Internship Report

(30th June, 2014 -- 28th July, 2014)

Submitted By:
Mr. Suneel Parwani
Industrial Electronics Engineering

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 INTERNEE PROFILE
Name : Suneel Parwani

Father Name : Jai Pirkash

Institute : IIEE, NED University Karachi.

Department : Industrial Electronics Engineering (6th Semester)

E-mail : suneel.parwani@iiee.edu.pk

Contact : +9-333-3480927

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 ACKNOWLEDGEMENT & PREFACE

I am very thankful to Almighty who gives me the potential and helps me in the smooth and
peaceful completion of my internship.

This report is about four week summer internship program, which I have completed at BYCO
Petroleum Pakistan Limited from 30th June to 28th July14.

I would like to thank my helpful supervisors, Mr. Qazi Bilal Zuberi, Mr. Sarang Ismail & Mr.
Shahid Yousuf for their immense service and support and utmost patience in throughout the
entire period of my training. The supervision and support given by them truly help me in the
progression and smoothness of the internship program. The co-operation is much indeed
appreciated.

Last but not least I would like to thank all the managers, engineers and workers who guided me
and shared their knowledge and experiences.

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 TABLE OF CONTENT
S. Topic Page No.
No.
1 About Byco 3

2 Single Point Mooring (SPM) Technology 4

3 Environment, Health & Safety 6-10

4 Lab 11-12

5 Operations 13-18

6 Inspections 19

7 Mechanical 20

8 Electrical 21

9 Instrumentation 22-30

10 Oil Movement 31-32

11 Conclusion 33

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 ABOUT BYCO PAKISTAN LIMITED
Byco is Pakistans emerging energy companies engaged in the businesses of oil refining,
petroleum marketing, chemicals manufacturing and petroleum logistics. Headquartered in
Karachi, we are serving our mission to fulfil the energy demand within and beyond borders.

Companies under Byco umbrella are:

structure & Logistics

They are engaged in manufacturing of a wide range of petroleum products such as

Liquefied Petroleum Gas, Light Naphtha, Heavy Naphtha, Kerosene, Jet Fuels, High Speed
Diesel and Furnace Oil for bunkers and energy generation with the objective to achieve
sustainable productivity, profitability and high standards to address the environment, health and
safety requirements.

Oil refining complex-I is located 50km from Karachi towards Hub in Balochistan Coastal area.
The location of an Oil Refinery has an important impact on its refining margin, since it
determines how well it can access feed stocks and distribute its products. The Location also
dictates whether feed stocks and product can be transported by sea via pipe lines or road. Coastal
area located Refinery like Byco typically has a competitive advantage over those located inland
due to lower logistics costs and having total refining capacity to 35,000 (barrels per day). The
Company also have settled another Oil refining complex-II with the capacity of 120,000 barrels
per day which.

They take pride in having the largest capacity crude oil storage tanks in the country. Their
petroleum distribution network supports movement of petroleum products and provides greater
economies of scale. Their marketing network supports retail outlets in more than 80 cities all over
Pakistan and is an emerging leader in oil marketing sector of our economy.

Their diverse and highly skilled workforce consists of approximately 800 dedicated employees
shared among Byco companies.

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 SINGLE POINT MOORING (SPM)
Technology
The Single Point Mooring (SPM) facility being set up for the first time in Pakistan will
revolutionize the handling of petroleum and oil products in the Country. The facility is being
setup to allow the handling of imported crude oil and other petroleum products through the SPM
an open sea anchorage with sub-sea and sub soil pipelines connecting it to the on-shore
facilities.

This facility is being set up in the deep sea, at a distance of approximately of 15 km from the
Byco site located at Mouza Kund, Balochistan, Pakistan. The floating jetty will be connected to
crude oil tank farm of approximately 130,000 metric tons, via 3.3 km on-shore pipelines and 11.5
km off-shore 28" pipelines.

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 EHS (ENVIRONMENT, HEALTH AND
SAFETY)
Introduction:
Environment, Health and Safety is the topmost component of Bycos business core values and
commitment. Refining industries employ large and complex refining units, processing highly
flammable oil materials at high temperature and pressure. EHS aim to add value and create an
improved environment for the customers by enhancing their relationships with the product,
employees and environment.

EHS

Environment Health Safety

The International standards that are being followed at the Byco are:
EMS (Environmental Management System) ISO 14,001
QMS (Quality Management System) ISO 9001
OHSAS (Occupational Health Safety Assessment Series) ISO 18,001
Emergency Response Time Department (ERT):
ERT department ensures all systems are in place that is required to mitigate and control any
undesirable and hazardous situation (causing threat to Environment, health & Safety) arising in
case of any failure or accident.
ERT Plan is based on the following fundamental principles:
1. Minimizing environmental impact
2. Minimizing harm to people
3. Minimizing damage to the machinery
4. Protecting the reputation of Refinery

Emergency Declaration:
The emergency is declared by the siren of alarm with 3 seconds up and down tone. At that time
the workers are ordered to go to Assembly points (people gathered here). There are 6 assembly
points located at different location that are safe.

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And when the condition is controlled, there is another alarm siren with continuous tone to indicate
that emergency is over and the conditions are under control and safe.
There are sensors, manual call points as well as emergency call number (1191) available so that
the emergency situation is controlled as fast as possible.

Hazards :
1. Fire
2. Bomb Threat
3. Leakage/spill (oil and chemicals)
4. Natural disasters
5. Non biodegradable waste
6. Emission of toxic gases (SOX, NOX, CO, CO etc)

Safety Measures:
1. The tanks are covered with pipelines with showering valve having water and foam in
them.
2. There are portable foam trolleys available at different areas of the plant area.
3. There are work permits allotted depending on the work requirements.
4. All the electrical and electronics devices are grounded properly.
5. There is a panel which look after the emergency call system
6. Proper medication and first aid is available
7. There are emergency response vehicles which are always ready to tackle the emergency
conditions.
ERT measurement & monitoring plan is to check & improve the systems in place, which
includes:-
1. Eliminate
2. Substitute
3. Engineering Control
4. Administrative Control

FIRE FIGHTING MECHANISM

There are four main classes of fire:

1. Class A (solid/combustible fire such as fires with wood or trash)
2. Class B (liquid/flammable fire)
3. Class C (electric fire)
4. Class D (metal fire)

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Firefighting is the act of extinguishing fires. Firefighting is a highly technical skill that requires
that professionals have years of training and education to become proficient. In Byco, there is a
panel of 4 people for this fighting.

Fire Fighting Material:

1. DCP (dry chemical powder) for combustible fire
2. Carbon dioxide for electrical fire
3. Foam (fluoroprotein i.e. 3% foam and 97% water)
4. Water

Safety Equipments PPES (personal protection equipments):

1. Hard helmets
2. Safety shoes
3. Cover all (dungaree for males and females)
4. Gloves
5. Mask
6. Goggles

Fire Fighting Equipments:

Equipments which helps in alerting from emergency situations:
1. Emergency response vehicles (2)
2. Fire extinguishers
3. Fire pumps
4. Foaming system
5. Smoke detectors
6. Fire Alarms
7. Smoke Detectors
8. PCV (Pressure Control Valves)
9. TCV (Temperature Controlling Valves)
10. LCV (level Control Valves)

EMERGENCY RESPONSE VEHICLES:

There are 3 vehicles termed as ERV
1. Emergency response vehicle I
2. Emergency response vehicle II
3. Ambulance

Emergency response vehicle I:

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It is old modeled fire tank. It contains Foam, water and DCU. The capacity of water is 2000 liters,
foam is 5000 liters and DCU is 1000 Kg. For DCU, there are 4 Nitrogen filled cylinders and
required pressure is 14 bars.

Emergency response vehicle II:

It is advance model of Fire Tender, can be used easily. It contains water and foam. The capacities
are 3000 liters water and 4000 liters foam.

MEDICAL CLINIC

Medical center is one of the most important departments working under the umbrella of EHS
department. In Byco the medical center has all the basic and necessary facilities available 24/7.

Facilities:
The medical center has following facilities:
1. An Ambulance
2. Consultation room
3. Proper storage for medicines
4. 10 first aid boxes
5. Well trained nursing staff

Activities of Medical Center:

The medical center is engaged in the following routine activities:
1. OPD
2. Record of employees to maintain health assessment
3. First aid treatment
4. Noise level test
5. Eye sight test
6. Vaccine record
Normally the cut and burn injuries are reported in the medical center.

Types of Burn:

1. 1st Degree burn: Redness on the skin and it feels burn.

2. 2nd Degree burn: Redness on the skin and blusters appears on the skin, in this burn
epidermis & endodermis layers are damaged.
3. 3rd Degree burn: In this type the endodermis layer and nerves got damaged.
4. 4th degree burn: In this type the bones got damaged and the person has very little
chances of survival.

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Safety Precautions:

i). Permit to work system:

There are four types of work permits in the industry
I. Hot Work Permit
All works in which temperature is involved, naked fire is used or flame is
generated requires hot work permit

II. Cold Work Permit

Works which dont require naked flame or temperature change is observed
will be done through cold work permits.
III. Confined Space Certificate
All work which is done in close area where lighting and air passage is not
available is under this category.
IV. Excavation Certificate
The refinery is grounded with pipelines and wires so the area should be
properly tested out before digging for any work then this certificate will be
issued.
ii). Fire Drill:
Fire drills are held every Tuesday at 11 AM to train the employees about the fire fighting
techniques and to keep the firemen in practice.

iii). Restrictions:
The principle hazards at refineries are fire and explosion. The use of matches, lighters, cigarettes
and other Smokey material is generally banned in the plant except in specially designated areas.

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 LAB
Laboratory is basically the eye of the refinery where quality is controlled of our products .It is the
place where our samples are checked. It is checked whether Byco products are meeting the
specifications suggested by A.S.T.M.

TESTS CONDUCTED IN LABORATORY

The following tests are conducted on the products.
Test Instruments Products
1. Pour point Ice Bath
2. Cloud point
3. Existent gum content check Existent Gum check meter MS
4. Flash point By Able Kero
By PMCC HSG and FFO

5. Oxygen Stability Oxygen Stability meter MS

JFTOT Jet Fuel
6. Water content check Dean Strack meter
7. Viscosity Viscosity Bath with two solvents
Acetone Jet Fuel
Water Crude, Diesel
and FFO
8. ASTM colour check Chromo meter
Coloured liquids naphtha
Transparent Liquids
9. Absorbance check Spectrophotometer
10. Conductivity Conductivity Meter
11. Sulphur Sulphur Check meter Sweet Naphtha
12. Distillation Distillation Unit Naphtha, MS,
Diesel
13. Fuming Hood
14. Octane number check ZeltexRON
15. Oxygen content Portable O 2 analyzer
16. Moisture Content Moisture Analyzer

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SIGNIFICANCE OF ABOVE TESTS:-

FLASH POINT:
The Flashpoint temperature is one measure of tendency of the test specimen to form a flammable
mixture with air under controlled laboratory condition. Flash point is used in shipping and safety
regulations to define flammable and combustible material.

POUR POINT:
The pour point of a petroleum specimen is an index of lowest temperature of its utility for certain
applications. It tells the lowest temperature of the product at which can be poured easily.

VISCOSITY:
Many petroleum products, and some non petroleum products, are used as lubricants ,and the
correct operations of the equipment depends upon the appropriate viscosity of the liquid being
used. In addition, the viscosity of many petroleum fuels is important for the estimation of
optimum storage, handling, and operational condition. Thus, the accurate determination of
viscosity is essential to many product specifications.

DISTILLATION:
The distillation characteristics of hydrocarbon have an important effect on their safety
performance, especially in case of fuels and solvents. The distillation characteristics are critically
important for both automotive fuels and aviation gasoline, affect starting , warm up, and tendency
to vapor lock at high operating temperature or at high altitude ,or both. The presence of high
boiling point components in these other fuels can significantly affect the degree of formation of
solid combustion deposit.

OCTANE NUMBER TEST

This test is basically run in CFR ENGINE room. This test checks the anti knocking characteristic
of the fuel. It is compared with the standard mixture of n-heptane and iso-octane.

COPPER STRIP CORROSION:

This method covers the detection of the corrosiveness of gasoline, naphtha, kerosene,
aviation turbine fuels having Reid vapor pressure no greater than 18 lb.
KINEMATIC VISCOSITY:
This method covers the determination of kinematic viscosity of liquefied petroleum
products, both transparent and opaque. This method is intended for application to liquid
For which the shear stress & shear rate are proportional
ASTM COLOR:
This method describes a procedure for visual determination of the color of wide variety of
petroleum products such as lubricating oil, heating oil, diesel fuel oil and petroleum
waxes.

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 OPERATIONS
In Byco, Crude is pumped to storage tanks and then passes from different process to meet the
demands of customers then release and supply to the customers through bowser tanks.
There are three portion of plant area,
1. Process
2. Storage
3. Supply

The process is divided into 4 units

1. CDU (Crude Distillation Unit)
2. LSU ( LPG Separation Unit)
3. HDT (Hydro Reformer Unit)
4. Merox

The refining process initiates from the crude tanks and follow the sequence of different process
given below:

Booster Pumps Feed Pump Heat Exchangers

Desalters Heat Exchangers Pre-Flash

Furnace Distillation Column Respective

Operations

1. CRUDE DISTILLATION UNIT

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Crude of the storage tanks are prepared by boosting with the help of booster pumps then supplied
to the feed pumps which send the crude to pre-heater then to Desalter at 105psi pressure in CDU.

DESALTER:
A desalter is a process unit on an oil refinery that removes salt from the crude oil. The salt is
dissolved in the water in the crude oil, not in the crude oil itself.
Conventionally, an AC (Alternating Current) electrostatic dehydration system is used to remove
high salinity formation water from the crude oil stream. This process relies on establishing a high
voltage AC electrical field in the oil phase of dehydrator/desalter vessels. The electrical field
imposes an electrical charge on water droplets entrained in the oil stream, thus causing them to
oscillate as they pass through the electrodes.
During this oscillation, the droplets are stretched or elongated and then contracted during reversal
of the imposing AC electrical field. During this agitation the water droplets co-mingle and
coalesce into droplets of sufficient size to migrate, by gravity, back into the lower water phase of
the vessel for disposal thus water is collected at the bottom while crude is at the top.
In BYCO, there is a Chemical (demulsify), use to separate water from the crude in desalter unit.

PREFLASH TOWER:
The crude then sends to pre-flash tower having 20 trays, here the crude and steam are comes in
contact and counter current is generated. The pressure of crude is 105 psi. This setup is done to
remove naphtha from the crude, i.e. naphtha being a lighter parts separates and collected at the top
of the tower while remaining crude is assembled at the bottom.
NOTE: Naphtha is removed because it increases temperature and pressure up to great extent.
Thus increment of feed is difficult but if naphtha is removed then feed can be increased.

PRODUCT OF PRE-FLASH TOWER:

The naphtha obtained from the tower is called total naphtha. Then total naphtha is passed through
fin fan coolers where steam is condensed and then obtained in the pre-face accumulator where
water is drained out and waterless total naphtha is obtained and propel to splitter.

The crude obtained from the pre-flush tower is sent for pre-heat, where it is passed through heat
exchangers.

HEAT EXCHANGER:
The heat exchangers used at ORC-1 are mostly Shell & Tube type with different specifications.
They are used at different processes for the same purpose, exchanging heat between two fluids.
The code that all heat exchangers follow is ASME VIII Division 1.
There are an old and a new train, each has two pipes, one carry crude while other carry product,
and these trains are used as heat exchanger.
Crude is present in the tube while product runs in the shell side and vice verse. The heat of
product is exchange with the crudes cold temperature.

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Some of these exchangers are as follows.
1. Resid HSD Heat Exchanger
2. HSD Crude Heat Exchanger
3. Resid Crude Heat Exchanger
4. Crude HSD Heat Exchanger
5. Crude Kero Heat Exchanger
6. Crude Resid Heat Exchanger
7. Hot Oil Heat Exchanger
8. Kero Cooling water Heat Exchanger
9. Cooling water Heat Exchanger

After passing through exchangers the crude is transferred to the furnace having 12 burners and
then Born Heater having 10 burners.

BORN HEATER:
It is a type of furnace working on the principle of Burner management system.
There are two sections in it.
1. Radiation
2. Convection
The dual type of burner is present in it. Its temperature is maintained at 220 C.

Crude flows in the convention section in the coil of pipes. It is a dual burner in which two types
of fuels are used. The inlet temperature to the burner is 220 o C and outlet temperature is 350o C.
There are four pipes entering in burner, Steam, Oil, Pilot and Gas. Where oil and gas are used as
fuel, pilot is used for ignition and steam is used as atomizer.

DISSTILATION UNIT:
The remaining crude then comes to distillation tower, there are levels and different products are
achieved. The separation is distillation tower is due to the boiling point range. There are 38 trays
in the tower where the oil the different boiling point is collected and that is carried in sump and
then accumulated in the side striper.

STRIPPING SECTION:
The product obtained from the distillation tower is collected in the stripping section; here some
chemical properties are tested and then refined (if required) according to the requirement.
Stripping section is involved because the product quantity is not defined.
In side stripers, kerosene and HSD are contained where naphtha in these products are separated
and carried to splitter.
At the bottom, Fuel Oil is obtained in which viscosity is altered and then stored in vessels to use
in furnace and also used as hot oil. Hot oil is pumped to the furnace and then to the heat
exchanger where it heats the other fluid and then return to the hot oil tanks.

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REFLUX:
Reflux material (naphtha contained in accumulator) is used in side striper for temperature control
of the kerosene to settle down at bottom and let naphtha to evaporate to top to get collected.

NAHTHA TREATMENT:
The naphtha collected in pre-flush unit and side stripers are now carried to the splitter where it is
heated then due to temperature difference, in tower at height where temperature is at 112 o C, light
naphtha is obtained which is 14% to 16% and at the bottom of the tower where the temperature is
170o C, heavy naphtha is present. Then heavy naphtha is carried to re-boiler and again recycled in
splitter tower and at the end it is carried to the Hydro-treater Unit and light naphtha is carried to
LPG Separation Unit (LSU).

2. LPG SEPARATION UNIT (LSU):

In LSU, light naphtha is the feed obtained from top of the splitter tower. Then it is carried to
Depropanizer, from where propane is separated and then taken to the Debutanizer in which
Butane is separated in same manner. Since LPG is composed of 40% Butane and 60% Propane as
per requirement then it is transferred to the LPG bullets after sweetening in Merox.

3. HYDRO-REFORMER UNIT:

In hydro-treater unit, the feed is heavy naphtha with hydrogen gas which is pre-heated with the
help of heat exchanger from the shell side up to 210o C and then heated in the furnace in order to
attain the temperature of 300o C which is compulsory for the reaction in the reactor. To cool the
product, it is passed through fin fan cooler and then trim cooler.Then it is accumulated in the
Product Separator. Where water is escaped from bottom, naphtha is obtained from middle
where the pressure of 5 bars is maintained through pressure control valve (PCV).

TRIM COOLER
A trim cooler is a type of auxiliary cooler that makes up a part of a process plant's cooling system.
Trim coolers are typically designed to work only part of the time (e.g. during the hottest weather)
and for only part of a complex cooling system.
The naphtha obtained from the Hydro-treater unit is then carried to the Desulphurizer tower.

DESULPHURIZER TOWER:
Naphtha is again preheated through heat exchanger and then to the tower. The level of the
naphtha is maintained up to 65% by Level Control Valve (LCV). Then it is reacted with
hydrogen gas from which sulfur reacts with H2 and form sulfur products which are then removed.
This process is repeated by reheating the naphtha from waste heat exchanger and then convention
zone of furnace till the sulfur content becomes less than 0.5 ppm in the product. Then remaining

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naphtha is free of sulfur that is sweet naphtha at temperature of 230o C which acts as a feed for
Reformer Unit.

REFORMER UNIT:
The reformer feed is carried to the heat exchanger for pre-heat. In reformer unit, there are 3
reactors in which different types or reactions are performed. For these reactions, a temperature of
490o C is required. For this, a furnace is provided prior to every reactor. The first furnace is largest
in size of these three and the third one is smallest because reaction in the first reactor is
endothermic and in the last reactor, exothermic reaction occurs. After completing the reactions,
the naphtha returns to the heat exchangers and then to product separator.

PRODUCT SEPARATOR:
In product separator, from top H2 is obtained from where some part of gas is recycling
compressor and some part is taken to booster compressor. From bottom, gasoline is obtained.
Gasoline is then sent to stabilizer to control Reid Vapour Pressure (RVP). Then it is run down to
storage.

4. MEROX:

Propane and light naphtha is carried to the Merox Unit. Here sweetening of propane and light
naphtha takes place. This is done by reacting Propane and light naphtha with the caustic soda.
Through which sweetening is done and light naphtha is converted to Gasoline and butane is sent
to run down.

The difference in gasoline obtained from Merox and Reformer Unit is the Octane number. The
octane number of gasoline obtained from Reformer Unit is 92. Whereas,the Meroxs gasoline has
octane number of 65.

The process flow diagram is attached here

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Process Flow Diagram

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 INSPECTION
The codes and standard followed by Byco are ASME, API, and ASTM.
There are two areas of inspection
1. Stationary area
The mechanical integrity is ensured here.
2. Rotatory area
In this area, vibrational motion is monitored.

MECHANICAL INTEGRITY:
The mechanical structure is observed and checked. The damages due to welding, temperature
increment is very dangerous for the refinery. Following things are monitored
1. Flame pattern
2. Refractory material
3. Tubes hanger expansion and carbonization
4. Transfer line temperature
5. Corrosion
6. Welding damages

VIBRARTION CHECK:
The displacement is observed in this test, the radial and axial vibration is checked in mm/s

INSPECTION SCHEDULE:
There are plans and schedules of the inspection department. The furnace is observed weekly,
locating pins are affected by thermal expansion. The heat exchanger is examined properly.

INSPECTION TOOLS:
The following tools are used for inspection purpose.

1. ALCOMETER:
It is use to check thickness of paint in micsrometer. The tanks of LPG unit are critical so thickness
of paint is sustained and properly check through AlcoMeter.

2. TEMPERATURE METER:
Ultraviolet light is used to check the temperature of the insulation.
3. SONA GAUGE:
The thickness of the material is checked, the material is greased first to get right and true reading.
In Byco, the thickness of flange is checked using sonagauge.

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 MECHANICAL
The mechanical department is mainly responsible for the overall maintenance of the plant and the
modification of existent utilities and installation of new equipments. To manage the work
efficiently the mechanical department is further divided into two sections i.e.

Mechanical

Stationary Rotary

The mechanical department in ORC-I is responsible for the maintenance of all the following
equipments and their parts like:

1. Heat Exchangers
2. Pumps
3. Compressors
4. Boilers
5. Turbines
6. Furnaces
7. Valves
8. Piping
9. Cooling Towers

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 ELECTRICAL
Byco has its own power generation through diesel generators. Its load is divided into two
categories.

1. Plant load
2. Lighting Load

For plant load, there are 3 generators of 1.5MW with 60Hz frequency. . Plant load generators are
rental generators from allied engineering. These generators are maker of Caterpillar. They work
on 60Hz frequency and provide 460 volts for three phase and 230 volts for one phase. The
continuous load of the plant is 1.7MW; critical load is 2MW whereas during shut down, the load
of reformer and boiler is 650 KVA.

Synchronization system is used in which all the generators are synchronized so that all the
generators bear equal loads and then transferred in the plant.

In Byco, one generator provides fixed power and two generators are on sharing. So that if any
changes occur then sharing generators will adjust according to it. The power factor should be
limited to 0.9. For controlling system of Caterpillar generators, RA Panel and PLC devices are
used.

PLC system is mounted in generator and RA panel is kept in control room from where all the
parameters are shown as well as all the changes are also recorded in it. From this panel automatic
synchronization can also be done. It is the most secured system provides 100% safety for
generator engines.

A device is also there named with Service Meter Unit (SMU) which indicated the service hour or
generators. From which the service and maintenance schedule is followed. These generators may
be shut down at extreme limits that are; min 23 Amp and at max 40 Amp.

For lighting load, there are two generators of 550KVA and 365KVA are used which includes
lightning and office load which is fulfilled by two own generators. One is made of Cummins has
the capacity of 550KVA and other is made of Perkins having the capacity of 365KVA operating
at 50Hz. For starting these generators, a charge breaker is used which is pumped 5 times. When
the breaker gets harder and its motor of synchronization gets started, then it is ready to get started.

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 INSTRUMENTATION
Instrumentation is defined as the art and science of measurement and control of process variables
within a production or manufacturing area. In Byco, the process are automated and controlled
through Distributed Control System.

HUMAN INTERFACE STATION:

There is a station where all equipments for controlling the plant is present, the process is observed
on the monitors working according to the defined processing. The annunciator is also located
here. All the wirings from Junction Box (JB) come to the cabinet located in the station and
interfaced with Field Control Station, then connected to DCS systems.

DISTRIBUTED CONTROL SYSTEM

A distributed control system (DCS) 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.

DCS (Distributed Control System) is a computerized control system used to control the
production line in the industry. The entire system of controllers is connected by networks for
communication and monitoring.

DCS is a very broad term used in a variety of industries, to monitor and control distributed
equipment.
Electrical power grids and electrical generation plants
Environmental control systems
Water management systems
Oil refining plants
Chemical plants
Sensor networks etc.

In Byco, the DCS of Yokogawa Cooperation of America is implemented.

CONTROLLING OF PROSESS VARIABLES

Pressure
Pressure is probably one of the most commonly measured variables in the plant. It includes the
measurement of steam pressure; feed water pressure, condenser pressure, crude oil pressure and
many more.

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Pressure is actually the measurement of force acting on area of surface. We could represent this
as: Pressure =Force /Area Or P= F/ A
The units of measurement are either in pounds per square inch (PSI) in British units or Pascal (Pa)
in metric. As one PSI is approximately 7000 Pa, we often use kPa and MPa as units of pressure
The measure of pressure is, therefore, relative and pressure measurements are stated as either
gauge or absolute.

Measuring techniques
The method employed here to measure the pressure in Byco is discussed below.

PRESSURE GAUGES

Bourdon Pressure Gauges

PRINCIPLE: The Bourdon pressure gauge uses the principle that a flattened tube tends to change
to a more circular cross-section when pressurized. Although this change in cross-section may be
hardly noticeable, and thus involving moderate stresses within the elastic range of easily workable
materials, the strain of the material of the tube is magnified by forming the tube into a C shape or
even a helix, such that the entire tube tends to straighten out or uncoil, elastically, as it is
pressurized.

Here Byco has C shaped bourdon tubes.

Bourdon tubes measure gauge pressure, relative to ambient atmospheric pressure, as opposed to
absolute pressure; vacuum is sensed as a reverse motion.

Diaphragm Gauges

Diaphragm consist of a tough and neoprene membrane connected to a metal spring. There is
hollow space present between the membrane One side of diaphragm is exposed to pressure being
measured, while the other side to some other area having different pressure.

PRESSURE TRANSMITTER

The transmitter consists of transducer and transmitter. The pressure is sensed and converted in
electrical quantity and then transmitted to the control section. Range of differential pressure is 0-
20m bar.

The transmitter installed varies with the liquid flowing. There are following positions to attach
pressure transmitter to obtain pressure readings
PT via Impulse line (pressure of clear liquid)
PT via diaphragm (pressure of liquid with suspended particles)
PT via impulse line on LO-SIDE Plugged (pressure of Slurry).

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 Level

Level is actually the height of liquid contained in the vessel.

Measuring Techniques
There are two types of level detection
1. Continuous level detection
2. Single point level detection
3.
The measurement techniques are follows:

Dipley Method
This technique includes a simple method i.e. to dip a rod in the container, the wet portion tells the
height of liquid.

RADAR Method
The ultrasonic rays are transmitted on the surface of the liquid, reflection phenomenon tells the
level of the liquid.

Differential Pressure Method

The method includes comparison of pressure at two different levels.
When the container is open
The pressure at dead level is compared with the atmosphere pressure so every predetermined
pressure reading indicates the level of the container.

When container is closed

The pressure of dead level is compared with the pressure at the upper portion of the container.
Thus level is determined.

Capillary tube Method

A sensor that changes internal pressure when temperature change. Capillary tube sensors use
temperature sensitive liquid.
In Byco, the tube is filled with viscous liquid and works on Differential Pressure system.

All above methods are employed at BBPL.

Temperature
The degree of hotness and coldness is termed as temperature. Or it is a measure of the thermal
energy per particle of matter or radiation.

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Measuring Techniques

Temperature via Thermocouple

The principle here is the voltage generated by the thermocouple is proportional to the temperature
difference between the point where temperature
is measured and the point where thermocouple I
connected to the device.
Properties
Millivolt range I available
Very low temperature to voltage sensitivity

Temperature via RTD

The principle is the passing current through
RTD generates a voltage across the RTD , by
measuring this voltage , resistance is determined
thus temperature is determined. The 0C
indicated the resistance of 100 ohm and
measuring up to 850C.

Types of RTD

2-Wire RTD
2-wire construction is the least accurate of
the 3 types since there is no way of
eliminating the lead wire resistance from
the sensor measurement. 2-wire RTDs are
mostly used with short lead wires or where
close accuracy is not required. Measured
resistance is
Rt = R1 + R2 + Rb

3-Wire RTD
3-wire construction is

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most commonly used in industrial applications where the third wire provides a method for
removing the average lead wire resistance from the sensor measurement. When long distances
exist between the sensor and measurement/control instrument, significant savings can be made in
using a three wire cable instead of a four-wire cable.
(R 1+2+R b ) - (R 2+3) = (R b )
The 3 wire circuit works by measuring the resistance between #1 & #2 (R 1+2) and subtracting
the resistance between #2 & #3 (R 2+3) which leaves just the resistance of the RTD bulb (R b).
This method assumes that wires 1,2 & 3 are all the same resistance.

4-Wire RTD
4-wire construction is used primarily
wire RTD the actual resistance of the
measurement. The 4-wire circuit is a
power the circuit and wires 2 & 3
differences in lead wire resistances
in the laboratory where close accuracy is required. In a 4
lead wires can be determined and removed from the sensor
true 4-wire bridge, which works by using wires 1 & 4 to
to read. This true bridge method will compensate for any

Thermistors differ from resistance temperature detectors (RTD) in that the material used in a

thermistor is generally a ceramic or polymer, while RTDs use pure metals. The temperature
response is also different; RTDs are useful over larger temperature ranges, while thermistors
typically achieve a higher precision within a limited temperature range, typically 90 C to
130 C

Flow

Flow measurement is the quantification of bulk fluid movement.

Factors Affecting Flow rate
Velocity of Fluid
viscosity of Fluid

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 Density of Fluid
Friction of Fluid with pipe

Measuring Techniques
Pressure-based meter
There are several types of flow meter that rely on Bernoulli's principle, either by measuring the
differential pressure within a constriction, or by measuring static and stagnation pressures to
derive the dynamic pressure.

FLOW TRANSMITTER:

In Byco, almost all the pressure transmitter are based on differential pressure measurement and
then extracting the actual flow of the liquid passing from
them.

The figure show is a type of FT used in Byco. There are two

openings, one is connected to upstream of the vessel while
other is inserted at the down side to create differential
pressure situation. The two wire loop system is used. There is
a purge screw to release access pressure manually and
isolation valve to isolate it from the line.
Difference of pressure is created by following.

1. Orifice Plate
An orifice plate is a plate with a hole through it, placed in the
flow; it constricts the flow, and measuring the pressure
differential across the constriction gives the flow rate. It is
basically a crude form of Venturi meter, but with higher
energy losses. There are three type of orifice: concentric,
eccentric, and segmented.

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 CONTROL VALVES
Control valves are valves used to control conditions such as flow, pressure, temperature,
and liquid level by fully or partially opening or closing in response to signals received from
controllers that compare a "set point" to a "process variable" whose value is provided
by sensors that monitor changes in such conditions. [1]
The opening or closing of control valves is usually done automatically
by electrical, hydraulic or pneumatic actuators. Positioners are used to control the opening or
closing of the actuator based on electric or pneumatic signals. These control signals, traditionally
based on 3-15psi (0.2-1.0bar), more common now are 4-20mA signals for industry, 0-10V for
HVAC systems, and the introduction of "Smart" systems, HART, Field bus Foundation,
and Profibus being the more common protocols.
A control valve consists of three main parts in which each part exist in several types and designs:

Valve's actuator
Valve's positioner
Valve's body

Types of control valve:

There are two basic types of control valves.
a) Rotary motion valves having ball, butterfly or plug type closures.

b) Linear motion valves having globe, diaphragm or pinch type closures.

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 Control Valve Classification

Control
Va l ve

Li near Rota ry
Moti on Moti on

Gl obe Di a phragm Pi nch Ba l l Butterfly Pl ug

Gl obe Angl e 3 wa y

Si ngle Double
Sea ted Sea ted

Diaphragm Valves
Features
Consists of a saddle or seat upon which the diaphragm
closes the valves
Can handle corrosive fluids
Applications
Used as shut off valves in food and beverage,
pharmaceutical and biotech industries

Ball Valve
Features
Tight Shut Off
Minimum obstruction for the flowing media
High flow capacity
Can withstand high pressure and temperatures
Applications
Used for hazardous and corrosive fluids

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 Butterfly Valve
Features:
High flow capacity
Unlike ball valve the disc is present in the flow
of the liquid and hence a pressure drop is
always induced in the flow.
Tight shut off
Applications:
Used in Steel, Sugar and textile industries

Pressure Safety valve (PSV):

Pressure Safety valve is a safety device to prevent bursting that caused by pressure equipment and
container or easy to cause pressure rise or the container internal pressure exceeds the limits.
Safety valve is a safety device that is widely used in pressure vessel, boiler, pressure piping and
other pressure systems, to ensure the safe operation of pressure systems. When the container
pressure exceeds the design requirements, the safety valve automatically opens, accompanied by a
popping sound, the escaping gas reduces internal over pressure, to prevent the container or
pipeline damage. And when the internal pressure reduces to normal operating pressure, the
container automatically shuts down to avoid over-pressure exhaust all the gas, lead to waste and
production suspension
The term safety valve should be limited to compressible fluid applications (gas, vapor, or steam).

Temperature relief valves:

Temperature relief valves, also known as temperature and pressure valves or T&P valves, are
used to prevent the dangerous buildup of water, vapor and gas pressure inside of a hot water
heater.
A metal valve, typically brass or steel, is screwed into a special outlet on the side or top of the
tank. The valve releases pressure, preventing the tank from leaking or exploding.

The residual steam and heat must be released to allay the threat of damage to the tank, pipe bursts
or explosion, thats why, Byco uses them in LPG Bullets.

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 OIL MOVEMENT
Oil movement department consists of transferring the crude from decanting to storage tanks then
to process area and then to the shipment region from where it is supplied.

In Byco, there are three section of Oil Movement,

1. Decanting
2. Shipment
3. Tanks

Crude is supplied from decanting region to storage tanks where it is stored. Then sample crude is
sent to the laboratory for BS & W (Bottom sediments and water) test. After successful result,
crude flows into the pre flash tower through a chain of pipes and pumps.
From Pre flash it is sent to the crude distillation unit for further treatment. After completion of
distillation process crude is sent to the crude separator to separate water from crude. Separated
water is then drowned into the sea and the crude is stored in storage tanks in its different forms.

According to engineering point of view, the main task of oil movement department is,
1. Planning:
When Crude comes to the decanting area, the tanks are designated in which the crude is
stored.
2. Monitoring
3. Material balancing:
The crude required is properly measure before and after receiving from third party.

OPERATION OF OIL MOVEMENT:

The operation of oil movement department is mainly focuses on,
1. Inter Tank Transferring
2. Plant Feed
3. Transport
4. Rundown

STORAGE TANKS:
Storage tanks available at BYCO are used for storing crude before and after the processing.
Storage tanks of 70 to 85 diameters are available at BPPL. Storage tanks consist of steel pipes that
are provided for the filling or discharge of crude. There are 37 tanks, 6 for crude while remaining
for product storage.

There are three types of tanks at BPPL:

3. Internal floating roof

4. External floating roof
5. Fixed roof

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 LPG BULLETS:
LPG bullets are cylindrical and horizontal containers used for storing Liquefied petroleum gas.
Similar types of LPG bullets are stored at BPPL for storing huge amounts of liquefied petroleum
gas.

PUMPS:
There are booster pumps and feed pumps are installed at BPPL. All pumps are centrifugal type.
Booster pumps are used for pumping crude from the tanks to the process area where as feed
pumps are used for pumping the crude with in the process area.

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 CONCLUSION
Throughout my Internship tenure at BYCO Petroleum Pakistan Limited, I was fortunate to work
amongst a number of outstanding and remarkable people, who constantly guided me throughout
my work with their valuable comments, teaching and positive criticism. Unable to completely
express my gratitude to those all people, I dearly thank them all for guiding me and making my
Internship a success.

Thank You

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