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INTRODUCTION:
Attock Refinery Limited (ARL) was incorporated as a Private Limited Company in November, 1978 to take over the business of the Attock Oil Company Limited (AOC) relating to refining of crude oil and supplying of refined petroleum products. It was subsequently converted into a Public Limited Company in June, 1979 and is listed on the three Stock Exchanges of the country. The Company is also registered with Central Depository Company of Pakistan Limited (CDC). Original paid-up capital of the Company was Rs 80 million which was subscribed by the holding company i.e. AOC, Government of Pakistan, investment companies and general public. The present paid-up capital of the Company is Rs 454.896 million. ARL is the pioneer of crude oil refining in the country with its operations dating back to 1922. Backed by a rich experience of more than 80 years of successful operations, ARLs plants have been gradually upgraded/replaced with state-of-the-art hardware to remain competitive and meet new challenges and requirements. It all began in February 1922, when two small stills of 2,500 barrel per day (bpd) came on stream at Morgah following the first discovery of oil at Khaur where drilling started on January 22, 1915 and at very shallow depth of 223 feet 5,000 barrels of oil flowed. After discovery of oil in Dhulian in 1937, the Refinery was expanded in late thirties and early fourties. A 5,500 bpd Lummus Two-Stage-Distillation Unit, a Dubbs Thermal Cracker, Lubricating Oil Refinery and Wax Purification facility and the Edeleanu Solvent Extraction unit for smoke-point correction of Kerosene were added.
SERIES OF FIRST
First refinery of the region (1922) First to start dispensing major products through pipeline using computerized metering system (1987) First to produce low sulfur furnace (less than 1%) (1998) First to produce low sulfur diesel (less than 0.5%) (1998) First to achieve ISO 9002 certification for quality control laboratory (1999) First to produce low lead premium gasoline direct from refinery process (1999) First to produce polymer modified asphalt (2001)
ARL MILESTONES
1910 Beginning of operations by AOC 1915 First discovery of oil at Khaur District by AOC 1922 Commissioning of two small refining units at Morgah near Rawalpindi with the capacity of 2,500 BPD 1937 Discovery of oil in Dhulian and installation of Dubbs and Lummus Plants with the capacity of 5,500 BPD 1968 Discovery of oil at Meyal and Toot oilfields 1978 Incorporation of ARL 1979 Conversion of ARL into a Public Limited Company and its listing on three stock exchanges of the country 1981 Refining capacity was increased by the addition of two distillation units of 5,000 & 20,000 BPD capacity each 1987 Commissioning of dispatches of petroleum products through pipeline to Oil Marketing Companies (OMCs) with computerized metering 1996 Effluent Treatment Plant 1999 Expansion and upgradation project with the installation of Heavy Crude Unit of 10,000 BPD and Catalytic Reformer Complex of 5,000 BPD 2000 Commissioning of Captive Power Plant with the capacity of 7.5 MW 2001 ISO-9001: 2000 certification
BOILER TYPES:
There are virtually infinite numbers of boiler designs but generally they fit into one of two categories: (1) Fire-tube or as an easy way to remember "fire in tube" boilers, contain long steel tubes through which the hot gasses from a furnace pass and around which the water to be changed to steam circulates, and (2) Water-tube or "water in tube" boilers in which the conditions are reversed with the water passing through the tubes and the furnace for the hot gasses is made up of the water tubes. In a fire-tube boiler the heat (gasses) from the combustion of the fuel passes through tubes and is transferred to the water, which is in a large cylindrical storage area. Fire-tube boilers typically have a lower initial cost, are more fuel efficient and easier to
Natural Gas 1,000 Btu/Cubic foot F Oil 18,750Btu/lb Coal 12,500Btu/ton Wood (Dry) 8,000Btu/ton Wood (Wet) 4,000Btu/ton
In a fuel oil fired boiler plant, fuel oil leaves the tank through a suction line and duplex strainer traveling then to the fuel oil pump. The fuel oil is then forced through the pump and then through the discharge line. From the discharge, line some fuel oil is burned and some returned to the tank through a regulating valve. In a natural gas, fired plant gas is supplied at a set pressure, which varies depending on the gas source. Gas systems are low pressure or high pressure. Through the regulator, gas is drawn into the burner and mixed with air supplied by a blower. This mixture is directed to the burner where it is ignited with the pilot light. In a high gas pressure system, gas passes through the regulator and gas is reduced to the proper pressure for the burner. Some boilers have combination burners, which can burn gas or fuel oil or a combination of both gas and fuel oil.
The quality of the reservoir water is checked weekly on Monday and maintained according to WHO standards for drinking water. Chemical laboratory personals are responsible for the tests and submit these results to shift engineer of boiler house. In ARL Boiler House (Utility Section), Four centrifugal pumps each with 100 Psi discharge pressure are housed, three standbys while one is in operation. From these pumps water is distributed as plant water, cooling water for merox and C-101 compressor, cooling of ID fan of Boilers 3 & 4, cooling of steam compressor, powerhouse and as makeup water for steam generation through water header distribution. Specification and other details of these pumps are as follow No. Of Make up Water Pumps Name Manufacturer Type P out 4 B, C KSB Pumps Centrifugal EIA-100/33 96 Psi or 3.5 Kg/cm2
The raw feed water being pressurized is allowed to enter the sandfilter-tank top after a strainer in-line of make-up water supply line. We have facility of one in service and other standby line for make-up water supply. Any maintenance or other jobs in water lines allow the smooth operation by other. A connection is also given to brine water pump for its priming and to soda plant facility for dilution and operational need. All the three sand filter tanks remain in operation/ running. The bottom furnishes the turbidity-free or much lowered TSS (Total Suspended Solids) feed water. A hosepipe taken from filters discharge serves in brine solution preparation by supplying raw water to the brine pit. Details of filters are as follows
Name No of Items Volume Filter Media Mesh Size Volume of Filter Media Operational Duration before Backwash P in P out Temperature
Softener receives hard water from top, where Amberlite IR 120 Resin granules through ion exchange method, make water soften by accepting the hardness-producing ions (Mg+2 & Ca+2) respectively, leaving the system water with soft ions (Na+1). Regeneration of exhaust Resin bed is carried out with 11w/w NaCl brine solution. Brine solution is supplied to softeners for regeneration from brine solution tanks via brine solution pump. Filtered water is taken from the inlet of softner-B line for ammonia solution preparation, which is used in deaerator for PH control. Specifications of softners are as follows Name No of items Type P in P out Design Temperature Vol of Vessel (Capacity) Vol of Media Type of Filter Media Resin Size Size of Nozzle Operational Duration Regeneration Chemical Used Quantity Quality Design Pressure Corrosion Allowance Empty weight of Vessel Na-zeolite softners 3 Gel type strongly acidic cation exchange resin 46 Psi or 3 bar 35 Psi or 2 bar 100 F 3.5 m3 1826 Liter each Sulphonated Polystyrene Resin 0.64 mm 0.25 mm 370 tons of Water before exhaustion Brine 8.2 m3/hr 11 w/w of NaCl 72.6 Psig 0 1600 Kg
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Clear 7.5 412 ppm Odourless/tasteless 36 ppm 10 ppm 247 ppm 270 ppm 0.2 ppm 190 ppm 57 ppm Nil Nil Nil 275 ppm 50 ppm
After the softening of the raw water one line goes to Tanks 152,153,154 for the storage of soft water whose level are maintained at 100%. From the same line of soft water a connection is taken for the process of producing steam. Low lift pumps are installed to increase the pressure up to system requirement. Specification details of these pumps are as follow. Name Low Lift pumps
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A pressure regulating assembly is attached with low lift pumps to regulate the system pressure and works on the system set pressure settings. After the low lift pumps the soft water is distributed into three branches one goes directly to deaerator which acts as bypass line for the heat exchangers train, one to Heavy Crude Unit HCU for the steam production in Kettle re-boiler for the system requirement and one to the heat exchangers train. The two low-lift pumps (~ 6 kg/cm2 discharge pressure each), one working while other being standby, takes the soft water after passing through angle-type strainer & pre-heats it in the heat exchangers no.02 & 03 with the exhaust of Lummus steam. The heating media of heat exchanger no.01 comes from flash vessels that receive CBD and IBD of Descon Boilers system. There are three parallel heat exchangers installed with no pressure and temperature gauges. There details should be taken from Technical Services Department. From the pre-heaters train soft water goes to mechanical deaerator where the oxygen and other dissolved gases are stripped off the water
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We have facility of pumping condensate back to plants on their demand through pumps whose specifications are as follows. Also if plants need low temperature condensate, the condensate to plants pump pumps the condensate to heat exchanger no.01 and after achieving required temperature condensate are sent to plants. Name No of Items Manufacturer Type Capacity Head HP RPM Motor Specification Rotor Condensate to Plants Pumps 2 KSB Pumps MOVI 32/5 15 IGPM 345 feet 3.35 2870
KL 16
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The pressure in deaerator is slightly above the atmospheric pressure and maintained at 0.06 Kg/cm2 gauge. This serves as the mechanical de-aeration system to remove oxygen and carbon-di-oxide in boiler feed water. Specifications of deaerator is as under Type Manufacturer Design Temperature Design Pressure Hydrotest Pressure Capacity Diameter Shell Thickness Head Thickness Mechanical Deaerator System Descon Engineering Limited 120 C 150 PsiG 187 PsiG 39.6 T/H 2200 mm 10 mm 10 mm
Only oxygen scavenger i.e. Na sulphite (19P) is used into the Deaerator. All the rest chemicals (scale inhibitorNalco 72210 phosphate based & alkaliner NH3 gas) are injected as per demand into the discharge of Feed Water Pump whose specifications are as follow Name No of Items Capacity Total Head Pump Input Drive Rating Liquid Temperature RPM Discharge Pressure Feed Water Pumps 3 30 TPH 16 barG 27.66 HP 40 HP Soft water 105 C 2900 17 Kg/cm2
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Boiler Feed Water General Specification PH Value at 25 C Hardness Oxygen as O2 Carbon Dioxide as CO2 Total Iron as Fe Total Copper as Cu Oil Boiler Water PH at 25 C P-Alkalinity Oxygen as O2 Carbon Dioxide as CO2 Total Iron as Fe Total Copper as Cu Oil
Clear, Color less and free of mud <9 < 0.02 meq/Kg < 0.02 mg/Kg < 25 mg/Kg < 0.1 mg/Kg < 0.005 mg/Kg < 1 mg/Kg
9 0.1-1 meq/Kg 0.02 mg/Kg 25 mg/Kg 0.1 mg/Kg 0.01 mg/Kg 1 mg/Kg
At ~ 16 kg/cm2, the feed water pump discharge directs to all the five Boilers (Descon & B&W). This soft water then passes through the economizer, absorbing the much valuable energy contents from the flue gases. Details of Descon system are as under but no information is gathered on B & W Boilers. Type Fire Tube Boiler
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12 T/H 15 BarG 12.5 BarG 193.3 C 105 C 22.5 m3 35.8 m3 657 mm 120 mm 50 mm 70 mm 14.0 BarG and 16.5 BarG 90 +- 2% 90 +-2 %
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120.7 C 232.5 C 150 C (On Gas) 175 (On Oil) Water Tube Boiler Bobcock & WellCock Company 2
Type Manufacturer No of Items Boiler Data Continous Steam Output Boiler HydroTest Pressure Operating Pressure Saturated Steam Temperature Feed Water Temperature High Water Level HWL Alarm Low Water Level LWL Drum Safety Valve Set Pressure Super Heater Safety Valve Efficiency Of Boiler Oil Firing Gas Firing Economizer Hydro Test Pressure
7 T/H 20 Kg/cm2 13 Kg/cm2 195 C 105 C 80% 40% 218.5,219,220 Psi 217 Psi
19 Kg/cm2
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165 C 220 C
The total average steam production is ~ 17-18 T/H. CBD (Continuous Blow Down) from the Boilers ~ 3 T/H, is forwarded to flash vessel where the steam enters the heat exchanger as discussed earlier, & the bottom is sent to condensate tank. Condensate from the plants also comes to the condensate tank where soft water is showered to recover the treated water. This recycled water is used in de-aerator. The steam from combined header is distributed to all the units. The complete PFD of the ARL boiler house with water, steam, fuel oil, fuel gas, service and instrument air is drawn and delivered to the Mr. Muhammad Anwar as future assistance and helpful material for newcomers trainees.
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