFICER) for his concern in giving the
opportunity to Peruse industrial training and for providing their
valuable guidance.

I take pleasure in thanking MR. B. RAJESH NAIK (CHIEF MANAGER

– TECHNICAL) for his excellence perception and sparing valuable time
despite their busy schedule.

I am thanking to all Supervisors, Operators and other Technical

department staff who engaged with us during the period of our
internship.

Also, I would like to extend my sincere gratitude and regards to the

non-teaching staff for their timely support. Finally, I thank one and all
who supported me directly in completion of my internship
successfully.

S R S MIDHIN VARMA,
Reg. No. - 12300377
 INDEX

1. PROFILE OF VISAKH REFINERY 6

2. INTRODUCTION TO FLUID CATALYTIC CRACKING. 12

3. GENERAL PROCESS DESCRIPTION 15

4. FEED ANDP PRODUCT CHARACTERISTICS 20

5. UTILITIES 28

6. SAFETY 36

7. PROCESS FLOW DIAGRAM OF FCCU 40

4
 CHAPTER-1

PROFILE OF VISAKH REFINERY

Hindustan Petroleum Corporation Limited (HPCL) is started as vacuum

refining company in 1952.It changed its name to HPCL on JULY 15/1974
from the name ESSO.

HPCL is one the largest public sector enterprises under the administrative
control of the Ministry of Petroleum and Natural Gas, Government of India
with a `Maharatna’ status. It has strong presence in the petroleum refining
and marketing sector with a market share of ~21% among Indian public
sector oil marketing companies (OMC), as on March 31,2021.

HPCL refineries at Mumbai and Visakhapatnam process crude into many

value added products that go into making more than 300 grades of
lubricants, specialties and greases. We remain the largest producer of base
oils with capacity to produce Group I, Group II and III base oils.

Their pan-India marketing network comprises 133 regional offices. This

network is supported by a supply and distribution infrastructure
comprising Terminals, Pipeline

5
Networks, Aviation Service Facilities, and LPG Bottling Plants, in land Relay
Depots, Retail Outlets, SKO/LDO, Lube and LPG Distributions.

HPCL serves the energy needs of millions through its widespread marketing
network. End users of their products include domestic, automotive,
commercial and industrial segments. Their business verticals include Retail,
LPG, Lubes, and Direct sales, Aviation, Natural Gas and Renewable.

HPCL is commissioned with an installed capacity of 0.65 MMTPA by contex

oil refining (India) Ltd.in 1957, Visakh Refinery was one of the first major
industries of Visakhapatnam and the first oil refinery in the East Coast.

It was taken over by GOVERNMENET OF INDIA in 1976 and subsequently

merged with HPCL in 1978. After nationalization, HPCL has transformed
itself into a mega Public Sector Undertaking.

HPCL Visakh Refinery is an integrated refinery facility spread over 723

acres. Currently the capacity is being increased from 8.3 MMTPA to 15
MMTPA.

In HPCL crude Oil is received from Off Shore Tanker Terminal (OSTT) /
Single Point Mooring (SPM) into crude tanks and all the three CDU's are fed
from these tanks. Finished products Naphtha, MS, SKO, ATF, HSD, FO, LSHS,
JBO, MTO, LDO and ASPHALT are received from process units and stored in
different designated tanks and subsequently shipped out to local terminals
and VVSPL.

There are 3 CDU'S in refinery all the light products from CDU'S are sent
for further treating units to DHDS, DHT, MS- BLOCK and VBU. And the
VGO from CDU'S is sent for cracking in FCCU's. There are 2 FCCU'S units
in HPCL-VR. ALL the products are handled by the section OIL
MOVEMENT AND STORAGE (OM&S).

Here the products stored in different tanks and them the intermediate
products to treating units also they provide crude to CDU'S. OM&S also
ships the finished products through white oil terminal and black oil
terminal.

6
There are 7 main blocks in HPCL-VR

❖ Production Block-1

1. Crude Distillation Unit -2

2. Crude Distillation Unit -3
3. Crude Distillation Unit -4

❖ Production Block -2

1. Fluid Catalytic Cracking Unit -1

2. Fluid Catalytic Cracking Unit -2

❖ DHDS BLOCK

1. Diesel Hydro De-Sulfurizing Unit

2. Hydrogen Generation Unit
3. Sulfur Recovery Unit

❖ Merox Block

1. Mercaptans Oxidation
2. Propylene Recovery Unit
3. Effluent Treatment Plant – 1
4. Effluent Treatment Plant – 2
5. Effluent Treatment Plant – 4

❖ MS BLOCK

1. Naphtha Hydro Treating Unit

2. Continuous Catalytic Unit
3. Naphtha Isomerisation Unit
4. FCC – Naphtha Hydro Treating Unit

❖ DHT BLOCK

1. Diesel Hydro Treating Unit

2. Hydrogen Generation Unit
3. Sulfur Recovery Unit

7
❖ OM&S BLOCK

1. Transfer Pump House

2. Additional Tankage Projects
3. LPG Plant
4. Marine Section (SPM, OSTT & OIL WHARFF)

8
PROCESS UNITS USED IN HPCL VISAKH REFINERY:

ATMOSPHERIC DISTILLATON UNIT:

It distils the incoming crude into various fractions in Atmospheric Distillation

Column (ADU) for further processing in other units.

VACCUM DISTILLATON UNIT:

It further distils the residual oil from the bottom of the ADU column. The
VDU is performed at pressure below atmospheric pressure.

FLUID CATALYTIC CRACKING UNIT:

It upgrades the heavier, higher — boiling fractions from the VDU by

converting them into lighter and lower boiling fractions, more valuable
products.

DIESEL HYDRO DE-SULFURIZING UNIT:

It uses hydrogen to desulfurize from the Diesel which comes to the CDU’s.

HYDROGEN GENERATION UNIT:

In this unit, Hydrogen is produced by naphtha treating with steam is occurs.

SULFUR RECOVERY UNIT:

In this unit, the sulphur is recovered from the H2S is done.

MERCAPTANS OXIDATION:

It desulfurizes the LPG, SKO and ATF by oxidising undesired mercaptans to

organics sulphides.

PROPYLENE RECOVERY UNIT:

Propylene is recovered

NAPHTHA HYDRO TREATINIG:

It uses hydrogen to desulfurize the naphtha fraction from the CDU or other
units within the refinery.
9
CONTINUOUS CATALYTIC REFORMING:

It converts the desulfurized naphtha molecules into higher octane

molecules to produce reformate which is a component of the end product
gasoline.

NAPHTHA ISOMERISATION UNIT:

It converts linear molecules such as normal pentane into higher octane

branched molecules for blending into the end product gasoline. It also used
to convert linear butane into ISO-Butane for use in the alkylation unit.

FLUID CATALYTIC CRACKING - NAPHTHA HYDRO CRACKING :

It uses the hydrogen to desulfurize the naphtha from the FCCU-1&2.

DIESEL HYDRO TREATING UNIT:

It uses hydrogen to desulfurize some of the other distilled fractions from

the CDU'S (such as diesel oil).

VIS BREAKER UNIT:

It upgrades the heavy residual oils from the VDU by thermally cracking
them into lighter, more valuable reduced viscosity products (such as HSSR).

SOUR WATER STRIPPING UNIT:

It uses the steam to remove H2S gas and NH3 from various waste water
streams for subsequent conversion into end product sulphur in the Claus
unit.

LPG TREATMENT PLANT:

Desulfurizes the LPG by treating with Amine is occurs.

OIL MOVEMENT & STORAGE:

It provides the storage for all the Raw materials/feeds and products for all
the units. And blending of products also done here. This block is responsible
for the transfer of feed to all the units and received products from the all
the units.

10
 CHAPTER-2
INTRODUCTION TO FLUID CATALYTIC CRACKING
Over the past 50 years, Fluid Catalytic Cracking has developed into a
major upgrading process in the oil refining industry for the conversion
of vacuum gas oils into more valuable products ranging from light
olefins to naphtha and middle distillates. The FCCU occupies a very
important place in a refinery because of its low cost conversion of
heavy oils to lighter more valuable products. The catalytic cracker is the
principle source of light olefin feed to alkylation units. The
attractiveness of the FCC process is related to its flexibility in
converting a variety of feed stocks from a wide range of crudes and its
favorable economics of operation.

DEVELOPMENT OF THE PROCESS

Cracking is a phenomenon by which large oil molecules are

decomposed into small lower boiling molecules. At the same time
certain of these molecules which are reactive, combine with one
another to give even large molecules than those present in the original
stock. The more stable molecules leave the system as cracked gasoline
and reactive ones polymerize forming fuel oil and even coke. Although
primary objective in development of the cracking process had been to
get more of gasoline, all other oils having boiling ranges intermediate
between fuel oil and gasoline are also produced.

THERMAL CRACKING

Dissociation of higher molecular weight hydrocarbons into smaller

molecular weight hydrocarbons through agency of heat is termed as
THERMAL CRACKING. The cracking of heavy hydrocarbons occurs
through the formation of intermediate free radicals by the breaking of a
carbon-carbon bond or carbon-hydrogen bond at high temperature.

CATALYTIC CRACKING

Decomposition of higher molecular weight hydrocarbons into smaller

molecular weight hydrocarbons in presence of catalyst is termed as
CATALYTIC CRACKING.

The cracking of heavy gas oil occurs through the formation of

intermediate positively charged organic species called carbonium ions
and carbonion ions in presence of catalyst at a moderate temperature
and pressure is known as catalytic cracking.

Catalytic cracking has many advantages over thermal cracking,

some of which are listed below.

1. Catalytic cracking gives more stable products.

2. Catalytic cracking unit operates under less severe conditions.
3. Catalytic cracking gives high octane gasoline.
4. It yields less dry gas i.e., methane, ethane and ethylene.
11
The originally developed process of cracking was Thermal cracking.
Use of catalyst for cracking was first investigated by HOUNDRY in
1927. The first catalytic cracker built in 1936 in the USA by Foundry
had fixed bed of catalyst pellets made from natural treated clays. The
process was batch wise, and a series of reactors were employed, each
one going through a cycle of reaction, purging, regeneration and
purging operations. The process had its inherent disadvantages of
being discontinuous and cumber some and moreover, each reactor
was subjected to reducing and oxidizing conditions in
quicksuccession.

The advantage of a continuous process led to the development of the

idea of ― moving bed of catalyst. The Thermofor and Foundry flow
catalytic cracking processes followed, where in the polluted catalyst
was continuously withdrawn from the reactor by means of a mechanical
conveyor or gas pressure carried to the regenerator and brought back
to the reactor, by similar means after burning off the coke.

Heat liberated in the regenerator from the coke burn-off was gainfully
utilized in heating and cracking the oil feed in the reactor, however, the
mechanical means employed put limit on the amount of catalyst that
could be circulated, which in turn meant less heat removal from the
regenerator. Lighter, costlier feed stocks which could vaporize with less
heat had therefore to be processed. The product distribution with
lighter feedstock was also not favorable, tendency being to produce
more gas and gasoline.

FLUID CATALYTIC CRACKING

A more radical development was made by shell. Standard Oil (N.J.

And Indiana), Kellogg, Texas Co and UOP in the early 1940‘s
devised a plant in which catalyst was used in the form of finely
divided powder. This type of catalyst can be kept in a fluid state by
blowing air, gas or steam through it, and so the name ―Fluid
Catalytic Cracking Unit. Moreover, by controlling the particle size
of the catalyst and the velocity of gas moving through it, a bed can be
formed, which, although in violent agitation has some of the
properties of a static quantity of liquid.

The development of the fluid catalytic cracking unit has permitted

much higher rates of catalyst circulation, and thereby the use of
heavier feed stocks of lower value, a point especially important where
viscosity of pour point considerations require destruction of heavier
materials.

12
 ADVANTAGES OF FCCU

From the Operating point of view:

1. Heat evolved in the regeneration of the catalyst is efficiently used.

2. Reaction temperatures are well controlled.
3. Catalyst regeneration temperature is well controlled
4. The catalyst available today is strong and retains its activity on a
high scale. The reactions are usually uniform over a long period of
time, and the product quality does not change with the lengthy
use of catalyst.

To reiterate the most important reason for the wide use of catalytic
cracking is the greater yield of high octane gasoline. The yield is better
than with any other thermal operation. Also, the gas produced consists
mainly of the preferred propane and Butane hydrocarbons with less
methane and ethane. The formation of heavier oils and tars is
minimized. The gasoline and the uncracked cycle Oil are more
saturated that those encountered in other thermal products mainly
because the concentration of Aromatics is higher.

13
 CHAPTER-3

GENERAL PROCESS DESCRIPTION

FUNCTION OF THE PLANT

The Fluidized Catalytic Cracking Unit catalytically cracks the vacuum

Gas oil (side streams) of VDU to various high priced hydrocarbons. In
this process catalyst is used in the form the very small spherical
particles which behave as a fluid when aerated with vapour. The
fluidized catalyst is continuously circulated from the reaction zone to
the regeneration zone. In addition to promoting the catalytic action, the
catalyst acts as the vehicle for the transfer of heat from one zone to
other. These two zones are the reactor and the regenerator.

FCCU consists of three sections – Catalyst section, Fractionation section

& Gas concentration Unit which operate together in an integrated
manner. The cracking section consists of reactor and regenerator which
together with J bends and close coupled riser form catalyst circulation
circuit. The catalyst travels up the riser to the reactor and disengages
at cyclone inlet in the flexi cracking process. The catalyst from the
primary and secondary reactor cyclone diplegs down through the
stripper to the regenerator across the spent catalyst J bend and back to
the riser.

The fresh feed and recycle streams know as combine feed enter the
unit at the riser, where they are vaporized and raised to the reactor
temperature by hot catalyst. The mixture of oil vapor and catalyst
travels up the riser and continues until the oil vapors are disengaged at
the primary cyclone inlet. The cracked products in the vapour phase go
to fractionators through the reactor vapour line. Coke is deposited on
the circulating catalyst in the reaction zone. The spent catalyst flows
from the reactor to the regenerator where coke is burnt off. The heat of
combustion raises the catalyst temperature to 650-730°C range and
supplies heat, most of which is transferred to the endothermic reaction.

The coke deposited on the circulating catalyst in the reactor is burnt off
in regenerator using air from Air blower. Catalyst gets separated from
the hydrocarbon vapors in the reactor and from flue gases in the
regenerator by means of set of cyclones provided at the top section of
reactor and regenerator.

The flue gas coming out regenerator is mixture of CO and CO2 gases
which are burnt in CO boiler for producing steam. The flue gases can be
vented to atmosphere through stack bypassing CO boiler.

In the fractionation section, the reactor vapors are fractionated into the
products clarified oil, Heavy cycle oil, Light cycle oil, un-stabilized
gasoline and wet gas. The unit is also designed to generate MP steam
in the exchangers by transferring waste heat from slurry and HCO
circulating streams of fractionators section. Un- stabilized Gasoline and
14
Wet Gas after compression are sent to gas concentration unit for further
separation.

15
In Gas concentration section Gasoline, LPG and Fuel gas are separated.
The composition of each stream is controlled for maximum product
value. Gasoline and LPG are sent to Meraux for further treatment. Fuel
gas from GCU joins refinery fuel gas system. Clarified oil/HCO is used as
fuel oil component. Gasoline produced in FCCU is having high octane
number. LCO is used as HSD/LDO component.

DESCRIPTION OF THE FLEXI CRACKING PROCESS

The Fluid Catalytic Cracking Unit (FCCU) is one of the most important
and widely used process unit aimed at maximizing the yield of
light/middle distillates by cracking of heavy oils in the presence of
catalyst. The unit may be divided broadly into three sections:

1. Reactor Regeneration Section (R-R section)

2. Fractionation Section
3. Gas Concentration Unit.

The heavy oils (mainly Vacuum Gas oils) are cracked in the presence of
a catalyst in the reactor section of the unit. This cracking reaction
cracks down the long chain, high molecular weight hydrocarbons into
lighter hydrocarbons. In course of the cracking reaction, coke is also
produced which remains on the catalyst particles and rapidly reduces
its activity. In order to maintain the catalyst activity at useful level, it is
therefore necessary to regenerate the catalyst by burning off the
deposited coke. To achieve this, the catalyst continuously flows from
the Reactor to the regenerator where the deposited coke is burnt off in
the presence of Oxygen (air). The regenerated catalyst is removed from
the regenerator and is lifted back into the reactor by reactor feed. The
regeneration of the catalyst is an exothermic process and thus provides
necessary heat for the cracking reaction, which is endothermic. The
flow of catalyst between reactor and regenerator is achieved through
fluidization.

The cracked product from the reactor is distilled and separated into
different product streams of desired TBP cut range in the fractionation
section. The net gas stream from the main fractionators overhead
condenser system is further processed in the Gas Concentration unit to
recover valuable LPG and naphtha range components. The non-
condensable gases are routed to SRU for fuel gas network whereas LPG
and stabilized naphtha are routed to storage after treatment.

The FLEXICRACKING process being utilized in the Visakh FCC Revamp is

a catalytic conversion process which converts vacuum gas oil feed to
fuel gas, LPG, high Octane gasoline, middle distillates, fuel blending
stock and coke. These materials are withdrawn as products except for
coke, which is consumed internally in the process to produce heat for
the cracking reaction.

The zeolite catalyst is typically a synthetic silica-alumina support matrix

with added zeolite, manufactured in the form of a fine powder with an
16
average particle

17
size of around 73 microns. Cracking catalyst can also be synthetic silica
– solid support matrix with added zeolite, or a clay based support matrix
with added zeolite. Although the catalyst is a solid, it is maintained in
suspension or fluidized by reaction products, steam, or air in the vessels
and catalyst transfer lines. In this fluidized state, the catalyst behaves
as a fluid and flows between theReactor and Regenerator.

The Reactor is operated between about 490 to530°C at approximately

1.3kg/cm2
g. Feed is introduced into the bottom of the reactor riser through steam
atomized injection nozzles. When the oil feed contacts the hot catalyst
in the riser, it vaporizes and cracks, providing the lifting force to carry
the catalyst up into the riser. It vaporizes and essentially all of the
conversion takes place in the feed riser [short Contact Time (SCT)
technology used in FCCU-1]. Oil vapors pass from Reactor over head to
the fractionation section where the products areas separated.

Catalyst with coke deposited on it from the cracking reaction, passes

down through a stripping section in the reactor vessel where it is
stripped with steam. This removes both the oil remaining on the surface
and oil vapors entrained between the particles of catalyst. The catalyst
then flows through a transfer line to the Regenerator.

In the Regenerator, coke is burnt off the catalyst with air in High
temperature Regeneration (HTR), partial CO burn mode of operation.
The Regenerators operates with dense bed temperatures of 675 -730°C,
and a dilute phase pressure of approximately 1.1 kg/cm2g. A CO
promoter can be used to assist the combustion of CO to CO2. The hot,
regenerated catalyst flows via an overflow well into the regenerated
catalyst transfer line and is transferred back to the reactor riser.

Flue gases pass up and out of the Regenerator through cyclones, which
removes any entrained catalyst. Combustion of residual CO is
completed in a CO Boiler where steam is generated.

FRACTIONATING SECTION

The reactor effluent comprising of cracked hydrocarbon vapors, steam

and non- condensables enter the fractionator at the bottom of the
quench section. The main column is a vertical cylindrical vessel
consisting of two sections, top section is the regular fractionator part
and the lower one is the desuperheating or quench section. The cracked
vapors from the reactor are cooled by circulating slurry pump around
and part of the vapors condense. The entrained catalyst if any in the
cracked vapor is scrubbed by the slurry pump around stream. The
column bottom liquid which serves as slurry pump around and net
bottom product is withdrawn from the fractionator and pumped using
slurry pumps.

Light cycle oil (LCO) is withdrawn from the chimney tray CT-1. This
stream is split up into two streams, LCO product and LCO PA. LCO PA
stream is used as an internal reflux whereas LCO PDT is stripped off
using MP steam in a stripper and withdrawn as a product which joins

18
Diesel pool or cutter. Heavy cycle oil (HCO) is withdrawn from the
chimney tray CT-2. This stream is split up into two streams,

19
HCO product and HCO PA. HCO PA stream is used as an internal
reflux whereasHCO PDT is stripped off using MP steam in a stripper
and withdrawn as a product which can be used as feed, dilutant to
settler and also joins CLO which joins theFO pool.

The main fractionator overhead vapor consists of naphtha and lighter

hydrocarbons together with steam and non condensables. The
overhead vapors from fractionator, along with wash water and spill back
stream from wet gas compressor are cooled in main fractionator air fin
cooler and finally in fractionator overhead trim condenser and the
three-phase mixture of noncondensables, hydrocarbon liquid and water
from trim condensers is routed to main fractionator O/H accumulator.A
portion of the condensed hydrocarbon is returned to the top tray of the
fractionator as reflux and the remaining liquid is withdrawn as
unstabilized naphtha/LPD.

GAS CONCENTRATION SECTION

The wet gas and unstabilized naphtha streams coming from the
fractionator overhead accumulator are the feed for gas concentration
section. In this section, the wet gases (consisting of light hydrocarbons
and non-condensable), LPG and stabilized naphtha are separated.The
net gases are routed to SRU fuel gas network whereas LPG and
stabilized naphtha are routed to storage after treatment.

PROCESSCHEMISTRY

FCC brings together heavy hydrocarbon feed with fluidized circulating

catalyst. During cracking reactions, carbon and hydrogen (i.e., Coke) is
deposited on catalyst which reduces the catalyst activity. This coke is
burnt in the regenerator, which generates the heat to sustain and
continue the reaction and the catalyst activity is also restored.

Gas oil is portion of crude oil that boils in 330-550°C range and contains
a mixture of paraffins, Naphthenes and Aromatics. About 50% of the
feed consists of saturated molecules (Paraffins and Naphthenes) and
remaining molecules contain at least one aromatic ring. Aromatic
molecules have saturated side chains and/or naphthene rings attached
tothem.
Paraffins, Naphthenes and side chains can crack to smaller molecules
whereas aromatic rings cannot becracked.

Type of molecules in Cracked products

Naphtha ------------- Paraffins, Naphthenes, Olefins, and 1-Ring

aromatics.

HeatingOil-----------2- and 3- Ringaromatics.

BottomsandCoke--------------4+ Ring aromatics.

20
MAJOR FCCU REACTIONS

Cracking reactions
Paraffins → Olefins +Paraffins.
Naphthenes →Olefins.
Aromatics → Unsubstituted Aromatics
+ Olefins.
Olefins → Smaller LPG Olefins.

Hydrogen Transfer
Olefins → Paraffins.
BranchedOlefins → Branched
Paraffins.
Olefins and Naphthenes → Paraffins
+Aromatics.

Dehydrogenation
Naphthenes → Cyclo Olefins
and Aromatics.Aromatics →
HeavyAromatics.
Isomerizati
on →
Olefins BranchedOlefins.
Cyclizati
on →Naphthene
Olefins s.
Alkylation
Aromatics → Heavy Hetrocyclic
(Coke).Aromati → Different
Aromatics
cs alkylaromatics.

21
 CHAPTER-4

FEED AND PRODUCT CHARACTERISTICS

The unique ability of fluid catalytic cracking units to automatically

adjust their operating conditions allows them to accommodate many
feedstock types and qualities. Feed stocks charged to FCCU‘s are made
up of virgin gas oils (Vacuum gas oils and atmospheric gas oils),
cracked gas oils, desphalted gas oils, atmospheric residue. The fluid
catalytic cracking unit is often called the ―heart of the refinery due to
its importance to the refinery due to its versatility to crack many types
of feed stocks.

EFFECT OF FEED STOCK QUALITY ON UNITOPERATION

The coke forming tendency of the feed greatly affects the FCCU heat
balance. Aromatics feeds have a higher coke forming tendency than
paraffinic feeds. Conradson carbon content of the feed adversely affects
its coke selectivity. Nickel and Vanadium content of the charge also
influence the coke yield by causing dehydrogenation of heavy products
that can from contaminant coke. Further the chemical composition of
the feed stock affects the yield and quality of products. Aromatic feeds
produce less gasoline than paraffinic feeds but the gasoline has higher
octane number because it is more aromatic. Sulfur from the feed is
found in all cat cracked products, requiring treatment for itsremoval.

Nickel, copper vanadium, iron and cobalt are dehydrogenation

catalysts. All these metals in the feed, deposit on the circulating
equilibrium catalyst and cause the hydrogen and coke yield to increase.
Although cobalt is not found in the feed, unless it comes in from
hydrotreaters ahead of the FCCU, it can be very troublesome.

Alkaline earth (calcium, magnesium and barium) and alkali metals

(sodium and potassium) that are present in crude oil are usually
removed in desalters. Unfortunately, some of these metals sometimes
still find their way into cat cracker feed stock from other sources such
as contaminated purchased feed stock or refinery boiler feed water that
contains water treating compounds. These contaminants are
destructive to fluid cracking catalysts because they can cause the
catalyst particles to sinter or even collapse. They unite with the catalyst
to from a eutectic that fuses at temperatures prevailing in the
Regenerator. Sodium and potassium are the most harmful to the
catalyst and about equal ineffect.

Quality of feed stock charged to a cat cracker is perhaps the biggest

single factor affecting unit performance. The following minimum
information is required to adequately describe the feed stock properties
of a cat cracker.

22
 HYDROCARBON CLASSIFICATION

The hydrocarbon types in the FCC feed are broadly classified as

paraffins, olefins,Naphthenes, and aromatics (PONA),

Paraffins

Paraffins are straight or branched chain hydrocarbons having the

chemical formula CnH2n+2. The name of each member ends with -ane;
examples are propane, isopentane, and normal heptanes. In general,
FCC feeds are predominately paraffinic. The paraffinic carbon content is
typically between 50 wt% and 65 wt% of the total feed. Paraffinic stocks
are easy to crack and normally yield the greatest amount of total liquid
products. They make the most gasoline and the least fuel gas, but also
the lowest octanenumber.
EXAMPLES PROPANE, ISOPENTANE, NORMAL HEPTANE.

Olefins

Olefins are unsaturated compounds with a formula of CnH2n. The name

of these compounds ends with ~ene, such as ethene (ethylene) and
propene (propylene). Compared to paraffins, olefins are unstable and
can react with themselves or with other compounds such as oxygen and
bromine solution. Olefins do not occur naturally, they show up in the
FCC feed as a result of preprocessing the feeds elsewhere. These
processes include thermal cracking and other catalytic cracking
operations.
EXAMPLES ETHYLENE, PROPYLENE.

Olefins are not the preferred feed stocks to an FCC unit. This is not
because olefins are inherently bad, but because olefins in the FCC feed
indicate thermally produced oil. They often polymerize to form
undesirable products, such as slurry and coke. The typical olefin
content of FCC feed is less than 5 wt%, unless unhydrotreated cooker
gas oils are being charged.

Naphthenes

Naphthenes (CnH2n) have the same formula as olefins, but their

characteristics are significantly different. Unlike olefins that are straight-
chain compounds, naphthenic are paraffins that have been bent" into a
ring or a cyclic shape. Naphthenes, like paraffins, are saturated
compounds.
EXAMPLES cyclopentane, cyclohexane, andmethylcyclohexane.
Naphthenes are desirable FCC feed stocks because they produce
high-octane gasoline. The gasoline derived from the cracking of
Naphthenes has more aromatics and is heavier than the gasoline
produced from the cracking of paraffins.
Aromatics

Aromatics (CnH2n-6) are similar to Naphthenes, but they contain a

resonance stabilized unsaturated ring core. Aromatics are compounds
that contain at least one benzene ring. The benzene ring is very stable
23
and does not crack to smaller

24
components. Aromatics are not a preferred feedstock because few of
the molecules will crack and the cracking of aromatics mainly involves
breaking off the side chains resulting in excess fuel gas yield. In
comparison with cracking paraffins, cracking aromatic stocks results in
lower conversion, lower gasoline yield, and less liquid volume gain, but
with higher gasolineoctane.

EXAMPLES------------Anthracene, Naphthalene,Fluorene.

The most widely used properties are:

1. °APIGravity
2. Distillation
3. AnilinePoint
4. Refractive Index(RI)
5. Bromine Number (BN) and Bromine Index(BI)
6. Viscosity
7. Conradson, Ramsbottom, Microcarbon, and Heptane Insoluble.

°API Gravity
The °API gravity measures the density of a hydrocarbon liquid. Specific
gravity (SG) is another common measurement of density. The liquid SG
is the relative weight of a volume of sample to the weight of the same
volume of water at 15.5°C.

Since °API gravity is inversely proportional to specific gravity, the

higher the °API gravity, the lighter the liquid sample. In petroleum
refining, °API gravity is routinely measured for every feed and product
stream.

The °API gravity is always reported at 60°F (15.5°C).Daily monitoring of

°API gravity provides the operator with a tool to predict changes in unit
operation. For the same distillation range, the 26°API feed cracks more
easily than the 24°API feed because the26°API feed has more long-
chain paraffinic molecules.
Long straight-chain paraffins are important to the economics of an FCC
unit. They crack easily to gasoline and LPG, with minimal production of
slurry and fuel gas.

Distillation

Boiling point distillation data also provides information about the quality
and composition of a feed. Distillation indicates molecular weight and
carbon number. It indicates whether the feed contains any "clean"
products that could be sold "as is." The feed to the FCCU is a blend of
gas oils from operating units as the crude and vacuum columns, In
recent years, the trend has been toward heavier gas oils and residue.
Residue is most commonly defined as the fraction of feed that boils
above 1,050°F (565°C). Each FCC feed stream has different distillation
characteristics.

The fractional distillation test conducted in the laboratory involves

25
measuring the temperature of the distilled vapor at the initial boiling
point (IBP), as

26
Volume percent fractions 5, 10, 20, 30, 40, 50, 60, 70,80, 90, and 95
are collected, and at the end point (EP). Three ASTM methods are
currently used to measure boiling points: D-86, D-1160,and D-2887.D-
86 is the most common method used in refineries. The distillation is
done at atmospheric pressure. It is used for samples with an EP less
than 750°F(400°C).

Distillation data provides information about the light fraction of feed

boiling at less than 650°F (343°C). Light virgin feed, the fraction that
boils under 650°F (343°C), often results in a greater LCO yield and
lower unit conversion. Sources of these fractions come from
atmospheric gas oil, light vacuum gas oil, and light cooker gas oil.
Lower conversion of light virgin feed is caused by:

1. Lower molecular weight means the oil is more difficult tocrack,

2. Light cooker stocks are veryaromatic.
3. Light aromatics have fewer crackable sidechains.

Aniline Point
Aniline is an aromatic amine (C6H5NH2). When used as a solvent, it is
selective to aromatic molecules at low temperatures, and paraffins and
Naphthenes at higher temperature. Aniline is used to determine
aromaticity of oil products, including FCC feed stocks. Aniline point (AP)
is the minimum temperature for complete solubility of an oil sample in
aniline. ASTM D-611 involves heating a 50/50 mixture of the feed
sample and aniline until there is only one phase. The mixture is then
cooledand the temperature at which the mixture becomes suddenly
cloudy is the anilinepoint.

The test senses solubility via a light source that penetrates through the
sample. The aniline point increases with paraffinicity and decreases
with aromaticity. It also increases with molecular weight. Naphthenes
and olefins show values that lie between those for paraffins and
aromatics. Typically, an aniline point higher than 200°F (93°C) indicates
paraffinicity and an aniline point lower than 150°F (65°C)
indicatesaromaticity.

Refractive Index
Similar to aniline point, refractive index (RI) shows how refractive or
aromatic a sample is. The higher the RI, the more the aromatics and
the less crackable is the sample. A feed having an RI of 1.5105 is more
difficult to crack than a feed with an RI of1.4990.

Bromine Number and Bromine Index

Bromine number (ASTM D-1159) and bromine index (ASTM D-2710) are
qualitative methods to measure the reactive sites of a sample. Bromine
reacts not only with olefin bonds, but also with basic nitrogen molecules
and with some aromatic sulfur derivatives. Nevertheless, olefins are the
most common reactive sites and the bromine number used to indicate
olefinicity of the feed. The bromine number is the number of grams of
bromine that will react with 100 grams of the sample. Typical bromine
numbers are:
27
 1. Less than 5 for hydro treated feeds
2 10 for heavy vacuum gasoil
3 50 for cooker gasoil

Viscosity
Viscosity indicates the chemical composition of an oil sample. As the
viscosity of a sample increases, paraffins increase, hydrogen content
increases, and the aromatic fraction decreases. Viscosity is normally
measured at two different temperatures: typically 100°F (38°C) and
210°F (99°C). Say bolt viscosity (ASTM D-88) is the most popular
method of measuring the viscosity of oils such as FCC feed. This
method covers two procedures:
1. Say bolt Universal Viscometer (SUV) for lightoils.
2. Say bolt Furol Viscometer (SFV) for heavyoils.

Conradson, Rams bottom, Micro carbon and Heptane Insolubles

One area of cat cracking not fully understood is the proper
determination of carbon residue of the feed and how it affects the unit's
cokemake. Carbon residue is defined as the carbonaceous residue
formed after thermal destruction of a sample. Cat crackers are
generally limited in coke burn capacity, therefore, the inclusion of
residue in the feed produces more coke and forces a reduction in
FCCthroughput.

Conventional gas oil feeds generally have a carbon residue less than
0.5 wt %; for feeds containing resid, the number can be as high as 15
wt%. Four popular tests are presently used to measure carbon residue
or concarbon of FCC feedstocks:
1. Conradson.
2. Ramsbottom.
3. Micro-method.
4. Heptane insolubles.

The object is to indicate the relative coke forming tendency of

feedstocks. Each test has advantages and disadvantages, but none of
them provide a rigorous definition of carbon residue or asphaltenes. The
Conradson test (ASTM D-189) measures carbon residue by evaporative
and destructive distillation.

IMPURITIES

In recent years, refinery has been processing heavier crudes. Heavier

crudes provide a slim economic margin but slim is better than none.
The cat cracker, as the main conversion unit, is designed to handle a
variety of feedstocks. Today's FCC feed stocks are generally heavier
and contain higher levels of impurities like nitrogen, sulfur, and metals.
These impurities have negative effects onunit performance.
Understanding the nature and effects of these contaminants is essential
in feed and catalyst selection as well as troubleshooting the unit.

28
The FCC (Fluid Catalytic Cracking) feed contains several impurities,
primarily large organic molecules. Common contaminants include
nitrogen, sulfur, nickel, vanadium, and sodium. Except for sulfur, these
contaminants poison the FCC catalyst, reducing its effectiveness in
producing valuable products. Sulfur increases operating costs due to
the need for additional treatment facilities.

Nitrogen:

- Exists as organic nitrogen compounds, reported as basic and total

nitrogen.

- Basic nitrogen neutralizes acid sites on the catalyst, temporarily

reducing activity.

- Burning nitrogen in the regenerator restores catalyst activity,

converting most nitrogen to elemental nitrogen and some to nitrogen
oxides (NOx).

- Nitrogen also forms ammonia and cyanide, which can cause corrosion
in equipment.

Sulfur:

- Present as organic-sulfur compounds like mercaptan, sulfide, and

thiophenes.

- Around 50% of sulfur in the feed converts to H2S during FCC, while the
rest remains in products.

- Sulfur content is measured by x-ray fluorescence spectrometry (ASTM

D-2622).

Metals:

- Metals such as nickel, vanadium, and sodium are present in crude oil
and concentrate in heavy residues.

- Nickel:

- Deposits on the catalyst matrix, promoting dehydrogenation and

increasing hydrogen and coke yields.

- High nickel levels cause higher regenerator temperatures and reduce

conversion efficiency.

- Vanadium:

29
 - Less dehydrogenation than nickel but more destructive.

- Migrates to the catalyst's zeolite structure, destroying it

permanently.

- Converts to vanadium oxides (e.g., V2O5) during regeneration, which

melts and damages the catalyst.

30
 TYPES OF ALUMINO SILICATE CATALYST

NATURAL CATALYSTS
Natural Catalysts is finely ground chemically treated clay and was the
original catalyst used in the process. The catalyst has tented to fall into
disuse in spite of some desirable features, the principal one being its
low cost compared with the low- alumina synthetic catalyst most
commonly used. Natural catalyst produces a slightly higher yield of
lower octane gasoline. However, because of its lower initial activity and
stability, a higher make-up rate is required for regeneration. Being
composed of irregularly shaped ground particles, natural catalysts tend
to erode standpipes and slide valves more rapidly and to break up more
easily producing fires which are most through the stack. Natural
catalysts are also observed to circulate less rapidly and the maximum
circulation rate of unit can often be increased by changing to a
microspheroidal catalyst.

SEMISYNTHETIC CATALYST
Semi-synthetic catalyst is manufactured from natural clay and is an
attempt to simultaneously obtain the advantages of the low cost of
natural catalyst and the high ―performance of synthetic catalysts. In
practice it appears that the properties and performance of semi-
synthetics are intermediate, and that all the disadvantages of natural
catalyst are encountered to a somewhat lesser degree. Both semi-
synthetic and natural catalyst finds a use in those units handling charge
stocks which are heavily contaminated with metals. In general,
however, the most economical solution to this problem is the
elimination of contamination by making changes in the feed
preparationunit.

SYNTHETIC CATALYST
Synthetic Catalysts are prepared chemically and in general are
microspheroidal catalysts with desirable physical properties, high initial
activity and good stability. Several types of synthetic catalysts are
available.

A) LOW-ALUMINACATALYST
Low-alumina catalyst containing 12-14% alumina is the original
synthetic catalyst. It possesses well balanced properties which are the
standard against which other catalysts are still compared.

B) HIGH ALUMINACATALYST
High-alumina Catalyst, containing 25-28% alumina, is a catalyst with
higher initial activity and superior stability. Equilibrium activity is higher
and hence operating severity can be reduced to maintain the same
conversion. High alumina catalysts usually result in a higher
regenerator temperature and the apparent bulk density is lower than
other catalyst. Low and high alumina catalysts are also known as
amorphous alumina-silicate catalysts.

31
CATALYST COMPONENTS

FCC catalysts are in the form of fine powders with an average particle
size in the range of 75 microns. A modern cat cracking catalyst has four
major components:
1. Zeolite.
2. Matrix.
3. Binder.
4. Filler.

Zeolite
Zeolite, or more properly, faujasite, is the key ingredient of the FCC
catalyst. It provides product selectivity and much of the catalytic
activity. The catalyst's performance largely depends on the nature and
quality of the zeolite. Understanding the zeolite structure, type,
cracking mechanism and properties is essential in choosing the "right"
catalyst to produce the desired yields.

Zeolite Structure
Zeolite is sometimes called molecular sieve. It has a well defined lattice
structure. Its basic building blocks are silica and alumina tetrahedra
(pyramids). Each tetrahedron consists of a silicon or aluminum atom at
the center of the tetrahedron, with oxygen atoms at the four corners.
Zeolite lattices have a network of very small pores. The pore diameter
of nearly all of today's FCC zeolite is approximately 8.0 angstroms(°A).

Matrix
Matrix is a component of the catalyst aside from the zeolite. Alumina is
the source for an active matrix. Most active matrices used in FCC
catalysts are amorphous. Active matrix contributes significantly to the
overall performance of the FCC catalyst. The zeolite pores are not
suitable for cracking of large hydrocarbon molecules generally having
an end point greater than 482°C. They are too small to allow diffusion
of the large molecules to the cracking sites. An effective matrix must
have a porous structure to allow diffusion of hydrocarbons into and out
of the catalyst, An active matrix provides the primary cracking sites.
The acid sites located in the catalyst matrix are not as selective as the
zeolite sites,but are able to crack larger molecules that are hindered
from entering the small zeolite pores. The active matrix precracks
heavy feed molecules for further cracking at the internal zeolite sites.
The result is a synergistic interaction between matrix and zeolite, in
which the activity attained by their combined effects can be greater
than the sum of their individual effects An active matrix can also serve
as a trap to catch some of the vanadium and basic nitrogen. The high
boiling fraction of the FCC feed usually contains metals and basic
nitrogen that poison the zeolite. One of the advantages of an active
matrix is that it guards the zeolite from becoming deactivated
prematurely by theseimpurities.

32
Filler and Binder
The filler is clay incorporated into the catalyst to dilute its activity.
Kaoline [Al2(OH)2, Si2O5] is the most common clay used in the FCC
catalyst. FCC catalyst manufacturers uses kaoline clay as a skeleton to
grow the zeolite in situ. The binder serves as a glue to hold the zeolite,
matrix, and filler together. Binder may or may not have catalytic
activity. The importance of the binder becomes more prominent with
catalysts that contain high concentrations of zeolite. The functions of
the filler and the binder are to provide physical integrity (density,
attrition resistance, particle size distribution, etc.), heat transfer
medium, and a fluidizing medium in which the more important and
expensive zeolite component is incorporated. In summary, zeolite will
effect activity, selectivity, and product quality. An active matrix can
improve bottoms cracking andresist
vanadium and nitrogen attacks. But a matrix containing very small
pores can suppress strippablity of the spent catalyst and increase
hydrogen yield in the presence of nickel. Clay and binder provide
physical integrity and mechanical strength.

33
 CHAPTER-5
UTILITIES

INTRODUCTION
The utility system consists of following:
1. InstrumentAir
2. PlantAir
3. SeaWater
4. Bearing CoolingWater
5. ServiceWater
6. DemineralizedWater
7. Boiler FeedWater
8. HPSteam
9. LPSteam
10. MPSteam
11. LP CondensateDistribution
12. Fuel Oil
13. Fuel Gas
14. Flushing Oil
15. Closed BlowDown
16. FlareSystem
17. Oily WaterSewer
1. INSTRUMENT AIR
The existing compressed air system in Merox plant is brought to
revamp and augment VREP-II air requirement. A new air compressor is
provided for this purpose and plant air is integrated into the existing
plant air pipe work from wherea tapping was taken for FCCU-
I(R).Instrument air is supplied into unit through a header which is
provided with isolation valve and spectacle blind at battery limit. A
pressure indicator indicates pressure at battery limit in DCS. Various
instrument air tappings are taken from this header. Instrument air
required for CO Boiler is also taken as an another header from the unit
header. A flow indicator is also provided on main header. Instrument air
is used as motive force pneumatically operated controlvalves.

2. PLANTAIR
A planter header supplies plant air to FCCU-I(R). The header is provided
with isolation valve and spectacle blind for positive isolation at battery
limit. A number of utility points are provided from this header. A flow
indicator is provided on main header to monitor in DCS. For decoking of
feed heater a tapping is taken from main header. A tapping is also
provided for CO Boiler requirements.

34
3. SEA WATERSYSTEM
The cooling water requirements for cooling purpose in the existing units
is met through a cooling water circulating system in which sea water is
used. This system consists of 5 cooling towers cells and six recirculating
sea waterpumps.
Sea water is supplied from this system and a tapping is taken from sea
water supply header(SWS) for FCCU-I(R) unit. The sea water
return(SWR) header joins the main sea water return header which is
routed back to the cooling tower.
Within the unit SWS and SWR bifurcate into two headers. One for MAB,
CAB and CO Boiler, other line is routed through cooling water booster
pump. The pump discharge is supplying sea water to all the sea water
coolers. A pump bypass line is provided for bypassing the pump. A flow
indicator indicate in DCS sea water supply to various consumers. All the
exchangers are provided with back flushing arrangement. This back
flushing water is routed through a header to the sewer via FCCU-I.

4. BEARING COOLINGWATER
Circulating bearing cooling water is used for pump gland and bearing
cooling, turbine oil coolers etc. where use of sea water is prohibited.
The existing system consists of two bearing cooling water systems
-BCW system at PP-I is servicing BCW requirement in units of VR.
-BCW system in IFO area is servicing BCW requirements in units of
VREP-I. BCW system for VREP-I caters requirement in CDU-I. VDU-
II, FCCU-II, PP-II, Merox, air compressors, offsites and PRU. To meet the
additional bearing cooling water requirement of units in VREP-II a
bearing cooling water system with 2 cooling tower cells has been
constructed near the IFO system of the refinerycomplex.
For catering to BCW requirements for FCCU-I a header is tapped off
from the main header from new BCW system. With the FCCU battery
limit isolation valve and spectacle blinds are provided on BCW supply
and BCW return lines. Flow indicator in DCS at battery limit indicates
flow to various consumers. A tapping has been taken for CO boiler
requirementtoo.
5. SERVICE WATERSYSTEM
Two pumps equipped in PP-I will accommodate this purpose. One pump
will cater to drinking water system located at PP-I and service water to
VR and VREP-II units while other pump will cater to DM plant feed to old
DM plant only.

35
A tapping has been made from this existing service water header to
meet FCCU-I service water requirements. The common service water
header supplies service water to unit. It is provided with an isolation
valve, spectacle blind and pressure indicator at battery limit. The
service water header supplies water to various hose stations in the
plant. Service water connections have been provided to MAB, CAB,
decoking pot and closed blow down drum. Service water is mainly
required for washing and cleaning. Flow indicator at battery limit in DCS
indicates consumption of service water in the unit. Service water is also
provided for MP steam blow down in steam generator blow down drum
for washing and to other equipment within the unit. Service water has
been used in start up in fractionator over head accumulator, HP
receiver, debutaniser over head accumulator. It has been used as wash
water in fractionator over head trim cooler and intercooler.

6. DMWATER
In raw water tank area new pumps provided for supplying DM plant feed
to VREP- I and VREP-II DM plants. From VREP -II DM water plant, DM
water is routed to and stored in DM water tanks. These tanks provide
suction to existing DM water distribution pumps. For supply of DM water
to FCCU-I DM water distribution line has been taken to unit. A common
DM water header supplies DM water to the unit from offsite. It is
provided with double block valve and a spectacle blind. Flow indicator
indicates DM water consumption is DCS with low flow alarm and flow
recorder and local pressure gauge shows supply pressure. DM Water is
used in MAB, CAB and fractionator over head accumulator.

7. BOILER FEEDWATER
In the existing system, two BFW systems are provided one for VR
supplying HP/MP BFW requirements of utility boiler in PP-I and steam
generators in CDU-I, FCCU-I and the other for VREP-I catering to BFW
requirements of CO boiler-I, utility boilers, FCCU-II and HRSGs in CPP. In
addition, there are two MP BFW pumps catering to BFW requirements of
steam generators in CDU-I and FCCU-II. To cater additional BFW
requirements an additional deaerator of capacity 120 T/hr is provided
parallel to the existing deaerators in PP-II area and the MP/LP BFW
requirements in all the units including CDU-I/FCCU-I/II block shall be
supplies from PP-II. For this purpose, the existing MP BFW pumps of
35m3/hr capacity is replaced with two new pumps of 120m3/hr
normalcapacity.

A tap off from the discharge from these pumps is utilized as MP BFW to
CDU-I , FCCU-I and VREP-II units from where a line is tapped off to FCCU-
I unit.
Block valve and spectacle blind have been provided at battery limit for
positive isolation. A local PI and TI are provided at battery limit. A FI in
DCS indicates consumption of BFW in unit. BFW is also used in steam
drum for generation of MP steam. It is also used to desuperheat MP
steam for use as atomizing steam in the atmospheric and vacuum
heaters. BFW is used in steam generator for MP steam generation. This
BFW is initially preheated in an exchanger by LCO and then routed to
36
generators. One HP BFW stream is taken into the unit by a header. This
BRW is used in CO boiler to produce HPsteam.

37
8. LP STEAMSYSTEM
LP steam requirement for FCCU-I shall be met by revamping of steam
distribution system located at PP-I unit. Here a tap off is taken from
header and the steam pressure and temperature is reduced into two
stages of pressure reduction and desuperheating. LP steam is also
generated by the BFW turbine which runs on MP steam. This LP steam
is also augmented for use in FCCU-I. The LP steam generated is
distributed to FCCU-I, CDU-/VDU-III, VBU, Merox, IFO block, offsite and to
existing LP steamheader.

Within the unit requirement of LP steam is met by a line taken from

offsite. A isolation valve and spectacle blind are provide at battery limit
of FCCU-I. TI, FI and PI at battery limit are provided to indicate
temperature, flow and pressure in DCS. FI has flow recorder and flow
totaliser in DCS. Local pressure indicator is also provided at
batterylimit.
MAJOR USES OF LP STEAM ARE AS FOLLOWS

o Sample pointpurging
o Heating medium forexchangers
o Sealing system for airblowers
o Body steam for steam outcolumns
o Quench steam for pump mechanicalseal
o Snuffing steam of firedheaters
o Soot blowers of fanblades
o Tracing of processlines
o Dilution of vented hydrocarbons from ventsystem
o Steam smothering andutility
o Dead end of CBDheaders.
9. MP STEAMSYSTEM
A common medium pressure steam header has been provided for FCCU-
I with double isolation valve and a spectacle blind at battery limit. PI, TI
and FI indicates MP steam pressure, temperature and flow rate in DCS.
MP steam is also produced in steam generators and decoking drum
and is hooked up to this MP steam header.

MAJOR USES OF MP STEAM ARE AS FOLLOWS

o Emergency steam to heatercoil

o Soot blowing steam toheater
o Decoking steam toheater
o Atomizing steam to fireguns
o To hosestations
o Stripping steam to main column, LCO and HCOstrippers
o Steam out purpose for different pumpdischarges.

38
10. HP STEAMSYSTEM
A HP steam header has been provided for FCCU-I with double block and
blind at battery limit. This HP steam header is floating with the
refinery steam header. HP steam is produced in CO boiler to maintain
the pressure in the header. A pressure transmitter with low pressure
alarm is provided at batterylimit.
11. LPCONDENSATE
LP condensate produced in MAB turbine is routed to the offsite through a
header.
12. FUEL GASSYSTEM
Fuel gas being produced in various units is routed to the sulphur block
for removal of H2S. The sweet gas is then routed to CPP, FCCU-II and
VREP-II units For FCCU-I a tapping is taken from SRU sweet fuel gas
header. The FG producedwithin the FCCU-I unit i.e ATG, is routed to
SRU as sour gas. FG supply header at battery limit is provided with
double block and spectacle blind. FI at DCS is provided to indicate FG
consumption within the unit. PI and TI are provided locally at battery
limit. FG lines are steam traced to avoid condensation in lines. Sweet
fuel gas from battery limit is routed to fuel gas KOD to separate the
condensate carry over. FG-KOD is provided with local level gauge and
high level alarm. To drain the condensate CBD and OWS connections
has been provided from the bottom of thevessel.

KOD overhead is routed to the unit through a header. A pressure

controller is provided to control the pressure of the fuel gas and it is a
split range controller. In case of high pressure of FG a pressure valve
will open to vent the gas to flare. In case of low pressure of FG that
pressure valve will open to allow LPG vapor to go in the FG header from
LPG vaporisr.LPG vaporizer level is controlled by a level controller. LPG
is taken from the unit. Provision has been given to route LPG from
Merox to LPG vaporizer. LPG will be vaporizing in the vessel with the
help of LP steam passing through the embedded coil. Pressure of the
vessel is controlled by pressure controller and also controls the steam
flow through the coil. Steam condensate is drained to steam station
through a steam trap. Bypass of the trap has been provided in case trap
has to be taken for maintenance. A PSV has been provided to care of
over pressure of the vessel. Fuel gas flow is measured by FI and PI
indicates pressure in DCS.

Fuel gas is supplied to various consumers through a header. FT will

show the consumption of FG in the unit. Piping provision has been given
to route the FG to the offsite header through double block blind at
battery limit.

39
MAJOR USES OF FUEL GAS ARE AS FOLLOWS

o To feed heater asfuel

o For purgingreactor
o LCO stripper vapor return for starup
o In CO boiler
o Flare header dead endpurge.
13. FUEL OILSYSTEM
To meet the additional FO requirement due to VREP-II the existing FO
system is modified and some additional facilities are incorporated foe
augmenting the existing FO system like a new FO tank, existing FO
pumps are replaced by a new set of four twin-screw type pumps.
Normally two turbine driven pumps will be in service. The FO heaters
are supplemented with an identical additional FO heater provided in
parallel to meet the desired viscosity.
The FO is pumped into the existing offsite header which caters to the
entire complex requirement. During normal operation of the refinery the
IFO requirements are met by LSHS. In case non- availability of LSHS due
to non- processing of low sulphur crudes finished fuel will be used as
fuel oil.
A tapping is taken from offsite header for catering FO requirements in
FCCU-I. The FO return is through a header from the unit which joins the
offsite header back to the FO offsite tank. Double isolation valves and
spectacle blind is provided on fuel oil supply (FOS) and fuel oil return
(FOR) headers at battery limit. A local TI and TI for DCS is also provided
on header. The FO headers are steam traced to avoid congealing.
Within the FCCU-I unit FO is supplied to CO boiler and feed heater
respectively with circulating lines back to return header. Constant
circulation is necessary in the FO lines to prevent congealing in the
headers whichmay occur during idleconditions.
14. FLUSHING OILSYSTEM
Flushing oil is normally with boiling range and properties comparing well
with gas oil. It is used as a flushing medium for displacing heavy
congealing and viscous material from equipment a piping during unit
shut down or other maintenance jobs requiring cleaning of equipment
from such hydrocarbons. It is also used as pump seal flushing oil and
instrument impulse tubing flushing. There are two types of FLO used in
the unit area.
1. One is heavy diesel which is used for equipment flushing during
shutdown and is designated as FLO. A tapping from FCCU-I HD run
down line is provided for HD flushing system. During initial start
up condition when HD is not available from FCCU-I, HD will be
received from the Merox flushing oilsystem.
2. The second FLO system considered is that with VGO and is
designated as FLOM. FLOM is used for flushing of instruments
impulse tubing and for flushing of pump mechanicalseal.

40
VGO is taken in the FLOM circuit by taking a tapping from feed pump
discharge. To remove the sediments from FLOM filters have been
provided. A DPI is provided to measure the difference between the
upstream and downstream of the filters. If differential pressure
increases the filter mesh has to becleaned.
The pressure in the FLOM header is maintained by a pressure valve.
FLOM is used in different instruments and pump seals like slurry pump
around, HCO product recycle and HCO pump around pumps use
VGO as flushing oil. The entire FLOM system is steam traced to
prevent congealing of VGO. An alternative provision has been made
from flushing oil header to FLOM and pumpseals.

15. EFFLUENTSYSTEM
All off specification hydrocarbon streams, hydrocarbon stream
contaminated with water, water contaminated with hydrocarbons and
other chemicals and such liquid streams that cannot be disposed of
directly are collected and treated either for recovery of hydrocarbons or
to render them harmless to receiving stream. For these purposes slop
system, CBD system, OWS system provided. These systems are
described sequentially below.

→ SLOPSYSTEM
Off specification hydrocarbon streams are routed to a slop header at
unit battery limit which are then routed to slop tanks. The slop
generated within FCCU-I is primarily dry slop. This header is routed to
the dry slop tank located in offsite. All product rundown lies have access
to slop header, when ever quality goes off specific may routed to slop
tanks.
→CLOSED BLOW DOWN SYSTEM
Those hydrocarbons streams that are either free of or only slightly
contaminated with water are received in closed blow down vessel. Such
hydrocarbon streams are generated especially during shut down
periods when equipment and system are drained under gravity to clean
up hold oil. The hydrocarbon in CBD vessel should be received at a
temperature well below flash point of lightest component present
inside.CBD network helps reducing amount of hydrocarbon loss.
Two underground CBD headers run across FCCU-I. LP steam and
flushing oil connections are provided at all dead ends of CBD headers
for line cleaning. The headers are finally routed to CBD vessel which is
an underground drum placed horizontally. Drum is provided with a coil
through which sea water or LP steam can bepassed.
LI and TI indicates level and temperature of CBD drum and are provided
with low and high level alarms and high temperature alarm for CBD
pump is interlocked with high/low alarms for auto start and auto stop.
Hydrocarbon is pumped out by CBD pumps to slop header in FCCU-I
unit
Under normal conditions it is expected to remain at atmospheric
pressure. A small purge of steam is provided at the vent of the drum to
41
guard against fire at the vent top due to lightening and static electricity
hazard. One service water connection is given to the drum for cleaning
purpose.

42
→OILY WATER SEWER
This system is also called as OWS is mainly to collect water
contaminated with hydrocarbon oil. Such streams are generated during
equipment draining and flushing during routine operation. Streams
suitable for OWS also generated as a result of floor washing. Cleaning or
spilled oil, drained streams etc. are received through OWS funnels are
routed to ETP-I through a combined header. Contaminated rain water
from unit paved area is also routed to OWS system. All equipments
having CBD connections are normally provide with OWS connection.
Care should be taken that at no time any spark reaches vapor space of
OWS tunnels. This may result in explosion immediately there or
elsewhere in network wherever explosive mixture of air and
hydrocarbon vapors is present in appropriate concentration for
explosion.
→SURFACE DRAIN SYSTEM
It is the peripheral surface drain with double block valve arrangement
to route it either to OWS or to storm sewer system depending upon its
oil content.
→FLARE SYSTEM
In the event of abnormal operating conditions or emergencies, the
hydrocarbon operating system may get pressurized. In order prevent
this from shooting up and crossing design limit of respective
system/equipment and causing accident and/or equipment damage, it
may become necessary to relieve same amount of non- condensable
hydrocarbon vapors to a system that renders them harmless. For this
purpose a network of flare header is provided for collection of relieved
vapors in unit to which all relevant equipments are connected. PSV`s of
the vessels of hydrocarbon service are all connected to a flare header.
Flare lines are designed for a pressure of 3.5 kg/cm2g and temperature
about 200oc. flare lines to be tested pneumatically because of line
support considerations. Entry of steam and condensate in flare header
to be avoided as it may lead to extinguishing of main flareflame.
All units PSV discharges, LPG product pump seal pot, debutanizer reflux,
primary absorber, stripper feed pump seal pot, LPG pumps, debutanizer
reflux pump casing vents, main fractionator overhead naphtha
accumulator pressure control vent, WGC 1 st and 2nd stage discharge
vent, main fractionators trim coolers, inter cooler, after cooler
condensers shell vents are routed to unit flare header.
FG dead end purge is provided on header to maintain a positive
pressure. The flare header from FCCU-I routed to the flare knock out
drum. LI indicates the level in DCS. A drain line is connected to CBD and
another drain line routed to OWS. PI and TI are provided locally on the
KOD. A flare flow meter is also provided at outlet of KOD and before the
battery limit. A flare header from top of KOD routed to flare in the
offsites. FI is provided on the header in DCS. The flare header is routed
to the newly installed flare system. Separate provision is given at unit
limit for keeping only gas plant flare system in service during shutdown
of revamp unit. FCCU-I flare header and gas plant flare header
43
separated with isolation valvesand blindingflanges.

44
 CHAPTER-6
SAFETY

Visakh refinery every day process and handles different type of

crude oils, liquid and gaseous petroleum products which are highly
inflammable volatile in nature and are required to be handled with due
care.

Fire prevention, fire protection and firefighting are three distinct

aspects very closely related to each other.

Fire prevention: It means adoption of safe practices at the design stage.

Fire protection: It involves provision of different facilities that help in

immediate handling of fire emergencies effectively.

Fire fighting: It is physical in nature, as it is handled with the help of fire

protectionfacilities.

Fire can be prevented to a large extent by having knowledge about the

causes of fire, so that action can be taken to prevent the combination of
events that result in fire.

Fire chemistry: Fire is a combustion process intense enough to emit

heat and light. Combustion is an exothermic, self-sustaining reaction.
Basic requirement for a fire to occur is oxygen. Heat and Fuel
represented as “Fire Triangle” but it is recognized that chain reaction is
also required for a fire to continue, represented as “Fire tetrahedron”.

FIRETRIANGLE FIRETETRAHEDRON

O2 HEA O HEA
FU
E
FUEL
CHAIN

1
0
METHODS OF EXTINGUISHING FIRE:

Limiting any one or more of the factors of fire tetrahedron can do

extinguishments of fire. These are classified as:
1. Starvation: Elimination offuel.
2. Smothering: Reducing O2% to below15%.
3. Cooling: Removal oftemperature.
4. Chemical flame inhibition: Breaking combustionreaction.

Classification
Fire involves Extinguishing media
of fire
Class A fire Materials such as Water
paper, wood,
Plastics etc.,
Water, DCP, CO2,
Class B fire Oils
Halonand Foam
Class C fire Gases Water, DCP,
CO2,
Halons.
Class D fire Metals Special powders.

Fire protection facilities:

It has been broadly divided into the following.

1. Fixed fire protectionfacilities

2. FireStation
3. Fire watersystem
4. Mobile Fire protectionfacilities
5. FireVehicles
6. Portable Appliances /Equipment
7. Extinguishers
I. DCP 10 kgExtinguisher
II. DCP 5 kgExtinguisher
III. 4.5 kg CO2Extinguisher
IV. 22.5 kg CO2Extinguisher
V. 75 kg DCPExtinguisher
8. Portable watermonitors

1
0
SAFETY EQUIPMENT:

1. BA sets
2. Airlinerespirations
3. Canisters withmasks
4. PVCaprons
5. Fire entrysuit
6. HC gastesters
7. H2S gastesters
8. COmonitor
9. O2monitor

Personal protective element:

It is equipment used to protect the person from hazards associated with
the work being performed. It acts as a barrier between the hazard and
the person exposed.

Types of PPE:
► Respiratory:
Canisters, Chemical
Air Supplied ----
cartridges Airline
respirators compressed Air
B.A. Set

Air purified ---- Surgical cotton mask, Dust

filter mask.

► Non-Respiratory:-

Head ---- HDPE helmets

protection
Ear protection ---- Ear plug, Ear Muffs
Eye protection ---- Panoramic view goggles
Hand ---- PVC hand gloves, Asbestos
protection gloves
Body ---- PVC Apron & Fire Entry Suit
protection
Leg protection ---- PVC gum boots, Industrial
safety shoes

1
0
GAS DETECTION SYSTEM

This system is designed to give early warning to the presence

and location of gas in order to one or more of the following:
Evacuation of
thepremises. Fire
fighting
Shutdown of
processplant. Control
ofventilation.

Gas detector types and their function:

1. Hydrocarbon gas detector: It is used for the detection of the

hydrocarbonsC1-C8 in the range of 0-100% of LEL. It is designed
for continuousoperation where speed of response and accuracy
as essential. It is powdered by 24VDC and provided 4-29mA
signal proportions to the gas concentration.

2. Hydrogen Sulfide (H2S) gas detector: It is used for detecting H 2S

in partsper million (ppm). Its mode of operation is part. Catalytic
and partsemiconductor and its sensitivity is 1 ppm H 2S inair.

H2 detector: The detector head uses the well-known SMRE (safety in

mines research establishment), thoriated palladium elements. These
elements when surrounded by a combustible mixture allow flameless
catalytic burning on their surface. The heat produced raises the
temperature and the electrical resistance of the active pellistor. The
resistance of this pellistor is compared in the wheat stone bridge
circuit to the resistance of the second reference pellistor. The
reference element provides automatic compensation for change in the
ambient temperature, humidity and pressure.

9
PROCESS FLOW
DIAGRAM OF
FCCU
 REACTOR AND REGENARTION SECTION

REACTOR OVER
HEAD VAPORS
DOUBLE TO MAIN
DISC REAGENARA ANTI COLUMN
SLIDE
VALVE TO R COKING
SECONDA CHAMBER REACT
TWO RY OR
CYCLON SECONDARY
PORT E CYCLONE
—>
SLID SEPERAT SEPERATOR
E OR PRIMARY
ORIFICE
VAL
CHAMBE PRIMARY CYCLONE SEPERATOR
VE CYCLON
R
E
SEPERAT
TOSTAC OR STEAM TO TEAM TO FEED
TORCH K ANTI- RISER
OIL ATOM COKING
NG 2”CATALY CHAMBER
STEAM ST
UNLOAD
6”CATALy NG
ST
LOADN
G
AIR GRID
2" CATALYST LOADING

CONTROL
AIR

S
SPENT CATALYST J-
T
BEND
E
SLIDE VALVE
REGENERATED A
CATALYST J-BEND SECONDARY
M CATALYS T STRPPN
SLIDE VALVE AIR G 5ECTION

TORCH OI R€SLU
TO RRY
REGEN STEAM
REGENERAT CAT
ES STAND
PIPE AIR EMERGENCY
STEAM FEED INJECTION
 CAT J-
BEND
NG STEAM COLD BLASTST
URIRR1 CREATION STEAM SPENT EAM
CREATION STEAM FEED FROM HEATER
RESLURRY CREATION STEAM
H
 FRACTIONATOR
WGC TOTAL SPILL
BACK
FROM INTERSTAGE
DRUM

VAPORSTOAIR

36 TOP REFLUX
FROMACCUMULATOR
RICH SPONGE OIL
2 SPONGE ABSORBER
7
VAPORS FROM LCO
2 STRIPPER
2 ,
5

PRESSUR LCO DRAWOFF

E TO
CHIMNEY
BALANCING TRAY- STRIPPER
LINE 2
LCO AS PUMP
AROUND
FRACTONAT
OR
5 HCOPUMPAROUN
D
SEIVETRAY-
4
HCODRAWOFFTO5TR|
CHIMNEY PPER
TRAY- HCO AS PUMP
1 AROUND
6
s

REACTOR DIS
OVERHEA C
D
VAPORS

RELIEFVALV
E
FEED DIVERSION SLURRY FROM
FROM HEATER STEAM
GENERATORASPUM
STRIPPING
STEAM

SLURRY TO
HEAT
EXCHANGERS
S