INPLANT TRAINING REPORT

BHARAT PETROLEUM CORPORATION LIMITED KOCHI REFINERY

SUBMITTED BY HEMALATHA MARDI P:504

ELECTRONICS AND COMMUNICATION ENGINEERING NIT CALICUT TENURE: 23RD MAY- 3RD JUNE

AKNOWLEDGEMENT

Firstly I would like to thank god almighty for giving me this opportunity. I express my sincere gratitude to Mr Sabu Jose and Mr Ramesh K. for their invaluable assistance and support.

I would like to thank Mr Anish P.V, Mr Rajeev M.C, Mr Raveendran Pillai, Mr Jacob C.V, and Mr Prathish K Babu for their time and effort.

I also appreciate the effort and risk BPCL KR has taken in including us in the daily busy schedule of its working hours.

I whole heartedly thank all the engineers and technicians who regardless of their busy routine have found enough time to educate us and exposing ourselves in the real working of an industry. BPCL KR has done a great role in integrating our theoretical knowledge with work experience.

INDEX

Company profile Introduction Process description CDU I CDU II FCCU DHDS Analyzers Control systems HART management systems TFMC Truck loading unit Wagon loading Conclusion

COMPANY PROFILE
Kochi Refinery was incorporated as a public limited company in September 1963, with technical collaboration and financial participation from Phillips petroleum company, USA. The refinery was commissioned on 23rd September 1966, with a crude processing capacity of 2.5 MMTPA .In addition to the crude distillation unit (presently CDU1), the units commissioned initially included a Vacuum Distillation, Visbreaker, Bitumen, Naphtha and Kerosene Hydro de-Sulfurisation and reformer units .Many new process units were added including secondary processing facilities, Aromatics Recovery and Diesel De-Sulfurisation units. Many of the processing units and associated facilities have undergone several modifications, including expansion and modernization projects.

The capacity was first expanded from 2.5 to 3.0 MMTPA in September 1973.The production of liquefied petroleum gas(LPG) and aviation turbine fuel (ATF) were commenced after this expansion. Bombay high crude was first processed in CDU1 in 1975.

Crude processing capacity of KR was further enhanced to 4.5 MMTPA by revamping the crude unit in 1984, along with the addition of secondary processing facilities including a 1.0 MMTPA Fluid catalytic cracking unit (FCCU).Installation of the FCC unit was necessitated due to the everincreasing price of crude oil and increased demand for middle distillates and lighter products. The FCC unit facilitates conversion of heavier hydrocarbon streams with lower demand to high value products like LPG, Gasoline and Diesel.

The crude processing capacity of the refinery was further increased to 7.5 MMTPA in the year 1994 with the addition of a new 3.0 MMTPA Crude Distillation Unit (CDU-2). The FCC Unit capacity was also increased to 1.4 MMTPA along with this, to match the crude capacity. A Vacuum Distillation Unit (VDU-2), Naphtha Stabiliser, Sour Water stripping unit and LPG treatment facilities were also included as a part of the installation of CDU-2. Subsequently a Sulphur Recovery Unit (SRU) for desulfurisation of refinery fuel gas was commissioned in 1995 as a part of the capacity expansion project. All the process units of the refinery are currently monitored and controlled using state-of-the-art Distributed Control System (DCS), with associated instrumentation and other facilities. The earlier Pneumatic control system used in some of the process units and utilities were changed over to DCS in stages. DCS was first commissioned in CDU1 block in November 1988 by changing over from pneumatic system. Older DCSs of CDU-1 and FCCU blocks and ARU along with CPP-1 were upgraded in June 2001.A plant wide network connecting DCSs of all the process units and other areas of the refinery, was commissioned along with the up gradation. A real time database system for storage, distribution and displaying of process data and other information was also commissioned with this .

Raw Material Linkages Indigenous Crude

BH Crude

LS Crude
Labuan- Malaysia Bonny light - Nigeria

Marib Light Yemen

MS Crude
Masila Yemen Murban UAE Essider- Libya

HS Crudes
Arab Mix- Saudi Iran Mix- Iran Dubai- UAE

Important Milestones in Growth:

Formed in joint sector with the financial & technical participation between Phillips Petroleum Company, USA and Duncan Brothers, Calcutta. Construction completed in 29months at a cost of Rs. 27 crores Commissioned on September 23, 1966 as a 2.5 MMTPA refinery. Crude oil refining capacity expanded to : o 2.5 MMTPA to 3.3 MMTPA in 1973 o 3.3 MMTPA to 4.5 MMTPA in 1984 o 4.5 MMTPA to 7.5 MMTPA in 1994 Installation of secondary processing facilities (1MMTPA FCCU) in 1984. Capacity augmented to 1.4 in 1994 & 1.75 with oxygen plant facility in 2005.

INTRODUCTION

Instrumentation Engineering has found major application in all sectors of the plant with it playing a vital role in optimization of labour, resource and time. The advent of electronic hardware, that replaced mechanical hardware, has led to greater accuracy, reduced response times and lesser maintenance. This in turn has augmented margins because of reduced cost of production and better product quality with very little production and quality analytic delay.

The purpose of the industrial visit was to acquaint the apprentice with all the major manifestations of instrumentation engineering on the premises of the refinery. I met Mr Sabu Jose who briefly described the role of the instrumentation engineering in the field of refinery. Then I was asked to report to Mr Ramesh K, who scheduled our tenure at the refinery for the remaining 10days at the refinery. He assigned us to different people for the allotted time slot, as per their expertise in the refinery, to augment our understanding of concepts imbibed within the confines of the classroom. We visited the following places: Captive power plant (control room) CDU I Stack and blending analyzers TFMC and offset

However I realised that two weeks would not suffice to see entire plant in detail, let alone indulge in its intricacies. As such I have attempted to put my best foot forward and tried to garner as much knowledge and experience from our guides and instructors. This is a brief report of what I learnt over the course of the two week I was here at the refinery.

PROCESS DESCRIPTION

CDU I 4.5 MMTPA DHDS

2.54 MMTPA

FCCU 1.75 MMTPA 23 PRODUCTS

CRUDE OIL TANK

CDU II 3 MMTPA

REFORMATE FROM CDU I

ARU

CDU- crude distillation unit FCCU- fluid catalytic cracking unit ARU- aromatic recovery unit DHDS- diesel hydro desulphurisation unit

CDU-1 BLOCK

CDU-1 consists of crude distillation unit, LPG recover unit, Naphtha splitter unit (NSU), Naphtha Hydro desulphurization unit (NHDS), Reform unit, kerosene hydro desulphurization unit (KHDS), visbreaker unit.

I.

Crude Distillation Unit (CDU-1)

In this unit, the crude oil is fractionated in to various wide bottling range steams such as naphtha, kerosene, diesel etc. Crude from storage tanks is pumped to the unit, passed through a preheat train, sent to a pair of desalters. The desalted crude is sent through another preheat train and fed to prefractionators column in which light naphtha (LN) is separated as the overhead stream. The LN contains LPG, which is recovered in the LPG, which is recovered in the LPG recovery unit. The flashed crude from the bottom of the prefractionators is pumped through another preheat train, heated on charge heaters, fed to the main crude fractionators .The distilled products are drawn from different sections. Heavy naphtha, kerosene1, kerosene2 and diesel base are the side products drawn from the column .The remaining crude (Reduced Crude Oil RCO) from column bottom is routed to FPU in FCCU.

II.

LPG Recovery Unit Naphtha is stabilized by recovering the LPG components in this unit. LN from the pre-fractionators column is fed to the stabilizer column, after pre-heating. LPG is recovered as the overhead product and is sent to the stabilizer column after preheating. Stabilized naphtha form the column bottom is sent to storage tanks or naphtha splitter.

III.

Naphtha splitter unit (NSU) The main function of the NSU is to produce 60-90 cut naphtha from the full range naphtha from mainly the BH crude. Splitter splits it into two with C5-C60 as top products and C60C140 as the bottom products. Splitter II further splits this into three sections C60C90, C90- C110, C110 -C140

IV.

Naphtha hydro-desulphurization plant (NHDS) Sulphur is a temporary poison for the reformer catalyst. Apart from the C60C90 cut naphtha also contains metals such as lead, arsenic etc. sulphur and such metals are removed in the NHDS. In the presence of catalyst (cobalt-molybdenum), hydrogen at sufficiently high

temperature, converts sulphur compounds into H2S, which can be easily removed from the system.

V.

Reformer unit The reformer unit was originally designed to boost the octane number of straight run naphtha to be sold as gasoline. The main function of the reformer unit is to produce benzene & other aromatic products from the C60C90 cut of desulphurized naphtha. Toluene is another major constituent of the reformate. Hydrogen formed is separated and recycled in the reactors. The main chemical reactions within this unit are: o o o o Dehydrogenation of naphtha into aromatics Isomerization of paraffin and naphthenes Dehydro-cyclisation of paraffin into aromatics Hydro cracking

Reformer unit is semi regenerative unit.

VI.

Kerosene hydro desulphurization unit The unit produces aviation turbine fuel (ATF) or jet fuel (JP5). This unit is also used for producing mineral turpentine oil (MTO) desulphurization of kerosene2 stream from CD for blending in diesel pool is another function of the KHDS unit.

VII.

Visbreaker unit Vacuum residue obtained from imported crude in the FPU has high viscosity. The visbreaker unit is used specifically to reduce this viscosity. Visbreaker, basically is a thermal cracking process wherein long chain hydrocarbon molecules in heavy feed stock are broken into smaller molecules having lower viscosity, thereby leading to a reduction in the velocity. This results in conserving valuable distillate products.

There are two alternate products for visbreaking: o Coil visbreaking- feed stock is cracked at high temperature (480500OC) in a furnace with sorter residence times to achieve this conversion. o Soaker technology- the feed stock is heated to relatively lower temperature (440-460 OC) and holding the charge in a soaker drum for larger residence times (20-25min) to achieve the required conversion.

CDU II BLOCK

Crude from storage is preheated, mixed with stripped water desalted again preheated and split into two for preheating. Its finally heated and flashed into the atmospheric column Atmospheric column overhead vapours pass through accumulator and overhead steam is sent to naphtha stabilizer, HGO, LGO, kerosene, HN are withdrawn with side streams. HN is routed to gas oil stream, kerosene to storage after stream stripping; gas oil steam is also routed to storage RCO from crude column bottom is sent to VDU. Cooling and condensation of vapours is then performed.

I.

Naphtha stabilizer: In this unstabilized naphtha is sent to CDU or to LAN/HAN storage. Naphtha caustic wash: It removes H2S and mercaptan from stabilized naphtha. It is done by separating hydrocarbons and cautic phases from a mixture of naphtha and caustics. LPG amine treatment unit: It was designed to remove H2S from LPG. This is done passing feed through amine absorption column and then processing in a regenerating boiler. LPG from absorption column is sent to wash drum, then to storage through a sand filter. Vacuum distillation unit (VDU): In this unit VGO feed from FCCU is produced, hot RCO is heated, fed to fractionating column. Slope oil is collected in hot well, vacuum diesel along with CDUs gas oil is sent to combined diesel pool. VGO obtained is stored in VGO storage of the FCCU. Slope distillation is partly recycle rest is routes with VR which is routed to LSHS storage.

II.

III.

IV.

V.

Sulphur recovery unit (LOCAT SRU): It removes H2S from refinery fuel gas by converting it into elemental sulphur. LOCAT is an oxidation process. Unit is an oxidation process. Unit can process fuel gas from HP & LP source. Amine absorption unit (AAU): It was installed as an alternative to LOCAT SUR. Centralized facility for regeneration for DEA in the DHDS block is made use of H2S is absorbed which is sent to DHDS amine unit. Aromatic refinery unit (ARU): Aromatic viz. benzene & toluene are extracted from reformate using salfolane as solvent. Utility system for the supply of plant air, instrument air, cooling air is a part of ARU.

VI.

VII.

FLUIDIZED CATALYSED CRACKING UNIT (FCCU)

The FCCU was commissioned in 1985. It converts the atmospheric residue from CDU I into additional middle distillates, motor spirit and LPG. There are many process units under FCCU. A substantial portion of the atmospheric residue (RCO) which varies from 30 to 45% of the crude throughout depending on the type of crude, was converted to FO by visbreaking or yielded as low sulphur heavy stock during earlier periods.

Feed to the unit is the VGO (Vacuum gas oil) generated from FPU (feed preparation unit) and vacuum distillation unit in CDU II.The functionality of the FCCU can be divided into:

1. Feed preparation unit (FPU) The purpose of the feed preparation unit is to make feed of required quality to be processed in FCCU. In this unit, RCO is distilled under vacuum into four different units mainly vacuum diesel oil (VDO),Light Vacuum gas oil (LPGO), Heavy vacuum gas oil (HVGO) & Vacuum residue (VR). 2. Bitumen unit In this unit, bitumen is produced from VR from vacuum column during asphalt bearing crude run. Normally VR from BH run is not used for bitumen make due to its low asphaltene content. VR from FPU is cooled to around 220oC and charged to which air from an air compressor is supplied through a distributer. 3. Fluidized catalytic cracking unit (FCCU) FCCU converts VGO in to higher value products such as LPG, Gasoline and diesel by cracking of heavier hydrocarbon molecules of VGO to lighter components. Silica-alumina catalyst in powder is used for promoting the cracking reactions. The reaction takes place at a high temperature and at a pressure above atmospheric pressure. 4. Gas concentration unit (GCU) In the GCU, LPG is recovered from both the overhead gas an liquid streams and in the process, gasoline is stabilized. The unit consists of a primary absorber and a sponge absorber for recovering LPG from fuel gas, a stripper for removing H2S from the liquid stream to fuel gas, and a debutanizer for separating LPG and gasoline. Sponge absorber uses LCO circulating reflux stream as the absorption medium. Fuel gas is routed to the refinery fuel gas system after removing H2S.

DIESEL HYDRO-DESULPHURIZATION PLANT (DHDS)

Diesel is currently, the most highly consumed petroleum product in India. Sulphur in diesel results in SO2 and other particulate matter that pollute the atmosphere. DHDS remedies this and it consists of:

I.

Hydrogen generation unit: The HGU is designed to produce hydrogen of 99.99% purity. Hydrogen is produced from naphtha using steam reforming. Naphtha having a sulphur content of 1000ppm is desulphurized in a pre-desulphurization section is to reduce the sulphur level in the feedstock. This is achieved by the reaction of sulphur compounds in naphtha with hydrogen in a catalytic reactor. Diesel hydro desulphurization unit: The DHDS unit is designed to desulphurize diesel/VGO in blocked out mode operation. It is designed to reduce the sulphur content of diesel blend stock. Sulphur recovery unit: The SRU converts and separates H2S contained in the sour gas and acid gas streams from sour water stripping unit and amine regeneration unit in the form of elemental solid sulphur. Amine regeneration unit: Di ethanol amine is the primary feed to this unit, which rich in H2S. Sour stripping unit: The main function of the sour water stripping unit is to treat sour water generation unit is to treat sour water generated from the DHDS/ hydrogen unit.

II.

III.

IV.

V.

ANALYZER

The industry standards today demand very high standards both for the sake of high quality products and for environmental safety. Analyzer is that component of the refinery that achieves this. An analyzer is a device that performs chemical analysis on samples or sample streams. Its purpose of commission is to ensure the quality of end products. It reduces the inadequacies in quality control methods prevalent in earlier industrial practices which cause heavy delay in the delivery of products and losses due to sub standard quality. The BPCL refinery relies mainly on online analyzer. The main characteristics of an online analyzer are: 1. Continuous operation for long periods with minimal skilled attention and maintenance. 2. It must withstand the hostile environment in which the product is formed/treated. 3. It should not pose a threat to the safety to the chemical process. 4. It must have very efficient sampling system.

NIR analyzer NIR analyzers are used for measuring properties of MS & HSD work on the same principle. PROSPEC III is the model used. A representative sample from the blend header is taken and introduced to the flow cell of the analyzer. Near the infrared rays of wavelength 800nm-1700nm are transmitted through the sample to obtain the absorption spectrum. The monochrometer consists of the lamp assembly, the filter wheel assembly and the grating wheel assembly. White light from a Tungsten-halogen bulb travels through the lenses, through the slit, through a fibre wheel and is incident upon holographic diffraction grating. The filter wheel houses several filters that are used for wavelength calibration. The concave holographic diffraction grating has equally spaced lines per mm on its surface and dispenses the light into continuum of wavelengths.

Oxygen analyzer 1. Paramagnetic oxygen analyzer: It consist of a thin pipe called bypass pipe at the center, a heating resistance wire is wound around it. There is a tap in the center which is a Wheatstone bridge together with fixed resistors R1 & R2. Also strong magnetic field is provided to the left half by means of a permanent magnet. Thus if a measuring gas which is on the left side of the bypass pipe contains O2 molecules which are highly paramagnetic are sucked into the central part of the magnet which has the largest field strength and it flows from left to right in the bypass pipe. However, O2 molecules which have reached the center of the magnetic field are heated by the resistance wire. Thus their paramagnetism is reduced and their proclivity to being sucked into the magnetic field is reduced. Therefore they are gradually pushed to the right from the gas flowing in from the left. The strength of this magnetic wind is proportional to the O2 content. The magnetic wind cools down in both the halves at different rates. The difference is directly proportional to the O2 content and is measured using the electric bridge circuit. 2. Zirconia probe oxygen analyzer: Zirconia sensor works on the principle of Nernst equation which states that the voltage developed across the zirconia cell is E=0.0496T log10 [P1 (O2)/P2 (O2)] Where, E= sensor output (V) T=absolute temperature (K) P1 (O2)=ref partial pressure P2 (O2) =sample gas partial pressure From this it is clear that as O2 concentration in the sample gas decreases the emf developed in the sensor increases.

CONTROL SYSTEMS

I.

Programmable logic controller (PLC) A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in batterybacked or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result Programmable logic controllers are microcomputers developed to handle Boolean operations. A PLC produces ON/OFF voltage output and can actuate elements such as electric motors, solenoids, fans etc. The basic operation of a PLC can also execute operations such as counting, delays and timers. PLC initiates relay actions through software Features: The main difference from other computers is that the PLCs are armoured for several conditions (such as dust, moisture, heat, cold) and have the facility for extensive input/output (I/O) arrangements. These connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. Some use machine vision. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays, solenoids or analog outputs.

The input/output arrangements may be built into a simple PLC, or the PLC may have external i/o modules attached to a computer network that plugs into the PLC. System scale: A small PLC will have a fixed number of connections built in for inputs and outputs. Typically, expansions are available if the base model has insufficient I/O. Modular PLCs have a chassis(also called a rack) into which are placed modules with different functions. The processor and selection of I/O modules is customized for the particular application. Several racks can be administered by a single processor, and may have thousands of inputs and outputs. A special high speed serial I/O link is used so that racks can be distributed away from the processor, reducing the wiring costs for large plants. User interface: PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday control. A human machine interface (HMI) is employed for this purpose. HMIs are also referred to as MMIs (man machine interface) and GUIs (graphical user interface). A simple system may use buttons and lights to interact with the user. Text displays are available as well as graphical touch screens. More complex systems use programming and monitoring software installed on a computer, with the PLC connected via a communication interface. Communications: PLCs have built in communication ports, usually 9-pin RS-232, but optionally EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually included as one of the communication protocols. Other options include various field buses such as DeviceNet or Profibus. Other communications protocols that may be used are listed in the list of automation protocols.

Most modern PLCs can communicate over a network to some other system, such as a computer running a SCADA (supervisory control and data acquisition) system or web browser. PLCs used in larger I/O systems may have pet-to-peer (P2P) communication between processors. This allows separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the communication link. These communications links are also often used for HMI devices such as keypads or PC-type workstations. Programming: PLC programs are typically written in a special application on a personal computer, and then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in batterybacked-up RAM or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard, PLCs can be programmed using standard-based programming languages. A graphical programming notation called sequential function charts is available on certain programmable controllers. Initially most PLCs utilized ladder logic diagram programming, a model which emulated electromechanical control panel devices (such as the contact and coils of relays) which PLCs replaced. This model remains common today. While the fundamental concepts of PLC programming are common to all manufacturers, differences in I/O addressing, memory organization and instruction sets mean that PLC programs are never perfectly interchangeable between different markers. Even within the same product line of a single manufacturer, different models may not be directly compatible.

II.

Distributed control systems (DCS) It refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. DCS is a microprocessor/computer based digital system used for basic control of various process parameters like flow, pressure, level, temperature etc. the system gathers process data from various sensors in the field, operate on these data such as a scale compare, calculate etc. as per preconfigured algorithms and send signals back to final control elements in field for achieving process control.

HART MANAGEMENT SYSTEMS

HART is an acronym for highway addressable remote transducer. The HART protocol makes use of the Bell 202 frequency shift key (FSK) standard to superimpose digital signals at a low level on top of the 4-20 mA. This enables two way communications to take place and makes it possible for additional information beyond just the normal process variable to be communicated to/from a smart field instrument. The HART protocol communicates without interrupting the 4-20mA signal and allows a host application (master) to get two or more digital updates per second from a field device. HART has been adopted by most of the major manufacturers of process control field equipment. It is an open standard that is administered by the HART communications foundation. As the digital FSK signal is phase continuous, there is no interference with the 4-20mA signal. The relative simplicity of the HART protocol makes it easy for both end users and suppliers to gain experience and benefits from the enhanced two-way communication capability of smart field instruments using this technology. The digital signal is made up of two frequencies 1200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sine waves of these two frequencies are superimposed on the direct current (dc) analog signal cables to provide simultaneous analog and digital communications. HART devices can operate in one of two network configurations Point to point Multidrop Point to point In point-to-point mode, the traditional 4-20mA signal is used to communicate one process variable, while additional process variables, configuration parameters, and other device data are transferred digitally using the HART protocol. The 4-20mA analog signal is not affected by the HART signal and can be used for control in the normal way. The HART communication digital signal gives access to secondary variables ad other data that can be used for operations, commissioning, maintenance and diagnostic purposes.

Multidrop The multidrop mode of operation requires only a single pair of wires and if applicable, safety barriers and an auxiliary power supply for upto 15 field devices. All process values are transmitted digitally. In multidrop mode, all field device polling addresses are >0, and the current through each device is fixed to a minimum value (typically 4mA).

TANK FARM MANAGEMENT CENTRE (TFMC)

The major equipments consist of storage tanks, LPG spheres, pumps, pipelines, automatic and manual valves and blending systems. Instrumentation system includes: Tank gauging systems For monitoring level temperature and water level of products in tanks. Tank gauging systems are provided by 3companies. The Honeywell ENRAF (radar and servo types), Emerson SAAB (radar type) and SBEM (servo and mechanical types). The radar systems use a 10GHz signal. This signal will be transmitted into the tank and gets reflected back from the top level. The time difference will give the current level. In the servo type a dispenser is used. The weight of the dispenser, according to the Archimedes principle, will give a measure of the level of the tank. Blending instrumentation which includes flow meters using orifice plate sensors, differential pressure transmitters, coriolis mass flow meter, pressure transmitters and control valves with I/P converter and blending analyser. LPG sphere safety system utilizing thermal fuses, pressure switches, solenoid valves etc. Gas monitoring system, LPG sphere deluge valve/sprinkler control panel etc. Major control systems in TFMC control room are: Foxboro (Invesys) DCS It integrates the tank gauging systems, blending systems etc. GE- Fanuc PLCFor achieving safety interlocks. Console interlocks switchesTo trip the sphere interlocks manually. Console bypass switchesFor the purpose of checking and calibration of level instruments. Console hardware annunciator-

Digital indicators such as ROP positions, safety circuit pressure low, sphere level high is provided with hardware annunciation with hooter in addition to the DCS indicator. ENRAF/ENTIS ATG system terminalfor maintenance and operational functions. Also for gauge operations such as rising and lowering displacers, checking alarms, configuring of ATGs etc. SBEM ATG system terminal ENRAF/ENTIS ATG system terminal Gas monitoring systemsFor detecting gas leaks. There are three systems used in KRL: o Detection instruments systems-installed at pump house area and truck loading area o Dil udyog system-installed at LPG spheres, benzene/toluene area o Pentax system-installed at all other areas controlled by TFMC It monitors sphere safety and controls the actuation of deluge valves.

TRUCK LOADING UNIT

All the petroleum products produced from BPCL Kochi refinery are distributed via truck loading units. The petroleum products are classified as white oil and black oil. These products include LPG, diesel, motor spirit, LSFO, HSD etc. the truck loading unit is divided into two areas with gantry in each area. In one area all white oil are handled and it is known as white oil loading area, whereas in the second area all the black oils are handled and it is known as black oil loading area. There are 12bays at white oil loading area. Each bay has a platform with 3loading arms. In some cases only 2loading arms are provided. Black oil loading area consists of 8bays. Each bay is provided with one or two loading arms. Each loading arm is provided with a mass flow meter, digital control valve (DCV) and local controller. Each bay is provided with a card reader. Control valves are provided for controlling flow and they are operated through batch controller. All lines are provided with strainers and deaeraters to remove foreign materials and air or gas residue. Batch controllers are locally located in the gantry and have display and keyboard for user interphase. Each batch controller gets flow data from mass flow meter, temperature data from RTD and truck earthing status from earthing relay. DCV is controlled by batch controller through two solenoid valves (one NO and one NC). Mass flow meter is connected to pressure transmitter which gives pressure reading for mass flow meter pressure compensation. As mentioned above, each bay is provided with a card reader. When the card issued to truck driver from the control room is shown to the correct bay, the data from the control room will be downloaded to the batch controller to start the loading. During and after loading the field operation like flow, temperature, total quantity loaded etc will be sent back to the control room for report generation and billing purpose.

LPG bottling plant: It has a capacity of 9800 cylinders per shift. The plant is designed for producing 14.2 kg domestic LPG cylinders and 19kg industrial LPG cylinders with center valves. This is one of the busiest and most profitable stations in the facility. There are four sections in the bottling plant filling

section, hot air sealing section, evacuation section and evacuation & purging section.

Truck loading computer system Entire operation is controlled by a computer system in the control room and a microprocessor based batch controller in field. The control room provides the following: Indication of all parameters Status of all loading points Stopping of loading Alarm displays and annunciation Graphic displays and indications Logging and reporting Self-diagnostic measurements Configuration displays

WAGON LOADING

31% of refinery products are moving by rail. Products such as MS, diesel, super kerosene, ATF and FO are being carried from the refinery to different parts of India. There are two gantry namely gantry-1 and gantry-2. Gantry I o Includes track I and track II o Loads only black and white oils o Track I can place conventional wagon o Track II only BTPN (boggy type pneumatic wagon) Gantry II o Includes track III and track IV o Loads only ATF o Track III only BTPN wagons o Track IV conventional wagons BTPN can place only 25wagons whereas conventional wagon places 38wagons.

Empty wagons are supplied by railway from irimpanam yard from which products to be dispatched to different parts of India is decided by the PDP (product dispatch planning). Then these empty wagons are placed in the KRL gantry and are being loaded with various products according to the demand of the oil companies like BPCL, IOCL and HPCL.

CONCLUSION

An overall brief study of the functioning of the various units of the BPCL Kochi Refinery was carried out. The ease in successful execution of analysis, control and error correction with the advent of electronic hardware and competent software over the erstwhile mechanical hardware, was demonstrated to us by our guides.

The tenure, though very short, helped us realize the implications of real time analysis and apt responses to various issues that arise in the various stages of the functioning of the plant. It is only through such an exposure, that we realize the significance of accuracy in measuring and controlling a parameter and the magnitude of the aftereffects of minor deviations.

The flaws within the prevalent system of education were accentuated by the training, which is dogmatic in nature and rendering is ill-equipped to solve problems, thus serving little purpose in the world extraneous to the college.