CHAPTER ONE: INTRODUCTION

1.1 ABOUT EDO REFINERY

REFINERY PROJECT DECISION

The decision to construct the third Nigerian National Petroleum Corporation (NNPC) refinery
in Edo was taken in 1974 along with that of the second NNPC refinery located at Warri.
However, it was decided that work would commence on the construction of the third refinery
whenever the projection of the consumption of petroleum products justifies it.

By early 1975, in view of the fuel shortages experienced then, the Federal Government decided
that work on the third refinery should be advanced. It was envisaged that the refinery was to
be a simple hydro skimming type refinery in order to meet up with the fuel demand then.

Based on the feasibility studies carried out, which took into consideration the consumption of
the various petroleum products within the Southern Zone, and adequate means of disposal for
the surplus products, a Refinery with crude oil capacity of 42,000 barrels per stream day
(BPSD) could be easily justified. Hence, the refinery was designed for a capacity of 60,000
BPSD. It was much later that the Federal Government decided that the capacity for any refinery
in Nigeria should not be below 100,000 BPSD. However, this would have led to the production
of large quantity of heavy ends. And one practical and viable solution is reprocessing the heavy
fuel oils.

In order to do this, the whole project plans had to be modified so that what initially was planned
to be simply a hydro skimming type refinery, developed into an integrated refinery. The
refinery would now be able to produce a wider variety of petroleum products, some of which
should be lubricating base oils. Hence, it became necessary to import suitable paraffinic based
crude oil from Venezuela, Kuwait or Saudi Arabia.

Products from the Refinery include; Fuels for use as Liquefied Petroleum Gas (LPG), Premium
Motor Spirit (PMS), Automotive Gas Oil (AGO) or Diesel oil, Kerosene, Fuel Oil, Sulphur
and those from the lubricating oils complex are Base Oils, Asphalt (Bitumen) and Waxes.

The lubricating oil complex of Edo Refinery is the first of its kind in West Africa and one of
the largest in Africa. The consulting firm, KING WILKINSON of Hague, Holland, in

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conjunction with NNPC engineers, developed the plan for the refinery. The contract for
construction was awarded to CHIYODA CHEMICAL ENGINEERING & CONSTRUCTION
COMPANY OF YOKOHAMA, Japan in 1977.

The Refinery project was completed and the Fuels Plant was commissioned in 1980. However
the Lubes Plant was commissioned in 1983 and Petrochemical Plant much later in 1988. The
initial operation and maintenance was carried out by Nigerian Staff and expatriate personnel
as technical back up. By 1985, Nigerian staff had virtually taken over all the maintenance and
operations.

SITE LOCATION

From the results of an extensive market research carried out on the petroleum products demand
pattern throughout the whole country, the northern zone showed an increasing demand pattern.
Through research, it became apparent that it would cost less to transport the crude oil by
pipeline than it would to transport the refined products to growing Northern markets by rail or
road. This factor contributed greatly to the decision to construct the third refinery. Edo proved
to be a central location for distributing petroleum products to depots in the northern zone, as
the Warri and Port Harcourt refineries proved for the supply of petroleum products to depots
in the southern and middle belt zones.

PLOT PLAN

Edo Refinery occupies an area of 2.89 Square Kilometers. The plot plan is designed with safety
and ease of maintenance in mind. The design also attempts to minimize operating costs. While
it is necessary to minimize pipe length to facilitate quick delivery of products from one process
unit to another, it is nevertheless not advisable to transport highly viscous fluid over long
distances. To achieve this, intermediate tanks are placed close to the various process units in
the plot plan thus using minimum length of pipe, which, to a large extent reduce cost of piping.

OUR BUSINESS

NPDC LIMITED is in the business of refining crude oil into high quality petroleum products
and the manufacturing of petrochemical and packaging products to the satisfaction of her
customers

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The refinery was designed to process both imported paraffinic and Nigerian crude oils into
fuels and lubes products and was constructed by Chiyoda Chemical Engineering and
Construction Company (now Chiyoda Corporation) of Japan. In December 1986, the design
capacity of the fuels plants of the Refinery was successfully increased from 50,000 BPSD to
60,000 BPSD, bringing the total refinery installed capacity to 110,000 BPSD.

In March 1988, the 30,000 MT/Yr. Linear Alkyl Benzene Plant under the then
PETROCHEMICAL Sector of NNPC was commissioned. The Plant is designed to derive its
entire raw materials including utility supplies from the Refinery.

In 1988, it was decided that the two plants should merge into a single subsidiary company of
NNPC in view of their interdependence, common goal and proximity. The company thus
formed is the Nigeria Petroleum Development Company Limited (NPDC).

VISION

To be the pride of the Nation

MISSION

To Refine Crude Oil into high Value Petroleum and Petrochemical Products and also
Manufacturing Packaging Products efficiently.

CURRENT BUSINESS DIRECTION

NPDC will transit from a cost center to profit center.

Carry out comprehensive capacity development programme focused on performance
management.

Stimulate upgrading and Rehabilitation of the Refineries.

In line with NNPC transformation journey, NPDC is not only concerned about domestic
situation but also to be a major global player. This will be achieved through technological
updates and re-engineering.

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The structure in Fig. I show the Managing Director as the Chief Executive and under him are
the two Executive Directors in-charge of Services and Operations Divisions. Within each
division are various Departments, Sections and Units.

1.2 COMPANY ORGANOGRAM

MANAGING DIRECTOR

Manager, supply chain management

Manager, Planning & Budget

Monitoring
Manager, Internal Audit

Deputy Manager, Total Quality

Management
Company Secretary/Legal Adviser

Executive Director Operations Executive Director Services

Manager, Production Manager, Finance & Accounts

Manager, Maintenance Manager, Administration

Manager, Engineering &Technical Manager, Human Resources

Services
Manager Production Programming & Quality Manager, Public Affairs
Control

Manager, Power Plant Utilities Deputy Manager, Security

Manager, Health Safety &

Environment

QUALIT`Y POLICY

NPDC LIMITED is in the business of refining crude oil into high quality petroleum products
and the manufacturing of petrochemical and packaging products to the satisfaction of her
customers. In pursuance of this policy, our Management team shall lead the quality process
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and all our employees shall be committed to meeting and continually improving all aspects of
our Quality Management System (QMS), our products and services.

1.3 HISTORY OF SIWES

SIWES was designed to enable students understand the practical applications of the basic
principles underlying the traditional engineering programs. SIWES is an antecedent of Student
Industrial Work Experience Scheme (SIWES) which was established by ITF in 1973 to solve
the problem of lack of adequate practical skills preparatory for employment in industries by
Nigerian graduates of tertiary institutions.

As a result of criticisms of graduates from Nigerian institutions as lacking practical skills in

general and, in particular, the relevant production skills needed by industry. Consequently,
some higher institutions introduced the Student Work-Experience Programme (SIWES) to
enrich the curricula of engineering courses (Uvah, 2004). (Civil, Electrical and Mechanical
Engineering).

SIWES was conducted during the long vacation in the institutional workshops under simulated
industrial conditions for 200 Level students of universities who have just been introduced to
engineering and technology courses. Students were allowed to use machines and tools available
in the workshops in the production of simple jobs and were introduced to some basic practices
which they were likely to encounter during industrial training. However, SIWES was not a
substitute for real industrial training. The scheme was designed to expose students to industrial
environment and enable them develop occupational competencies so that they can readily
contribute their quota to national economic and technological development after graduation.
According to Akerejola (2008), the major benefit accruing to students who participate
conscientiously in Students Industrial Work Experience Scheme (SIWES) are the skills and
competencies they acquire. The relevant production skills remain a part of the recipients of
industrial training as life-long assets which cannot be taken away from them.

1.4 OBJECTIVES OF SIWES

According to ITF (2003), the followings are SIWES objectives:

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 1. To provide an avenue for student in higher institution of higher learning to acquire
industrial skills and experience during their course of study.
2. To prepare students for industrial work station that they are likely to meet after
graduation.
3. To expose student for work methods and techniques in handling equipment and
machineries that may not be available in their various institutions.
4. To provide student with opportunities to apply their educational knowledge in real
world situations there by bridging the gap between theory and practical.
5. To create an opportunity for social interaction with different categories of students in
different institutions thereby encouraging everlasting friendship.
6. To prepare student for some future challenges.

1.5 SAFETY PRECAUTIONS IN THE WORKSHOP

Before anyone can use equipment and machines or attempt practical work in a workshop you
must understand basic safety rules. During the course of my industrial training at Stallion
Motors Limited, There were certain means which was the company's approach to safety and
these safety precautions are taken to avoid the person working in the workshop from being
harmed and from harming others working in the workshop

1. Oil should not be allowed to pour in the workshop as this can cause accident.
When oil spills in the workshop may be by while draining the oil from a vehicle
or while replacing it, it should be cleaned immediately or else covered with saw
dust. The spill of oil on the floor can lead to domestic accidents such as one
slipping and falling which may further lead to injuries. And since oils are very
flammable, it can cause fire outbreak.
2. Gangways of every workshop should be kept free from obstacles. Gangway is
the path through which workshop attendants pass through. This is to be kept
free from obstacles for easy and free movement in the workshop.
3. Always use caution when working on a hydraulic lift. Lock out levers and power
switches so the hydraulic lift cannot be started while someone is doing repairs.
Always check for leaks by passing a piece of cardboard or wood over the
suspected area. Use lift adaptors designed for contact on the lifts and make sure
the vehicle is placed at the centre of gravity.

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 4. This is the first thing to be considered before working in any workshop and any
worker without this not allowed into workshop or even work in it. All workers
should not joke with wearing overalls before working in workshops.
5. Every-day clothing must be appropriately covered while working in the
workshop and shorts are never permitted. Safety shoes with steel toe caps must
be worn at all times. Protective clear safety goggles must be worn in designated
Eye Protection Areas and ear protectors must be worn when required and in
designated areas. Long hair can easily be caught in moving machinery and must
be secured by being tied back.

1.6 LOG BOOK

This book is to assist the student to keep record of the training. It will show the departments
and sections in which the student has worked and the periods of time spent in each. The
student is supposed to notify the institutional coordinator by filling in a form provided,
regarding the details where he/she is attached. This should be communicated to the above
within the first week of getting the attachment depending on the standard of the institution.
The daily work carried out during the period of training is to be recorded clearly. A weekly
summary report is also written, this is a summary of the work done in a week and should
cover a report of work covered with sketches and diagrams where applicable. Students are
required to present the logbook weekly to the industry-based supervisor for assessment of
content and progress. The supervisor can use any page for his/her comments where
necessary.

The university supervisor will check the logbook when he/she visits the students to ensure that
proper training is being received, and record his/her comment on the paper provided for that
purpose, towards the end of the book. The industry-based supervisor(s) will make comments
on a weekly basis on the sheet of paper provided. This is to ensure that if the student is to rotate
to several departments and units each unit supervisor will comment on the student performance.

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CHAPTER TWO: LITERATURE REVIEW

PLATFORMING UNIT

Platforming is a catalytic reforming process to convert low quality naphtha in the

presence of hydrogen into high grade motor fuel or aviation gasoline blending components.
Platforming is also used to produce aromatic rich feedstock for subsequent extraction yielding
benzene, toluene, xylene and heavier aromatics. The charge to a platforming unit should
contain a minimum of pentane and lighter compounds. While this lighter material is not in any
way to be considered harmful, it does take up plant capacity which might more profitably be
used in the reforming of the heavier fractions. This is so because the lighter gasoline normally
has a reasonably good octane number. Like the name platforming implies platinum
reforming The Platforming process can be described as following conversion.
COMPOSITION OF PLATFORMER FEED AND PRODUCT

Naphtha feed to a platforming unit typically contains C6 through C11paraffins, naphthenes, and
aromatic. The purpose of the platforming process is to convert HC aromatics from the
naphthenes and paraffins, either for use as a motor fuel (because of their very high octane
ratings) or as a source of specific aromatic compounds. In motor fuel applications the naphtha
feed generally contains the whole range of C6 through C11 hydrocarbons, essentially
maximizing the amount of gasoline produced from the crude run. In aromatics applications,
the naphtha feed generally contains a more select range of hydrocarbons (C6; C6-C7; C6-C8; C7-
C8) which serve as the source of the desired aromatic product. For either application the basic
naphtha chemistry is identical. However, aromatic processing, in most cases, emphasizes C6
and C7 hydrocarbon reactions which are slower and more difficult to promote.

Naphtha from various crude sources varies greatly in their ease of reforming. This ease of
reforming is primarily determined by the amount of the various hydrocarbon types (paraffins,
naphthenes, aromatics) contained in the naphtha. Aromatic hydrocarbons pass through the
platformer essentially unchanged.

Most naphtha reacts rapidly and efficiently to aromatics. This is the basic reaction of
platforming. Paraffin conversion to aromatics. In high severity applications, paraffin
conversion is higher, but still slow and inefficient.

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PLATFORMING REACTIONS

The following reactions take place in the platforming process to an extent dependent on the
severity of the operation, the quality of the feed, and catalyst type.

DEHYDROGENATION OF NAPHTHENES:

The final in the formation of an aromatic from a naphthene (either a

cyclohexane; as shown below) the reaction of a cyclohezane to the corresponding aromatic is
extremely rapid and essentially quantitative. Naphthenes are obviously the most desirable feed
components because the dehydrogenation reaction is easy to promote and produces hydrogen
as by product as well as the aromatic hydrocarbons. The reaction is very endothermic. It is
promoted by basic catalyst function, and is favored by high reaction temperature and low
pressure.

Dehydrogenation conversion of naphthenes

CH3 CH3

CAT +3H2

Methyl cyclohexane toluene

DEHYDROCYCLIZATION OF PARAFFINS:

Dehydrocyclization of paraffins, as shown below, is the most difficult platforming reaction to

promote. It consists of a very difficult molecularrearrangement from paraffins to naphthenes.
In the case of light paraffins, equilibrium considerations limit this reaction.The paraffin
cyclization step becomes easier as the molecular weight of the paraffin increases, because of
increased statistical probability for the formation of the naphthene. Somewhat counteracting
this effect is the increased probability of the heavier paraffins to hydrocrack.
Dehydrocycilization is favored by low pressure and high temperatures. Both metal and acid
catalyst functions are needed to promote this reaction.
Dehydrocyclization: conversion of paraffins to
naphthenes
CH3

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 CAT +H2
C7H16
Heptanes
Methyl Cyclohexane
HYDROCRACKING:

Because of the strained ring isomerization and ring formation reactions that the
feed alkylpentanes and paraffins must undergo and because the catalyst needs to have an acid
is strong. Paraffin hydrocracking is relatively rapidly and is favored by high pressure and high
temperature. The disappearance of paraffins from the gasoline boiling range via hydrocracking
does concentrate aromatics in the product and hence contributes to octane improvement. The
reaction does, however, consume hydrogen and results in lower platformate yield
Hydrocracking

Cat

C8H18 + H2 CH4 + C7H16

Octane methane Heptane

ISOMERIZATION OF PARAFFINS AND NAPHTHENES:

a. The isomerization of a cyclopentane to a cyclohexane as shown below must occur as
the first step in covering the cyclopenataneto an aromatic. This isomerization involves
right rearrangement and the probability for ting opening to form a paraffin is quite high.
Therefore, this reaction of alkyclyclopetanes to cyclohexanes is not quantitative. The
reaction is strongly dependent on the processing conditions
b. Parrafinisomerization, as shown below occurs readily in commercial platforming
operations but at typical operating temperature the thermodynamic equilibrium is not
strongly in favor of the more desirable (higher octane) branched isomers. In motor fuel
applications this reaction does make a contribution to octane improvement of the
naphtha.
CH3

C7H16 CAT CH3 C - CH2 -CH2 - CH3

N - Heptanes CH3 2, 2, dimethylpentane

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Isomerization reactions result from carbonium on intermediate reactions. These reactions are
promoted by an acidic catalyst function, and are slightly dependent on operating pressure.

Figure 1.1: PLATFORMING REACTOR

PLATFORMING PROCESS DESCRIPTION

The feed naphtha is being received from tank 51 storage through the battery limit and routed
to the suction of pump 12P501A/B Tied into the suction of the pumps a 2 start-up by pass line
from the outlet of the Platformer Stabilizer bottoms coolers. The charge pumps 12-P501 A/B
discharge via a 4 line through the reactor exchange system to the charge heater 12-H501. flow
is controlled by 12FV501. Upstream of 12FV501 but downstream of the orifice plate is a 2
start-up bypass line which is routed via double block valves into the products separator disposal
line to the stabilizer connected with the line discharging unstabilized gasoline from 12C504
(Products separator). Thus prior to start-up naphtha can be circulated from the charge pumps
through the Stabilizer feed system to the Stabilizer column 12C506 and out through the
Stabilizer bottoms exchanger and coolers to the suction of the naphtha charge pumps.
Downstream of 12FV501 the reactor charge line joins an 8 line carrying recycle gas from the
discharge of the recycle gas compressor 12K501. The 10 combined feed (naphtha and recycle
gas) is routed to the shell side of the cold combined feed exchanger 12E501A/B, where the

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combined feed is heated by part of the rector products stream which has previously been cooled
by passing through the hot combined feed exchanger 12E502. From 12E501A/B the combined
feed passes to the shell side of the hot combined feed exchanger 12E502 where it is heated by
the total flow of hot reactor products. The combined feed leaves 12E502 at about 350oC. and
is been routed to the main section of the heater 12H501 where it is heated to a temperature of
about 540oC.The combined feed now passes to the top of No. 1 reactor, 12R501, and down
through the catalyst bed. Heat is absorbed in the reactor, due to the predominantly endothermic
reaction, the process stream is now routed through the radiant tubes of the 1st intermediate
section of 12H501 and heated a design outlet temperature of 526oC before being passed to the
top of No. 2 reactor 12R502. The products from No.2 reactor are next heated in the intermediate
heater. The process stream is routed through No. 3 reactor 12R503 (downward flow).

All burners are gas fired (10 in the charge heater, 8 in the 1stinterheater and 3 in the
2ndinterheater) and fitted with individual gas pilots. The effluent from No.3 reactor 12R503
passes via a 10 line to the tube side of hot combined feed exchanger 12E502. The 10 outlet
line from 12E502 subdivides into two lines via:

10 line which routes reactor products to tubes side of stabilizer reboiled 12E504 and then to
the tube side of the cold combined feed exchanger 12E501 A, joining line B).

An 8 line which by passes reactor products around the stabilizer direct to 12E501A.The
reactor products leaving 12E501B are routed via a 10 line to the shell side of reactor products
condensers 12E503 B a 10 line takes the gas/liquid stream to reactor products separator
12C504.

LIQUIFIED PETROLEUM GAS (LPG) UNIT

The LPG unit consists of the following section:

Section Function

Compressor Section to liquefy the gas

Depropanizer Section to eliminate propane and lighter components
Debutanizer Section to remove Butane from the SRG (C5 +)
Product Treatment To eliminate Sulfides from LPG

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Compressor Section

Gases from the main crude overhead receiver 10D503 flow under receiver
pressure 10PIC570A to the compressor suction drum 14D508. Crude unit overhead drum
pressure is controlled by relieving to flare. Gas from the top of the suction drum flows to the
compressor first stage pistons assembly by a pulsation dampener which damps out the pulsation
set up by the reciprocating machine. The compressor first stage piston assembly is double
acting. The one stroke of the piston compresses and discharges on its leading edge and at the
same time the other side of the piston sucks and pulse in. The returning piston reverses the
action This first stage compression delivers gas to the inter-stage drum via two water cooled
condensers 14E501 A/B which by cooling, causes liquid hydrocarbon and water to separate
out in the drum 14D502, while hydrocarbons flow to the Depropanizer; liquid feed pump
suction 14P501.

Crude Unit Stabilizer off gas is fed into the inter-stage drum (14D501) downstream of the
condenser 14E501A/B. Gas flows from the top of the inter-stage drum through an internal
demister pad to the compressor second stage suction piston assembly and enters via a suction
snubber which damps down the pulsating effect.

The second stage piston assembly is again double-acting; either side of the piston both sucking
and compressing but unlike the first stage has only one suction and one discharge valve on each
side of the piston. This second stage assembly does not have an end pocket. Discharge from
this second stage compression may be disposed according to the desired operation, either
recovering crude unit overhead gas to fuel through 14PI524 or feeding the Depropanizer
14C502 for LPG make.
Depropanizer Section

The Depropanizer section can operate on fuel gas mode or LPG mode. During start-up this
section will be operating on fuel gas mode and will be switched over to LPG mode once unit
is stabilized. The hydrocarbon liquid flows to suction of depropaniser charge pump 14P501
and is discharged to the depropaniser combined feed inlet via 14LV501.

Depropaniser feed enters the depropaniser column, the Overhead vapours flow through the
shell of a water cooled condenser 14E503 into the depropaniser overhead receiver 14D503.
Water collects in the receiver boot and is disposed to sewer. Hydrocarbon liquid is withdrawn

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from the receiver by the depropaniser reflux pump 14P502A/B and is discharged to the top tray
of the column. A common spare is provided for depropanise rand debutanizer reflux duty
(14P502 B) Uncondensed vapours pass through a stainless steel demisting pad into the refinery
fuel gas main. Depropaniser bottoms flow through the shell side of the depropaniser reboiler
14E502, rebel heat being provided by O.P. steam.
Debutaniser System

Net bottoms make from depropaniser passes to tray 16 of the debutanizer column. Overhead
vapours flow from the debutanizer column through the shell side of a water cooled condenser
14E505 into the debutanizer Overhead receiver 14D505. Hydrocarbon liquid is withdrawn
from the overhead receiver by the debutanizer reflux pump 14P503 or 14P502B, part of this
liquid is returned to the top tray of the column as reflux, the balance is disposed either via the
caustic wash vessel to storage as LPG product, or is routed to the LPG regasser 14-E-507.
Uncondensed vapours passing from the receiver to the refinery fuel gas main. Debutanizer
bottoms flow through the shell side of the debutanizer reboiler 14E504 heat being provided by
L.P steam. Net bottoms make, C5 product, is routed via a cooler 14E506A-C to gasoline
disposal line.
Product Treatment Section (Optional depending on type of crude processed)

LPG product is treated in the caustic wash vessel 14D506 to remove hydrogen sulphide, before
disposing to storage.

Addition of fresh caustic soda is made batch-wise using the fresh caustic pump at the C.D.U.
Spent soda is withdrawn from the base of the caustic wash vessel by the caustic pump 14P505
and is disposed to the process area spent caustic tank.

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Regasser Section

LPG regassing is carried out in a kettle type regasser 14E507. Provision is made for the
disposal of LPG direct from the unit and also from Horton sphere storage to the base of the
tubular exchanger. reboiling heat is provided by L.P. steam passing through the tubes of the
regasser, condensate being disposed to sewer via a steam trap. As shown in fig below

Figure 1.2: PROCESS FLOW DIAGRAM OF THE LPG UNIT

Product Storage Facility

LPG storage capacity is provided by 3 identical Horton sphere. The sucking of each sphere is
provided with a remote control, air operated shut off valve, and a drain pipe at grade below the
vessel to facilitate water draining without hazard. Product disposal lines are:

6 to refinery jetty via west fence

4 to marketing and off-take facilities via east fence.
4 to regasser

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2.2 UTILITY UNIT

The utility section of the refinery involves things needed for a process plant to run effectively.
They are the engine house of a process plant. These include;

Electricity: for a process plant to run efficiently there ought to be uninterrupted power supply.
To that effect the refinery generates its power itself as it operates its own gas turbine system to
ensure sufficient plant power supply.

Air: another important tool used in the process plant is the air generation which is very
important in the control of instrument, cooling process and other important use applied to it.

Water: this is more or less the most important utility in the process plant as its use cannot be
over emphasized. It is divided into sections as;

Service waters- these are waters on standby for emergency and effective supply of plant water

Cooling water- this is used for the cooling tower where water flows down to various
equipments to reduce heat gained.

Treated water-this is the removal of minerals in water and making it ready for steam generation

Domestic water- these are water used generally for drinking and other purposes.

Steam: the steam is very essential in the process plant as it is used to reduce cost in terms of
driving the turbine engines and also effective in atomizing heavy distilled products to ensure
proper flow. There is The High pressure steam, Medium pressure steam, and the low pressure
steam dependent on the use.

Fuels: this is usually used during start up process to power the heaters before the plant generates
its own fuels to power heaters.

Other unit which I had a brief practical rundown of the process involved in it includes
VACUUM DISTILLATION UNIT

The atmospheric residue gotten from the bottom of the main crude distillation unit is the feed
for this unit. It is processed in the vacuum column under very low pressure (vacuum) but at
slightly higher operating temperature than in the CDU. The products from this vacuum are light

16
vacuum gas oil (LVGO), heavy vacuum gas oil (HVGO) which is the main feedstock residue
(VR).

The LVGO and HVGO are combined to form a composite product - vacuum gas oil (VGO)
which is the main feedstock for the FCCU.

The bottom product of the vacuum column, vacuum residue (VR) is sent to storage for blending
into fuel oil.
NAPHTHA HYDROTREATING UNIT

The purpose of this unit is to chemically treat the straight run naphtha from the crude distillation
unit to remove compound of arsenic, lead, Sulphur, nitrogen, oxygen etc., little amounts of
which in the naphtha constitute poisons to the highly expensive catalyst of the catalytic
reforming unit the passed through charge heater to raise the temperature to reaction conditions
before introduction into the NHU reactor. The product of the unit is called hydro treated
Naphtha which is the feedstock for the catalytic reforming unit (platformer unit)
KERO HYDROTREATING UNIT

The unit is principally to upgrade straight run kerosene to specifications acceptable for aviation
Jet use. The operation is similar to the NHU in terms of removal of sulfur, nitrogen and oxygen,
and improves the quality of the smoke and freezing point of the product.

The raw kerosene from the CDU is mixed with hydrogen and catalytically treated to produce
Aviation Turbine Kerosene (ATK).
FLUID CATALYTIC CRACKING UNIT

This is a very important unit in the refinery and often referred to as the cash cow of refining
operations. The purpose of the unit is to catalytically convert heavy diesel oil from CDU and
VDU into more valuable products such as LPG, FCC gasoline, light Cycle Oil and decanted
oil.

The feedstock is heated in a series of heat exchangers, then atomized by steam and
injected into the reactor riser where catalytic cracking reaction occurs. The reaction product
and catalyst flow up to the cyclones where the hydrocarbon separate from the catalyst. The
spent catalyst flows downwards the spout catalyst storage pipe to the regenerator where the
coke deposited on the catalyst during the reaction is burnt off and re-circulated back to the

17
riser. The hydrocarbon vapours exit the reactor to the main fractionation tower where they are
fractionated into gas, gasoline, light cycle oil and bottom slurry or main column bottom (MCB).
The gas is sent to the gas concentration unit (GCU) for further processing, where gasoline, LPG
and gas are recovered. This gas is the source of the feedstock for dimersol alkylations units.
The propylene rich feed of the gas is an alternative source of feedstock for the polypropylene
plant at Eleme Petrochemical Limited (EPCL)

The FCC Gasoline and LPG are treated at the MEROX unit for removal of sulfur compounds,
and then sent to the PMS pool as a blending component. While LPG earlier treated at gas
treatment plant is routed to Area 4 storage. The light cycle oil and the main column bottom
(decanted oil) are used to produce low and high pour fuel oils used by sea vessels.
2.3 EQUIPMENT USED IN THE PLANT:

DESALTER

Normally crude oil contains a small amount of brine or residual water that is associated with
the crude oil both as a fine suspension of droplets and as more permanent emulsions. The water
contains different types of salts (especially sodium, calcium and magnesium chloride), these
hydrolyze and can liberate hydrochloric acid which causes corrosion during processing, fouling
of heat exchangers and the promotion of coke formation in the pipestill tubes. The main purpose
of desalter is the removal of these impurities from the crude oil, through intimate washing with
water in a mixing valve located at the inlet of the desalter. In operation the mixture of crude
and water enters the top of the Desalter and is conveyed to the zones of electric field by a
distributor. The high alternating voltage between the electrodes causes the finely divided
suspension of dissolved salts present in the crude to coalesce in large droplets which settle out
rapidly. Maximum setting is assisted by correct temperature control. Desalter injection water
is the water collected from the crude column overhead receiver fed to desalter water tank
10D508 under level control (10LV522) and/or integrated with process water make-up. The
injection water is preheated in the exchanger 10E514A/B with the water effluent coming from
the desalter. Injection water is then injected in the crude through the mixing valve 10-PDV-
553 while the water effluent is sent to sewer after quench. As shown below

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Figure 2.3: DESALTER DRUM

HEATER

Heater coils comprise of four parallel passes. The crude oil at the outlet of 10-E-
504 A/B/C/ (shell-side) supplies the crude fired heater 10-H-501 from which are four 6
branches dividing the crude oil flow into four parallel heater passes. Each pass is controlled by
a flow indicating controller (10 FICs 521, 522, 523, 524) actuating flow control valves. Flow
through the four heater passes may therefore be balanced with respect to flow and heater outlet
temperature. In the heater heat is supplied in order to obtain sufficient vaporization in the flash
zone of the crude column. The heater is designed to fire fuel-gas. After subdivision into four
heater passes, the streams recombine into two common outlets, then leading to a transfer line
and later-on to the crude distillation column 10-C-501. Crude outlet temperature from the
heater is controlled with 10-TIC-506 which resets Fuel Gas Pressure Indicating Controller 10-
PIC-501, automatically adjusts the supply of fuel gas to the heater in accordance with the
request of the temperature controller. In the convective zone of the heater there is the steam
generation system, consisting of water circulation and steam superheating. Additional burners
are part of the steam generation system, which allow the production of steam and can be used
during the shutdown of the crude charge heater or to allow an increase of production of steam
during the manual.

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Figure 3.4: HEATER

HEAT EXCHANGERS

Heat exchanger is a device in which two fluids flow on either side of a solid boundary wall
which separates them. It transfers heat from the hot fluid to the cold fluid, it consists of two
main parts namely; the shell and tube. In the refinery there are various types of heat exchangers.
There are parallel flow exchangers, counter flow exchangers, single pass exchangers and multi
pass exchangers. They can be classified as follows:

Heaters- Heaters are used primarily to heat process fluids. Steam is used for heating.
Coolers- Coolers are used to cool process fluids. In the refinery there are fin fan coolers,
trim coolers and shell and tube coolers.
Condensers- Condensers are coolers whose purpose is the removal of latent heat instead
of sensible heat and to condense the fluid.
Reboilers- Reboilers are used to supply heat requirements in the distillation process.

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Figure 4.5: HEAT EXCHANGER

PUMPS

Pumps are simply mechanical devices used to transport basically liquid from one point to
another, this is done by increasing the pressure of the liquid to be able to move it through
pipelines or to raise it to a higher level. The most common pumps used in the refinery are
centrifugal pumps and reciprocating type pumps which are booster pumps. The pumps can be
driven by electric motor or steam turbine The differences between centrifugal and reciprocating
pumps are as follows

Centrifugal pumps discharge fluid per volume continuously while reciprocating pumps
discharge fluids per volume per time.

Centrifugal pumps are used for low pressure work which deals with large volume of fluid while
reciprocating pumps are used for high pressure work, mostly chemical dosing

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Figure 1.6: PUMPS

COMPRESSORS

Compressors are devices used for pressurizing fluids by volumetric reduction, it is used in the
utility section to generate plant air and instrument air, it is made up of a suction end which
collects air from the atmosphere and compressed it, then sends to storage through the discharge
end, it is also used in the LPG unit for pressurizing gas

Figure 5.7: COMPRESSOR

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COLUMNS

Are tall metal cylinder internally fitted with perforated horizontal plates used to promote
separation of miscible liquids ascending in the cylinder as vapor, the common of the columns
in the plant are the main crude distillation column, strippers, Debutanizers, Depropanizers.

Figure 1.8: MAIN CRUDE DISTILLATION COLUMN

Other plant equipments include DRUMS, TANKS VALVES (check valves, pressure safety
valves, control valves, chain valves), COOLING TOWER etc.

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 CHAPTER THREE: ACTUAL WORK DONE

3.1 STEAM TRACING

Steam tracing system

A steam tracing is a heat tracing which use the steam as heating medium. The heating
medium of steam tracing can be saturated Low Pressure (LP) Steam or Medium
Pressure (MP) Steam or High Pressure (HP) Steam. The condensing temperature can be about
150-180 0C (for LP steam) or 200-270 0C (for MP steam) and 350-400 0C (HP steam).

A steam tracing system could be:

A closed system, in which all condensate discharge from steam traps are collected for
re-use or recovery.
An open system, when approaches are not available or rare cases in which the
condensate are discharged into a drain or atmospheric.

A typical piping system of steam tracing consists of:

Traced lines: the process pipeline carrying process fluid that require steam tracing.
Steam supply line that connects the steam supply header with the steam tracing
manifold or condensate recovery line that connects the condensate header with the
condensate recovery manifold.
Steam or condensate manifold.
Tracer line: the pipe carrying steam along the traced line.
Steam traps: for removal of the condensate in used steam, steam traps are installed at
regular intervals. It should be located at the lowest point of the tracer.

A typical steam tracing manifold installed lower than header is given as below:

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CLEANING PUMP SUCTION STRAINER

Advantages

Self-cleaning, with very low maintenance requirements

Construction options: hot dip galvanized, expoxy coated carbon steel, and 304/316
stainless steel combined
Heavy duty, corrosion resistant construction for a long service life
No exterior moving parts
Hydraulically powered
Simple installation

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 Available in: 12 mesh (1680 micron), 18 mesh (1000 micron), and 24 mesh (710
micron)
When combined with a V-Series automatic self-cleaning screen filter, any water
source can be filtered down to 10 micron!

General Information

If you pump water, you know how important it is to keep equipment running smoothly and
water flowing freely. Whether you are pumping water from a stream, canal, river, ditch, pit,
sump, or pond, you need the water to be free of debris that could block water flow, damage
the pump, clog water distribution equipment or damage process equipment.

The Self-Cleaning Intake Suction Screen is galvanized or epoxy coated and utilizes a heavy
12, 18, or 24 mesh, stainless steel screen designed to increase pump efficiency. The screen
continuously removes debris from water. This saves time and money in fuel, pumping
efficiency, and maintenance costs. The suction strainers can be used for numerous
applications with intake.

The suction strainer is attached to the end of the pump in the water source. All water pulled in
must traverse the screen before entering the intake pipe. The screen stops trash and debris
from entering and causing costly maintenance requirements in your system. The pump
discharge return line drives two spray bars that continually rotate, jet water at the screen, and
blast debris away from the screen at 2.8 to 4.5 bar (40 to 65 psi) operating range.

The pump intake suction strainer has no external moving parts. It can be installed at any
altitude without the operation being affected. The strainer is uncollapsible and corrosion
resistant and also has a standard flanged connection. Other connections are available upon
request.

3.2 COMMISSIONING A PUMP

1. Ensure that the pump installation is complete and mechanical completion is approved.
2. Ensure that no damage occurs between mechanical completion & precommissioning.
3. Repair all damages to the equipment paint finish.
4. Ensure that the pumps are identified location wise and service wise.

26
 5. Note the details of each motor such as make, model number, frame size, kW rating and
RPM.
6. Check that the Water Booster piping network is complete with proper valves, drains,
vents, strainers, pressure switches & instruments in place as per final approved shop
drawing.
7. Ensure that the Water Booster network is hydraulically pressure tested and approved.
8. Ensure that the entire system is cleaned internally & externally.
9. Ensure the pumps bearings are lubricated/greased as per
manufacturer recommendation.
10. Ensure the pump shafts are rotated by hand freely & impeller is dynamically balanced.
11. Ensure that electrical power connections and earthing is proper.
12. Ensure that the field wiring is pre-tested for continuity and insulation resistance.
13. Check & ensure that the motor is in accordance with the approved material submittal.
14. Ensure that all the relevant valves are in open position. Pump discharge valve should
be in closed position.
15. Check for free rotation of motor shaft by hand. Direction of rotation and RPM shall be
checked during commissioning.
16. Check the pumps are properly bolted & the pump casing is vented.
17. Check for proper installation of pressure gauges.
18. Check identification and labeling for equipment.
19. Check & ensure that the mechanical seal is properly placed.

fig 2.1: Pump

Commissioning Procedure for Pumps

27
1. Ensure that all the precommissioning checks are carried out successfully.
2. Ensure that pipe alignment is done.
3. Ensure the discharge valve is closed.
4. Open the suction valve & allow water to flow into the pump.
5. Start the pump and record shut-off head.
6. Open the discharge valve fully & record the head of the pump.
7. Check pumps for overheating by feeling it physically by hand (there is no specific
criteria for checking the overheating of pump).
8. Check for any undue vibration/noise (it is just physical hearing of undue vibration /
noise during operation).The specification does not call for noise level of pumps or
individual equipment. Noise level measurement shall be in line with the separate
procedure.
9. Check & record the expansion vessel pressure setting.
10. Calculate the actual pump performance and plot actual performance curve.
11. Check current, voltage & rpm of the motor & record the values.
12. Complete controls & interfacing with the BMS shall be checked in line with the
approved procedure.
13. Check & ensure that the pumps shut off at low water level.
14. Disinfection of the piping network shall be carried out as per the approved method
statement.
15. The main pump will start only below 14.5 bar & will stop at 16 bar, there is sufficient
time for the pump to transfer from star to delta thus avoiding the frequent running of
pump only in star mode. Further the star-delta transformation timing shall be minimized
to ensure the same.
16. Once one main pump starts & stops, during the next cycle one of the other pumps will
act as a duty pump, hence avoiding the frequent running of the same pump in a
particular period.
17. The wiring diagram of pump controls & schematic piping shall be displayed near or
inside the control panel.

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CHAPTER FOUR: EXPERIENCE GAINED AND CHALLENGES ENCOUNTERED

4.1 EXPERIENCE GAINED

During the course of the 2016/2017 SIWES program, the following experiences were gained:

Commissioning of the cooling tower, Heater&pumps

priming of pumps to avoid cavitation
Regeneration of the demineralized bed,
Generation of steam (low & middle pressure steam) for driving our turbine pumps
Refining process of raw crude into finished petroleum products such as PMS, kerosene,
diesel, aviation kero, etc.,

CHALLENGES ENCOUNTERED

The following challenges were encountered during the program:

i. There are fewer staff in my place of attachment, thereby making them too busy to attend
to the IT students.
ii. The working hour is too long thereby making me not to have time for myself in
engaging in other activities.
iii. The IT student are not restricted to a particular work, work are assign to the coppers
and staff.
iv. Lack of cooperation and support from companies and organizations.
v. It was also observed in the course of this study that students project reports were not
corrected.
vi. Delay in release of funds for supervision and students industrial training allowances.
vii. Inadequate monitoring of students on industrial training.

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CHAPTER FIVE: CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

Following the successful completion of the 2016/2017 SIWES program, the following
conclusion are drawn:

1. The program provided an avenue to acquire industrial skills and experience.

2. The program provided adequate exposure to work methods and techniques in
handling equipment and machineries that are not be available in the school.
3. It provided good opportunity to apply their educational knowledge in real world
situations there by bridging the gap between theory and practical.
4. It also created an opportunity for social interaction with different categories of
students in different institutions thereby encouraging everlasting friendship.
5. Finally, it is a good training ground for future challenges.

5.2 RECOMMENDATIONS

Having gone through the three months industrial training, the following are suggestions to
improve the effectiveness of SIWES:

1. Companies should show more commitment to the training of engineering students

so as to improve the quality of training given.
2. Government should endeavor to improve business relationships with companies
that have SIWES students, as a way of adding importance to the scheme, in
reality.
3. Students or trainees should learn to comport themselves well in these companies
so as not to send a bad signal which may discourage such company from taking
or accepting future SIWES students.
4. The ITF should make monthly allowance available for students, so as to put end
to financial difficulties that may arise as a result of transportation problem.
5. The institution and ITF should help the student to get the place of attachment, so
that the program will commence as planned.
6. Companies/Organizations should be sensitized through organization of
workshops/seminars in order to acquaint them with their expected roles towards
students on industrial training.

30
 7. Students should be paid their IT allowance to time so that they can be motivated.

Students should be taught how to write reports and their reports should be read through and
corrected.

31
REFERENCES

ed.). Marcel Dekker, Inc. ISBN 978-0-8247-7150-8.

Leffler, W.L. (1985). Petroleum refining for the nontechnical person (2nd ed.). Penn Well
Books.ISBN 978-0-87814-280-4.

James G, Speight (2006). The Chemistry and Technology of Petroleum (Fourth ed.). CRC
Press.0-8493-9067-2.

UOP, Bonny Light Nigerian Crude oil evaluation by UOP, dated Aug. 1982 revision.

SOIMI, operating manual CDU OPHR (June 1965)

SOIMI, operating manual LPG OPHR (June 1966)

SOIMI, operating manual CRU OPHR (June 1965)

Dr. kkdagde RSUST siweshandbookNovember 2014

Austin oniwon et al NNPC HSE bulletin first edition October 2010

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