Process Description Report

HBU-1

Submitted by
 Muhammad Aamir Sultan

1/8/2024
Submitted to
 Mr Saleem Hasrat
 Senior Process Engineer
Process Description Report

TABLE OF CONTENTS

1 ACKNOWLEDGEMENT.................................................................................................3
2 INTRODUCTION..............................................................................................................4
2.1 Crude processing capacity...........................................................................................4
2.2 Downstream & Utilities...............................................................................................5
2.3 Refinery Products........................................................................................................6
3 TECHNICAL SERVICES DEPARTMENT.....................................................................7
4 HOWE BAKER UNIT –I (HBU-I)....................................................................................8
4.1 Process Description HBU-I.........................................................................................8
4.1.1 Crude Preheating..................................................................................................8
4.1.2 Naphtha (Preflash).............................................................................................10
4.1.3 Preflash Bottoms................................................................................................10
4.1.4 Naphtha (Main Tower).......................................................................................11
4.1.5 Kerosene.............................................................................................................11
4.1.6 HSD Product......................................................................................................12
4.1.7 HSD Pumparound..............................................................................................12
4.1.8 Diesel fuel oil (DFO).........................................................................................12
4.1.9 Furnace fuel oil (FFO).......................................................................................12
4.1.10 Naphtha Stabilizer..............................................................................................13
4.1.11 LPG treatment section........................................................................................13
5 DESALTER.....................................................................................................................14
5.1 Desalter Parts.............................................................................................................16
5.2 Electric desalting process parameters:.......................................................................17
6 FIRED HEATERS...........................................................................................................18
7 DISTILLATION..............................................................................................................20
7.1 Distillation Process....................................................................................................20
7.2 Column Internals:......................................................................................................21
7.3 Atmospheric Distillation Tower:...............................................................................21
7.4 Vacuum Distillation Tower:......................................................................................21
7.5 Stabilization Tower:..................................................................................................21
7.6 Stripping Tower:........................................................................................................21
8 COLUMN REFLUX........................................................................................................21
8.1 Types of Refluxes:.....................................................................................................22

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Process Description Report

8.1.1 Cold Reflux........................................................................................................22

8.1.2 Hot Reflux..........................................................................................................22
8.1.3 Internal Reflux...................................................................................................22
8.1.4 Circulating Reflux..............................................................................................22
8.1.5 Reflux ratio.........................................................................................................22
8.2 Controlling Tower Temperature................................................................................22
8.2.1 Reflux ratio.........................................................................................................22
8.2.2 Temperature Gradient........................................................................................23
8.3 Tower Pressure Controlling.......................................................................................23
9 Tripping Values of HBU-I...............................................................................................23
10 Activities Performed........................................................................................................24
11 Jobs Observed..................................................................................................................24
12 Self-Study & Course Attended.........................................................................................24

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Process Description Report

1 ACKNOWLEDGEMENT
First of all, I would like to thank Allah almighty for providing me opportunity to work in one
of the reputed organizations in oil refining sector, where I can polish my technical and
interpersonal skills by seeking guidance from experienced individuals.
I am happy to be a part of Process department which is considered as a backbone for
processing plants, starting from design stage till optimization for better and smooth
processing.
I would like to extend my gratitude to my supervisor Mr. Saleem Hasrat (Senior Process
Engineer) for his continuous support and valuable advices that helped in boosting my
technical and interpersonal skills. He was always kind and supportive towards me during this
learning process.
Lastly, I would like to thank the whole staff of TS for providing healthy learning
environment.
 Muhammad Aamir Sultan
 Senior Management Trainee

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Process Description Report

2 INTRODUCTION
Attock Refinery Limited (ARL) has a rich history dating back to 1922, marked by a
continuous evolution of its plants, progressively integrating cutting-edge technology. The
refinery's remarkable capacity encompasses the processing of crude oils ranging from the
lightest to the heaviest grades, currently handling crudes with API values spanning from 12 to
65. Notably, ARL boasts a diverse portfolio of petroleum products, including LPG, Premium
Motor Gasoline, Naphtha, Solvents, Jet Fuels, Kerosene, High Speed Diesel, Light Diesel
Oil, Jute Batching Oil, Furnace Oil, and Asphalts.
Between 1999 and 2016, ARL embarked on a substantial upgradation project. During this
period, the refinery implemented a strategic plan aimed at enhancing its infrastructure,
optimizing processes, and integrating advanced equipment. This initiative not only
modernized the refinery's capabilities but also bolstered its efficiency and product quality,
further solidifying its position in the petroleum industry.
In 2016, ARL completed a major expansion and up-gradation project comprising Diesel
Hydrodesulphurization (DHDS) unit (to reduce Sulphur contents in High-Speed Diesel in
order to meet Euro II specifications), Pre-flash Unit (to enhance refining capacity by 12,400
BPD), Isomerization unit (to enhance premium Motor Gasoline) and expansion of the
existing captive power plant by 18MW. Keeping in view expansion and up-gradation, ARL
commissioned secondary effluent treatment plant in 2014. After Completion of project the
refining capacity has increased to 53,400 BPD with improved specification of products.
 A Preflash Unit to enhance the refining capacity from 43,000 BPD to 53,400 BPD
 Isomerization Unit to further improve the octane pool and reduce benzene and
aromatics of the gasoline product
 Diesel Hydrodesulphurization (DHDS) unit and its auxiliary units to produce Euro-II
sulfur specification diesel
 Captive Power plant expansion- by 18 MW
 Associated Auxiliary Units and Utilities

2.1 Crude processing capacity

Total crude processing capacity ARL is 53,400 barrels per stream day (BPSD). There are four
crude processing units in the refinery named as HBU-I, HBU-II, HCU and LUMMUS.
Following graph shows crude processing capacities of each unit.

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Process Description Report

53,400 BPSD

10000, 19%, HCU

5000, 9%,
LUMMUS

32400, 61%,
6000, 11%, HBU- HBU-I
II

HBU-I HBU-II LUMMUS HCU

2.2 Downstream & Utilities

The refinery has strategically installed various downstream units to ensure that its products
meet the necessary specifications and adhere to industry standards. These units encompass
ISOM, Reformer, DHDS, and Merox, each playing a pivotal role in the refining process.
Alongside these, the refinery also houses auxiliary units like HYU, Amine treating units,
Sour water strippers, and sulphur recovery units, all contributing significantly to the overall
operational efficiency.
In alignment with strict environmental regulations, the refinery has integrated ETP (Effluent
Treatment Plant). Emphasizing its commitment to environmental responsibility. Moreover,
addressing substantial energy requirements, the refinery operates multiple boilers and a
dedicated power plant to support its extensive operations and sustain the energy demands of
the facility
Downstream Units
Naphtha Hydro treating and Reformer 5,000 BPSD 1999
Reforming
Light Naphtha Hydro treating Isomerization 7,000 BPSD 2016
and Isomerization
Diesel Hydro Desulphurization Diesel Hydro 12,500 BPSD 2016
treater
Naphtha Merox Unit Merox 4,400 BPSD 1979
Kerosene Merox Unit Merox 1,600 BPSD 1979
Auxiliary Units
Hydrogen Unit Hydrogen 5,500 NCMH 2016

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Process Description Report

Sour Gas Treatment Unit Amine Treating 3,600 Kg/hr. 2016

Sour Water Treatment Unit Sour Water 7.0 CMH 2016
Stripper
Sulphur Recovery Unit Sulphur 15.0 TPD 2016
Recovery
Effluent Treatment / Environment Control Units
Slant Ribbed Coalescers Two SRC Units 85 IGPM --
each
Dissolved Air Flotation DAF Units 85 IGPM --
Effluent Secondary Treatment ETP-II 200 USGPM 2014
Unit
Boiler House
Steam Boilers Five Boilers 12 Tons/hr. 1996
each
Steam Generation Unit Three Boilers 26 Tons/hr. 2016
each
Power Plant
Captive Power Plant Three Engines 7.5 MW each 2001
Captive Power Plant Three Engines 6.0 MW each 2016

2.3 Refinery Products

Refinery Products from various Units are as follows:
 LIQUEFIED PETROLEUM GAS (LPG)
 EXPORT NAPHTHA
 PREMIER MOTOR GASOLINE (PMG)
 PREMIER MOTOR GASOLINE (PMG 95 RON)
 MINERAL TURPENTINE (MTT)
 KEROSENE OIL
 AVIATION FUEL (JP-1)
 AVIATION FUEL (JP-8)
 HIGH SPEED DIESEL (HSD)
 LIGHT DIESEL OIL (LDO)
 JUTE BATCHING OIL (JBO)
 FURNACE FUEL OIL (FFO)
 RESIDUEL FURNACE OIL (RFO)
 LOW SULFUR FUEL OIL (LSFO)

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Process Description Report

 BITUMEN (GRADE: 60/70)

 BITUMEN (GRADE: 80/100)

To ensure smooth and efficient operations, the refinery is segmented into various
departments, each with its unique hierarchy tailored to its specific job description.

3 TECHNICAL SERVICES DEPARTMENT

The Technical Services Department (TSD) is crucial for ensuring the smooth functioning of
the Refinery by offering a wide range of technical assistance. Its responsibilities span various
areas such as Production Planning, Energy Audits, Optimization, Process Design, Refinery
economics, and preliminary assessments, as well as Plant Monitoring, Product Quality
Control, and Research & Development. TSD's role extends to providing technical aid for
ongoing and future projects: evaluating and endorsing all process alterations while
considering their necessity, technical feasibility, and economic rationale for each proposed
adjustment.
 Monitoring of Plant operations, upsets, deviations and suggest corrective actions
including bi-annual Technical Monitoring of complex for sustained & efficient
operation.
 In-house pre-feasibility and process design of small size projects to improve
reliability, capacity increase and energy conservation to utilize margins within
existing system.
 Acquire services of engineering firms to finalize resolution of Plant issues.
 Inputs for Management Information System
 (Technical Committee Inputs, Monthly News Letter, Weekly & Fortnightly
Highlights, Turnaround reports etc.)
 Technical Monitoring / Inventories /Specific Consumptions Audits
 Troubleshooting and Technical solutions
 Production Loss Analysis & Reporting
 Modifications / Technical Reviews / Re-Engineering
 Engineering For Long Term Projects
 Liaison with Process Licensors
 Start-up / Shutdown Coverage / SOPs
 Lube Oil Quality Monitoring
 Development of Procedures and execution of Special Activities
 Specifications of New Equipment / Machines / Instruments / Catalysts /Chemicals /
Oils and their acceptance
 Turnaround & Emergency Services
 (Catalyst / Packing - Loading / Unloading, activation, refractory dry outs and
Chemical Cleaning)
 Assistance to other departments

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Process Description Report

4 HOWE BAKER UNIT –I (HBU-I)

Howe Baker unit - 1 was commissioned in 1981 with refining capacity of 20,000 barrels per
stream day of light sweet crude. It was revamped in 2016 and refining capacity is increased to
32,400 BPSD. Now this unit is fully integrated in two stage crude distillation. First stage
splits Naphtha while second stage separates other fractions.
Following are the main sections in HBU-I:

HBU-1

Crude
Preheating Preheating Preflash
Desalting
Stage 1 Stage 2 Fractionation

Atmospheric Naphtha Crude

fractionation Stabilizer Preheating

Following are the products obtained by this unit;

 Liquefied petroleum gas (LPG)
 Gasoline (Naphtha)
 Kerosene
 Jet fuel (JP-1)
 High speed Diesel (HSD)
 Light Diesel Oil (LDO)
 Furnace fuel Oil (FFO)

4.1 Process Description HBU-I

4.1.1 Crude Preheating
Light Sweet Crude coming from crude tanks 1A/2A/3A/1B (flows naturally due to tank head)
is available at battery limits at 120 kPa. This crude passes through bucket filter, autoclave and
strainer to remove impurities and particulates so that it can’t enters the charge pump. In
autoclave particulates settle down by centrifugal action of motor driven impeller, while
bucket filter blocks sediments and allow only crude to pass through it. Crude then passes

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Process Description Report

through brodimeter which measures the flow of crude. After brodimeter, crude is pumped
through P-301 A/B which increases the crude pressure up to 1700 kPa and passes through
FT-141 which measures the crude charge flow rate. Crude is then split into two streams. One
stream passes through FCV-137 and enters in heat exchangers pre-heat train A. Pre-heat train
A contains E-301, E-302, E303A & E-303B where crude is heated by LWK (Light Weight
Kerosene), Heavy naphtha (from Preflash) & naphtha pump around (from V-301)
respectively. Other stream passes through FCV-134 and enters in pre-heat train B. Pre-heat
train B contains E-321, E-322, E-325 & E-326 where crude is heated by HSD product, Heavy
naphtha (from preflash), HSD product & Heavy naphtha (from preflash) respectively. Both
streams combine with each other after heating in pre-heat trains & process water from boot of
naphtha’s accumulator is injected in crude. Purpose of injecting water in crude is too weak
the emulsion. Crude then passes through mixing valve to further weak the emulsion, due to
turbulence created by pressure drop in mixing valve. After mixing valve, crude enters into
desalter for removal of salts and BS&W (Bottom Sediment & Water) present in crude.
Desalter is designed for the crude containing salts up to 35lb/1000bbl. Temperature inside
desalter is maintained at 90 to110 o C. Temperature is provided in desalter because by
increasing temperature viscosity of liquid decreases and salts removal becomes easy. Pressure
in the desalter is 1000 kPa. Pressure is provided in desalter to avoid the evaporation of water
otherwise salts removal will not be efficient. Desalter pressure is controlled by flow control
valves (FCV-134 & FCV-137) present at inlet of preheat trains A & B. Tricock valves are
available to monitor water and crude level in the desalter. If water level increases inside the
desalter, it is drained and passes through exchanger E-335 where it provides heat to incoming
fresh water makeup water. LCV-302 is present at the end of effluent discharge line of desalter
which serve the purpose of level controller for desalter.
Normally two types of desalter are used depending upon the type of crude and the salts
present in them. These are;
 Electrical desalter
 Electrochemical desalter (Demulsifies addition)

Electrical desalter is being used at HBU-I. Electric field is provided in electrical desalter to
break the emulsion. Voltage of 400 – 440 volts is provided & step-up transformer increases it
to 18 kV. Two electrodes (Anode & Cathode) are present in the desalter. Voltage provided
creates vibration in the crude layer and water settles down in the form of coalescence due to
high specific gravity as compared to crude. Three layers are present in the desalter; bottom
most layer is of water. Layer above water is of emulsion. Top most layer is of crude. Water
level in crude must be less than 30% and should not touch the electrodes, otherwise it can
result in electrical shock. An Ammeter is provided with desalter to identify if any current is
present in desalter. If current exceeds the set point limit desalter will trip.

In normal operating conditions, salts and BS&W at inlet and outlet of desalter are given
below

Parameters Desalter Inlet Desalter Outlet

Salts (lb/1000bbl) 6.5-7 0.4-0.5
BS&W (%) 0.5 0.1
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Process Description Report

After salts removal, crude is pumped through booster pump P-313A/B to increase the
pressure of crude. Normally it is bypassed, but if pressure drops then it can be used to boost
the pressure. Crude then splits again into two streams. One stream enters into preheat train C,
containing exchangers E-304, E-305, and E-306 where crude is heated by HSD pump around,
FFO (Furnace Fuel Oil) & HSD pump around respectively. After leaving exchangers, crude
passes through a flow control valve FCV-103 & enters into heat exchangers E-307B/A, E-
308, E-323, E-331A & E-331B where crude is heated by HSD product, DFO (Diesel Fuel
Oil), HSD pump around & FFO respectively. Other stream enters into preheat train D which
contain exchangers E-324, E-318, and E-317 where crude is heated by DFO, FFO, HSD
pump around respectively. After leaving exchangers, crude is flow controlled through FCV-
138 & enters into exchangers E-327, E-328, and E-320A & E-320B where crude is heated by
HSD product, HSD pump around & FFO respectively. Crude flows in the tube side while
products on shell side but in new exchangers (E-320A, E-320B, E-331A, E-331B & E-323)
crude flows on shell side and products in tube side.
Both streams combine with each other in a header. Crude then leaves the header & FFO is
injected in crude through FCV-104. Purpose of FFO injection in crude is to avoid the heater
tubes from thermal shock because at high temperature some vapors of crude are formed &
heater tubes are not designed for vapors so FFO keeps the heater tubes fill. Crude then enters
in pre-flash tower V-309 on 4th tray at about 190 o C. Total 28 trays are present in pre-flash
tower. Light naphtha is separated from top and cooled in air cooled condenser E-309 and
received in overhead accumulator V-311. A vapor line before condenser E-309 directly enters
in V-311 through pressure control valve PCV-437 in order to maintain pressure of the tower.
Fuel gas line from gas gathering also enters at the outlet of V-311 LP gas outlet line. Tower
top temperature is controlled by naphtha reflux through FCV-156.Liquid level inside the
tower is controlled through FCV-103 and FCV-138 present at preheat trains C & D after
exchangers E-306 and E-317 respectively.
4.1.2 Naphtha (Preflash)
Lighter naphtha is collected in overhead accumulator V-311 from where it is pumped through
P-314A/B. Part of naphtha is refluxed through FCV-156 to the tower top, while remaining
enters into the suction of P-303A/B which serve as feed pump for naphtha stabilizer. FCV-
169 is present at the discharge of P-303A/B which serves the purpose of level control of
overhead accumulator V-311.
Heavy naphtha is withdrawn from 14th tray through P-317A/B, exchanging heat with crude
through heat exchangers E-326, E-302, E-322 and splits into two streams. One serves as
naphtha pump around and enters the column at 17th tray through FCV-157. Second stream
passes through FCV-173 to the trim cooler E-330 and routed to storage.
4.1.3 Preflash Bottoms
Remaining crude leaves, the pre-flash from bottom and divided into two streams. One of the
streams is pumped through P-318A/B at a pressure of 950 kPa and after passing through
FCV-158 crude enters in a header. Crude then divides into four passes and enters in
convection zone of pre-flash reboiler H-302 at about 190 to 200 o C through FT-160, FT-161,
FT-162 and FT-163. Purpose of dividing crude into passes is that flow area is increased and

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Process Description Report

hence heat transfer rate is increased. Crude first enters in convection zone of heater and then
goes to radiation zone. Crude leaves the radiation zone of pre-flash reboiler in four passes at
about 345 o C and enters in a header from where it again enters in pre-flash at the bottom of
tower. Heated crude enters to maintain a level in pre-flash and to provide heat required to
separate the naphtha from crude.
Second stream is pumped through P-321A/B at a pressure of 1000 KPa and after passing
through FCV-159, FFO is injected in crude through FCV-104. Then de-coking steam is
injected in crude which is used during plant start up to steam out the crude circuit from heater
to distillation column. Crude then divides into four passes and enters in convection zone of
heater H-301 at about 200 o C through FT-124, Ft-125, FT-126 and FT-127. Crude leaves
radiation zone of heater in four passes at about 356 o C and enters in distillation column V-301
on 4th tray in single pass. 40 trays are present in distillation column.

Two types of heaters are in operations at HBU-I;

 Cylindrical type heater (H-302)
 Box type heater (H-301)
Radiation zone tubes are vertical while convection zone tubes are horizontal in cylindrical
heater. Pre-flash reboiler is cylindrical heater.
Convection as well as radiation zone tubes are horizontal in box type heater. Heater H-301 is
box type. Stripping steam is provided in distillation column to decrease partial pressure so
that separation of the crude into its constituent fractions is more efficient. Purpose of
stripping steam is to reduce the partial pressures of hydrocarbons in crude and allow more
separation at specified temperature. Fractions are separated in column before their end points;
i.e.; their boiling points are reduced due to stripping steam addition.
4.1.4 Naphtha (Main Tower)
Naphtha vapors leaves from top of the tower where they are condensed in overhead
condenser E-309, and stored in overhead accumulator V-305. Total 8 cells are present in E-
309, two of them are for V-301 and 6 are for V-309. Like preflash there also exist a vapor
line that enters overhead accumulator V-305 through PCV-403. There is also a fuel gas line
entering at LP gas discharge line. Tower top pressure is controlled by PCV-403 and LP gas
discharge line.
Naphtha is pumped through V-305 via pump P-302A/B and splits into two streams. One
stream enters at tower top through FCV-106 and serve as top reflux. Tower top temperature is
also controlled by this reflux flowrate through FCV-106. Second stream passes through FCV-
107 (which regulates the level of V-305), and enters into heavy naphtha line coming from
FCV-173 to the trim cooler E-330.
In order to reduce the overhead condenser load, naphtha is withdrawn from 37 th tray and
pumped through P-312A/B, get heat exchanged with crude in E-303A/B and enters in top
reflux line after FCV-106, through FCV-102.

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Process Description Report

4.1.5 Kerosene
Kerosene is withdrawn from 27th tray through LCV-305 where it enters in side stripper V-302
for flash point correction. Stripping steam is introduced in V-302 at the bottom which
removes lighter ends from top and enter into V-301. Kerosene product is pumped from
bottom of V-302 using P-304A/B, get cooled by exchanging heat with crude in E-301, further
cooled by trim coolers E-333A/B & E-310, and sent to storage through FCV-108.
4.1.6 HSD Product
High speed diesel is withdrawn from 15 th tray and enters in stripper V-303 for flash point
correction through LCV-304. Lighter ends move to top where they enter back in main
column at 18th tray. HSD Product is withdrawn form bottom of V-304 via pump P-319A/B,
split into two streams. Each stream passes through E-307A/B & E-327 and combined through
FCV-147A & FCV-147B respectively. This combined stream enters E-325 & E-321 where it
transfers heat to the crude, further cooled in air cooled exchanger E-311 and a trim cooler E-
319 before leaving for storage.
4.1.7 HSD Pumparound
HSD is withdrawn from 15th tray via pump P-307A/B and split into three streams. Stream one
act as a heating medium for stabilizer bottom reboiler and is controlled through temperature
controller of stabilizer through FCV-111. Second stream enters in exchangers E-323, E-306
& E-304 where it exchanges its heat with the crude and passes through FCV-149. The third
stream enters in E-328 and E-317 and passes through FCV-152. All the streams are then
combined and sent to the atmospheric tower V-301 at 18th tray as HSD Pumparound.
4.1.8 Diesel fuel oil (DFO)
Diesel fuel oil DFO is withdrawn from 9 th tray throughLCV-303 and enters into side stripper
V-304 for flash point correction. Lighter ends began to rise in top and are directed back to the
atmospheric column. DFO is pumped from the bottom of the stripper via P-306A/B, and
exchanges its heat with crude by passing through exchangers E-308 and E-324. It is further
cooled in air cooled condenser E-312. Steam tracing is provided while cooling in E-312.
After cooling, DFO passes through flow control station FCV-109 to both storage and slope.
There is another line used to add DFO to FFO at LCV-302 as well.
Main purpose of installing side strippers is to correct the flash points of the side draw
products. It is because while side product is withdrawn from the tower, lighter components
which are desired above the side draw product get into the side drawn product and decreases
the flash point of side drawn product. So lighter ends get stripped out in strippers and the
properties of product will be up to the mark.
4.1.9 Furnace fuel oil (FFO)
Furnace oil is pumped from bottom of atmospheric tower via pump P-308A/B/E and split into
three streams. One stream serves as recycle residue to the heater H-301 and its flow is
regulated through FCV-104. Second stream is cooled by exchanging its heat with crude
through heat exchangers E-331A/B & E-305 and passes through flow controller valve FCV-
150A. Third stream is cooled by exchanging its heat with crude through heat exchangers E-
320A/B & E-318 and then passes through flow control station FCV-150B. All of three
streams are combined and sent to air cooled exchanger E-313 for further cooling of FFO.

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Process Description Report

Steam tracing is provided inside the cooler. After this FFO is passed through flow control
station FCV-302 and routed to the storage or slop. Level of atmospheric column V-301 is
also controlled through FCV-302.
Following table shows different fractions and their corresponding withdraw trays,
temperature and specific gravity.

Product Draw Off Temp (o C) Draw off tray Flash Point (o Specific Gravity
C)

Naphtha 138 Column’s top N/A 0.7 – 0.75

LWK 200 27th 35 0.75 – 0.8

HSD 275 15th 54 0.8 – 0.85

DFO 325 9th 54 0.920 (Max.)

FFO 356 Column’s 66 0.960 (Max.)

bottom

Naphtha goes to stabilizer section where RVP (Reid Vapor Pressure) of naphtha is controlled.
Naphtha’s RVP @ 37.8oC = 9 Psi
“Vapor pressure of hydrocarbon when it is heated at 100 oF (37.8oC) is called Reid vapor
pressure.”
4.1.10 Naphtha Stabilizer
Unstabilized Naphtha passes through heat exchanger E-401 A/B where it gets heated by
stabilized naphtha from reboiler E-403 and then enters into stabilizer at 22 th tray. Top product
is withdrawn from the tower, cooled through air cooled exchanger E-402, and sent to trim
cooler E-407 for further cooling and then received in overhead accumulator V-402. A vapor
line is directly added in V-402 through PCV- which serve as the tower’s pressure control.
Total 44 trays are present in the stabilizer. LPG is pumped from bottom of accumulator V-
402 via pump P-401A/B and cooled through trim cooler E-406 and splits into two streams.
One stream serves the purpose of reflux and enters the tower top through FCV-112. The
second stream is sent to LPG treatment section. Stabilized naphtha is withdrawn from bottom
of reboiler E-403, where reboiler temperature is maintained by heating the stabilizer bottom
in reboiler with hot HSD Pumparound stream. Stabilizer bottom temperature is maintained at
135 o C by controlling flowrate of HSD Pumparound through FCV-111.
Stabilized naphtha leaves the reboiler from bottom, exchange its heat with stabilizer feed in
exchanger E-401A/B, further cooled in air cooled condenser E-404 and trim cooled through
exchanger E-405. The stabilized naphtha is then routed to the storage through LCV-308. The
level inside reboiler is also controlled through LCV-308.

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Process Description Report

4.1.11 LPG treatment section

The second split stream from exchanger E-406 enters in a coalescer filter, where water is
removed and pumped by P-501A/B and sent to cooler E-501 for further cooling. This stream
then passes through FCV-113 and enters in first stage caustic washing stage V-501. LPG
coming from HCU also joins this line. Level of stabilizer overhead accumulator V-402 is also
controlled through FCV-113. Caustic washing reduces acidic content of LPG.
Caustic washing is done in two stages so that minimum caustic is utilized and ensure that the
caustic leaving the vessel is spent to maximum level. Fresh caustic enters in vessel V-502
where less acidic LPG is present. Caustic is recycled from bottom pump P-303A/B through
LCV-312. It is recycled to both V-501 and V-502. Level is also controlled through LCV-312.
Bottom stream from V-501 is also recycled through P-502A/B. Level of this vessel is
maintained through LCV-311 which is for spent caustic disposal.
After caustic washing LPG enters in V-503, where it is water washed to remove extra caustic
in it. Fresh makeup water from utility water system is pumped through P-504A/B and mixed
with bottom recycle from pump P-505A/B before entering in V-503. Level is maintained by
LCV-313, which enroute the spent water to the disposal.
LPG finally moves towards salt drying section where water content in LPG is removed. Two
vessels, V-504A & V-504B are packed with salts are present for this purpose. Water is
removed from bottom drain after regular intervals, while LPG leaves from the top. Pressure is
controlled through PCV-405 and LPG is sent to the storage bullets.

5 DESALTER
Desalter is used for removal of salts, suspended solids and water-soluble trace metals/slits,
iron oxide and sand particles from the crude. Main purpose of desalter is:
 To remove Metals which may poison to Catalyst of downstream units
 To improve plant life.
 To obtain high degree of operating flexibility due to sludge or high tank bottom
sediments
Crude Salt Chemistry
 Salts are generally measured in PTB (parts per thousand barrels).
 Salts concentration in crude depends upon the Source of Crude.
 Salts are inorganic in nature and are soluble in water (inorganic) and insoluble in
crude (organic).
Types of Desalting
 Simple/Natural desalting
 Chemical desalting
 Electrochemical desalting
Simple/Natural Desalter
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Process Description Report

Desalter in which Settling time is given to the crude. Salts, sediments, water and sludge settle
down in the bottom of vessel due to gravity and then drained. While desalted crude leaves
from the top of desalter.
Example of this type of desalting is drainage of sludge and water from storage tanks and
Settling Vessel F-2 present at Lummus plant.
Chemical Desalting
 Desalter in which chemical is added to the crude in order to remove salts, sediments,
water and sludge.
 Chemicals reduce the surface tension for making removal of salts and water easy.
Both Natural and Chemical desalter are useful for crude having low salts or mostly for batch
processes.
Electrochemical Desalting
 Desalting process by use of chemical along with electric field.
 Demulsifier is used as a chemical while electrode connected to step up transformer
used for electric field generation.
 Mostly used where salt content is high and strong emulsion is created in crude.

In a refinery, crude oil containing high levels of salt will go through a desalter before being
fed to the atmospheric distillation tower
Removal of salts is important for reducing corrosion in the distillation tower and downstream
processing units. If not removed, the salt will hydrolyse when crude is heated in heaters to
form acids which will result in corrosion. Also, the salt can form deposits on heat exchanger
surfaces over time, resulting in fouling and reducing exchangers efficiency.
In the desalter, the crude oil is heated and then mixed with 5-15% volume of fresh water so
that the water can dilute the dissolved salts. Frequently, an electric field is used to encourage
water separation. Demulsifying chemicals are also used. For high levels of salt and/or to
achieve very low final concentrations, two- or three-stage desalting may be used
Desalting also removes suspended solids such as sand, dirt, and rust particles picked up in
transport.
Preheated crude, fresh water along with small amount of chemical injected to Desalter
through mixing valve to form Emulsion.
Small water droplets containing salts get charged and began to vibrate when electric field is
applied. These charged particles combine to form a large particle which settles down by
gravity.

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Process Description Report

Electric Desalting steps

 Formation of emulsion of crude oil and water up to some required extent.
 Breaking of emulsion of crude oil and water by mean of electric field.
 Settling of salts at bottom.

5.1 Desalter Parts

Transformers
 Provides electric filed.
 A.C Current provided by Transformer that helps in emulsion breaking
Inlet Crude Header
Cylindrical in shape having caps on both ends with holes on its surface. Holes are random
and flow is laminar.
Float Arrangement
To keep the required water level in the Vessel. LCV-301 on the effluent drain is connected to
float arrangement.
Outlet Collection header

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Process Description Report

Rectangular in shape having circular holes in it.

Mud wash line
The line is equipped with nozzles which enhance the velocity head of water when operated.
Operated in order to remove sludge.
Effluent Header
Having circular holes to drain effluent continually. Containing LCV-301 to maintain required
water level.
Tri Cocks
Sample points used to check water level, interface level and Crude condition.
Electrodes
Electrodes are connected to Transformer. Electrodes are in form of bed hanging in the vessel.
Bed vibrates when field created through them.
Pressure Safety valve (PSVs)
Mechanical Safety of Vessel because the Desalter operate at high Pressure.
Mixing Valve
Used to form emulsion of water salts and crude at the inlet of Desalter.

5.2 Electric desalting process parameters:

Process water or wash water
 Injected to increase the contact b/w water and crude to create strong emulsion
 To enhance the solubility of salt in water.
 Wash water should not contain any oxygen, under spec carbonates, bicarbonates and
sulfates.
 pH should be maintained b/w 6 to 8.
De-emulsifier chemical
 These are Chemicals used for breakage of emulsion.
 Demulsifier weaken the oil layer around water to coalesce with other droplets. In
some cases, changes the polarity so that the droplets attract each other to form
coalescing effect.
 Excess demulsifying agent effects adversely

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Process Description Report

Temperature
 Decrease in temperature increase the viscosity of crude and decrease the solubility of
salts in water, which is not favorable for desalting process.
 High Desalter Temperature cause increase in solubility of water, formation of tight
emulsion and carryover of salts and water.
 Temperature in desalter should be 90oC to 150oC, varying from crude to crude.
Pressure
 High pressure keeps system from boiling.
 Agitation results from boiling can carry over lot of BS&W.
Level
 Operating level of water must be maintained below the lower electrode.
 Conductivity of water causes electric current flow and eventually shut down the
electric system.
 If level is allowed to raise it will carry over the interface with crude to the tower
causing tower upset and exchangers fouling as well.
 Low level cause carryover of crude with effluent water, which results in crude loss.

6 FIRED HEATERS
Fired heaters, also commonly called furnaces, are
a primary source of thermal energy for process
heating operations in petroleum refining and
chemical plants. These are used for heating,
vaporization, and thermal cracking of various
Following are different parts of fired heaters:

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Process Description Report

1. Stack: exhaust chimney or vertical pipe through which flue gases escape the fired
heater
2. Convection Tubes: tubes located in the convection section
3. Header Box: internally insulated compartment enclosing headers or manifolds
4. Radiant Tubes: tubes located in the radiation section
5. Casing: a metal shell, typically lined with refractory, enclosing the firebox and
convection section
6. Refractory Lining: heat-resistant lining; commonly made from cast able or ceramic
fibre
7. Convection Section: area where hot flue gases leave the radiant section and circulate
at high speed through a tube bundle
8. Arch (or Bridge wall): location where flue gas exits the radiant section
9. Radiant Section: area where tubes are directly heated by radiation from burner flames
10. Breeching: transition where flue gas travels from the convection section to the stack
11. Finned Tube: specialized tube with extended fins that increase surface area and heat
absorption
12. Corbels: refractory material used to direct flue gases onto tubes as it passes though the
convection section
13. Crossover: connecting piping between any two coil sections
14. Shield Section/Shock Section: non-finned tubes that shield the convection section
from direct radiation
Heaters are considered to be a sensitive equipment in refinery. Therefore, heaters safety is
important. Tubes may get damaged due to overheating or coke deposition can form which
ultimately reduces the transfer temperatures. Heater’s outlet temperature is controlled through
fuel gas / fuel oil flowrates. If fuel flowrate reaches the minimum value, it will automatically
shut down the heater. It will also shutdown if crude flowrate reaches the minimum value.
Block and bleed valves are available at fuel oil and fuel gas inlets which are a part of
emergency shutdown system.
Heater’s startup
 First of all, fully open the damper so that all hydrocarbons and gases are removed
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Process Description Report

 Close the louvers.

 Enter the snuffing steam or purging steam to remove gases present in heater and
create draft.
 Then ignite the pilot burner through igniter.
 Then open atomizing steam and open the fuel valve to ignite the main burners.
 Open the louvers and adjust damper opening.

7 DISTILLATION
A process in which a liquid or vapor mixture of two or more components is separated into its
components / fractions of desired purity due to difference in volatility between components,
by the application of intimate contact between uprising vapors and downcomer liquid.

7.1 Distillation Process

The liquid mixture that is to be processed is known as the feed and this is introduced at feed
tray. The feed tray divides the column into a top (enriching or rectification) section and a
bottom (stripping) section. The feed flows down the column where it is collected at the
bottom in the reboiler. Vapor rises to the top and get intimate contact with down comer liquid
to achieve the separation by collecting lighter ends to the top and heavier ends in bottom.
Heat is supplied to the reboiler to generate vapors. The source of heat input can be any
suitable fluid, although in most chemical plants this is normally steam. In refineries, the
heating source may be the output streams of other columns. Mostly fired heaters are used for
reboiling purpose. The vapor raised in the reboiler are re-introduced into the unit at the
bottom of the column. The liquid removed from the reboiler is known as the bottom product
or simply, bottoms.
The vapor moves up the column, and as it exits the top of the unit, it is cooled by an overhead
condenser. The condensed liquid is stored in a holding vessel known as the reflux drum or
overhead accumulator. Some of this liquid is recycled back to the top of the column and this
is called the reflux. The condensed liquid that is removed from the system is known as the
distillate or top product. Top temperature of column is controlled through reflux flowrate. It
is important to control the tower top temperature because yield of top product is directly
influenced by the temperature at the tower top.
It is also important to maintain the column level as well. Proper reflux liquid should be
distributed at each tray so that vapor liquid contact is enhanced to ensure proper fractionation.
In multi components distillation different side cuts are also leaving from distillation column
at different intermediate trays. These side drawn products contain some lighter components in
them that are desired at the top of column. Due to these lighter ends flash point of product is
reduced. In order to overcome this problem, auxiliary strippers are installed for each side
drawn product.

7.2 Column Internals:

Trays: stage wise process (used to hold up the liquid to give better separation)

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Process Description Report

 Sieve
 Valve
 Bubble cap

7.3 Atmospheric Distillation Tower:

The first step in any petroleum refinery, in which the separation of the crude oil into various
fractions, is carried out through atmospheric distillation unit. These fractions may be products
in their own right or may be feed stock for other refining or processing units. It is called as
atmospheric distillation because pressure of tower is kept nearly equal to atmospheric
pressure.

7.4 Vacuum Distillation Tower:

Vacuum distillation or distillation under reduced pressure is a type of distillation performed
under pressure less than atmospheric pressure, which allows the purification of compounds
not readily distilled at ambient pressures or simply to save energy.
It is used to reduce the temperature for the distillation. It is used for heat-sensitive materials
where very high temperatures would otherwise be needed to distill relatively nonvolatile
materials. It is used for effective processing of higher boiling point solvents without igniting
them or causing thermal breakdown. Using lesser operating pressure helps to achieve
separation which is difficult at atmospheric pressures.

7.5 Stabilization Tower:

It is a fractionation operation conducted for removing high-vapor pressure components. It
removes C1 to C4 range hydrocarbons from naphtha.

7.6 Stripping Tower:

Is the process where the requirements, to strip a volatile component or group of similar
components from a relatively non-volatile solution or product by the action of stripping gas
or steam. In a multi draw fractionating tower intermediate products contain some lighter
ends, which are supposed to be separated at the top. Side strippers helps to remove those
lighter components.

8 COLUMN REFLUX
The word reflux is defined as "flowing back". Applying it to distillation tower, reflux is the
liquid flowing back down the tower from each successive stage

8.1 Types of Refluxes:

8.1.1 Cold Reflux
Cold reflux is defined as reflux that is supplied at temperature a little below than the
temperature at the top of the tower. Each pound of this reflux removes a quantity of heat

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Process Description Report

equal to the sum of its latent and sensible heat required to raise its temperature from reflux
drum temperature to the temperature at the top of the tower. Normally it is applied at the top
of the tower and the temperature at tower top is maintained through this reflux flowrate.
8.1.2 Hot Reflux
It is the reflux that is admitted to the tower at the same temperature as that of corresponding
tower temperature. It is capable of removing the latent heat because no difference in
temperature is involved.
8.1.3 Internal Reflux
It is the reflux or the overflow from one plate to another in the tower, and may be called hot
reflux because it is always substantially at its boiling point. It is also capable of removing the
latent heat only because no difference in temperature is involved.
8.1.4 Circulating Reflux
It is also able to remove only the sensible heat which is represented by its change in
temperature as it circulates. The reflux is withdrawn and is returned to the tower after
exchanging heat. Circulating reflux is also called as Pumparound, and it is used to reduce the
load at overhead condensers and ensure maximum reflux heat recovery.
8.1.5 Reflux ratio
It is defined as the amount of internal reflux divided by the amount of top product. Since
internal hot reflux can be determined only by computation. Plant operators usually obtain the
reflux ratio by dividing actual reflux by the top product. It is denoted by R which equals L/D.
In general, increasing the reflux improves overhead purity and increases recovery of the
bottom product. The number of stages required for a given separation will be dependent upon
the reflux ratio used.

8.2 Controlling Tower Temperature

8.2.1 Reflux ratio
When reflux ratio is increased, the amount of reflux increases. The top product will therefore
be purer. In general, the higher the reflux ratio, the fewer the number of trays required for a
given separation. However, too high a ratio may cause flooding in the tower resulting in poor
separation and causing 'off-spec' products throughout the system. The reflux rate is normally
controlled by a temperature controller in the vapor outlet which operates a control valve in
the reflux pump discharge. An increase in tower top temperature will cause the valve to open,
increasing the reflux rate, and vice versa.
8.2.2 Temperature Gradient
If feed and bottom temperatures are too high, too much heavy vapor will rise up the tower
and put side-stream products off-spec. This condition, combined with high reflux rate will
again lead to flooding and poor separation. Opposite conditions can lead to liquid starvation
across the trays and again, a very upset process will result.
High top temperature will result in heavy components in the overhead product.

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Process Description Report

Low top temperature will result in a lighter top product.

8.3 Tower Pressure Controlling

Distillation pressure control uses either mass or energy balances around the unit. Mass
methods control pressure by regulating the amount of flow into or out of the tower.
Energy methods regulate the heat flow into and out of the tower.
In general, mass flow methods control the tower vapor inventory. This may be done directly
by throttling the vapor rate out of the system or indirectly by manipulating downstream
equipment that evacuates vapors from the system.
To ensure the safety of plant there is an emergency shutdown system installed at plant. Plant
will automatically shut down if any of the conditions meet the minimum or maximum
operating values.

9 TRIPPING VALUES OF HBU-I

Utilities Transmitter Tripping Value

Low crude charge FT-141 33m3/hr.

High transfer Temp. of H-301 TT-202 371 o C

Low field gas pressure of H-301 PT-406 14 kPa

Low fuel oil pressure of H-301 PT-419 214 kPa

Low LP gas pressure of H-301 PT-420 6 kPa

Low atomizing steam pressure of H-301 PT-423 300 kPa

Low pilot gas header pressure of H-301 PT-424 14 kPa

High tower top pressure PT-425 300 kPa

High transfer temp. of H-302 TT-252 327 o C

Low field gas pressure of H-302 PT-431 256 kPa

Low field gas burner pressure of H-302 PT-433 80 kPa

Low pilot gas header pressure of H-302 PT-432 28 kPa

Low fuel oil pressure of H-302 PT-442 274 kPa

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Process Description Report

Low atomizing steam pressure of H-302 PT-436 412 kPa

Low pre-flash level LT-330A 20%

High pre-flash top pressure PT-444 483 kPa

Low pre-flash bottom flow FT-158B 70 m3/hr.

Low crude heater charge flow FT-159B 70 m3/hr.

10 ACTIVITIES PERFORMED
 Line tracing of HBU-1
 Daily plant visit
 Assisted in updating daily plant status.

11 JOBS OBSERVED
 Observed cleaning of exchangers E-335 & E-310
 Observed hydro testing of exchangers E-335 & E-310
 API seal flushing plan upgradation for HSD Pumparound pump P-307A

12 SELF-STUDY & COURSE ATTENDED

 Attended fortnightly training sessions on pumps, heat exchangers, desalter, fired
heaters and compressors at CCR conference room.
 Studied fundamentals of crude distillation.
 Attended three days safety training by HSEQ department.
 Attended monthly fire fighting drill.

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