TATIPAKA REFINERY

ONGC, RAJAHMUNDRY ASSET

BY
K.GIRIDHAR RAO
I/C. TATIPAKA REFINERY

INTRODUCTION
Tatipaka mini refinery is the first step towards downstream business
taken by ONGC in the line with its vision to become an integrated Energy
Major. This is to utilize the marginal fields discovered by ONGC major. Tatipaka
refinery located at Tatipaka, East Godavari District, Andhra Pradesh, is the first
re-locatable skid mounted refinery in Asia commissioned on 3 rd of September
2001.
Before the existence of the refinery, the crude and condensate of
Rajahmundry asset was transported to HPCL refinery at Vishakhapatnam. Any
interruption in transportation of crude/condensate affected production of gas
from the wells and subsequently the consumers of the gas. After HPCL fire
accident in 1995-96, the crude supply had to be discontinued for safety
reasons and there was no alternative at the time except to transport the crude
oil all the way to Narimanam refinery in Pondicherry 1200km from
Rajahmundry.
Soon the need for refinery was felt to ensure smooth and uninterrupted
production from the wells. Other advantages of Tatipaka refinery:

Avoid huge crude handling charges, wharfage at loading & unloading

points, Insurance, transit loss and to cairn energy.
One of the four value added products, HSD is utilized for meeting the
requirement of the drilling rigs and installations of Rajahmundry asset,
Cauvery asset. Also HFHSD is produced specially to meet offshore
stipulated requirements and is supplied through Kakinada offshore base.
Huge energy saving for the country on account of saving on transportation
of crude to Narimanam.
Minimize safety hazards in long distance transportation of crude oil.
The value added product meets the needs of local customers.

Salient features:

Project cost: Rs 26 cr.

Refinery capacity normal: 1500bpd (max: 2000bpd).
Basic engineering and design: IOGPT Mumbai.
Product yield:
Naphtha : 35%
SKO
: 13%
HSD: 28%
RCO
: 24%
Tatipaka Mini Refinery is Asias first skid mounted re-locatable mini refinery.
The process control is done by a highly automated and sophisticated system of
DCS (Distributed Control System) - CS1000 which has been provided by
Yokagawa.

PROCESS DESCRIPTION
CRUDE AND CONDENSATE STORAGE
Crude received from nearby fields is stored in SR1 crude storage tank.
Condensate received from Tatipaka GCS and other installations is stored in
SR2A and SR2B condensate storage tanks. Crude and condensate are blended
in the ratio of 75:25 and fed to the first stage preheating by Crude feed pumps
P-101 A/B at a discharge pressure of 10 kg/cm.
FIRST STAGE PREHEATING

Crude is preheated by kerosene heat exchanger, RCO heat exchanger

and diesel heat exchanger namely E-101, E-102, E-103 A/B.
In E-101 the heating medium is kerosene product at 165C which is
coming out from kerosene stripper and crude is heated from 35C up to
72C.
Similarly, In E-102 the heating medium is RCO at 210C coming out of E106 and crude is further heated up to 108C.
Finally, In E-103 the heating medium is HSD at 240C coming out of
secondary diesel heat exchanger E-105 and crude is further heated up to
135C.

DESALTER

The desalter is a process vessel that removes salt from the crude by
dissolving the salts in the wash water and then removing the brine water
(water with dissolved salt) from the crude. Water is added to crude
before entering desatler and mixed properly by a mixing valve. As a
result, the temperature of crude reduces from 135C to 125C.
Desatler operates at temperature of 125C at a pressure of 14.7 kg/cm
A.
De-emulsifying chemicals are also added at this stage to break down
emulsion in crude.
A high emf of 22 KV is applied in the desalter to provide the electrostatic
field. which will separate water by gravity.
Part of the salts in crude oil, particularly MgCl, is hydrolysable at
temperature of 120C. Upon hydrolysis, chloride gets converted into HCL
which will find its way to distillation columns. This will corrode the
overhead condensers. Hence the desalter is essential in the refining
operation.
Desalter reduces the salt content of the crude to 0.5ppb max (at the
outlet) from 50ppb at the inlet resulting in above 90% removal. The
Basic Sediments and Water content (BS&W) is 0.2% w/w.

CRUDE PREHEATING SECOND STAGE

Desalted crude coming from desalter passes through E-104 A/B

(crude/kerosene CR heat exchanger) is heated up to 165C by kerosene
circulation reflux from 22nd tray of atmospheric crude column.
After passing through E-104 A/B, Crude passes through crude-diesel CR
heat exchanger E-105 A/B where crude is further heated up to 185C by
diesel circulation which is taken from 35 th tray of atmospheric crude
column.
Then crude is again heated up to 215 C by hot RCO product coming
from atmospheric column bottom in Crude-hot RCO exchanger E-106.

CRUDE FURNACE
The Crude Furnace is a vertical cylindrical Heater with Radiant and
Convection sections. It is designed for an absorbed Heat Duty of 1.91MMKcal/
Hr for the Crude service and 0.0046 MM K cal / Hr for Steam Super Heater
service. Crude Feed enters the top of the Convection Section at 211 0C. After
getting heated with the Flue Gases, passes into Radiant Section where it is
further heated up to 350 0C.
Radiant Section has 28 Nos. of 4 dia. Sch. 40, ASTM-A-335 Gr. P5 bare
tubes, which are arranged vertically in a single pass, with a total Radiant Heat
transfer area of 55.52 m2. There are 12 Nos. of 3 dia., Sch. 40, ASTM-A-335
Gr. P5 bare tubes in 3 rows and 20 Nos. Finned Tubes in 4 rows, 3 dia., Sch.
40, ASTM-A-335 Grade P5. A single row of 11/2 dia. Sch. 80, ASTM - a 106,
gr. B bare tubes for Steam Super Heating were also provided over the top of
the Crude Feed coils.
The furnace is equipped with 3 Low NOX Natural Draft Gas burners with
Pilots having ignition facility for heating. Burners are located at the furnace
floor. Fuel gas with a heating value of 9200 Kcal/kg enters the burners at a
pressure of 0.5 kg/cm g. An excess 20% of combustion air is taken from the
Natural Draft burners. Flue gas at a temperature of 350C escapes to the
atmosphere through furnace stack. Stack is provided with a Damper control,
and is actuated manually by winch and cable system from grade level. Furnace
Fire Box is provided with Snuffing steam connections for the Radiant Section
and Convection Section for snuffing out the combustibles.
Along with crude/condensate mixture feed, de-mineralized water from
the boilers in the form of saturated steam is also superheated in the furnace
for routing it to the crude column and also the strippers.

ATMOSPHERIC CRUDE COLUMN

The atmospheric crude column is the unit wherein, by heat transfer and
mass transfer (distillation) operations, fractionates present in the crude oil are
extracted. It is equipped with 49Nos, SS 410 valve type trays and shell
internals. Top section is cladded with Monel up to 4th tray.
The column is having an ID of 1067 mm X 34309 mm T/T. It is designed
for 4 Kg/cm2 A at 1750C (top section), 350C (mid section), 400C (bottom
section). The crude column operates at near atmospheric pressure (0.8
kg/cm) and fractionates the crude oil into Naphtha, Superior Kerosene Oil
(kerosene), High Speed Diesel (diesel) and Low Sulphur Heavy Stock products.
This column is provided with 49 trays. Partially vaporized crude (15% liquid, 85
% vapour) from the furnace enters the column on tray number 44. The region
between 43rd and 44th tray is flashing zone. The significance of flashing zone is
that it is the zone (of length 2.5m) wherein the partially vaporized (85% vapor
and 15% liquid) crude feed (entering the column at pressure of 2.5kg/cm 2) by
difference in pressure of column (0.8kg/cm 2) separates into vapor and liquid
components. The liquid component drops down (as L.S.H.S) 6 trays onto tray
#49. The vaporized component moves upward to tray#1. Super heated steam
at 6 Kg/cm2is used for the stripping steam. Steam Stripping is done to remove
lighter constituents from the Reduced Crude.
The vapors are allowed to move out from the top portion of the column
to overhead condensers. Here the vapor gets condensed into light naphtha
(containing lighter hydro-carbons i.e. derivatives of propane group and butyl
group) and is fully taken back as reflux to the crude column. With the use of
naphtha reflux, the subsequent refluxes-diesel (as circulating reflux) are
extracted (using centrifugal pump). After the required quantities of refluxes
(naphtha, kerosene & diesel) are achieved, the vapors are allowed to exchange
heat as well as transfer MASS with the suitable.
Coming to the tray design, the trays used in the column are valve trays
(known as Tweetle trays). The upper extended surface of the tray is known as
Weir. The lower extended surface of the tray is the Downcomer. The inter
tray distance are approximately 0.7m (except flashing zone trays). The trays
are so designed that the level of weir of one tray lies higher than that of the
preceding trays downcomer, in order to restrict the super heated steam flow
through the gap between the weir and downcomer of the tray and the column
wall, by creating liquid seal which, otherwise, would hamper the vapor-liquid
contact time in the preceding tray thereby reducing the intended heat and
mass transfer efficiency and subsequent distillation. The maximum pressure
drop per tray is 6 mm of Hg. The design load is 75 of the load corresponding to
flooding.

Coming back to the distillation part, after the necessary reflux

requirements are met, the distillation process starts, at the respective
trays(where reflux enters), by virtue of contact between the vapor and the
respective reflux, there occurs heat and mass transfer. The reflux being at
lower temperature than the respective vapor, condensation of vapor occurs.
The condensed liquid level starts rising on the respective tray and thereby
flooding occurs and liquid pours on the trays below.
Nozzles are designed for drawing out the respective products. The
nozzles are connected to flow and pressure control valves. After achieving the
requisite liquid quantity (level), the nozzle connected to respective stripper is
activated and thereby liquid draw occur (heavy naphtha tray#11, kerosene
tray#22 and diesel tray#35). Heavy naphtha tray is maintained at 108-111C,
kerosene draw 178-181C, diesel draw 265-271C, bottoms 325-344C,
atmospheric column top 108-111C.
SIDE STRIPPERS
Stripper columns are used to remove Low boiling point or gaseous
components from a liquid stream. The principle of operation is based on
Avagadros Principle and Daltons Law of Partial Pressures. Daltons Law states
that the pressure exerted by a mixture of gases is equal to the sum of the
separate pressures, which each gas would exert if it alone occupied the
volume. Avagadros Principle states that equal volume of gas at the same
condition of temperature and pressure will contain the same number of
molecules regardless of type or weight.
This partial pressure effect is used in striping out light hydrocarbons from
the side stream of the fractionating columns. Strippers are also used to remove
gases like Oxygen, Nitrogen or H2S from liquid streams.
The strippers are basically packed towers with structured packing. The side
streams Heavy Naphtha, SKO, and HSD taken from the column are fed into the
side strippers at the top through a liquid distributor. Superheated steam enters
the stripper from the bottom through a vapour distributor. The overhead
vapours are taken back to the atmospheric crude column and the bottom
products are taken to the product coolers. The maximum pressure drop across
the packing is 0.45 inch of H2O per ft. of packing. The tower operates at a load
corresponding to 75% flooding.
CIRCULATING REFLUXES
In order to maximize the heat recovery and balance the tower loading,
heat is removed by way of circulating refluxes from kerosene and diesel
sections. Refluxes (light naphtha reflux at tray#9, kerosene circulating reflux
at tray#19 & diesel circulating reflux at tray#32).

OVER HEAD SECTION

The overhead vapor from the crude column at 114C is withdrawn under
pressure control and is condensed and cooled in overhead condenser to 55C.
The condenser utilizes cooling water as the cooling medium. This condensed
overhead product separates out as hydrocarbons and water in the overhead
accumulator. Water is withdrawn from the boot under level control and sent to
the effluent plant for treatment. Naphtha from overhead condensed is pumped
to naphtha stabilizer and part to atmospheric column under level cascade
control. Crude column top temperature & reflux controller sets reflux demand.
A split range pressure maintains the overhead pressure by controlling fuel gas
makeup and vapor to flare.
NAPHTHA STABILISER
The unstabilized naphtha from overhead naphtha accumulator of the
crude column is stabilized by the removal of light ends in naphtha stabilizer
column. The light ends are recovered as fuel gas and stabilized naphtha at
168C is obtained from the bottom of column under level control. The
necessary heat to vertical reboiler is provided by diesel circulating reflux under
temperature control of the naphtha stabilizer bottom. The stabilized naphtha is
further cooled in using cooling water and sent to storage tanks.
The stabilizer is provided with a stab-in exchanger to condense the
overheated vapor. Water is used as cooling medium and water flow is
controlled by column top temperature control. The off gas from the top of
column is sent to fuel gas system. Column pressure is controlled by a pressure
control provided on fuel gas line.
The stabilizer is a packed tower with structured packing. The top
diameter is 305 mm and the bottom diameter is 460 mm with total height of
20.974 m. The total packing volume is 1.59 m. The maximum pressure drop
across the packing is 0.45 inch of H 2O per ft. of packing. The tower operates
at a load corresponding to 75% flooding.
HEAVY NAPHTHA SECTION
Heavy naphtha is withdrawn as side product from tray#11 of the crude
column at a temperature of 144C under level control of side stripper bottom.
Light ends in heavy naphtha steam are stripped in heavy naphtha side-stripper
using super heated steam. Stripper vapors routed back to tray#9 of crude
column. The bottom product, heavy naphtha pumped by gear pumps and
cooled in the heavy naphtha cooler using cooling water. Part of this stream is
blended with final diesel product and the rest is mixed stabilized naphtha in
naphtha storage tanks.

KEROSENE SECTION
Kerosene is withdrawn as side product from chimney tray, which receives
liquid from tray#22 of the crude column at a temperature of 186.7C under
level control of side stripper bottom. Light ends in the kerosene stream are
sent back to tray#19 of the crude column. The hot bottom product of kerosene
stripper is pumped by gear pump under flow control to crude/ kerosene
exchanger. Kerosene product is further cooled in kerosene product cooler to
40C and is stored in kerosene storage tanks.
DIESEL SECTION
Diesel is withdrawn as side product from tray#35 of crude column at a
temperature of 290C under level control of side stripper bottom. Lighter ends
are sent back to tray#32 of crude column from diesel stripper. Hot bottom
product diesel from stripper is pumped to stage1 preheating of crude followed
by cooling the diesel product in cooler and sent to diesel storage tank for
storage.
LOW SULPHUR HEAVY STOCK SECTION
Stripped RCO at a temperature of 330C is withdrawn from the bottom of
crude column under level control cascaded with flow control. R.C.O is pumped
to crude preheat train and the cooled product is sent to storage.
STORAGE TANKS AND LOADING BAY
All the products are cooled to ambient conditions (40C) before storage,
except the bottom product LSHS which gets congealed at lower temperatures.
Therefore it is stored in a steam traced and insulated storage tank. The
Naphtha product is stored in a floating roof tank while the remaining products
are stored in fixed roof tanks. The details of the product storage tanks are
given below.
Sl. Product
Capacity Diameter Height
Temperature
Type
No
Stored
(m)
(m)
(m)
(C)
Floating
1
Naphtha
700
9.95
9.00
40
Roof
2
SKO
Fixed Roof
443
8.50
7.80
40
3
HSD
Fixed Roof
509
9.00
8.00
40
4
LSHS
Fixed Roof
401
8.25
7.50
95
The products from the storage tanks are pumped to the loading bay for loading
into the tankers. Product loading pumps with a pump rate of 60 m/hr are
used for this purpose. These products are loaded into the tankers by loading
arms in the loading deck at the loading bay. The loading bay has a fire water
sprinkler system for any fire emergency situations.

STEAM GENERATION SYSTEM

The steam generation system consists of a water treatment plant and a
boiler system. The raw water from the raw water reservoir is first treated in
treatment plant to remove the impurities and dissolved salts and then fed into
the boiler system to produce steam.
Water Treatment Plant
In the water treatment plant, the treatment is done at Primary treatment
section and De-Mineralized water plant section.
Primary Treatment Section
Raw water is stored in the raw water reservoir of capacity 1500 m. In the
primary treatment section, raw water is pumped into the lamella clarifier
where it is mixed with Alum and flocculent (Magnafloc). The clarified water
then enters a multimedia vertical pressure sand filter, which has a capacity of
10 m/hr and operating at 2.6 kg/cm where the smaller particles get filtered
from the water. This water is then pumped to the DM plant using raw water
pumps.
De-Mineralized Water Plant
De-Mineralized water plant has a capacity of 2 m/hr. It consists of a dual
media filter, a cation exchanger and an anion exchanger. Water entering the
dual media filter undergoes micro filtration to remove micro particles. Dual
media filet operates at a pressure of 3.5 kg/cm g and the filter mediums are
LDPE powder and rings. Water then goes through the Ion exchange process in
two Ion exchangers namely cation exchanger for the removal of Magnesium,
Calcium ions and anion exchanger for the removal of Sulphates, chlorides etc.
Both exchangers consists of Ion exchanger resins which should be regenerated
with due course of time. Cation exchange resin is regenerated using
Hydrochloric Acid and anion exchange resin using Sodium Hydroxide.
Regeneration cycle time is approximately 2.45 hours in which 33 litres of HCl
(33 %) and 12 kg of NaOH(100%) is used. The inlet and the outlet raw water
characteristics are given below.
Characteristics
INLET
OUTLET
Pressure , kg/cm g
3.5
1.5
Temperature, C
30 - 40
30 - 40
Total Hardness(as CaCO3),
124 - 156
5
ppm
Total Dissolved Solids, ppm
484 - 668
< 30 micro siemens
Turbidity, NTU
11 - 13
Nil
Silica(as SiCO2), ppm
10 - 11
0.5
pH
8 - 9.5
8 - 9.5

Boiler System
The boiler system is a once through, Coil Type, Instant Steam
Generator. It is a fully automatic Packaged Boiler with all the necessary
accessories mounted on a common chassis. It consists of two boilers on under
operation and other stand-by.
The Furnace section of the boiler consists of a Membrane Coil (Helical
Coil with in between spacer strips) where fuel is burnt. The coil is housed in a
jacket assembly consisting of inner and outer jacket. Refractory cover is
mounted on the topside of the helical coil. The bottom side of the coil is filled
with refractory. Gas burner is mounted on the top cover of the outer jacket.
Aluminum radiators are provided in the annular space between the inner and
outer jackets. To reduce the outer skin temperature, third (outermost) jacket
has been provided. Glass wool insulation has been filled in the annular space
between third (outermost) and middle jacket.
Apart from the main boiler section, Economizer and Heat Optimizer are
provided before the Feed Water Pump. Economizer is a jacket and Tube type
heat exchanger and Optimizer is a Tube in Tube type heat exchanger. The
necessary fuel handling system is also provided along with the boiler.
Fuel is burnt in the Membrane Coil by the Gas burner using the air from the
Combustion air Fan. Cold air from the combustion air fan is passed through
the annular space between inner and middle jacket to preheat and in-turn
recover the heat from the flue gas. Since the coil is blinded from the rear end,
the flame reverse with in this coil (First and Second pass) and takes a turn at
the top and enters into the annular space between the Membrane Coil and the
inner jacket (third pass). While the heat transfer in the membrane coil is by
radiation, the heat transfer in the third pass is by convection. At the outlet of
the boiler, the flue gas is exhausted through the Economizer to recover heat
from the flue gases.
Water from the Feed Tank enters the Economizer through the Optimizer
before entering the feed water pump.
The economizer outlet is again
connected to the Optimizer. This water circuit maintains the temperature of
the water entering the feed water pump maintained below 80C, which is the
maximum temperature the reciprocating pump can withstand.
The steam output from the boiler is 680 kg/hr and the steam pressure is 7.0
kg/cm at 175C.
Steam from the boiler is sent to

Crude furnace as snuffing steam and also to produce supersaturated

steam for use in Naphtha, Kerosene and Diesel strippers and Crude
column bottom.
Desalter
Closed Blow down Drum
LSHS storage tanks to maintain the temperature of LSHS.

COOLING WATER SYSTEM

Cooling water is used to cool the products and other liquids within the
system by taking away the heat. In the refinery, cooling water is mainly used
in product coolers E-107 A/B (for HSD), E-108 (for kerosene), E-110 (for
heavy naphtha), E-113 (for naphtha), overhead condenser E-109 A/B,
stabilizer condenser E-111 and in Closed Blow down Drum. The water from the
coolers and condensers are cooled in cooling tower and pumped back using
cooling water pumps. Make up water is added for evaporation losses. A
number of chemicals like ammonia for pH control, Dispersant, Antiscalant,
Biocide to prevent the activities of micro-organisms like bacteria, are added
into the cooling water. The list of chemicals added to the cooling water is given
below.
Sl.
No
1
2
3
4
5

Chemical
Liquid
Ammonia 7%
Antiscalant
(Maxtreat-2521)
Dispersant
(Maxtreat
7200D)
Biocide
(Maxtreat 606)
Biocide
(Maxtreat 608)

Qty. Level

Mix
with

Total per
day Kgs/Day

pH > 7

Water

150 LPD

30 Ppm for 4.5

m3/hr

Water

15 Ppm for 17.5

m3

Water

100 Ppm for 17.5

m3
100 Ppm for 17.5
m3

Water
Water

1(Shock
Treating)
1 (Shock
Treating)

Remarks

Once in 2
weeks
Once in 2
weeks

Cooling Tower
Cooling tower cools the water coming from product coolers and
condensers. There are 2 cooling towers of Induced Draft Cross flow type in the
refinery. Tower dimensions are 2.4m x 5.71m x 3.22m. Each has a capacity of
300 m of water per hour. The Inlet water temperature is 40C and after
cooling, the outlet is at 30C. Design heat duty is 2.04 MM Kcal/hr.

CORROSION CONTROL
Corrosion is one of the many environmental factors that can reduce the
life of a distillation column.
Crude oil contains many corrosive agents;
Chlorides, Organic Acids, Water and Sulfur compounds. Chlorides (especially
Calcium and Magnesium Chlorides) will hydrolyze above 120C to form

Hydrochloric Acid, HCl. H2S is formed in the heater by thermal decomposition

of Sulfur compounds in the crude.
The corrosion attack of Hydrogen Chloride appears in the Overhead
system at a point where water begins to condense.
The Calcium and
Magnesium Chloride content of the crude determine the HCl concentration in
the condensed water, the removal efficiency of the desalter, and the quantity of
Stripping Steam used.
HCl corrosion can affect the Overhead piping,
condensers, the Reflux drum, pump, and water line. The corrosion attack of
HCl is accelerated in the presence of Hydrogen Sulfide, H 2S.
Close control of the condensate pH is important to minimize the HCl
corrosion potential.
If pH decreases much below 5.0, system corrosion
increases rapidly. Above a pH of 6.0 the amount of H2S that dissociates to H+
and HS- ions increases. A significant concentration of Bisulfide ion in the water
phase will also increase system corrosivity.
COOROSION CONTROL CHEMICALS
Filming Amine
An Amine filming corrosion Inhibitor is added to the Overhead line. The
amine chemical adheres to the metal walls of the Overhead system to provide
a very tenacious film against aqueous corrosion. The Amine chemical is
effective over a wide range and is completely soluble in hydrocarbons.
Chemical used: COROMAX ML 5872.
At the rate of 10 ppm for every
10,000 kg of Overhead vapor.
Neutralizer
An aqueous Ammonium Hydroxide Solution is added separately but in
conjunction with the Filming Amine.
This Neutralizer reduces acidity by
promoting a uniform pH in the condensing steam. The reaction of neutralizer
with HCl and H2S acids produces Ammonium Chloride salt that can deposit in
the Overhead condenser and cause severe corrosion.
CHEMICAL STORAGE TANKS
In refining operations, many chemicals are involved foe example Corrosion
inhibitor, Ammonia as neutraliser, Demuslifier, Acid etc. These chemicals are
stored in specific tanks and are pumped into process streams in required
amounts. The details of the chemical storage tanks are given below
Sl. No

Chemical Stored

Capacity
(m)

Temperature
(C)

1
2
3

Corrosion Inhibitor
Demulsifier
Ammonia Solution

3.50
0.79
3.50

40
40
40

ADDITION OF NEW PRODUCTS

With the in house expertise, two new products were added to the
refinery viz. High Flash High Speed Diesel (HF HSD) and Mineral Turpentine Oil
(MTO).
HFHSD PRODUCTION
In 2005, with the start of ONGCs East Coast operations at Kakinada,
calls for a huge requirement of HFHSD (HSD with flash point > 66 C) for the
offshore rigs and supply vessels. Tatipaka refinery until then was producing
HSD (FP> 35 C) for onshore applications of Rajahmundry and Cauvery Assets.
The possibility of producing HSD with a higher flash point of above 66 0C was
explored by team refinery.
Design data suggested that the production of HSD with Flash Point > 80
C was possible with existing column without any modifications. So the
operating parameters like steam flow rate, coil outlet temperature from
furnace and pump around flow rates of HSD and SKO were calculated and
tried. However, the desired specifications for the HF HSD could not be met.
The samples were failing either in Flash Point or Pour Point criterion. Upon
careful analysis of the lab reports of samples, the poor separation of HSD and
SKO cuts was found out to be the root cause for samples failure. Using
theoretical calculations and analysis the average cut point temperature for HSD
of 275oC was calculated and using the TBP curve of feedstock it was estimated
that the yield of HSD would also increase to about 22% for this cut point.
To cope with increased HF HSD production, the exchangers E-107 (HSD
cooler) was found to be inadequate to accommodate the additional heat duty.
So additional heat exchanger E-107-B, parallel to existing exchanger was
designed and installed with due consideration to hydraulic requirements.
Further, it was found that the steam flow rates through the strippers and
column are regulated manually by isolation valves and the required rate of
steam in a controlled manner were not being supplied. So for precise control
of superheated steam into strippers, flow control valves in the steam inlet lines
were installed and desired steam flow rates could be achieved. Subsequent to
these modifications, the HSD samples tested met the specifications of HFHSD.
Since then Tatipaka Refinery started supplying HF HSD to offshore rigs.
o

MINERAL TURPENTINE OIL

The refinery is run by frequent change of feed mix of crude & condensate
by monitoring ullage of Naphtha and LSHS Storage Tanks. Also, discounts were
offered on Naphtha & LSHS due to marketing problem. Due to this, Refinery
margins were affected. There was a drastic change in market dynamics due to
supply of Reliance Gas. Hence, the in-house crew of the came up with idea of
diversifying the products by converting SKO to Mineral Turpentine Oil (MTO).

The production of SKO of 13-14% can be replaced by MTO to improve

refinery profit margins. Mineral Turpentine Oil (MTO) is an intermediate
product between Naphtha and SKO. It is a low odor solvent. It has fast setting
power and high solvency power. It is widely used in paint and solvent
industries, which give it a huge market demand.
Applications of MTO
Adhesive industries
Paint and resin industries
Thinner industries
Agro-chemicals, households' insecticides, fungicides industries.
Paint catalysts, driers, coating and industries
Textiles, cloth, paper, printing-processing industries
Degreasing and cleaning purpose in machineries, machine spares
manufacturing industries
Experimentation was done for production of MTO in place of SKO in July,
2010. This was done by process modification in the plant with in house
expertise without any Capital expenditure and additional manpower. The
operating parameters were modified and feed mix was controlled. Lab tests
were successful at M/s ONGC & M/s HPCL and the quality parameters also
endorsed by IOGPT. If Need arises, the product MTO can be interchanged with
SKO as per market demand without any changes in the plant.
This diversification could generate additional revenue of Rs17 Crore per annum
after considering the SKO subsidiary and Rs2 Crore with SKO subsidiary. The
project obtained the approval of competent authority and MTO production
started from 01.4.2011.
The project received CMD innovation group award for the team in 2011.

UTILITIES
The plant runs on un-interrupted power supplied by gas generators of
380KVA and 500KVA capacity. The fuel gas used here is the low pressure gas
generated in GCS which other wise would have been flared, resulting in global
warming. The pneumatic control of all the control valves needs air, which is
provided by an air compressor. The Effluent generated is treated in the Effluent
Treatment Plant located in the adjoining plant of GCS.
The power supply to the control system has been provided by uninterrupted
power supply (UPS).The product dispatch is done through loading bay. All the
activities are recorded in an ERP package called SAP on a daily basis, which
can then be viewed across ONGC.
The plant is equipped with gas detection and fire detection systems. The MCC
room is equipped with smoke detector as well. The plant is equipped with
latest fire detection and suppression system which confirms to OISD
standards. Different system safety interlocks has been provided in the DCS
control system to initiate actions that prevents any damage to plant,
equipment and personnel.

LIST OF AWARDS FOR TATIPAKA

REFINERY
WON THE GROUP AWARD FROM DIRECTOR (ON-SHORE) FOR
SUCCESSFUL COMMISSIONING OF REFINERY IN 2002.
GREENTECH ENVIRONMENT EXCELLENCE SILVER AWARD FOR
2003-04
GREENTECH ENVIRONMENT EXCELLENCE SILVER AWARD FOR
2004-05
GREENTECH SAFETY SILVER AWARD FOR 2003-04.
GREENTECH SAFETY SILVER AWARD FOR 2004-05
GREENTECH ENVIRONMENT EXCELLENCE GOLD AWARD FOR
2006.
GREENTECH ENVIRONMENT EXCELLENCE GOLD AWARD FOR
2011.
CERTIFICATE OF APPRECIATION FROM NATIONAL SAFETY
COUNCIL, AP CHAPTER IN RECOGNITION OF THE EFFORTS
TOWARDS OHSAS-18001 SERIES in 2005.
C&MD INNOVATION GROUP AWARD IN 2011 FOR TEAM
REFINERY FOR INTRODUCTION OF NEW PRODUCT MTO.
WON THE HIGH TECHNICAL AUDIT RATED AWARD FROM
DIRECTOR (T&FS) DURING THE YEAR IN 2008-09