Chennai 

Petroleum Corporation Limited
(A Group company of IndianOil)

Refining Process, Refinery Configuration

& Design Aspects

Slide 1
PRESENTATION PLAN

REFINERY PROCESSES

REFINERY CONFIGURATION

PROJECT DESIGN ASPECTS

Slide 2
REFINERY PROCESS - Overview

STEPS IN REFINING PROCESS

SEPARATION PROCESS

CONVERSION PROCESS

FINISHING

Slide 3
 REFINERY PROCESSING STEPS

Crude oil Separation Conversion Finishing

Objective – Breaking up a - Fundamentally changing – Improving the

mixture into its the chemical structure qualities of
components of a product by: products by:
• Breaking down • Blending products
molecules of different
• Combining qualities to get an
molecules optimal mix
• Rearranging • Treating products
structure (typically with
hydrogen) to
remove impurities

Examples – Distillation/ – Coking – Gasoline blending

fractionation – Cracking – Hydro-treating
– Extraction – Alkylation (combining)
– Isomerization
(rearranging)

Slide 4
SEPARATION PROCESS

Slide 5
DISTILLATION COLUMN

Slide 6
 DISTILLATION PRINCIPLE

Separation of components from a liquid/vapor mixture via

distillation:
Depends on the differences in boiling points of the
individual components

Depends on the concentrations of the components

present
Hence, distillation processes depends on the vapour pressure
characteristics of liquid mixtures.

Slide 7
DEW POINT , BUBBLE POINT AND RELATIVE VOLATILITY

The Dew-point is the temperature at which the

saturated vapour starts to condense.

The Bubble-point is the temperature at which the liquid

starts to boil.

Relative volatility is a measure of the differences in

volatility between 2 components, and hence their boiling
points. It indicates how easy or difficult a particular
separation will be.

Slide 8
 MAIN COMPONENTS OF DISTILLATION

Column

Column internals
Trays
Packing

Reboiler

Condenser

Reflux Drum

Slide 9
 OPERATING VARIABLES

• Temperature

• Pressure

• Draw off and reflux rates

• Pump around

• Stripping steam rate

Slide 10
 CRUDE- FEED PREPARATION

Effect of Bottom, Sediments & Water:

– Deteriorates equipment performance

– Shorter run length
– High Energy Consumption

This can be achieved only by proper feed preparation.

Impurities in crude:
– Inorganic salts
– Acids

Desalting helps to remove these impurities

Slide 11
 PREHEAT TRAINS & FURNACE

Pre-heat trains:

–Utilize the heat available in the products and PA

–Reduces the fuel consumption in the furnace

Furnace:

– Natural draft

– Forced Draft

– Balanced Draft

Slide 12
ATMOSPHERIC DISTILLATION

Slide 13
VACUUM DISTILLATION

Slide 14
 VACUUM DISTILLATION

Vacuum distillation can improve a separation by:

• Prevention of product degradation

• Reduced mean residence time especially in columns using packing

rather than trays.

• Increasing capacity, yield, and purity.

• Reduced capital cost, at the expense of slightly more operating cost.

Slide 15
CRUDE DESALTER

Slide 16
CRUDE FURNACE

Slide 17
CRUDE ATMOSPHERIC COLUMN

Slide 18
 Lube Oil Base Stocks

• SPINDLE
• LIGHT NEUTRAL
• INTERMEDIATE NEUTRAL
• 500 NEUTRAL
• HEAVY NEUTRAL
• BRIGHT STOCK

Slide 19
 LUBE PROPERTIES

Properties / Viscosity Viscosity Pour Point

Components Index
Paraffins Low High High

Naphthenes Medium Medium Medium

Aromatics High Low Low

Slide 20
 LUBE PROCESSING STAGES

S.NO PROCESS PROPERTY

CONTROL
1 Vacuum Distillation Viscosity,
Flash Point
2 Solvent Extraction/ Viscosity Index

3 Solvent Dewaxing / Iso- Pour Point

Dewaxing
4 Hydrofinishing Colour / Oxidation
Stability

Slide 21
 LUBE PROCESSING BLOCK

Crude Furfural 
Atm. Distl 
Column Extraction 
Unit

MEK  Lube 
Extract Raffinate DWO LOBS
Dewax  HyFi 
RCO
Unit Unit

NMP 
Vac. Distl Extraction 
Vacuum
Unit
Distillatn 
Column
DAO
Extract Slack Wax

Vac.
PDA 
Residue Unit Pitch

Slide 22
 WAX PROCESSING
INERT GAS

NH3
REFRIGERATION

SOLVENT
RECOVERY HY.FI PRODUCT
FILTERS UNIT
FROM WAX STORAGE

FEED CHILLING

DEOILED WAX
STORAGE
SOLVENT
RECOVERY
FROM
FOOTS OIL FOOTS OIL
Slide 23
CONVERSION AND TREATING PROCESS

Slide 24
 CONVERSION AND TREATING PROCESS

•Conversion Process:

Thermal processes

Catalytic processes

•Treating Process

Catalytic processes

Chemical treating process

Slide 25
 THERMAL (VISBREAKER UNIT)

Mild thermal decomposition (vis‐breaking)

Reduction of viscosity & pour point of feed

Desirable Reaction – Cracking

Some polymerization condensation reaction also occurs–
Coke formation

Slide 26
 THERMAL (VISBREAKER UNIT)
0.95 kg/cm2 GAS

160˚ c
GAS
96˚ c 9.8 kg/cm2
39

26 210˚ c STAB NAPHTHA
Stabiliser

GO
STEAM
130˚ c
426˚ c 25 mmhg GAS + SLOPS

7.7 kg/cm2

LVGO

300˚ c 380˚ c HVGO

VISBREAKER
STEAM
440˚ c
FEED VACUUM 
300˚ c FLASHED
FRACTIONATOR CRACKED 
HEATER SOAKER VACUUM RESIDUE
FLASHER Slide 27
(Thermal) Delayed coking

Slide 28
 CATALYTIC (REACTORS)
Reactor Design
Better performance and operational flexibility can be
achieved:
–Choice of catalyst

–Choice of feed

–Operating conditions

–Reactor configuration

–Synergy with other units

–Better internals

Slide 29
 REACTOR INTERNALS
Inlet nozzle
Distributor nozzle

Debris basket 

Alumina Catalyst
balls 

Catalyst unloading 
nozzle
Outlet nozzle Screen Slide 30
 REACTOR INTERNALS
Inlet nozzle
Distributor nozzle

Debris basket 

Alumina Catalyst
balls 
Quench

Catalyst

Catalyst unloading 
nozzle
Outlet nozzle Screen Slide 31
 CATALYTIC REFORMING

CHEMISTRY:
• De‐hydrogenation

• Isomerisation

• De‐hydro‐ cyclization

• Hydro‐cracking

Slide 32
 CATALYTIC REFORMING
DEHYDROGENATION:

C7H14 ‐‐‐>  C7H8   +   3H2
Methylcyclo hexane Toluene

RON: 73.8 119.7

• Reaction is highly Endothermic
• Promoted by low pressure and high temperature
• Occur on metal site (Platinum)
• Fastest reaction in Reforming

Slide 33
 CATALYTIC REFORMING
ISOMERISATION:
Naphthene Naphthene Aromatic

C + 3H2

Methy Cyclo Pentane Cyclo Hexane Benzene

RON - 89.3 RON - 110 RON - 120

• Reaction is mildly Exothermic

• Occur on acid site(Al2O3 and HCL)

• Second fastest reaction in Reforming.

Slide 34
 CATALYTIC REFORMING
DEHYDROCYCLISATION:
Aromatic
Paraffin
C
-C-C-C-C-C-C-C- + 3H2

n-Heptane Toluene
RON 0.0 119.7

•Reaction is Endothermic

•Promoted by low pressure and high temperature

•Occur on acid and metal site

•Slowest reaction in Reforming

Slide 35
Naphtha Hydrotreating & Cat. Reforming

Naphtha

Impurities: S,N,
Metals Naphtha
Hydrotreating
Hydro treated
Risk of poisoning
Naphtha
CCR catalyst
Impurities:
Nil or low

No Risk of
poisoning
CCR catalyst
Reformate
High Octane
Low octane
Number: 102
number
Continuous
Catalytic
Reforming
Hydrogen
Rich gas

Slide 36
NHT CCR

Slide 37
CCR REACTOR-REGENERATOR

Slide 38
 NHT ISOM

NHT Section - Main reactions

• Hydrorefining reactions
• removal of impurities
• Desulfurization
• Denitrification
• Hydrogenation reactions
• saturation of the olefins and diolefins
• Demetallation reactions
• removal of metallic impurities

ISOM Section - Main reactions

• Benzene hydrogenation to form cyclohexane
• Isomerization (eg. N-pentane to i-pentane)

Slide 39
 NHT ISOM
R2
R1 F1
Recycled H2

Diene Reactor
C1 C2

HDS Reactor
K2 A/B To R1
Feed NHDT C4
Surge Drum
Feed Heater Separator
Naphtha

NHDT Stripper
H2 Dryer
C13
R4 R3

Second Isomerization
K1A/B C17

Isomerization
C16

Heart cut Naphtha

Make-up H2 compressor

Reactor
Reactor

First

Feed Dryer

Splitter
C19
Light Isomerate
Storage
Stabilizer
Isom
Deisohexanizer

LPG Product
C22 To FCC
C5/C7+ Cut
LPG Separator

LPG Stripper

C29 C30

Heavy Isomerate
To Isomerate Storage
Slide 40
 HYDROCRACKER BLOCK

Reaction Chemistry
• Hydro-treating Reactions
a) Demetallization
b) Desulfurization
c) Denitrification
d) Olefins Saturation
e) Aromatics Saturation

• Hydrocracking Reactions

Catalyst (Ni3S2)
CnH2n+2 + (x-1) H2 x C n/xH2n/x +2 + Heat

Slide 41
 HYDROCRACKER

Make-up H2. Recycle gas Make-up H2

compressor Amine
(RGC)
treating from HGU

Quench Make-up H2
H2 Gas compressor
Recycle gas
Off-gas to PSA
Feed (for
VGO preheating Reactors HP H2 recovery)
feed and Furnace
172.5 Kg/cm2
filtration gas separator
3780C
LP
Liquid hydrocarbon gas separator

Fuel gas (to header)

Lighter hydrocarbons Light end LPG (to storage)
recovery Light Naphtha (to MS pool / HGU)
section Heavy Naphtha (to Diesel pool / CRU)
Product
Lighter hydrocarbons
stripper

Heavier
hydrocarbons Kerosene / ATF
3600C
Furnace Fractionator
Diesel..

UCO (to FCCU) Slide 42

CPCL HYDRO CRACKER

Slide 43
 Products to
Main Column

FLUID CATALYTIC CRACKING UNIT

Reactor
Flue 500°C
Gas
680°C Flue Gas
Slide Valve

Stripping
Steam
Regenerator
650°C

Spent Catalyst
Slide Valve

Air
43000 Regenerated Catalyst
Raw OiL
nm3/hr Slide Valve
120 m3/hr
Catalyst circulation
370°C
10 MT/min
Slide 44
FINISHING PROCESS

Slide 45
DHDT UNIT (Hydrodesulphurization)

Slide 46
 DHDT REACTOR

Parameters SOR EOR

Reactor Inlet Pressure, kg/cm2g 77.7 79.6
Reactor Inlet Temp, C 331 375
Reactor Outlet Temp., C 351 388
Reactor Outlet Pressure, 75.0 75.0
kg/cm2g

Reactor Dimensions
Height, m 31.3
Width, m 4.4

Slide 47
 SULFUR RECOVERY UNIT

Chemical Reactions

Step 1:
H2S + 1 ½ O2 → SO2 + H2O + Heat

Step 2:
2H2S + SO2 → 3/n Sn + 2 H2O + Heat

Overall reaction of Claus Process

3H2S + 1 ½ O2 → 3/ n Sn + 3 H2O + Heat

Slide 48
 Sulphur Recovery Block

rich amine to ARU

Acid Gas
Amine
rich amine from
Lean amine Regn.
process units
(ARU)
Thermal
Sulphur Recovery Unit

Tail Gas Converter

Treating lean amine

Catalytic
Converters 2-stage Sour water from
SWS process units
Unit
Sulphur
stripped
water

Slide 49
CPCL SRU

Slide 50
 PRESENTATION PLAN

1. REFINERY PROCESSES

2. REFINERY CONFIGURATION

3. PROJECT DESIGN ASPECTS

Slide 51
 Refinery Configuration
Key Considerations & Available Options

Slide 52
 A TYPICAL REFINERY CONFIGURATION
Ref. Fuel
GAS Gas System LPG
Amine
Treating
CRUDE   Amine  Sulphur  PROPYLENE 
OIL LPG Amine/ Merox Regeneration Recovery PBFS/ MEKFS
STORAGE
Treating
HEXANE
NHT/ ISOM Isomerate
LT. NAP Naphtha Naphtha (45‐90 C) H2
Hexane Plant MS
Atmospheric
Distillation

Splitter
Hydrogen (H2)
Hydrogen
Generation NAPHTHA
Naphtha (90 ‐130C)
HY. NAP Catalytic  Reformate
Reforming
ATF
ATF ATF Treating
SK
Diesel SK
DHDS/ DHDT
Long 
H2 DIESEL
Residue LUBE Distillates
Extraction Dewaxing Lube HDT
LUBE OIL 
Wax Deoiling & Wax  Hydro finishing BASE STOCKS

VGO PARAFFIN
Distillation

Hydrocracker WAX
Vacuum

VB VGO/ HCGO
LCGO / VB Gas Oil

Coker Naphtha

LCO/ HCO
VB Naphtha

LPG Propylene  FO
Treating Recovery
UCO
FCCU ASPHALT
Cracked 
Merox Treating Gasoline
LPG
Short SULPHUR
Residue Visbreaking
Biturox Unit
Delayed Coking COKE

LCGO  HCGO Slide 53

Global Economic Downturn & Recovery

Slide 54
Global Oil Outlook

Slide 55
 India - Net Oil Import Dependence

Reference: IEA WEO 2009

Slide 56
Projects Classification

Slide 57
 Drivers for New Projects Identification
• Supply – Demand Balance

• Change in the market scenario

• Impact of products Slate / demand (Zero FO export, Dieselization,

etc.)

• Stringent Product Specifications

• Environmental improvement / regulations

• Profitability through capacity expansion

• Diversification into new areas

• Achieving overall economics of scale in operations

Slide 58
 Impact of Product Demand
Global Product Demand 2009 to 2030

Reference: OPEC WOO 2010

Slide 59
 Stringent Product Specifications
GASOLINE Euro-III Euro-IV Euro-V
Sulphur, ppm 500 150 50 10
RON, min 88 91 91 95
MON, min - 81 81 85
RVP (max), Kpa 60 60 60 60
Benzene (max), vol% 5/3 1 1 1
Aromatics (max), vol% - 42 35 35
Olefins (max), vol% 21 21 18

DIESEL Euro-III Euro-IV Euro-V

Sulphur, ppm 500 350 50 10
Cetane Number 48 51 51 51
95% recovery, °C 370 360 360 360
Flash Point (Abel), °C 35 35 60

Product Spec Changes Mean More Complex Refineries

Slide 60
 Drivers for Revamp Projects Identification

• Capacity Expansion

• Quality Improvement of products

• New Technology Implementation

Slide 61
 Crude Feed Selection

High Sulphur Crudes (Dubai-Brent crude spread)

Heavy Crudes

High TAN crude

High nitrogenous / mercuric crude

Tar Sands, Oil Shales

Slide 62
 Trend in Crude Processing
Heavy/Sour Crudes

• Over half of world’s oil supply is heavy & sour crude

• New refineries built with capability to handle heavy crudes.

• Marker Crude Dubai rose higher than Brent in Dec ‘08 due to
– Rise in demand for sour crude
– OPEC production cuts, etc.

• Not only is sour crude seeing more demand growth, it also

outstrips light, sweet crude in production growth.

• Share of sour, heavy crude is likely to increase vis-a-vis light,

sweet crude.
Slide 63
 Processing of Opportunity Crudes
High TAN Crudes
• The Total Acid Number (TAN) is the amount of potassium hydroxide in
milligrams that is needed to neutralize the acids in one gram of oil
• TAN >1.0 leads to NAC (naphthenic acid corrosion)
• Share of High TAN crude in overall oil production
– Current - 20%
– In next five years - 25%
• Acidic Crudes Characteristics
– Yield low ‘S’ Gas Oil
– Low Cetane value
• Handling of Acidic Crudes
– Blending with non-acidic crudes & Specialized Metallurgy & Chemical
Injection for corrosion abatement

• E.g.)– Penglai (Australian), Duri (Indonesian), Marlim (Latin America), etc.

Slide 64
 Processing of Opportunity Crudes
High Pour Crudes

• High Pour Crudes need to be blended with normal crude for

pipeline transportation.

• Pricing benchmark of these crudes need to be considered for

economic viability.

• Processing of high pour crudes also require Coker facilities

within the refinery.

• For example: Handil (Indonesian), Rajasthan crude

Slide 65
 Types of Refineries

• Topping Refinery

• Skimming Refinery

• Cracking (hydro/catalytic) Refinery

• Coking refinery

• Integrated Refinery

• Lube Refinery

Slide 66
 Processing Units in Oil Refineries

• Primary Processing Units

– Distillation
– Blending
• Secondary Processing Units
– Catalytic Cracking
– Hydro-cracking
– Catalytic Reforming
– Isomerization / Alkylation, etc
• Bottom Upgradation Units
– Visbreaking
– Delayed Coking
• Treating Units
– Hydrotreating

Slide 67
 BORL Configuration, Bina, M.P

Units Capacity (MMTPA)

Crude / Vacuum Distillation Unit
6.0
(65% Arab Light and 35% Arab Heavy)
Full Conversion Hydrocracker 1.95
Diesel Hydrotreater 1.63
Delayed Coker Unit 1.36
Hydrogen Unit 0.07
Naphtha Hydrotreater 1.0
CCR Reformer Unit 0.5
Isomerization Unit 0.3
Sulphur Recovery Unit 2 x 180 MTPD

Slide 68
 Refinery Configurations
Cases Studied
S.No SECONDARY UNITS RESID UNITS
1 VGO HDT + Petro‐FCC DCU
2 OHCU + Conv‐FCC DCU
3 Full Conv. HCU + DHT (Integrated) DCU
4 VGO HDT + Petro‐FCC SDA + Slurry HCU
(50% DAO)

5 OHCU + Petro‐FCC SDA + Slurry HCU
(50% DAO)

6 Full Conversion HCU SDA + Slurry HCU
(50% DAO)

7 Conventional FCC DCU
8 Full conversion HCU DCU
9 VGO HDT + Petro‐FCC  SDA + Slurry HCU
(60% DAO)

10 OHCU + Petro‐FCC SDA + Slurry HCU
(60% DAO)

11 Full conversion HCU SDA + Slurry HCU
(60% DAO)
Slide 69
 Sample Block - VGO HT + PFCC + DCU
LPG
ALKYLATION

PPU
POLYPROPYL
ENE
NHT/CCR/ISOM

Euro IV
GASOLINE

CDU/
VDU
Euro V
GASOLINE
DHT
VGO 
HDT

KERO

DCU Euro IV
GASOIL

Euro V
FCC‐PC GASOIL
FCC Nap.Splitter

BITUMEN

COKE

Slide 70
Sample Block - FC HCU + DHDT + Slurry HCU
LPG
ALKYLATION

NHT/CCR/ISOM 

Euro IV
GASOLINE

CDU/
VDU
Euro V
GASOLINE
DHT

KERO

Euro IV
GASOIL

HCU Euro V
GASOIL

SDA Slurry 
HCU BITUMEN

COKE
Slide 71
 Refinery Power & Utilities

• Raw water & Drinking water system

• Compressed air system
• Fuel gas system
• Fuel oil system
• Condensate Recovery system
• Nitrogen System
• Cooling towers
• DM water treatment plants
• Generation & Distribution of steam
• Generation & Distribution of Power
• Flare system

Slide 72
Slide 73
Refinery ‐ Integration Benefits

Processing
Supply Products Distribution
Treating

Environmental
Concerns

Asset
Utilization

Slide 74
 Integration with Petrochemicals
Petrochemical Sector: 13% annual growth projected
Major Petrochemicals : Ethylene, Propylene, Butadiene, PVC, HDPE, BTX, etc.

Crude Oil

Associated Gas Naphtha Naphtha

Ethane LPG Methane

Olefins Aromatics

Ethylene Propylene C4s PyGas Benzene Toluene Xylene

Slide 75
 Integration with Petrochemicals
Cases Studied

Case-1: VGO HDT, FCC-PC, DCU, AC and PC

Case-2: OHCU, FCC-PC, DCU,AC and PC

Case-3: OHCU, DCU, AC and PC (in this case OHCU bottoms are
routed to Naphtha Cracker)

Case-4: VGO HDT, FCC-PC, LC Fining, AC and PC

Case-5: Part MRDS, DCU, FCC-PC, AC, and PC

Slide 76
 Integrated Refinery with Aromatics complex

HY.
CDU / FCCU / NAPHTHA HEAVY NAPHTHA
OHCU / DCU HDT REFORMER
CCR
SPLITTER

LT. REFORMATE SULFOLANE EXTRACTION UNIT

BENZENE 340 TMT
BENZENE TOLUENE EXTRACTION
TRANS ALKYLATION

HY. REFORMATE
XYLENE FRACTIONATION UNIT
PARA XYLENE 800 TMT
XYLENE ISOMERISATION
PARA XYLENE SEPARATION

Slide 77
 Integrated Refinery with Petrochemical Block

PART DIESEL
FROM DHDT
VGO ETHYLENE
Syn. Diesel/ HY. NAPHTHA
Vac. GASOILS /
DHDT CRACKER
Crk. GASOILS Naphtha
UNIT UNIT FCC OFF GAS
CPCL NAPHTHA
PROPYLENE
668 TMT
ETHYLENE
1200 TMTPA
SWING UNIT LLDPE / HDPE
362 TMT

HDPE UNIT HDPE

400 TMT

MEG
MEG UNIT 700 TMT
DEG
135 TMT

Slide 78
 FCC Unit with Petrochemical Block

FCCU PC

POLY
PROPYLENE PROPYLENE POLY PROPYLENE
RECOVERY UNIT PROPYLENE UNIT
432 TMT 1120 TMT
CRACKED LPG

PROPYLENE EX-
CRACKER
668 TMT

Slide 79 of 64
Slide 79
 Refinery – Power Integration
Gasification:  A  commercially  proven  process  that  converts 
hydrocarbons  such  as  heavy  oil  /  petroleum  coke,  and  coal  into 
hydrogen and carbon monoxide (synthesis gas).

4 CH + 2 H2O + O2 4 H2 + 4 CO
(Fuel) (Water) (Oxygen) (Hydrogen) (Carbon Monoxide)
“Syngas”
Gasification Technology

•Competitive with unconventional & alternative resources

•Extensive commercial application
•Generate value added products
•Feedstock and product flexibility

Slide 80
 Gasification – Multiple Segment 
Options
Fuels by F-T
Synthesis

Power

PetCoke/ Syngas
Hydrogen /
Coal Power / Steam

Sulphur
Chemicals

SNG thru’
Slag
Methanation

Slide 81
 Refinery – Power Integration
Coke from Coker Unit can be Gasified to produce Syngas & Power / Hydrogen

Slide 82
 Project – Execution Methodology
Phase-I Phase-II
Conceptualization of Project Project Completion

Project Formulation Carry out PGTR

Preliminary Feasibility Unit Start-up & Stabilization

Report (PFR) Stage

Pre-Commissioning &
Licensor Selection Commissioning stage

Process Package Preparation Mechanical Completion of the unit

Detailed Feasibility Report (DFR)

Project Implementation Phase

Final Investment Approval from Board

Slide 83
 Phase-II Breakdown Structure
PFD REVIEW

P&ID REVIEW

ENGINEERING KICKOFF

FLUSHING/
HAZOP & 3D MODELING LEAK TEST

P&ID
ORDERING/FABRICATION CHECK/INERTING

1ST DRYOUT
ERECTION/CONSTRUCTION
CAT. LOADING

2ND DRYOUT
P&ID CHECK/INSPECTION
FINAL INERTING

PRE-COMMISSIONING
FEED CUT-IN

START-UP & PGTR

Slide 84
Parameters Studied during the Project Evaluation

Various Refinery Configurations will be evaluated based on

• Economic Feasibility
• Capex & Opex of projects
• Yield of Distillates
• Refinery Margins
• Plot Plan Availability

• Financial Appraisal
• Net present value
• Internal Rate of Return

Slide 85
 Financial Appraisal
• Financing Assumptions
• D/E ratio, interest rate, repayment tenor, moratorium period, etc.
• Macro-economic assumptions

• The net GRM for the project worked out by deducting

• Operating Costs

• Net incremental cash flows to the project worked out by deducting

• Tax Outgo
• Capital investment
• Net working capital from the net benefit
• Financial viability of the project established by computing post-
tax IRR and NPV
Net Incremental Cash Flows = [ Incremental GRM ] less [ Opex +Income Tax +
Core Capital Investment + Increase in Net Working Capital ]

Slide 86
 PRESENTATION PLAN

1. REFINERY PROCESSES

2. REFINERY CONFIGURATION

3. PROJECT DESIGN ASPECTS

Slide 87
PROJECT DESIGN ASPECTS

Slide 88
 Design Aspects

• Unit/Equipment Design Philosophy – (Margin & Turndown)

• Battery limit philosophy for units

• Vacuum Design

• Instrumentation Philosophy

• Metallurgy of Equipments (e.g. DSS for Water Coolers)

• Piping Material Specifications

• Energy efficiency / integration systems

• Adherence to Standard Design & Codes

Slide 89
 Codes & Standards
BIS Bureau of Indian standards

ASME American Society for Mechanical Engineers

API American Petroleum Institute

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

AISI American Iron and Steel Institute

AWWA American Water Works Association

SSPC Steel and Structure Painting Council

MSS-SP Manufacturer Standardization Society - Standard Practice

NACE National Association for Corrosion Engineers

BS British Standard Specification

Slide 90
 Codes & Standards
• ASME Codes
• For Mechanical devices such as pressure vessels, boilers
• (e.g.) ASME Section 8, B 31.3 : Standards of process piping

• API Standards
• Designed to help users improve the efficiency and cost-effectiveness
of their operations
• (e.g.) API 610 : centrifugal pumps
• (e.g.) API 682 : mechanical seals
• (e.g.) API 6D : Pipeline Valves
• (e.g.) API 560 : Fired Heaters
• (e.g.) API 616 : Gas Turbines
• (e.g.) API 617, 618 : Compressors

Slide 91
 Other Codes & Standards…contd.
• IS (Indian Standard) Codes
• For civil works and construction
• (e.g.) IS-456 for Plain & Reinforced Concrete

• TEMA Standards
• For Heat Exchangers

Slide 92
 Meteorological Design Data
Sl# Parameter Minimum Normal / Maximum /
Average Design
(A) METEOROLOGICAL DATA
1 Elevation above mean sea level, m 3.5
2 Barometric pressure, mbar
3 Ambient temperature, °C tmin =18 tnor = 35 tmax =45
4 Relative humidity, % @ tmin @ tnor 80% @ tmax
5 Rainfall data (mm) (a) for 1-hour 100
period 450
6 Wind data (a) (b) wind
for 24-hour
velocityperiod 180 km/hr (as per
IS:875 Part-III).
(b) wind direction North East & South
West
(B) DATA FOR EQUIPMENT DESIGN
1 Design dry bulb temperature, °C 38
2 Design wet bulb temperature, °C 29
3 Low ambient temperature for MDMT, °C NA
4 Design air temperature for air cooled exchangers 40
where followed by water cooling, °C
5 Design air temperature for air cooled exchangers 42
where not followed by water cooling, °C
6 Coincident temperature and relative humidity for Air Blower / Air Compressor 80 % at 45 o C
design.
7 Min. Design temperature for equipment 65 o C
Slide 93
 Plant Life

• Default plant operating life as 15 years with 5% salvage value will

be considered for economic calculations.

• The default plant equipment design life shall be taken as follows:

a) 30 years for heavy wall reactors and separators
b) 20 years for columns, vessels, heat exchanger shells and similar
services.
c) 12 years for piping, furnace tubes, High Alloy exchanger tube bundles.
d) 5 years for Carbon Steel / Low Alloy heat exchanger tube bundles.
e) 15 years for reactors removable internals

Slide 94
 Utility Conditions @ Unit Battery Limits
Sl Parameter Minimum Normal Maximum Mech Design
1 VERY VERY HIGH PRESSURE (VVHP) STEAM
Pressure, kg/cm2g 90 95 95 104/FV
Temperature, oC 495 505 505 505
2 VERY HIGH PRESSURE (VHP) STEAM
Pressure, kg/cm2g 44.8 48 54.9 58.0/FV
oC
Temperature, 379 425 435 440
3 HIGH PRESSURE (HP) STEAM
Pressure, kg/cm2g 29.5 30.5 32.5 36.0/FV
Temperature, oC 270 280 290 300
4 MEDIUM PRESSURE (MP) STEAM
Pressure, kg/cm2g 9.5 10.5 12.5 15.0/FV
oC
Temperature, 200 220 240 280
5 LOW PRESSURE (LP) STEAM
Pressure, kg/cm2g 2.7 3.5 4.0 7.0/FV
Temperature, oC Saturated 170 190 240
6 CONDENSATE RETURN
Pressure, kg/cm2g 5.0 13
Temperature, oC 140-150 210
7 SERVICE WATER
2g
Pressure, kg/cm 6.0 10.5
Temperature, oC Amb. 65
8 COOLING WATER
2g
Supply Pressure, kg/cm 4.5 8.0
Return Pressure, kg/cm2g 2.5 8.0
oC
Supply Temperature, 33 65
Return Temperature, oC 45 65
9 DEMINERALISED WATER
Pressure, kg/cm2g 7.0 8.0 9.0 14..0
Temperature, oC Amb. Amb. Amb. 65

Slide 95
 Utility Conditions @ Unit Battery Limits

Sl Parameter Minimum Normal Maximum Mech Design

10 BOILER FEED WATER (MP/HP)
Pressure, kg/cm2g 19.0/38.0 29.0/55.0
Temperature, oC 105-110 150/150
11 PLANT AIR
Pressure, kg/cm2g 5.0 6.0 6.5 10.0
Temperature, oC Amb. Amb. Amb. 65
12 INSTRUMENT AIR
Pressure, kg/cm2g 5.0 6.0 10.0
Temperature, oC Amb. Amb. 65
13 FUEL GAS
Pressure, kg/cm2g 2.5 3.0 3.8 7.0
Temperature, oC 40 65
14 REFINERY FUEL OIL
Supply Pressure, kg/cm2g 10.0 12.0 17.5
Return Pressure, kg/cm2g 2.5
Temperature, oC 80 165-200 220 250

15 SURFACE CONDENSATE (EX TURBINE)

Pressure, kg/cm2g 6.0 15.0
Temperature, oC 40 100
16 NITROGEN
Pressure, kg/cm2g 5.0 6.0 7.0 9.5
Temperature, oC Amb. Amb. Amb. 65

Slide 96
 WATER SYSTEMS
Backflush arrangement shall be provided for
All cooling water consumers
Only overhead condensers
Cooling water consumers with water line sizes greater than ” NB.

Back flush lines to be provided with same size as main cooling water line when main line size is ≤ 6”. One size lower to be provided for main
line size > 6” For much higher line sizes e.g 14” and above to be decided based on case to case basis

Slide 97
 Water Quality
l Parameter Cooling Water Cooling Water DM BFW
make up ( from Water
TTP of ETP)
PH 7.2-7.5 7.2-7.7 6.8-7.2/8.3-8.5 8.5-9.5

Turbidity, NTU <2 <=30 Nil

Total suspended solids, < 10 mg/l <=30 mg/l
Total dissolved solids, 850-1050 mg/l 2500-3000 mg/l
Conductivity micro mho/cm 1200-1600 at 250C <=5000 at 250C < 0.3 at 25oC 0.3 max at 250C

Ca Hardness as CaCO3, 130-210 mg/l 500-750 mg/l

Total Hardness as CaCO3, 250-360 mg/l 850-1200 mg/l Nil mg/l Nil ppm

Total cation/anion asCaCO3,

Total Silica as SiO2, 20-25 mg/l 100-125 mg/l < 0.02 mg/l <0.02 ppm
Chlorides as Cl, 340-400 mg/l 800-1000 mg/l
Free chlorine, 0.3-0.6 mg/l
Sulphates as SO4, <500 mg/l
Organophosphates as PO4, mg/l 3-4 mg/l
Dissolved oxygen 0.005 ppmv
Total Iron as Fe, 0.01 mg/l <=1.0 mg/l Nil mg/l
Copper + Iron, 0.01 max
Lead as Pb, microgram/l
Mg , Hardness 120-150 mg/l
Zinc as Zn, 1.0-1.5 mg/l
Chromium as Cr, mg/l
Polymeric dispersant, 20-25 mg/l
Zinc Sulphate as Zn,
Dissolved Fe, mg/ l
Oil content, <10 mg/l Nil mg/l
KmnO4 value at 100 oC, <30mg/l Nil mg/l Nil ppm
Hydrazine (residual), 0.02 ppm
Morpholine (residual), 1(approx) ppm
Slide 98
 Water Quality…contd
l Parameter Treated Raw Water as DM water Desalinated water as DM water
Make up make up
PH 7 - 7.8 7-7.8
Turbidity, NTU 15 NA
Total suspended solids,
Total dissolved solids, NA mg/l 350
Conductivity micromho/cm NA 493
Mo Alkalinity, 240 (as CaCO3)mg/l 2.9 (as CaCO3)mg/l
Ca Hardness as CaCO3, 176 mg/l 1.3 mg/l (as Ca)
Total Hardness as CaCO3,
Total cation/anion asCaCO3, 608 NA
Total Silica as SiO2, 40 0.1
Colloidal Silica as SiO2, mg/l
Sodium as Na, 344 (as CaCO3) mg/l 135.3 (as CaCO3) mg/l
Potassium as K, mg/l
Chlorides as Cl, 172 mg/l 142-220 mg/l
Free chlorine,
Sulphates as SO4, 121 mg/l 12.5 mg/l
Poly phosphates as PO4,
Nitrates as NO3, NA mg/l 0.2 mg/l
Total Iron as Fe, 0.3 mg/l NA
Copper + Iron,
Mg , Hardness NA mg/l 4.5 mg/l
Zinc as Zn,
Zinc Sulphate as Zn,
Boron, mg/l NA 1 mg/l
Dissolved Fe, mg/ l
Oil content,
KmnO4 value at 100 oC, 20 mg/l NA
Hydrazine (residual),
Morpholine (residual),
Slide 99
 Compressed Air & Nitrogen System

Sl Parameter Plant Air Instrument Air

1 Dew Point at atmospheric pressure water-free (-)40oC

2 Oil Content, ppm nil nil

Sl Parameter Inert Gas Nitrogen

1 Dew Point at atmospheric pressure (-) 100oC

2 Oil Content, ppm nil

3 Nitrogen purity, vol% 99.99
4 Oxygen content, vol ppm 3 (max)
5 Carbon dioxide content, vol ppm 1 (max)
6 Carbon monoxide content, vol ppm nil

Slide 100
 Refinery Fuel Systems

Liquid fuel system for the project shall be one of the following.
No liquid fuel system applies to the project.
Existing liquid fuel system in Refinery III shall cater to the project,
After Augmentation, if required. Alternately, new liquid fuel system
shall be provided.

Fuel gas system for the project shall be one of the following.
No fuel gas system applies to the project.
Existing fuel gas system in Refinery III shall cater to the project,
After Augmentation, if required.
New fuel gas system for the total project:
(a) Integrated to existing facility
(b) Independent of existing facility

Slide 101
 Fuel Systems
Burner turndown requirements have to be met at liquid fuel pressures at burner
not less than the normal anticipated return header pressure. The fuel oil system
shall be designed for a recirculation rate of 2:1.

Fuel gas liquid knockout drums and tracing for piping shall be separate for
each process unit.

In-line strainers in burner piping are recommended for each unit. These shall
be located not more than 20 meters upstream of the burner manifold and shall
be 1 on-line + 1 spare strainer with mesh sizes 100 for Fuel Oil, Fuel Gas and
atomising steam.

In-line strainers for FO, FG and atomising steam to be provided on common

header supplying to all heaters within each unit.

Hot liquid fuel temperature shall be assumed to drop by 5oC between unit
battery limits and burner manifold.

Slide 102
 Fuel Oil Specifications
Sl Parameter Case-1 Case-2 Case-3 (Note-C)

1 Name PG VR BH UCO+VR
VR+VAC.DIESEL
2 Crude stock
3 Density @ 15oC, kg/m3 930 - 1030 978 852-857
4 Sulfur content, wt% 4 (Note-1) 0.84 0.27
5 Nitrogen content, wppm 3700 1000 (max.) 300
6 Nickel content, wppm 18 3
7 Vanadium content, wppm 200 5 11
8 Sodium content, wppm 80 12
9 Copper content, wppm <1
10 Iron content, wppm 1.9
11 Water content, wppm traces*
12 Flash Point, oC 66 (min)
13 Pour Point, oC 66
14 Viscosity @ 50 oC, cst 7500 5.0 @ 80 oC
15 Viscosity @ 100 oC, cst 700 900 @ 90 oC 3.36
16 Viscosity @ 200 oC , cst 50 @ 120 oC
17 Temperature, oC required for 20 cst

18 Initial Boiling Point @ 1atm, oC

19 Conradson Carbon Residue, wt% 17 - 22 13.6 3

20 Ash content, wppm 0.2 0.12 0.1

21 Hydrogen: Carbon ratio, wt:wt 0.128 0.124 0.124
22 LHV, kcal/kg 10000 10425 10000
23 Sediment -

Slide 103
 Fuel Gas Specifications
COMPONENT Case A Case B Case C Case D Case E Case F Case G
MOLE % Max FG
Normal Refinery Start
production
Operation up case
H2O 0.81 0.13 1.29 0.43 0.31 0.69

H2 35.35 80.1 0.0 0.86 45.49 34.48 74.96 25.63

C1 29.43 8.01 0.0 25.95 26.35 11.41 32.6
ETHYLENE 0.45 0.24 0.0 0.0 0.79 0.18 0.32
C2 16.08 4.04 9.43 15.06 13.29 6.23 20.64
PROPYLENE 1.21 0.64 0.0 0.0 2.11 0.47 0.85
C3 7.96 2.59 44.08 6.06 8.53 3.09 9.44
IC4 1.99 0.93 9.09 1.48 3.06 0.76 2.23
1BUTENE 0.50 0.26 0.0 0.0 0.87 019 0.35
NC4 3.22 1.63 36.07 2.59 5.36 1.24 5.43
1C5 06 0.17 0.04 0.77 1.05 0.13 0.27
NC5 1.32 0.79 0.0 0.94 2.31 0.57 0.87
C6+ 0.78 0.31 0.0 0.78 0.83 0.34 0.5
H2S Note-1 Note-1 Note-1 Note-1 Note-1 Note-1 Note-1
NH3 0.00 0.00 0.00 0.00 0.01 0.00 0.00
0.21
N2 0.30 0.16 0.0 0.0 0.53 0.12
TOTAL 100.00 100.00 100.00 100.00 100.00 100.00 100.00
MW 20.004 8.2533 48.79 16.717 22.537 8.9845 22.66
KGM/HR 354.51 667.9 0.353 275.5 203 914.7 507.4
KG/HR 7091.5 5512 17.2 4605 4575 8218 11498
LHV, Cal/kg 11798 14544 10964 12184 11648 14120 11613

Slide 104
 Refinery Flare system
Flare systems for the project shall be:
Existing Refinery flare system will be used, if found adequate.
Alternately, new flare header shall be provided for the project.
Single flare for all released streams
Normal flare for hydrocarbons and Acid gas flare for released acid gases
Separate high-pressure flare header for flared hot, hydrogen rich
gases
Hydrocarbon drain from the Flare K.O. drum will be routed by gravity flow
to the CBD. In addition, pump-out facility will be provided for
the Flare K.O. drum.

Philosophy of relieving flammable vapors shall be:

Vapor releases of all molecular weights to be connected to flare system
Vapor releases below molecular weight of vented to atmosphere
Hot hydrogen-rich gases (>300°C) vented to atmosphere
Other:

For adherence to OISD standard # 106, individual units shall be provided with a flare
knock-out drum whenever significant liquid relief is anticipated from the pressure
relieving devices, apart from the main knock-out drums at the flare stack. Unit
designer / contractor shall specify a horizontal unit flare KOD, sized to separate out
liquid droplets down to a size of 400 μ.
Slide 105
 Refinery Flare system
Maximum flare backpressure shall be considered for sizing of pressure
relief devices
# Flare system Built- up back Superimposed back Built-up back pressure
pressure, pressure at unit at PSV outlet,
kg/cm2g battery limits, kg/cm2g
kg/cm2g
1 Normal flare 0.2 default = 1.5 default = 1.7
2 Acid Gas flare 0.2 default = 0.5 default = 0.7
3 High Pressure flare

Overpressure (as percentage of set pressure) for sizing relief valves

# Contingency Low pressures High pressures

< 70 kg/cm2g > 70 kg/cm2g
1 Steam generating / consuming equipment 5% 5%
under IBR (as per IBR) (as per IBR)
2 Fire case 20% as per designer
3 Thermal relief 25% as per designer

4 Operational failures 10% as per designer

Slide 106
 Liquid Pumpout & Drain Systems
Non-congealing hydrocarbon drains:
Buried Closed Blowdown drum shall be:
Standard size of ± 10m3 to cater to only residual drains.
Individually sized for each unit for single largest equipment inventory.
Provided with cooling coil
Connect equipment to closed blow down (CBD) network leading to a CBD drum.
CBD drum will be located in a pit
and the same will be sand filled. Design CBD system for 200oC.
Congealing hydrocarbon drains:
Combined with non-congealing hydrocarbon drains.
Provided with combined cooling and heating coil

Steam generator blowdown drains:

Flash MP and HP blowdowns for recovery of LP Steam. The LP steam vessel
liquid to be cooled in a CW exchanger to 40 deg C and route to Cooling tower sump through
cooling water sump/pumps.
Caustic drains:
All bulk caustic inventory drains shall leave process unit under own pressure or be pumped out.
For residual caustic drains such as unpumpable vessel bottoms, level gage drains, etc., one of the
following shall be adopted:
Provide underground caustic CBD system with buried vessel and pumpout.
Collect residual drains by temporary facility like drums and jars.
Provide caustic drains to nearby neutralization pit outside the unit area.

Slide 107
 Liquid Pumpout & Drain Systems
Acidic drains:
(a) Amine systems
Bulk amine drains shall be only lean amine, displaced to amine storage tank. All
rich amine streams shall be routed to amine regeneration section under own pressure
or under inert gas pressure or displaced with water.
Residual amine drains shall be connected to a buried amine closed blowdown
system located in the Amine Regeneration section. Amine-bearing drains from Amine
Wash sections shall be routed to this buried vessel or collected through temporary
facilities.
Individual units handling amine will be provided with separate buried amine
closed blowdown system from where amine stream will be pumped to regeneration
unit.

(b) Sulphuric acid systems

When consumed only in non-process areas, temporary facilities will be defined.
Sulphuric acid storage and unloading facilities near cooling tower (existing).

(c) Process sour waters

1. Process sour waters shall normally be routed to identified sour water strippers.
Residual drains or during intermittent situations where unavoidable, these may be
drained to oily water sewer. The effluent treatment plant designer shall be advised to
incorporate provisions to receive the single largest parcel of such sour water.
2. Flare water seal drum sour water to be sent to sour water stripper.

Slide 108
 FLUSHING OIL SYSTEMS

Normal flushing oil (FLO)

- No flushing oil tank and pumps will be provided in outside battery limits.
- OSBL flushing oil header will be provided with mainly CDU/VDU Gas oil, which will have hot
or cold gas oil to the header. The main header also will have alternate source of FLO.
- For external flushing of pump’s API seal plans, or for purging instruments in congealing
service, the FLO pressure will be boosted. For this purpose, a separate vessel with (1+1) screw
pumps will be provided independently with in the respective unit. The connection for make up
flushing oil to vessel will be provided from maintenance Flushing oil header.

Heavy flushing oil (HFLO)

Straight run Vacuum Gas Oil from CDU/VDU will be taken as Heavy Flushing Oil for external
flushing of hot, heavy fluid handling pump’s API seal plan. To maintain the temperature of VGO
about 80-110 C, the separate vessel with steam coil will be provided with in the unit. A separate set
of screw pumps (1+1) will be provided to pump the flushing oil to necessary pressure level for pump
seal flushing.

Sl# Stream Operating condition Mechanical Design

P, T, oC P, kg/cm2g T, oC
kg/cm2g
1. Flushing Oil (Gas Oil) 6.0-16.0 40-103 27.0 141
2. Heavy Flushing Oil (VGO) 4.0-6.0 70-80 27.0 100

Slide 109
 Energy integration

Improvement in overall energy efficiency shall call for unit-level and total plant-level
optimization of energy. Designer of a particular unit shall indicate the following at
the outset of design activities:
(a)The total energy consumption expressed as equivalent fuel oil (Btu/bbl or FOE
(b)The preferred temperatures for hot feeds and products from an energy
(c)integration standpoint, if these are significantly different from that stipulated in
unit BEDB.
(c)Energy shall be preferentially recovered into process streams. Steam generation
shall be considered thereafter to recover excess available energy. Steam
generation levels shall be chosen to preferably match the corresponding steam
level demand within unit.
(d) Low-level energy recoverable for external consumption, say, for Boiler Feed
Water preheat serving other units.

Slide 110
 Vacuum Design

Vacuum design conditions shall be stipulated for:

(a) Equipment operating normally under vacuum conditions

(b) Equipment that are subjected to vacuum conditions during start-up,

shutdown, regeneration or evacuation.
(c) Liquid full vessels that can be blocked in and cooled down

(d) Distillation columns and associated equipment that can be subjected to

vacuum conditions through loss of heat input.

(e) All steam users consuming steam during normal operation.

(f) Pressure vessels containing liquids having vapor pressure at minimum

ambient temperature less than atmospheric pressure.

Vacuum design conditions are not to be specified for the eventuality of blocking
in after equipment steam-out or operator maloperation.

Slide 111
 EQUIPMENT DESIGN PHILOSOPHY
%turnup %turndown
Process Towers (atmospheric or above) 10%
Process Towers (vacuum) 10%
Fired Heaters (potentially coking services) 15%*

Fired Heaters (clean services) 15% *

Heat exchangers (fouling service): overdesign on duty 10%

Heat exchangers (fouling service): overdesign on flow 10%

Heat exchangers (clean service): overdesign on duty 10%

Heat exchangers (clean service): overdesign on flow 10%

Tower overhead exchangers: overdesign on flow & 20%

duty and reboilers
Pumparound exchangers: overdesign on flow 20%

Recycle compressors 10%

Make-up compressors 10% minimum

Pumps in general 10%

Reflux and pumparound pumps 20%
3-phase separators (in and out flowrate) 10%
2-phase separators(in and out flowrate) 10%
Crude preheat exchangers 15%
Slide 112
 Selection Of Mechanical Design Conditions

Equipment and piping systems shall be designed for the most stringent
coincident temperature and pressure conditions, accommodating the maximum
expected working pressure and temperature without causing a relieving
condition

A pressure system protected by a pressure relief device connected to the flare

system, shall have a mechanical design pressure, calculated at the location of
the relieving device, as the higher of the following:
I)For operating pressures above 70 kg/cm2g, mechanical design pressure
shall be as per designer, subject to a minimum of 77 kg/cm2g.
II)For operating pressure up to and including 70 kg/cm2g, design pressure
shall be the highest of the following:
Maximum operating pressure (kg/cm2g) x 1.1
Maximum operating pressure + 2.0 kg/cm2

Vessels operating under vacuum shall be, in general, designed for an external
pressure of 1.033 kg/cm2abs and full internal vacuum, unless otherwise
specified

Slide 113
 Selection Of Mechanical Design Conditions

For a full liquid system at the discharge of a centrifugal pump, the

mechanical design pressure shall be as under:

Pdes = Pmax suction + ΔPmax

where,
Pmax suction = Maximum pressure at suction vessel bottom
during suction system relieving conditions (as per 8.2.1.2)
ΔPmax = Pump differential pressure at pump shutoff head
with maximum operating density. If not known:
ΔPmax = 1.2 x ΔH x ρmax : constant speed pump
ΔPmax = 1.1 x 1.2 x ΔH x ρmax: variable speed pump
ΔPmax = 1.3 x ΔH x ρmax : high head multistage pump

For a full liquid system at the discharge of a positive displacement pump,

the mechanical design pressure shall be the higher of:

Pdes = Prated discharge + 2 kg/cm2

Pdes = 1.1 x Prated discharge

Slide 114
 Selection Of Mechanical Design Conditions

For shell-and-tube heat exchangers, the low pressure (LP) side shall be
preferably specified with a design pressure at least equal to 10/13 of high
pressure (HP) side design pressure, in order to avoid having to install a
pressure relief device on the LP side

For systems operating at or above 0oC, the mechanical design temperature

shall be the higher of the following:
Tdes = 65°C
Tdes = Tmax + 20°C
Tdes = Trelief (excluding fire relief temperatures)

For systems operating below 0°C, the mechanical design temperature shall
be equal to the lowest anticipated operating temperature.

Slide 115
Furnace - Design Aspects

Slide 116
 FURNACE
TYPES OF FURNACE
• Cylindrical furnace
– Low plot space
– Low cost
– Higher heat flux
– For clean services
• Box furnace
– High plot space
– High cost
– Even heat flux
– For fouling services

Slide 117
 FURNACE
TYPES OF FURNACE
• Natural Draft
– Air for combustion enters due to pressure difference
• Forced Draft

– FD fan is used to supply air, usually air gets heated up in

convection zone.
• Balanced Draft

– FD fan is used to supply air and ID fan is used to suck the flue
gas and heat is exchanged between air and flue gas through an
external heat exchanger (APH)

Slide 118
 FURNACE
TYPES OF FURNACE
• Single fired heater
– Common pattern in heaters
– For low fouling / sensitive fluid
– Peak flux >80% of average flux
• Double fired heater
– For high fouling service
– Low residence time
– Fire on both side of coil
– Uniform heat flux & peak flux < 20% of average flux

Slide 119
 Fired Heaters
Selection of fuel
Fired heaters shall be designed for continuous operation with:
100% firing on either fuel oil or fuel gas or any combination of both,
unless constrained to reject use of fuel oil from reasons of process or acid
gas dew point.
100% firing on fuel gas for heaters less than 1.5 MMKcal/hr.

Target efficiencies
Achievable fired heater efficiencies depend on service, furnace heat duty,
process temperatures and quality of fuel. Highest target efficiencies shall be
pursued by a unit designer, as found economically justified. Options such as
cast tube and glass tube air preheaters, steam generation and superheat, etc.,
shall be evaluated.
Target efficiency shall be:
92% on fuel gas fired heaters only
90% on combination firing heaters (with either fuel oil or fuel gas or dual fuel
mode)
Excess Air Fuel Oil Fuel Gas
Natural Draft 25 % 20 %
Forced Draft 20 % 15 %

Slide 120
 Fired Heaters
Heater stack
Stacks shall be individually mounted on each heater unless there are
considerations such as grade-mounted APH or combined APH system for a
group of heaters.

Minimum fired heater stack heights shall be the higher of indicated heights in
respective unit BEDB Part-A documents or as calculated from the formula
below:

H = 14 (Q)0.3
(Minimum stack height as per TNPCB / MoE&F to be provided, SOx
/ NOx nozzles to be provided)
where, H: stack height, metres
Q: total SO2 emission, kg/hr

Slide 121
 HEX - Design Aspects

Middle of Radiant Section Convection Section

Furnace Burner

Slide 122
 FURNACE
OPERATION
• Draft inside the furnace
• Air ingression
• Arch pressure slightly positive – Stack damper
• Combustion air control thro’ Air registrars
• Excess air : 5-10% for gas and 10-15% for fuel oil
• Monitored & controlled by Arch zone O2 analyser
• Skin temperature
• Stack temperature

Slide 123
 FURNACE

INTERLOCKS SPECIAL OPERATION

• Process fluid low / no flow • Economiser
• Fuel oil / gas - ring pressure • Steam Soot blowing
low • Steam – air Decoking
• Arch pressure high – Steam spalling
• APH interlocks – Temperature cycling
– FD fan trip – Coke burning

– ID fan trip • Convection water wash

– Arch pressure high

Slide 124
 Standard fired heater piping & instrumentation
(a) Low-low fuel oil supply pressure shuts down fuel oil supply and return
(b) Low-low fuel gas pressure shuts down fuel gas supply but keeps pilots running.
(c) Low-low heater pass flow shuts down fuel oil and fuel gas but keeps pilots running.
(d) Low Low pilot gas pressure shuts down the pilot gas supply
(e) Low-low differential pressure between atomising steam and fuel oil shuts down fuel oil
supply and return.
(f) Emergency shutdown shuts down fuel oil and fuel gas as well as pilots.
(g) Emergency coil steam, manual or automated, depending on criticality.
(h) Draft gage connections at:
• Burners • Below convection • Above stack damper • Below stack damper
(i) Flue gas sampling connections at:
• Below convection section • Below stack damper
(j) On-line analysis with location as per (g), connections mounted at the same plane:
• O2 analyser • NOx analyser • SOx analyser • SPM analyser • CO analyzer • HC
analyser
(k) Temperature measurement connections below convection section, below stack
damper, at hearth level.
(l) Skin thermocouples shall be considered for measuring temperature of furnace tubes. Slide 125
 HEX - Design Criteria

Material selection
Thickness Calculations
Shell, Channel, Covers, Tube sheets
No of shell passes
Velocity of the fluid
Pressure Drop
Tube Pattern
Consideration of Fluids through Tubes
Easy maintenance
Tube size, U- Tube, Cover header, Fluid choice

Slide 126
 HEX – Material of Selection

Tube MOC
Tube with Stainless
Metallurgy Steel
with Carbon
steel

Slide 127
HEX - Codes & Standards

Typical TEMA Type

Heat
Exchangers

Slide 128
 Codes & Standards
Which type of TEMA Heat Exchanger?

Slide 129
 HEX - Design Aspects
Criteria for selection of TEMA Type
Shell side Tube side Fouling TEMA type
Fouling Resistance Resistance (Hr-m2-°C/kcal)
> 0.0002 > 0.0002 Floating head
≤ 0.0002 > 0.0002 Floating Head
> 0.0002 ≤ 0.0002 U tube bundle
≤ 0.0002 ≤ 0.0002 Fixed tube
sheet/ U-tube
bundle
Preferred Sizes for Shell && Tube HEX

Tube Metallurgy CS / Low Alloy High alloy/SS/Brass

Tube Diameter 25 mm 25 mm
Tube Thickness 2.5 mm 2.0 mm
Tube Length 6.0 m

Slide 130
HEX - Design Aspects
Tube Pitch Selection

Pitch  Pitch  Shell Side  Flow 

Pattern Angle Fluid Regime

Triangular 30° Clean All

Rotated 
60° Clean Rarely used
Triangular

Square 90° Fouling Turbulent

Rotated 
45° Fouling Laminar
Square

Slide 131
HEX – Sample Datasheet (Pg 1/2)

Slide 132
HEX – Sample Datasheet (Pg 2/2)

Slide 133
 PUMPS
DESIGN
• Selection of type of pumps
• Sparing of pumps 
# Operating pumps Rated capacity per pump Spare pumps

2 50% of total normal flow 1

3 33% of total normal flow 1

4 25% of total normal flow 2

• Specification of pump seals
• Specification of drives
• Minimum flow bypass (MFB) provisions & controls

Slide 134
 Steam Turbine drives

When to select a steam turbine drive?

Steam turbine drives shall be specified in extremely critical services where even
short-term failure of a drive can result in a shutdown from where an operational
recovery is difficult, time-consuming or has a large economic penalty, such as
irreversible catalyst poisoning.
Steam turbine drives shall also be specified for the following drives, that, among
other considerations, shall ensure that a power failure does not automatically
lead to a steam failure:

(a) Cogeneration / Steam generation plant BFW pumps yes no

(b) Cogeneration / Steam generation plant FD Fan yes no
(c) Cooling water pumps yes no
(d) Compressor lube oil & seal oil pumps yes no
(e) Hot well pumps yes no
(f)Emergency evacuation pumps yes no

Slide 135
PUMPS – Sample Datasheet

Slide 136
 IBR Requirements
Scope of IBR
Steam generators / steam users shall meet IBR regulations. Major IBR
requirements are summarized below:
a) Vessels: Any closed vessel exceeding 22.75 litres (five gallons) in
capacity which is used exclusively for generating steam under pressure and
include any mounting or other fittings attached to such vessels, which is
wholly or partly under pressure when steam is shut-off.
b) Piping: Any pipe through which steam passes and if:
i) Steam system mechanical design pressure exceeds 3.5 Kg/cm2 g OR
ii) Pipe size exceeds 254 mm internal diameter
c) The following are not in IBR scope:
i) Steam Tracing
ii) Heating coils
iii) Tubes of tanks
iv) Steam Jackets
d) All steam users (heat exchangers, vessels, condensate pots etc.) where
condensate is flashed to atmospheric pressure i.e. downstream is not
connected to IBR system are not under IBR and IBR specification break is done
at last isolation valve upstream of equipment.
e) All steam users where downstream piping is connected to IBR i.e.
condensate is flashed to generate IBR steam are covered under IBR
f) Deaerator, BFW pumps are not under IBR and IBR starts from BFW
pump discharge.
Slide 137
 INSTRUMENTATION

• Instrumentation Philosophy for all equipments & pipelines

• E.g.) Packed Towers 
For column differential pressure indication two separate PT shall be provided 
and differential pressure shall be derived in DCS.

– Local differential pressure indication for each bed: yes no
– Local differential pressure indication for total section: yes no
– Control Room differential pressure indication for each bed: yes no
– Control Room differential pressure indication for critical beds: yes no
– Control Room differential pressure indication for total section: yes no
– 1+1 Basket strainers in lines going to packed beds:  yes no
– Single basket strainers in lines going to packed beds:  yes no

Slide 138
 Utility Line Instrumentation
UTILITY local DCS PAL/ local DCS TAL/ DCS FAL/ DCS
PI PI PAH TI TI TAH FI FAH FQ

MP STEAM

LP STEAM

Condensate

CW supply

CW return

Instrument Air PAL

Plant Air
Inert Gas
Fuel Gas
Fuel Oil
DM Water
Service Water

Flare
Slide 139
Block & Bypass Valve Size for Control Valve Manifold
Line Block & By paas Control Valve Size
Size Valve
0.5 0.75 1 1.5 2 3 4 6 8 10 12 14 16
0.5 Block 0.5
Bypass 0.5
0.75 Block 0,75 0.75
Bypass 0.75 0.75
1 Block 1 1 1
Bypass 1 1 1 Notes:
1.5 Block 1.5 1.5 1.5 1.5 1.All sizes are nominal sizes in
Bypass 1.5 1.5 1.5 1.5 inches.
2 Block 2 2 2 2 2.Bypass pipe diameter shall
Bypass 2 2 2 2 be same as bypass valve.
3 Block 2 2 3 3 3.Bypass valve will be globe
Bypass 2 2 3 3 valve upto 8" size and gate
4 Block 3 3 4 4 valve above 8".
Bypass 3 3 3 4
6 Block 4 6 6
Bypass 4 4 6
8 Block 6 6 8 8
Bypass 6 6 6 8
10 Block 8 8 10 10
Bypass 8 8 8 10
12 Block 10 10 12 12
Bypass 10 10 10 12
14 Block 12 14 14
Bypass 10 12 14
16 Block 14 16 16
Bypass 12 14 16

Slide 140
 Control Valve –
Sample Datasheet

Slide 141
 PIPING & INSULATION
• Insulation thickness for heat conservation, personnel protection, electrically 
traced lines  & cold insulation
• Material Usage
– Cellular Glass for process temperatures upto 350ºC.
– Rock Wool for process temperature upto 550ºC
– Calcium Silicate for process temperatures from 551 – 760ºC.
• Adherence to stipulations of OISD standard # 118 for min. inter‐equipment 
spacing and inter‐distance between process unit and offsites
• Steam tracing for piping handling congealing services shall be: 
– Steam tracing within unit battery limits, electric tracing for offsites upto 
150°C
– Steam tracing within unit battery limits, electric tracing for offsites upto 
250°C
– Steam tracing for both battery limits and for offsites
– LP Steam upto vacuum gas oils, MP Steam for heavy residues
– MP Steam for all congealing services
Slide 142
 Environmental Parameters

• Sulphur Recovery for reduced sulphur emissions

• Flare gas recovery unit to recover hydrocarbons

• Usage of low sulfur fuel in all process heaters/boilers

• Incorporation of Low NOx Burners/DeNOx Technology

• Continuous Ambient Air Monitoring & Stack Monitoring

• Segregated collection of solid wastes.

• Oil sludge treatment is done through chemical, mechanical and

bio-remediation routes.

Slide 143
Environ Impact
Assessment Study

144
Slide 144
Isopleths Showing Measured SPM Concentrations
Scale

0 1000 2000 m
-15000 -10000 -5000 0 5000 10000 15000
15000 15000
Pollutant: SPM

Unit: ug/m3
10000 10000
Y Direction (North) Distance, m

300

5000 5000
250

34
29
28
30
32
3135
36
39
41
40
33
27
0 38
37
13
15
16
17
18
147
12
5
2021
22
23
1
2
3
4
9
8
10
11
6
19 26
25
24 0 200

150
-5000 -5000

100

-10000 -10000
50

0
-15000 -15000
-15000 -10000 -5000 0 5000 10000 15000
X Direction (East) Distance, m
145
Slide 145
 Ambient Air Quality Data

Min Max Avg

Sl.No. Parameter µg/m3
1 SPM 18 287 70 – 234
2 RSPM 15 147 34 – 70
3 SO2 6 40 7 – 12
4 NOx 3 15 3–7
5 H2S 1 23 1–4

6 NH3 5 57 6 – 34

7 HC and VOC 10 14 -

Fugitive Emissions from the Work Zone Area of MRC – Benzene < 1 ppm
(OSHA)
146
Slide 146
 Environment – Noise & Water
Parameter Residential Commercial Industrial Inside the
Plant Area
Noise levels 46 - 82 72 - 79 66 - 79 77 - 84
(dBA)

Standard 55 65 75 85
(dBA)

Water Environment

Surface Water
Ground Water
Bacteriological Quality

147
Slide 147
 Risk Analysis Study

37.5kW/m2
(315m)

12.5kW/m2
(591m)

4.0kW/m2
(1032m)

Heat Radiation Effects due to BLEVE (CDU‐VDU)

148
Slide 148
 Risk Analysis Study
Individual & Societal Risk Factors due to that project are studied &
analysed

Slide 149
Slide 150