OISD/DOC/2019/13

I
Page No.
 OISD/DOC/2019/13

II
OISD-STD-109
Revised edition
FOR
RESTRICTED
CIRCULATION

PROCESS DESIGN AND OPERATING PHILOSOPHIES

ON
BLOWDOWN AND SEWER SYSTEM

OISD-STANDARD - 109
First Edition, November 1988
Amended Edition, August 1999
Revised Edition, January 2015

OIL INDUSTRY SAFETY DIRECTORATE

th
8 Floor, OIDB Bhavan,
Plot No. 2, Sector - 73
Noida– 201301 (U.P.)
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Page No. III

Page No.
 OISD/DOC/2019/13

IV
OISD-STD-109
First Edition
November 1988
Amended edition,
August 1999
Revised edition,
January 2015

FOR RESTRICTED
CIRCULATION

PROCESS DESIGN AND OPERATING PHILOSOPHIES

ON
BLOWDOWN AND SEWER SYSTEM

Prepared by:

COMMITTEE ON
PROCESS DESIGN AND OPERATING PHILOSOPHIES

OIL INDUSTRY SAFETY DIRECTORATE

th
8 Floor, OIDB Bhawan
Plot No.2, Sector - 73
Noida - 201 301 (UP)
Website: www.oisd.gov.in
 OISD/DOC/2019/13

Page No. V
Preamble

Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.

While statutory organizations were in place all along to oversee safety aspects of Indian petroleum
industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and
Natural Gas, Government of India as a knowledge centre for formulation of constantly updated
world-scale standards for design, layout and operation of various equipment, facility and activities
involved in this industry. Moreover, OISD was also given responsibility of monitoring
implementation status of these standards through safety audits.

In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts and
iterating through seeking & validating inputs from all stake-holders – operators, designers, national
level knowledge authorities and public at large – with a feedback loop of constant updation based
on ground level experience obtained through audits, incident analysis and environment scanning.

The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in the
Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not
affected implementation of the OISD standards. It also goes to prove the old adage that
selfregulation is the best regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.

Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge
Organizations – both in the field of standard development and implementation & monitoring in
addition to updation of internal knowledge base through continuous research and application
surveillance, thereby ensuring that this OISD Standard, along with all other extant ones, remains
relevant, updated and effective on a real time basis in the applicable areas.

Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides
other issues, calls for total engagement from all levels of the stake holder organizations, which we,
at OISD, fervently look forward to.

Jai Hind!!!

Executive Director Oil Industry Safety Directorate

 OISD/DOC/2019/13

Page No. VI
FOREWORD

Petroleum refinery & Gas processing plants comprise of Crude & vacuum Distillation units along
with a number of complex secondary units like Catalytic Reforming ,Fluidized catalytic cracking ,
Delayed Cokers ,Vis-Breaker, Hydrotreater, Hydrocracker & Hydrogen Units including process like
Sulphur Recovery units and Amine treatment/recovery units and facilities like Flare etc. From the
above units, various blowdown streams such as aqueous blowdown, hydrocarbon blowdown and
chemical blowdown of liquid streams containing water, oil, chemicals or a combination of two or
more of these are required to be drained & routed to safe destination either during the normal
operation of the units or during shutdown/emergency situations.

Though these blowdown streams are usually waste products, their handling and disposal is
paramount importance in enhancing the safety of the plant and protecting environment. This
necessitates the introduction of inbuilt safe and efficient handling and treatment facilities as well as
fire protection facilities in the system.

This standard was first released in November 1988 and was subsequently amended in the year
1999. With adoption of new process & technology especially the secondary processing facilities
coupled with capacity augmentation of existing facilities and recommendations from recent incident
analysis necessitated up-gradation of this standard and subsequently revised was issued in Jnauary
2015.

This standard is meant to be used as a supplement and not as a replacement for existing codes &
practices. The provision of this standard if implemented objectively will go a long way to improve the
safety & reduce accidents in the Oil & Gas Industry. Users are cautioned that no standard can be a
substitute for the judgment of responsible & experienced engineer. Suggestions are invited from the
users after it is put into practice to improve the standard further. Suggestions for amendments to
this standard should be addressed to:

The Coordinator

Committee on “Process Design and Operating Philosophies on

Blowdown and Sewer system”

Oil Industry Safety Directorate.

OIDB Bhawan, 8th Floor, Plot‐2, Sector‐73 Noida, UP‐201301
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Page No. VII

NOTE

OISD publications are prepared for use in the oil and gas industry

under the administrative control of Ministry of Petroleum and

Natural Gas and shall not be reproduced or copied and loaned or

exhibited to others without written consent from OISD.

Though every effort has been made to ensure the accuracy and

reliability of the data contained in these documents, OISD hereby

expressly disclaims any liability or responsibility for loss or

damage resulting from their use.

These documents are intended to supplement rather than replace

the prevailing statutory requirements.

 OISD/DOC/2019/13

Page No. VIII

FUNCTIONAL COMMITTEE

(SECOND EDITION, January 2015)

Sl.No. Name Organisation Position in Committee

1 Shri S.S. Sunderajan BPCL-MR Leader

2 Shri V. N. Satheesan ESSAR Oil Ltd Member

3 Shri M.K. Sinha Technip KTI Member

4 Shri Gangadin Gautam EIL Member

5 Shri A.G. Gupta RIL Member

6 Shri V.S. Agashe HPCL-VR Member

7 Shri U.K. Bhowmick IOCL-C HSE, Ref., Member

8 Shri B.K. Das BRPL Member

9 Shri P.K. Das NRL Member

10 Shri Avijeet Saha HPCL-VR Member

11 Shri Neeraj Bagai OISD Member

Coordinator (till 19.05.2011)

12 Shri S.Thangaraj OISD Member

Coordinator (from 20.05.2011 to

30.11.2014)

13 Shri Dharmvir OISD Member

Coordinator (from 01.12.2014)

In addition to the above, several other experts from industry contributed in the preparation,

review and finalisation of this document.

OISD/DOC/2019/13

Page No. IX
 OISD/DOC/2019/13

Page No. X
COMMITTEE
ON
PROCESS DESIGN AND OPERATING PHILOSOPHIES

List of Members

Sl.No. Name Designation & Position in

Organisation Committee

1. Shri W.D. Lande Dy. Gen. Mgr. Member

HPCL Leader

2. Shri G. Raghunathan Ch. Manager, Co-opted

HPCL Member

3. Shri N. Lal Dy. Gen. Manager, Member

ONGC

4. Shri N.N. Gogoi Dy. Gen. Mgr., Member

OIL

5. Shri S.V. Puthli Sr. Manager, Member

HPCL

6. Shri M.A. Sreekumar Sr. Manager, Member

CRL

8. Shri A. Vardarajan Sr. Manager, Member

MRL

9. Shri B.K. Trehan Addl. Director, Member,

OISD Co-ordinator

In addition to the above, several other experts from industry contributed in the
preparation, review and finalisation of this document.
 OISD/DOC/2019/13

Page No. XI

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON BLOWDOWN

AND SEWER SYSTEM

CONTENTS
Sl. Description Page
No. No.
1.0 INTRODUCTION 1
2.0 SCOPE 1
3.0 DEFINITIONS 1
4.0 CLASSIFICATION OF BLOWDOWN STREAMS 2
4.1 Classification Based on Composition 2
4.2 Classification based on Temperature 3
4.3 Classification Based on Volatility & Viscosity 4
5.0 SAFE HANDLING 5
5.1 Aqueous Blowdown 5
5.2 Hydrocarbon Blowdown Streams 7
5.3 Emergency Blowdown for LPG and Cryogenic Vessels 9
5.4 Chemical Blowdown 10
5.5 TTL/TW gantry Blow down System 10
6.0 DISPOSAL OF BLOWDOWN 11
6.1 Closed Blowdown System 11
6.2 Sewer Drain System 12
6.3 Basic Design Guidelines for Oily-Water Sewers 15
6.4 Special Sewers 17
7.0 REFERENCES 18
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Page No. XII

Fig.1 24

Aqueous Blowdown
- Continuous in Nature
Hydrocarbons
 OISD/DOC/2019/13

Page No. XIII

Fig.2 Aqueous Blowdown - Likely to Contain Volatile 25 & 26
a, b
Fig.3 Continuos Boiler Blowdown 27
Fig.4 Water Draw off from Crude Tanks 28
Fig.5 Draining of Product Tank & LPG Vessels 29
Fig.6 Draining / Venting of Hot Pumps 30
Fig.7 Draining / Venting of LPG & Cryogenic Product Pumps 31
Fig.8 Sampling System 32
Fig.9 Gas-Condensate blowdown 33
Fig.10 Typical CBD System 34
Fig.11 Blowdown Drum 35
Fig.12 Draining System at Gantry Quench Drum 36
Fig.13 Single Compartment & Double compartment Sealed Manhole 37, 38 &
a, b & 39
c
Fig.14 Sour Water Degassing / Surge Drum 40
 OISD/DOC/2019/13

OISD – STD – 109 Page No. I

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON
BLOWDOWN AND SEWER SYSTEM

PROCESS DESIGN AND OPERATING PHILOSOPHIES

ON BLOWDOWN AND SEWER
SYSTEM 1.0 INTRODUCTION

Blowdown is a liquid stream containing water, oil, chemicals or a combination of two or more of
these which are required to be drained from various process equipment in the hydrocarbon industry
under different operating situations like start up, shutdown, normal operation or emergencies. Since
majority of these streams are usually waste products (however in some situations these may be
recoverable), their handling and disposal often gets a low profile in the plant design and operation.
However, the importance of handling these blowdown streams in enhancing the safety of the plant
cannot be underestimated.

2.0 SCOPE
This document covers the design and operating philosophies for safe handling and disposal of
liquid blowdown from various process equipment in the Refineries, Gas Processing &
Petrochemical Plants and their storage facilities. Pressure relief of vapour/liquid and their disposal
is not covered in this document for which OISD - 106 Standard on “Pressure Relief and Disposal
System” should be referred to.

3.0 DEFINITIONS

3.1 Blowdown:

Blowdown is a liquid stream containing water, oil, chemicals or a combination of two or more of
these which are required to be drained from various process equipment in the oil & gas industry
under different operating situations like start up, shutdown, normal operation or emergencies.

3.2 Cryogenic:

Cold substances i.e. Gas, Liquid or Solids having subzero temperature.

3.3 Congealing & Viscous Fluids:

Congealing fluids are those which thicken and resist to flow due to higher viscosity at ambient
temperatures. These fluids are normally stored at elevated temperatures to maintain fluidity.

3.4 Effluent:

Effluent is a liquid such as sewage, Hydrocarbon or chemical contaminated water or other liquid,
partially or completely treated or in natural state as the case may be flowing out of reservoir,
process unit basin or treatment plant.

3.5 Manhole:

Manholes are used in sewer mains as junction points and sediment traps, and to access for
maintenance and inspection.
 BLOWDOWN AND SEWER SYSTEM OISD/DOC/2019/13

3.6Non Volatile: OISD – STD – 109 Page No. 2

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

Substance that does not change from solid/ liquid state to vapour or gas state at normal
temperature and pressure condition is called non volatile substance.

Seals (hydraulic seals) are used to isolate various parts of sewer system, preventing vapour
travel and spread of fire or explosion.

Sewer is an underground pipe or open channel in the sewage system for carrying water of
sewage to a disposal point.

3.9Sewerage:

Sewerage is a system of sewers and ancillary sewage from its point of origin to a treatment
facility or other point of disposal.

The word ‘shall’ is used to indicate that

provision
the is mandatory.

3.11Should:

The word ‘should’ is used to indicate that the provision is recommendatory as per good
engineering practice.

3.12Storm water:

Storm water is a system for rain water discharge from catchment area.

3.13Volatile Compounds:

Compounds which can easily become vapour or gas from the solid or liquid state at normal
temperature & pressure conditions are called Volatile Compounds.

4.0CLASSIFICATION OF BLOWDOWN STREAMS

The blows down streams are classified based on the nature, frequency and other characteristics,
these streams can be classified as below:

4.1CLASSIFICATION BASED ON COMPOSITION

Depending on the composition of blowdown streams, these may be classified as:

4.1.1Aqueous Blowdown:
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
3.7 Seals:
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 3

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

3.8 Sewer: 3.10

Shall:

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 4

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

BLOWDOWN AND SEWER SYSTEM

These streams contain water as the major constituent with small amounts of
hydrocarbons. Such streams are usually encountered during the normal running of the
units. These streams may be continuous or intermittent in nature. Some typical examples
are:
i) Water draw-off from reflux drums
ii) Water-caustic (or other solvents) draw-off from treating units iii)
Brine water draw-off from desalters and heater treaters. iv) Water
draw-off from oil separators.
v) Stripped water draw-off from sour water strippers vi)
Water draw-off from crude oil tanks and other products tanks.

4.1.2 Hydrocarbon Blowdown

These streams contain mainly the hydrocarbon fractions and may be encountered during
normal operation, start-up, normal shutdown and emergency shutdown. These streams
are usually intermittent in nature. Some typical examples are:
i) Intermittent draining of process equipment during normal operation.
ii) Drains and vents/bleeders on pumps, pipelines, and manifolds iii)
Sampling of products from equipment and piping iv)Emptying of an
equipment during planned shutdown
v) Emergency draining of process equipment like furnace, tower or vessel etc,
vi) Coker plant blowdown vii) Oily condensate
viii) Water coming from all hydrocarbon pollutable paved areas mainly including process
unis, non volatile product loading gantries, pumps stations etc.

4.1.3 Chemical Blowdown

These streams contain aqueous solutions of chemicals and may have small quantities of
hydrocarbons. Such streams may be continuous or intermittent in nature. Some typical
examples are:

i) Caustic drains from treating plants

ii) Reactor washes
iii) Effluents from water treatment plants
iv) Water draw-off from sour water sources which may contain sulphides, H2S,
ammonia & phenol etc.
v) Cooling Tower blowdown vi) Amine Blowdown
vii)

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 5

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

BLOWDOWN AND SEWER SYSTEM

ii) BLOWDOWN AND

Vacuum Gas Oil SEWER SYSTEM
iii) Vacuum Residue
4.2CLASSIFICATION BASED ON TEMPERATURE
iv) Reduced Crude Oil

Blowdown v) streams
Fuel Oil vi)
as classified above can further be grouped depending on the temperature.
These streams
Bitumencan be hot
vii)or at ambient temperature or be under cryogenic conditions. The
hazards involved in handling different blow down streams and the technique of handling and
Wax
disposal of each one of such streams will be different. Some typical examples of such streams
are:

5.0 SAFE HANDLING

4.2.1Hot Blowdown

i)
The facilities Coker plant blowdown
and procedures of safe handling of various blowdown streams will vary with the type
and general
ii) grouping of these
Fractionating towerstreams
blowdownas listed in clause 4.0. While designing it must be ensured
that the facilities shall be designed for maximum reuse of blow down water after proper treatment.
iii) upon
Depending Hot heat exchanger/reboiler
the type of blowdown, blowdown
some typical handling facilities are recommended as under:
iv) Samples of hot products
5.1 Aqueous Blowdown:
v) Vents/drains from hot equipment
Generally
vi) Boileraqueous blowdown streams
blowdown-continuous consist of water with small amounts of hydrocarbons.
and intermittent
Depending upon whether these
vii) Decoking drum blow down streams are continuous or intermittent and the nature of
hydrocarbons associated with them, the handling arrangements will vary as described in
some typical
4.2.2Cryogenic examples below:
Blowdown

5.1.1 Continuous aqueous Blow Down- Non Volatile:

i) Drains, vents, and bleeders on equipment operating at sub-zero temperatures like
cold draining
boxes, refrigeration systems, condenser
etc.
Water from barometric drums/ hot well vessels of vacuum units,
ii) water sealvents
Drains, vessel
andinbleeders
flare area is typical
on flashing examples of continuous aqueous blowdown with
liquids.
some non volatile HC.
iii) Drains, vents and bleeders on high pressure gas transmission lines.
This blowdown
4.3CLASSIFICATION BASED ON stream shall AND
VOLATILITY be routed to sour water stripping unit with a level indicator
VISCOSITY
and controller. In case of tripping of sour water pump, the arrangement shall be available
Based onto routevolatility,
relative it to oilythe water sewerstreams
blowdown by means
may beof classified
a U sealas(if operating
volatile under atmospheric
or non-volatile.
Similarly pressure).
these may be A viscous
low level andalarm shouldtype
congealing be or
provided
the freetoflowing
ensure thatblowdown
type all liquid streams.
is not drained out
allowing escape
Some typical examples are: of HC gases. See fig 1.

5.1.2
4.3.1 Aqueous blowdown – Volatile
Volatile

i) In equipments like light end reflux drums, desalters etc. where process water/ steam is
Gas condensates
continuously withdrawn as liquid water, medium to large quantity of lighter volatile
ii) LPG
hydrocarbons can also get carried away along with the water.
iii) Gasoline and lighter naphtha
iv) These blowdown
Hot-heavy streamsabove
hydrocarbons shall their
not be routed
flash points.to OWS directly to avoid any hazardous
situation. Such streams from pressure vessels which have provision to separate water
4.3.2Non-Volatile
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
i) Kerosene
ii) Heavier hydrocarbons below their flash points.
4.3.3Viscous/Congealing
OISD/DOC/2019/13
i) High pour point Crude Oil
OISD – STD – 109 Page No. 6
PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

and HC shall be routed through a closed system to CBD with the following
instrumentation to enhance safety.

BLOWDOWN AND SEWER SYSTEM

1. Automatic level indicator & controller to maintain water/Hydrocarbon inter-phase

level.

2. High and low inter-phase level alarm independent of level indicator/controller from a
separate tapping to ensure that Hydrocarbon is not carried along with water or water
is not carried along with Hydrocarbon (as part of reflux, crude etc).

The blowdown stream shall be routed to effluent treatment plant (ETP) / Sour water
stripper (SWS) or to some other equipment as the process demands. A typical scheme
for handling such streams is depicted in fig 2a.

In case the aqueous blowdown contains entrapped gases, the stream shall be routed to a
disengaging drum. The vapours released from the top of the drum shall be routed to
closed flare header and the free water shall be drained to OWS as shown in fig 2b.

5.1.3 Boiler Blowdown

Blowdown from a boiler/waste heat steam generator is done usually at high temperature
and high pressure to maintain the water quality for steam generation. Such streams
should be handled carefully to avoid personnel hazards. A typical scheme of handling
boiler blowdown is depicted in Fig.3. Boiler or steam generator generally operate at high
pressure and their blowdown streams are generally flashed into lower pressure steam
system or heat energy is recovered in heat exchangers before final safe disposal. A
stream of cold ambient water is mixed with the hot effluent water to cool it before
discharging into oily sewer or storm water drain.

5.1.4 Water Draw-off from Crude Oil Tanks

This is an important routine operation intermittent in nature and can lead to lot of
problems if not done properly. Though, it is satisfactory to drain free water from the
crude oil tanks into oily water sewer leading to waste water treatment plant, draining of
emulsion and wax etc. into the oily sewer can lead to unsafe conditions in addition to
increasing the load on the waste water treatment plant. It is recommended that the
emulsion etc. from the crude tanks be received in a slop tank located in the crude tank
farm area. The capacity of the slop tank should be adequate to handle the wax and BS &
W likely to be present in a single largest crude tank. The slop tank should be provided
with steam coils or alternative heating facilities to help break the emulsion. A typical
scheme for handling such streams is depicted in Fig. 4 More than one crude tank can be
served with a single slop tank located inside the crude tank(s) dyke area. However, if
there are many large size crude oil tanks, more than one slop tank may be required

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 7

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

After draining the free water from the crude tanks to oily water sewer, if oil water
emulsion is observed, the draining should be lined up to the slop tank where the contents
should be heated to the desired temperature to break the emulsion and allowed to settle
for separating oil water phases. The water phase from the slop tank should be drained to
oily water sewer and the oil content should be pumped back to the crude tanks by two
slop oil pumps (1 operating + 1 standby) located outside the tank dyke. The slop tanks(s)

BLOWDOWN AND SEWER SYSTEM

should be provided with temperature gauge at different elevations of the tank. A level
indicator and a high level alarm should be provided at the slop tank as shown in Fig.4.
These indications and alarms should be taken to the control room and / or the local
instrument panel as the case may be.

It is essential that draining operations from the main crude tanks and the slop tank shall
be properly supervised by the operator to avoid large quantities of crude getting carried
over into the sewer.

5.1.5 Other Aqueous Blowdown - Intermittent in Nature

Such blowdown streams are not continuous, but required to be handled during frequent
draining or venting operations while the plant or facility is under normal operation.
Typical examples of such systems are - water draining from boot leg of reflux drum,
compressor suction knockout drum etc. Usually, these streams consist of water, but may
carry some traces of hydrocarbons. However, if not handled properly, large quantities of
hydrocarbons can be drained along with water which can pose serious hazards.

The blowdown shall be provided with manually operated double valves to enhance the
integrity of isolation. It is essential that intermittent draining of water from storage tanks
shall always be done under supervision. A typical arrangement of draining water from
product storage, LPG storage vessels is depicted in Fig.5.

For LPG, Propylene, Propane etc storage vessels, the draining connection shall be given
at downstream of ROV at bottom line and water shall be drained through a Dead man’s
valve as depicted in Fig.5

5.2 HYDROCARBON BLOWDOWN STREAMS

i) Hydrocarbon blowdown streams contain mainly hydro-carbons. Most of these streams

such as compressor suction knock out drums, are intermittent in nature and are required to
be handled during frequent draining or venting operations while the plant or facility is under
operation. Such streams are also required to be handled during a planned or emergency
shutdown or start up of the plant/facilities. It is essential that such operations shall always
be done under supervision. The blowdown drain or vent lines shall be provided with double
valves to enhance the integrity of isolation and routed to CBD/flare.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 8

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

Draining from the process equipment can also be done with on/ off control valve. For this
system should have suitable instrumentation/ shutdown logics to ensure safety of system.
ii) Sour Water Disengaging Drum

Sour water from different process units is collected in sour water disengaging drum before
sending to sour water stripper. The hydrocarbon oil gets separated from the sour water and
floats oil on top of water, which subsequently overflows to other side of chamber in the
disengaging drum. The drum is floating with acid gas flare system. The hydrocarbons are
drained out time to time from the oil chamber.

BLOWDOWN AND SEWER SYSTEM

Draining should be done through a drain line provided with i). Alarm for the minimum level
of the oil chamber ii). Remote operated shutdown valve to isolate the drain to stop any
emergency escape of H2S vapour into atmosphere. H2S gas detector/monitor should be
provided near the drain point for early detection. A typical arrangement of such a blowdown
drum is depicted in Fig. 14. The excess stripped water from the sour water stripper, if any,
should be routed to ETP through a separate header and not to be drained in to OWS
system.

5.2.1 Draining and venting from LPG/Cryogenic Product Pumps:

Draining and venting of pumps handling LPG and other cryogenic products should be
done very carefully. The products coming out of these pumps would flash immediately
giving large quantities of vapours and also create low temperature in the vent and drain
piping.

Such pumps shall be drained/ vented to flare/ closed system. The drain connection to oily
sewer/ CBD shall be provided with isolation to facilitate draining of water or liquid
hydrocarbons. A typical scheme for handling such streams is depicted in Fig.7. Double
valves shall be provided on the vent and drain header line

While handling cryogenic liquids, the temperature in the vent/drain lines may drop down
due to flashing of liquid form higher pressure to lower pressure. This phenomenon should
be considered while selecting the materials for such piping. Also due to this phenomenon
ice formation can take place around isolation valve and hence second isolation valve in
such draining system shall be anti-freezing type.

5.2.2 Draining/Venting from other Hydrocarbon Pumps:

During start up operation, it is required to drain or vent/bleed hydrocarbon pumps

occasionally. Drain connection to oily sewer/ CBD with valve shall be provided to
facilitate draining of water or liquid hydrocarbons. Double valves shall be provided on the
vent and drain header lines as shown in the Fig 6.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13

OISD – STD – 109 Page No. 9

PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

Venting and draining of pumps handling hot products can lead to hazardous conditions
due to auto ignition. This risk is higher especially for hot and heavy products like fuel oil
etc. whose auto-ignition temperatures are usually lower (250 Deg - 300 Deg. C range). A
typical scheme for handling such streams is depicted in Fig.6. A suitable arrangement
for cooling of such hot material being drained and vented from the pump shall be
provided to cool the liquid before draining to closed system.

The pumps handling Class-A hydrocarbons shall be drained to CBD only.

5.2.3 Draining of Equipment for Shutdown:

Various equipment are required to be drained free of hydrocarbons and other hazardous
materials during shutdown for maintenance or inspection. For infrequently used
connections normally associated with equipment maintenance, the drain lines shall be

BLOWDOWN AND SEWER SYSTEM

provided with double block valves and the connection shall be plugged/ capped/ blinded
for integrity of isolation. Drain lines carrying such streams from process equipment
having significant inventories shall be piped to the unit closed blowdown drum(s) or a
pump out header for the safe recovery of the hydrocarbon product. Fig.10 depicts a
typical arrangement of the draining system.

5.2.4 Sample Points:

Closed sampling system should be provided for all sample points with an objective to
avoid/minimize Hydrocarbon draining / venting to atmosphere. Sampling lines should be
small in size (preferably½” dia.) and the dead portion of the sample line shall be
minimised (preferably limited to less than 2 feet). Each sampling line shall be provided
with two valves, one isolating valve and the other regulating valve. Process related
sample points should be located at one convenient location in the unit and a collection
tray shall be provided below the sample points. Open draining of the hydrocarbon
streams shall not be allowed within the unit area. The drain from the sample point shall
be routed to OWS. Hot products should be provided with suitable sample coolers. See
Fig.8 for a typical sample point’s installation.

LPG sampling shall be done as detailed in OISD-STD-144 and gas sampling shall be
done in closed loop system.

5.2.5 Gas-Condensate Blowdown:

When the blowdown stream consists of condensate drawn-off from gas-liquids

separators inter/after condensers/coolers or compressors etc. the blowdown line should
be provided with automatic shutdown valve actuated on low level in the separator to
avoid gas blow-by in the downstream liquid system which usually operates at lower
pressure. A typical scheme for handling such streams is depicted in Fig.9

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

EMERGENCY BLOWDOWN FOR LPG AND CRYOGENIC VESSELS

During a fire emergency, above ground vessels containing LPG and other such products
pose additional hazards because of BLEVE (Boiling Liquid Expanding Vapour Explosion)
effect. The fire increases the internal pressure and weakens the vessel until the vessel can
no longer contain the pressure. The vessel ruptures violently, with its parts propelled to
great distances. The released liquid flashes often resulting in a large fireball. The fireball
can cause very widespread damage due to flame contact. Although the fire ball lasts only a
few seconds, its effects can be devastating. Pressure vessels containing LPG or other such
liquids located in the process areas have higher risks to BLEVE as compared to storage
vessels in the offsite area.

In a fire situation, therefore, it is desirable to empty out the liquid inventory of the process
vessels containing LPG etc. to a safer location. Such vessels therefore should be
connected to fuel gas system/ flare/ unit blowdown drum through adequately sized line so
that the liquid content of the vessels can be quickly emptied in the shortest possible time
(say 5-10 minutes). The blowdown line from the vessel should be provided with a tight shut

BLOWDOWN AND SEWER SYSTEM

off shutdown valve remotely operated from the control room. The blowdown drum can be
the common light oil blowdown drum located at one corner of the unit and connected to the
flare header. The liquid contents from the blowdown drum can be pumped for reprocessing
or recycle etc. The capacity of the drum should be adequate to receive the total contents of
a single process vessel containing LPG or similar materials. This drum should not be
combined with hot blowdown drum which receives heavy and fouling type products (e.g.
CBD). A typical arrangement of such a blowdown drum is depicted in Fig.11. Refer
OISDSTD-106, Standard on “Pressure Relief and Disposal System” for more details on
blowdown drums.

Similar blowdown for large size offsite storage vessels is usually not practicable. However,
facilities for transferring inventory of LPG etc. from one storage vessels to other should be
considered.

5.4 CHEMICAL BLOWDOWN

Like aqueous blowdown streams, chemical blowdown streams and drains may be
continuous or intermittent. These should be handled with care to avoid accidents. The
design and operating philosophies for handling continuous and intermittent aqueous
blowdown streams shall be as discussed earlier under “Aqueous Blowdown”. The
continuous chemical blowdown streams shall be controlled automatically through the vessel
level control and where there is a possibility of hydrocarbon phase coming out with the
chemical, disengaging drums should be provided. The integrity of isolation of intermittent
blowdown streams by double valves, blinds or caps shall be ensured and routed to OWS/
Chemical sewers as applicable. Refer section 6.2.3 for disposal of chemical blowdown
streams. Examples are amine blow down, solvent blow down, caustic drains, drains from
chemical additive storage and pumping area etc.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON TTL /
TW
gantry
Blow down system:

i) In rail/road gantry there are chances of oil spillage from loading arms drippings after
removal of loading arm from tanker. To avoid this oil spillage and loss of material an
open funnel shall be provided to collect the hydrocarbon dripping from loading arms
which shall be routed to slop header. Through slop header shall be routed to an
underground vessel similar to CBD drum in the gantry area. The material from this sump
shall be pumped to slop tank. A typical sketch -12 is attached

ii) Open channel fully covered with grating shall be provided around the Tank wagon/ tank
truck gantry to collect any oil spillage during the loading. Oil and water collected from
loading areas shall be routed to ETP. Where ETP facility does not exist, as in the case
of terminals/bulk plant/depots, local oil collection and separation system shall be
provided. Depending on size, this could be a catch basin or trap, API separator or similar
facility. A slop tank should be earmarked for storing separated oil.

BLOWDOWN AND SEWER SYSTEM

6.0 DISPOSAL OF BLOWDOWN

The various blowdown streams should be disposed off safely to their respective destinations.
Selection of disposal system will depend on the type of blowdown stream. Disposal system shall
be closed pressurised system or gravity sewers.

6.1 CLOSED BLOW DOWN SYSTEM

All hydrocarbon blowdown streams free of water and chemicals etc. which are drained
from various vessels and equipment are received in a Closed Blowdown Drum (CBD) at
one corner of the unit.

The closed Blowdown (CBD) system eliminates atmospheric venting and useful in case
of toxic and hazardous gases. It eliminates the risk of liquid back up into other module at
different levels.

The vessel/ equipment shall be depressurised before draining to CBD. Liquid levels in
equipment shall be lowered to minimum practically possible level using normal process
connections before it is fully depressurized through draining via CBD system.

Depressurization can lead to cooling of vessel contents. The vessel should be allowed to
regain ambient temperature before admitting to the CBD system. Care must be taken to
minimise the risk of back pressure due to line blockage and draining of vessel under full
pressure.

i) All drains from equipments shall be connected to CBD header.

ii) All CBD lines in the unit shall be isolated from equipment by double block valves
and intervening spade or spectacle blind.
iii) CBD header shall be buried pipeline with suitable external protective coating to
prevent it from corrosion.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

iv) CBD header shall be sloped towards the CBD Drum (buried / placed in a pit) to
prevent any vapour reaching / flashing in the drum.
v) At the dead end of the CBD header steam and/ or inert gas connections shall be
provided for proper purging and cleaning of the header.
vi) The blowdown drum can be a common drum for more than one process units and
shall be located underground at a leeward side of the unit with its vent routed to
flare. CBD can be buried or placed in open pit.
vii) In case CBD is buried, the drum shall have suitable external protective coating to
prevent it from corrosion. The providing cathodic protection to buried drums for
corrosion protection can also be considered. A Brief Write up on design and
requirement of CP System for buried CBD is given in Annexure-I.
viii) In case CBD is kept in pit, a system shall be installed to evacuate the liquid/ HC
accumulated in the pit.
ix) Vapours from CBD vent shall be directed to flare system. The CBD vent can be
opened to atmosphere with the provision of snuffing steam only if flare system is
not available in the installation.
x) Liquid collected in CBD shall be pumped to slop tank / suitable destination.
Vertical submersible pump is used for pumping out the contents of CBD and it

BLOWDOWN AND SEWER SYSTEM

shall have automatic starting and stopping facility on high and low liquid levels in
the drum.

At least two pumps with independent power supply as specified in OISD-STD-106 for
flare KOD pump shall be provided in case unit flare KOD contents are routed to CBD.

The CBD shall have level indication in the control room inline with OISD-STD-152. CBD
shall be provided with suitable heating/ cooling coils as per the material being handled.

The blowdown streams shall be routed to feed system, slop tank or downgraded to other
products, by suitably designed closed piping system. These streams shall not be put into
sewers from safety and loss considerations. A typical scheme of such system is
depicted in Fig. 10.

6.2 SEWER DRAIN SYSTEM

Gravity sewer drains are extensively used in the petroleum industry for the routing of
various waste and blowdown streams containing oily, chemical and other wastes etc.
Generally such items of plant or facility get low profile, but the importance of their good
design and operating practices cannot be under-estimated from the safety and loss
prevention point of view. Important guidelines for the design and operation of sewer
system are provided in this section. These waste water streams should be segregated
and treated suitably for recycle/ reuse to minimise water consumption.

Depending upon the nature of waste streams, the sewers should be segregated as
below:-

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

6.2.1 Oily Water Sewers:

Oily water sewer shall collect oily waste/drain from pump, equipments through funnel
points and shall run with separate headers and manholes. The regular oil contamination
areas shall also be segregated and discharge from these areas shall be collected in a
catch basin to be joined in oily water sewer.

The following aqueous streams generally have some oil content carried by them. These
streams should be routed to effluent treatment plant through oily water sewer system. The
recovered oil should be reprocessed and treated effluent water shall be reused to conserve
water:

i) Oily water from process unit - Reflux drums, separators, disengaging drums, etc.
ii) Gland and seal cooling/quenching water from pumps/compressors etc.
iii) Brine water/sour water. iv) Process wash water.
v)Oily water from hot wells.
vi) Floor and paving drains including contaminated rain water vii) Oil +
water overflow from quench drums.

BLOWDOWN AND SEWER SYSTEM

viii) Once through water from barometric condensers ix) Hydrocarbon tanks’ drains x)
Sample point drains. xi) Oil contaminated steam Condensate if no condensate recovery
and treatment
facilities exist.
xii) Tank Dyked area drains

6.2.2 Storm Water Sewers:

Waste water which has no oil and other objectionable material can be handled by storm
water system. This system includes closed conduits and open channels/ditches. Following
streams should be routed to storm water sewer system.

i) Rainfall from clean areas (oil/chemical free)

ii) Boiler blowdown
iii) Steam condensate
iv) Tank Dyked area drains (additional routing should also be provided to oily water
system in case dyke water is contaminated with oil)
v) Treated water effluent from DM water plants if PH and COD are Okay.
vi) Process cooling tower blowdown,

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

vii) Captive power plant cooling tower blowdown streams Unit Storm water

Drainage:

To collect the uncontaminated rain water, a peripheral storm water ditch shall be provided
all around the unit with suitable grating. The water thus collected shall be routed to OSBL
(Outside Battery Limit) storm water drain by providing two way valve arrangements at
outlet point at battery limit. The discharge of the drain shall be normally open to OSBL
storm water drain. In case of accidental contamination taking place in uncontaminated
area, the two way valve shall be operated to route the water to contaminated rain water
sewer (CRWS) instead of storm water drain.

Tank farm Storm water Drainage:

Open ditch shall be provided in tank farm along the inside face of dyke/ fire wall. A sand
trap shall be provided at out let point of tank farm. A three way valve arrangement shall be
provided just outside the tank farm to route the water discharge of tank farm area either to
offsite storm water drain or to OWS depending on whether the water is uncontaminated or
contaminated.

Identification of Sewer System and Route Marker:

BLOWDOWN AND SEWER SYSTEM

Following details shall be distinctly displayed near manhole top slab.

a.Service Name
b.Size of Sewer
c.Flow Direction
d.Manhole number

6.2.3 Chemical Sewers:

Sewers carrying drains/effluent wastes containing chemicals shall be segregated from

other sewers since these streams often require different treatment than oily water streams
before final disposal. Such streams are also generally corrosive and may require special
materials of construction for the sewers. Since the nature of treatment may be chemical
specific, it is necessary that the quantities, type and compositions of all such streams likely
to be handled in the process areas; chemical storage, handling and dilution etc. should be
thoroughly studied to decide their segregation and treatment.

If chemical waste affects only oxygen demand and solid content of the effluent, these can
be discharged to the oily water system downstream of primary oil separation but upstream
of biological treatment. However, when pH, odour, taste, colour, turbidity etc. are affected,
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

appropriate special treatment should be considered at suitable stage before biological

treatment. Since each chemical may require a specific treatment, it is difficult to generalise
the treatment facilities here. Detailed guidelines for effluent treatment facilities are
therefore not included in the scope of this document. The requirements of chemical effluent
streams of amine and spent caustic which are most commonly available in refineries are
given below:

i) Amine Blow Down Stream:

Amine drains from equipments handling amine solution (e.g. vessels, columns,
lines & pumps, etc.,) shall be routed to a dedicated underground Amine blowdown
drum floating on acid flare.

Amine drains shall not be routed to any other hydrocarbon CBD system due to
following reasons:

a) Draining of amine to hydrocarbon blow down system will lead to contamination

ofhydrocarbon stream as the mixing of amine and hydrocarbon blow down
system will result in amine entering the slop tank (subsequently to crude oil tank)
which will result in corrosion of downstream system during reprocessing of slop.

b) Amine mixing with hydrocarbon will form foaming in the amine scrubbers
whichleads to poor performance of scrubber and high pressure drop in the amine
columns.

BLOWDOWN AND SEWER SYSTEM

c) Amine is very expensive item and can be reused whenever there is planned
shutdown of the unit, any residual amine in the system can be collected
separately in a blow down system and pumped back to the amine storage from
amine blow down vessel for reuse.

ii) Draining condensate from H2S rich gas from amine & stripper Sour Gas KODs

The liquid condensate from H2S rich gas of amine KOD & stripper Sour Gas KOD
are required to be drained continuously to amine blow down drum and sour water
blow down drum respectively to prevent choking of drain lines. Draining should be
done with provision of minimum level control of KODs to prevent escape of vapour
into blow down system and choking of the drain line.

Amine blowdown drum shall be provided with submerged pump. Liquid from this
drum shall be sent to ARU for reprocessing. For design requirement of ABD shall
be similar to hydrocarbon CBD as given in Clause 6.1.

iii) Spent Caustic:

Caustic drains should be collected in caustic drum and pumped out through
submergible pumps to the wet air oxidation treatment facility for treatment (as

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

described in Annexure II) before routing to Biological/activated sludge treatment or

final disposal.

6.2.4 Sanitary Water Sewers:

Sanitary water sewers should collect waste from toilet facilities and route these to a
treatment system in the complex, municipal sewer system or to a septic tank depending
upon the local condition. The treated sanitary effluent may be discharged to the treated
oily water system, to the storm water system or independently to the desired disposal
point.

6.3 BASIC DESIGN GUIDELINES FOR OILY-WATER SEWERS

6.3.1 Layout of Oily Sewers:

Oily water sewer (OWS) shall consist of underground carbon steel sewer, funnel points,
clean outs, leak proof RCC catch basins and manholes, vent pipes, etc.

A) REQUIREMENT OF SEALED MANHOLES:

The layout of most oily water sewers consists of a trunk sewer with branch connected to
process units, dyked areas and other work areas. The main trunk sewer should be
isolated from branch sewers by sealed manholes so that the vapours cannot back up into
processing areas. Seals play a vital role in maintaining safe operation of a sewer system.
Sealed manholes shall be provided on oily sewers at the following locations:

(a) Process Units

BLOWDOWN AND SEWER SYSTEM

i) At unit battery limit of the unit area a sealed manhole shall be provided to cut
off from any fire in offsite areas or vice versa.
ii) Within process units, sealed manholes shall be provided in such locations so
that each sub-unit within the unit is isolated from other areas. Where such
demarcation is difficult, one sealed manhole for every 30 M length of unit
sewer shall be provided.
iii) At change of direction of sewer line. iv) At entry of branch line to manhole.

(b) Offsite Areas

i) At connection manholes of branch sewers to main sewers to isolate each

facility contributing oily waste from the risk of fire. Such connections may be
from tank farms, offsite pump stations, oil loading/unloading areas, railway
gantry areas, compressor house, etc.
ii) On main sewer lines at suitable points so as to provide fire barriers for
segregation of vital hazardous installations from each other. In general sealed

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

manholes on main sewer lines shall be provided at intervals of not more than
300 meters.

B) TYPE OF SEALED MANHOLES

The following fire sealed manholes should be provided:

(a) Single compartment sealed manholes with bent pipes seal type shall be used for
CS pipes upto diameter 16”.
(b) Double compartment type sealed manholes shall be provided for CS pipes greater
than 16” dia and for all sizes of RCC pipes.
(c) A minimum of 150 mm fire seal shall be provided for both single and double
compartment type manholes.

Fig. 13a, 13b & 13c depict Single compartment and double compartment type
sealed manholes.

Sewers, in general, should be designed for gravity flow. In a tightly sealed system, a
rise in water level would reduce the vapour space causing obstruction to flow.
Therefore vents shall be installed on the manhole to maintain atmospheric pressure in
the sewer and to release vapours to safe locations. Following shall be ensured during
design stage to ensure that accidental release of vapours do not create unsafe
condition:

i) At least one vent shall be installed on manhole for every 100 meter in offsite area,
ii) Vents shall not be located near furnaces etc.
iii) The vent of height shall be 3 metre above the nearest tallest structure within 15
metre radius.

BLOWDOWN AND SEWER SYSTEM

iv) In critical locations, the vent pipes should be provided with steam snuffing
connections.
v) Vents should be connected to VOC control system to minimise VOC emissions.

6.3.2 Capacity

The branch sewers from processing areas should be designed for the greater of the
following two situations
i) Rainfall plus process waste water with the sewer flowing at 2/3 of full depth.

ii) Process waste water plus expected fire water runoff with sewers running full.

The design capacity of the trunk sewer should depend on the cumulative amount of used
cooling water and condensate from various processing areas and the storm drainage
from the paved areas and the largest tank dyke area. Trunk sewers generally drain large
water shed; therefore, fire water flows are not governing for their sizing. However, this
should be checked.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

A minimum velocity (at half full or running full) of 0.6 m/sec should be maintained in the
branch and trunk sewers to avoid settling of solids. If the water consists of large
quantities of sediments, the minimum velocity should be increased to 1m/sec. The
maximum velocity should be limited to 2.4 m/sec. The slope of sewers should be decided
based on the sewer size.

6.3.3 Material of Construction:

Material of construction for sewers shall be as per IS 1239 ERW.

i) Inside process units, tankage area, offsite pump house and other paved areas CS
pipes shall be used.
ii) For offsite main header in unpaved area RCC Hume pipes shall be used.
iii) In case salt water is likely to be used in plant and discharged to drainage system,
cement coated piping shall be used.

All underground CS pipes shall be provided with external double wrapping and coating /
FRP coating for corrosion protection.

6.4 SPECIAL SEWERS

Because of special nature of some effluent stream-high pour point, wax content, viscosity
and other fouling characteristics as is the case with asphalts, waxy lube/intermediates and
other similar products, their drains should not be routed to oily water sewers directly as
there is danger of the entire sewer system getting choked. Such product drains should be
handled separately. Some specific cases are mentioned below:

6.4.1 Asphalt Drains

BLOWDOWN AND SEWER SYSTEM

All equipment and areas where effluent streams containing asphaltic material is likely to
be handled should be segregated from other areas by a 4”-6” high concrete bund wall
having a baffle at one end. A small water stream should always be kept flowing in the
bund. The water should overflow into a catchpit having two compartments from where
the water should overflow into the oily water sewer. Asphaltic material which gets trapped
in the catchpit should be occasionally scrapped off manually by isolating one
compartment. Provision should also be made for steaming the catchpit in case required.

6.4.2 Waxy Drains

All equipment and areas where effluent streams containing waxy materials are likely to
be handled should be likewise segregated from other areas by a 4”-6” high concrete
bund wall having a baffle at one end. The water should overflow from the baffle into the
oily water sewer. The wax will get deposited within the bund from where it should be
scrapped off occasionally.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

6.4.3 Drains at Remote Locations

Sometimes because of small capacity of an installation and/ or its remote location, it may
not be feasible to have elaborated oily water sewer system and treatment facilities.
Under such situations, local sumps shall be provided for collection of oily water effluents
from such an installation. Oil sumps shall be designed as miniature oil separators with
outlet baffles to retain oil. Suitable skimming arrangement shall be provided to withdraw
oil to a storage pit, from where it can be pumped out to slop, tank or barrels etc. Oil
sumps however are not very efficient for compete removal of oil from waste.

Alternatively, a “Tilted plate” type of oil-water separator can be specified. Oil removal in
such separators is very good and the treated wasted water almost oil free. If waxy or
fouling type of products are envisaged in the waste water, a grid screen or a filter should
be used upstream of these separators.

7.0 REFERENCES:

1. Design guides to Refinery Sewers, J.D. Brown and G.T. Shannon an API Survey.

2. API-521, 1982 Guide for Pressure Relieving and Depressurising Systems.

3. Safety Digest of Lessons Learned, Section 3, API Publication, 758, 1980.

4. Design for Process Safety, Hydrocarbon Processing, December, 1985.

5. OISD Standard 106 on Pressure Relief and Disposal System.

6. OISD STD 152 Safety instrumentations for process system in hydrocarbon industry

7. OISD STD 144 on Liquefied Petroleum Gas (LPG) Installations

8. IS standard no IS 1239

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

BLOWDOWN AND SEWER SYSTEM

Annexure-II
BLOWDOWN AND SEWER
SYSTEM
Spent caustic treatment through wet air oxidation technology

Spent caustic streams are generated from the purification process of Naphtha,
Gasoline and LPG streams and contain pollutants Annexure-I
like Sulphides, oil, phenol,
BOD/COD and spent caustic. It can be treated through the process of Wet Air
Oxidation Treatment before routing to Biological/activated sludge treatment wherein
Sulphides are converted to soluble sulphates, which is harmless.
Brief write up on Cathodic Protection (CP) system for CBD drum
The process chemistry is based on the conversion of the obnoxious Sulphides to less
objectionable sulfates & Thiosulfates with air at elevated temperature and pressures.
Cathodic Protection: are water soluble & retained in the effluent water and the sulfates
The thiosulphates
are completely harmless and nontoxic.

The principle
Cathodic reactions
protection in oxidation tower
is an electrochemical are: which is the most effective method
technique
for corrosion prevention. It is a least costly method for protecting immersed structures
2Na2S + 2O2 + 2H2O Na2S2O3 + 2NaoH
in soil and aqueous medium against corrosion. Sacrificial anode and impressed current
Nathe
are 2S + 2O2 for applying
methods Na2SOcathodic
4 protection. In sacrificial CP system, electrons
are generated from a base metal which is more anodic to the protected structures.
Some portion of Thiosulfate is further oxidized to sulfate as follows.
Whereas in impressed current CP system, electrons are supplied from a DC source
Na2inS2electrolyte
and O3 + 2O2 +the
2NaOH
current is fed Na 2SO4 a
through +H 2O
non-consumable electrode. A reference
electrode is used to check the efficacy of the CP system.
The spent caustic contains the impurities such as Sulphide, COD as high as 10,000
mg/litre & 15,000 mg/litre respectively along with phenol & oil. The conventional
Biological
General processforfinds
description it difficult
CP system for CBDto vessel
treat theses pollutants. The Typical wet air
oxidation process efficiently reduces theses impurities.

The spentcurrent
Impressed caustic is stored
cathodic in settling
protection tanks
system to equalize
shall be installedfluctuations in caustic
for buried CBD vessel flow & to
remove
having floating
shallow oil fromclose
distributed top of the tanks.
anode The caustic
ground beds. tanks
Each vessel should
shall have be blanketed with
Nitrogen. The spent caustic is preheated with hot oxidized caustic from the Reactor in
independent CP system comprising of one 50V/50A T/R unit, requisite no. of anode
a heat exchanger. This hot spent caustic solution after mixing with process air &
beds associated
steam with AJB
in injector and the
enters CJB, feed
reference cells, The
reactor. test station
air flowbox,will
cables
be etc. Each by Flow
controlled
controller
vessel & the
shall have steam
anode beds,flow
4 nos.bypermanent
the temperature controller
reference cells, of the
2 drainage Reactor. Here
cable
sulphide gets
connections oxidised to
and associated sulphate
cables, in the
structural andreaction sections and separated by sieve
civil works.
trays in order to ensure a sufficient distribution of caustic and air.

Each
Theanode bed temperature
reaction shall be of shallow, 1200distributed
close and
is approx type consisting
C at the beginning andofincrease to approx
0
136 C duewire
continuous to exothermic reaction.
anode. The power Theunit
for T/R caustic
is fedstream goes
from one upward
Power in co-current
distribution box. flow
Inwith
orderthetooxidation
accuratelyair and leaves
monitor the CPthe reactor
system, at its
4 nos. head afterreference
of permanent being separated from the

electrodes (Cu/CuSO4) with pre-packed

“OISD hereby expressly chemical
disclaims any liability orbackfill are to
responsibility for be
lossplaced in 12,
or damage 3, 6 &
resulting
from the use of OISD Standards/Guidelines.”
9 O’clock positions for each vessel. Spacing of wire anode from vessel shall be kept
900mm.
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

oxidation air. The wet and hot oxidation air usually containing stripped hydrocarbons
is vented via high point vent pressure controller to atmosphere. Hot oxidized
caustic is cooled down by exchanging heat with the cold incoming spent caustic feed
to the reactor. The oxidized caustic is routed to the biological treatment system /

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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PROCESS DESIGN AND OPERATING PHILOSOPHIES ON

BLOWDOWN AND SEWER SYSTEM

Typical scheme of the Wet Air Oxidation process for spent caustic treatment

High point vent

PRC

Steam

Spent Caustic
From tanks
Process Air

Reactor

Injector

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Oxidized Caustic to OISD/DOC/2019/13
BiologicalTreatment

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Annexure - III

Use of Single / Double compartment sealed manholes for OWS (Oily Water Sewer) in
Hydrocarbon Industry

For all sizes of RCC (Hume) pipes double compartment sealed manholes are only used to avoid
use of bends as the sealing of joints in case of RCC (Hume) pipes is not proven as leak proof.

Carbon steel pipes up to 16” diameter are used for construction of single compartment sealed
manholes. Perfect sealing of pipe bend is achieved by welding.

Length ofthe bends of CS pipes larger than 16” dia is very high. For construction of single
compartment sealed manholes with these large length of bends leads to increase in the depth of
these manholes. Construction of such deep chambers is not advisable from techno economic
considerations. Hence double compartment sealed manholes are used for these larger sizes of CS
pipes.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 OISD/DOC/2019/13
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25
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38“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
35“OISD
36
37 OISD/DOC/2019/13
“OISDhereby
herebyexpressly
expresslydisclaims
disclaimsany
anyliability
liabilityor
orresponsibility
responsibilityfor
forloss
lossor
ordamage
damageresulting
resulting
from
fromthe
theuse
useofofOISD
OISDStandards/Guidelines.”
Standards/Guidelines.”

OISD – STD – 109 Page No. 25

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