A Report On

Summer Training at ONGC Petro additions Limited

By
Manasi Lavhekar
Neha Giri
Abhijeet Mate

B.Tech Chemical Engineering

Vishwakarma Institute of Technology, Pune

May - June 2017

At
Utilities and Offsites Department
ONGC Petro additions Limited
Dahej Special Economic Zone, Dahej-392130

Dist: Bharuch, Gujarat

 Acknowledgements

We are profoundly grateful to Mr. Vinod Salve - Sr.manager of U&O for his expert
guidance and continuous encouragement throughout to see that this training rights its target since
its commencement to its completion.

We would like to express our deep gratitude to Mr. Nirmesh Sharma, DGM HR, ONGC
Petro additions Ltd., for accepting us to undergo training at ONGC Petro additions Ltd.
At last we must express our sincere heartfelt gratitude to all the employees of ONGC
Petro additions Limited who helped us directly or indirectly during this course of work.

Neha Giri
Manasi Lavhekar
Abhijeet Mate
 Contents
1. Introduction
2. Safety Induction
3. Utility
3.1 Raw water treatment plant
3.2 Cooling Tower
3.2.1 Cooling Tower 1
3.2.2 Cooling Tower 2
3.2.3 Cooling Tower 3
3.3 DM plant
3.4 Instrument Air Plant Air
3.5 Inert Gas System
3.6 Captive Power Plant
3.6.1 Gas Turbine
3.6.2 Steam Turbine
3.6.3 Balance Of Plant
3.6.4 Heat Recovery Stean Generation System
3.6.5 Utility Boiler
4. Offsite
4.1 Types of Storage
4.2 Requirement of Different Storages
4.3 Over pressurization
4.4 Over filling
4.5 Gas leaking
4.6 Fire case
 Chapter 1

Introduction

ONGC Petro addition Limited (OPaL) a joint venture Company of Oil and Natural Gas
Corporation Limited (ONGC), Gujarat State Petroleum Corporation Ltd (GSPCL) and Gas
Authority of India Limited (GAIL) is planning to set-up a grass root Petrochemical complex
based on dual feed i.e., C2/C3/C4 & Naphtha at Dahej special Economic Zone (SEZ),Gujarat.
OPaL is poised to become a key player in the growth of the polymer industry, because it
has all the essential ingredients to become one of the best performing operators in the global
petrochemical industry. Moreover, to utilize the advantage of this highly competitive and
dynamic market, OPaL synergizes with the strengths of its promoters. OPaL has the combine
advantage of adequate indigenous feedstock supplies, talented man power, ready market and
above all a better and brighter domestic market.
The demand for polymers in India is huge and is expected to further rise with the growth
in GDP. India will continue to be in deficit of polyethylene in thye foreseeable future. Moreover
this also works as a perfect downstream integration for ONGC – the key promoter who will be
supplying the feedstock required for this project from its Hazira, Uran and Dahej facilities.
 Chapter 2
Safety Induction

For any chemical industry safety is one of the most important parameter which has to be taken
into consideration.
Safety includes study and prevention of hazard and Risk .
Hazard- Inherent property of material which damages environment , asset or humans .
Types of Hazards-
1) Process hazard (eg- leakages )
2) Workplace hazard (eg- excavation , working on height )
3) Environment hazard (eg- pollution due to emission of SOx , NOx )

Risk
A probability or threat of damage, injury, liability, loss, or any other negative occurrence that is
caused by external or internal vulnerabilities, and that may be avoided through preemptive
action.
Risk = Frequency × consequences

Prevention of Risk-
Risk can be prevented using PPE (Personal Protective Equipment)
1) Helmet- prevents falling hazard
2) Handgloves- to handle any kjnd of hazardous chemicals
3) Earplugs- for >85 db we need double earing protection
4) Goggles- to avoid exposure to any chemicals splashes

National Fire Protection Association (NFPA)

The National Fire Protection Association (NFPA) is a United States trade association, albeit with
some international members, that creates and maintains private, copyrighted standards and codes
for usage and adoption by local governments. This includes publications from model building
codes to the many on equipment utilized by firefighters while engaging in hazardous material
(hazmat) response, rescue response, and some firefighting.
 Chapter 3
Utility

Utility is the heart of any industry which includes supply of water, electricity and air through the
following plants:
1) Raw water Treatment plant
2) IAPA / IGS plant
3) DM water plant
4) CPU
5) CPP

3.1. Raw Water

3.1.1 Raw Water Reservoirs:
GIDC supplies 20MGPD of raw water which is stored in 4 reservoirs.Out of which 2 reservoirs
are used for fire water each having capacity 25000 m3 and from the other 2 reservoirs one is for
treated water and the other is for untreated water each having capacity of 1,25,000 m3.

3.1.2 Raw Water Treatment Plant

Main role of RWTP is to remove turbidity, dissolved solids ,suspended solids and to reduce
microbiological growth.
Water from untreated raw water reservoir comes to the treatment plant where it passes through
the strainer which contains metallic mesh to remove suspended solids of larger size. Next step in
treatment of water is dosing of ClO2 to reduce microbial growth.Then it passes through the
ultrafiltration membrane. There are 10 pumps to supply water to the 10 skids with 160
membranes each. There are 2 outputs of the candle filters i.e. permeate water and rejected water.
Permeate water is sent to the treated water reservoir and reject water is sent back to the untreated
water reservoir. After every 30 minutes the membrane is backwashed for 115 seconds. Backwash
water is pumped through the membrane from inside to outside of the membrane and transferred
to the backwash tank. Then it is passed to the clarifier in which polyaluminium chloride (PAC)
and polyelectrolyte is added for coalescence and settling of the larger particles. The clear water
after sedimentation is sent to the sump. The clear water from the sump is sent to the ETP for
further treatment. The slurry after sedimentation is sent to the centrifuge for further separation.
The separated solid is sent to the lagoon as manure and the liquid is sent to ETP.
Finally the treated water from the ultrafiltration membrane is sent to the first reservoir.

3.1.2.1 Uses of treated raw water

Treated raw water is then used as CT make up water, service water, drinking water, DM plant
and fire water make up.
3.1.2.2 ClO2 Dosing:
Separate provision is provided for preparation of ClO2 in RWTP.
Na ClO2 + HCl --------------> ClO2 + H2O

R2 R1
Rejected
R
1
PERMEATE

Stainer 4 Membrane
No
s

NTU

Clarified
tank
Flocc Tube
Cl Flash ulator
Backwash 2
settler
mixer
tank O

backwash
filter

CIP
tank

Centrifuge
HCl
tank generator Sludg
discarded)
e
R2
NaCl2
Otank
3.1.3 Pump House
3.1.3.1 Fire water pump house
Fire water reservoirs are connected to the fire water pump house through a common header.
There are 15 pumps out of which 4 are jockey pumps with capacity of 175 m3/hr each, 5 pumps
are HT (high tension) pumps - 1000 m3/hr each and 6 pumps are diesel operated pumps. Jockey
pumps maintain pressure in the discharge header upto 13.5 kg/cm2. If there is power failure in
the industry then diesel starts operating.

3.1.3.2 Raw water pump house

Treated raw water reservoir is connected to the raw water pump house via common header.
There are 12 centrifugal pumps each having capacity of 1500 m3/hr. Out of which 4 pumps are
CT make up pumps, 3 are for DM water plant, 3 are for service water and the remaining 2 are for
fire water makeup.
3.2 Cooling Towers:

Principle - A cooling tower is a heat rejection device that rejects waste heat to the atmosphere
through the cooling of a water stream to a lower temperature. Cooling towers may either use the
evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air
temperature .

Cooling Tower Approach

The difference between the Cold Water Temperature (Cooling Tower Outlet) and ambient Wet
Bulb Temperature is called as Cooling Tower Approach.

Approach = Cold Water Temperature – Wet Bulb Temperature

The lesser the approach the more efficient is the cooling tower.
In the ideal case, the cold water temperature will be equal to the wet-bulb.

Cooling Tower Efficiency

Cooling Tower Efficiency =
(Hot Water Temperature – Cold water Temperature) x 100/ (Hot Water Temperature – Wet bulb
temperature)

The cycle of concentration

The cycle of concentration is a dimensionless number. It is a ratio between parameter in Cooling
Water to the parameter in Makeup water. It can be calculated from any the following formulae.

COC= Cl in Cooling Water / Cl in Makeup Water

Blowdown
As the cooling water circulates in the cooling tower, part of water evaporates thereby increasing
the total dissolved solids in the remaining water. To control the Cycle of Concentration blow
down is given. Blowdown is the function of Cycle of concentration. Blowdown can be calculated
from the formula:
B = E/ (COC-1)
B = Blow Down (m3/hr)
E = Evaporation Loss (m3/hr)
COC = Cycle of Concentration.

Evaporation Loss Calculation

The Evaporation loss can be calculated from the heat balance across the cooling tower. The
amount of heat to be removed from Circulating water according to Q = m Cp DT is C x Cp x R
The amount of heat removed by evaporative cooling is Q = m x Hv is E x HV
On Equating these two, we get
E = C x R x Cp / HV

E = Evaporation Loss in m3/hr

C= Cycle of Concentration
R= Range in °C
Cp = Specific Heat = 4.184 kJ / kg / °C
HV = Latent heat of vaporization = 2260 kJ / kg

Sources of cooling water-

1. DM plant
2. IAPA
3. Nitrogen plant
4. DFCU
5. CPP

3.2.1 Cooling Tower-1

There are 20 cells with induced draft arrangement each with a capacity of 4000 m3/hr. The inlet
temperature is 40-45°C and it is brought down by cooling towers to 33°C.
Cooling Water from the cells flows through the cooling water channel and is sent to the sump
(80,000m3 ) . Cl2 and H2SO4 is dosed in the sump to rdeuce the bacterial activity and adjust pH
respectively.
Antiscalant, anticorrosants and polymers from formulation tank are dosed in the sump.polymers
help in dispersion of the scaling formation. There are 12 centrifugal pumps ( 9 working and 3
standby) each with a capacity of 9000 m3/hr and with a pressure of 4.5 kg/cm2 . The inlet
pressure for the cooling water is 1.5kg/cm2 as the hot water channel is located almost at 15m
height.

3.2.1.1 Cell Structure

A cell has a fan at the top and a mist eliminator. From hot water channel water is passes to the
nozzles which are situated below the mist eliminators. Water from nozzles flows over the fills
and gets collected in the cold water channel.The fills gives larger residence time.

3.2.1.2 Side sand filter

There are 4 sand filters with 400 m3/hr capacity each. A taping from cold water inlet header is
taken and passed to the side sand filters which contains 2% of 80000 m3/hr. In side sand filter
there are different layers of sand, gravels and pebbles. It removes the suspended solids from the
water. When the delta P exceeds 0.5 kg then no further filtration takes place as all the solid will
accumulate on the surface of sand in filters. Hence to remove the solid accumulatedon the
surface backwashing has to be done with air and hot water. Air will loosen the bed and then we
pass the water from the outlet of sand filter. The backwashed water is then sent to ETP.
3.2.1.3 pH
The pH of cooling water is maintainted in between 7.5 to 8.5.
Increase in pH will cause increase in scaling formation and decreasing the pH will cause
corrosion. Hence anticorrosive agents (phosphates) and antiscalants are used.
H2SO4 is dosed to maintain the pH . It even prevents scaling by reacting with calcium to form
CaSO4 which is soluble in water.

3.2.1.4 Chlorine Dosing

The microbiological growth of aerobic bacteria is reduced by dosing Cl2 to the supply water.
H2O + Cl2 -----> HOCl
Chlorine is stored in cylinder of 1000 kg ( 900 kg liquid and 100 kg gas) and is dosed with the
help of ejector.

3.2.1.5 Sump
Cooling water from cold water channel comes to the cooling water sump. Then it is passed to
the various units of the plant through 12 pumps each having capacity of 9000 m3/hr. Out of these
12 pumps, 9 pumps are working and 3 are standby. Dosing of all the chemicals takes place in the
sump. Losses are recovered by adding makeup water in the sump.

3.2.2 Cooling Tower -2

CT-2 works in the similar way with only 10 cells. Water from CT-2 is circulated to polymer
units(PP, HDPE, PE Swing)

3.2.3 Cooling Tower -3

CT-3 has 6 cells each having capacity of 4000 m3/hr. Water is pumped by 3 centrifugal pumps (
2 running, 1 standby) each having capacity of 9000 m3/hr. These pumps can also be run by 3
turbines if there is trip in electricity. These turbines rotates by HP steam (101 bar).
Water from CT-3 is supplied to Captive power plant.
3.3 Demineralisation Plant
The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot
be used for the generation of steam in the boilers. The impurities present in the water should be
removed before it’s use in steam generation The necessity for reducing the corrosive nature &
quantity of dissolved and suspended solids in feed water has become increasingly important with
the advent of high pressure, critical & supercritical boilers.

3.3.1 Impurities in water:-

The impurities present in the feed water are classified as given below -
1. Undissolved and suspended solid materials.
2. Dissolved salts and minerals.
3. Dissolved gases.
4. Other materials (as Oil, Acid) either in mixed or Unmixed forms.

3.3.2 Demineralisation Chemistry -

Demineralization is an ion exchange process to remove the dissolved solids present in the water.
For removal of dissolved solids in water, it is passed through the bed of a polymeric based
compound known as ‘resin’. Units containing the resin are known as ‘ion exchangers’ and in the
ion exchanger as water passes ions having similar chargers are get replaced by the resin. e.g. in
cation exchanger , + ve charge hydrogen ion of resin get replaces other +ve charge ions like
calcium, magnesium , sodium present in water .

3.3.3 Deminerlisation Process

3.3.3.1 Activated Carbon Filter.

Feed water available at 6 Kg/Cm2 pressure at the b/l of DM plant is fed to Activated Carbon
Filter. The Feed Water enters the ACF from top and water free from free Chlorine is collected at
the bottom. The Activated Carbon charged inside the filter adsorbs the free Chlorine and organic
matter if any present in the water.
Backwash of filters is carried out using feed water stored in the filter water backwash tank with
the help of backwash pumps.

3.3.3.2 Strong Acid Cation Exchangers (SAC):

Weak acid cation exchanger treated water is passed through. Strong Acid Cation units. These
units are charged with strongly acidic cation exchange resin. These units exchange all the cations
into hydrogen, forming respective acids. The regeneration of SAC Exchangers is in
countercurrent mode. 30 % Hydrochloric acid is used for regeneration of SAC & MB cation
resin .Water required for regeneration is tapped from discharge header of degassed water transfer
pumps for SAC & MB. The Acid injection through ejector into SAC from the respective
measuring tanks by diluting the acid to approximately 5%. Back Wash facility is provided for
SAC , however this shall be carried out once in 6 cycles for SAC or pressure drops exceeds the
limit. After every backwash of SAC double regeneration is to be performed.

3.3.3.3 Degasser System:

Degasser Tower is filled with PP raschig rings. Air is forced from the bottom of the tower by
Centrifugal Blowers, while the water flows down through the packed bed of PP rings. The
carbonic acid present in the water splits up into carbon dioxide gas and water. This carbon
dioxide gas is stripped off and escapes from the top of the tower. The water free from the
carbonic acid is collected in the Degassed water tank and is pumped to up-stream units through
the five numbers of degassed water pump provided.

3.3.3.4 Weak Base Anion Exchanger (WBA):

The Degassed water passes through Weak Base Anion Exchanger which removes the sulphates
completely and major part of chlorides. Weak Base Anion Unit is regenerated using thoroughfare
technique. The spent NaOH from SBA is injected to Weak Base Anion Exchanger which
regenerates the Weak Base Anion Resin in Co-current mode.

3.3.3.5 Strong Base Anion Exchanger (SBA):

The WBA water enters Strong Base Anion Exchanger. Here the resins are regenerated at very
high level and the resins in hydroxyl form (OH) exchanges balance strong anions from WBA and
weak anions HCO3, and Silica in the form of Silicic acid to form pure water.
Regeneration is carried out by sodium hydroxide by counter current mode.

The combination of Weak Base and Strong base Anion Exchangers is regenerated by
Thoroughfare regeneration technique. NaOH (48%) Lye rayon grade is used for regeneration of
weak and strong base anion resin. The water required for regeneration of Anion Exchanger is
tapped from the DM water storage tank using the DM water regeneration pumps. The caustic
injected through injector the caustic into Strong Base Anion Exchangers from the Dilution cum
Measuring Tank by diluting the caustic approximately 5% through ejector. Backwash facility
provided for both WBA & SBA. However, SBA back wash shall be carried out once in 5 cycles
or pressure drop exceeds the limit. After every back wash of SBA double regeneration is to be
performed.

3.3.3.6 Mixed Bed Exchanger

MB unit has both Strong Acid Cation Resin and Strong Base Anion resin mixed in a single
vessel. The regeneration of these resins is carried out, i.e. cation by Hydrochloric Acid and anion
by caustic. The MB Exchanger functions as many numbers of DM Plant because both Cation and
Anion Resins are mixed in homogeneous in this unit. Hence the DM Water from this unit is get
polished.
This unit ensures consistent quality of DM water with a pH 7 ± 0.2
 Demineralisation water plant

--- DMF AC
R22 SA
- R1 R/W inlet F
C
Treated water/ raw water dual media Carbon filter strong acid
Activated
filter cation Ex.
RWTP blower

Degasser
SBA WBA tank
Mixed
exchanger
DM bedEx
.
water

DM1 1 DM2 2
storage storage

CPU/power

To process
3.4 Instrument Air Plant Air (IAPA)
Plant air is highly compressed and used directly for pneumatic instruments as well as for filter
beds backwash air. Instrunenthusiastic air is used to operate valves.
The only difference between plant air and instrument air is that instrument air has no moisture.

Instrument air
Air is sucked from the atmosphere with the help of 3 stage centrifugal compressor (2 running and
1 standby) with the capacity of 10000 m3/hr. In the first stage of the compressor pressure is 0.88
in second stage it rises upto 3.17 and finally increased to 7 kg pressure. After each stage of
compressor the air gets heated due to compression hence it is cooled in the heat exchanger. The
cooled air upto 48 degree is passed through the dryer to remove moisture. The dryer is filled with
alumina which works on the adsorption principle and removes moisture from wet air to achieve
dew point of -40 degree celcius. The dryer cycle is 8 hrs. The heating and cooling time is 6 and 2
hrs respectively. During power failure small portion of dry air from the dryer outlet is
compressed through a reciprocating compressor and the pressure is increased from 8 kg to 27 kg
and stored in HP buffer vessel. Emergecny buffer vessel is provided to cater IA during power
failure to atmospheric vaporiser in nitrogen
system,steam generation system,emergency cooling and DM water pumps as well as its own
internal consumption. Upon restoration of power, this vessel will be pressurized (filled up) with
high pressure instrument air from the single HP Air Compressor provided in the system.
In case of low air availability to the compressed air system provision is kept to give preference to
the instrument air on low pressure in instrument air line.
 :

Atm 3 stage
air
compressor Process air
8.6
bar

Activate
IA
alumia
Storage
dryer
tank After filter
filter
3NOS
3.5 Inert Gas System
There are four main air compressors two for each plant. Atmospheric air is sucked through the
suction filter and compressed to the 8.6 kg pressure required for liquefaction in a three stage
centrifugal compressors .
The discharge from common header from third stage of two air compressors is cooled in an
aftercooler to about~40-43 degC.
The air from the aftercooler is cooled in a one stage direct cooler. In the tower, chilled water
from vaporisation cooler is sprayed at the top section to cool the air from the compressor. The air
is thus cooled to close to approx 12-15 deg C . The moisture in the incoming air is condensed in
the this tower and any droplets from air is separated in the high surface knitted type demister pad
mist eliminator located at the top of the tower before exit . The hot water from the bottom of the
tower is send back to the cooling water return header.

3.5.1 Water chilling through evaporation :

Dry waste gas from the cold box is sent to vaporisation cooler . Normal cooling water is taken
from the supply header and spayed at the top of the tower through nozzles for high contact .The
waste gas gets humidified at the outlet exit conditions and water gets cooled . The chilled water
is sent to direct cooler to cool the hot air . Any water droplets from waste gas is separated in the
high surface knitted type demistor pad mist eliminator located at the top of the warm section
before waste gas is vented to atmosphere. The Chilled water from the bottom of the tower is
pumped to the direct cooler for air cooling Chilled water pumps from the vaporisation cooler are
provided to pump chilled water to the top of the direct cooler.

3.5.2Drying
The chilled air at a temp. of 12-150C is then passed to adsorber vessels where the saturated
moisture & carbon dioxide are removed from the process air by using Alumina and Molecular
Sieves respectively. Dual PPU After Filters are included to remove the fine dust of adsorbent
to prevent dust from entering the cold box. The carbon dioxide & Moisture content in the process
air is monitored with the help of on-line CO2 & Moisture analyzers ex ppu after filter.After 4-5
hrs of operation, the on-line adsorbent vessel is taken off-line in order to regenerate the saturated
adsorbents. This is achieved by switching the air & regeneration gas streams by means of
automatic on/off control valves. The regeneration stream that is waste air from the cold box is
heated to the required regeneration temperature by an electric regeneration gas Heater . The hot
gas passes down through Molecular Sieves and Activated Alumina layers, removing Carbon
Dioxide & Moisture from saturated adsorbents before venting to atmosphere. The adsorbent
material is then brought back to its on stream operating temperature by passing the cold waste air
through the bed.
3.5.3 Step Cooling ,liquefaction and distillation:
The major part of the dry air is cooled down to saturation temperature by the return gases from
the Distillation Column in the main heat exchanger. The cold air from main heat exchanger is
rectified in the column, where oxygen-rich liquid air and gaseous nitrogen with the purity of
1PPM(max) O2 are obtained respectively at the bottom and at the top of the Distillation column.
The rich liquid drawn from the bottom of column is throttled and then vaporized in the bath type
Reboiler/ condenser at a pressure of about ~3 Kg/cm2 by the condensation of gaseous nitrogen
obtained from column top, thus obtaining liquid nitrogen. This waste air vapor from the bath
type reboiler condenser is warmed up in the bottom section of main heat exchanger by giving
away the cold to Air inlet to column, and is delivered to the expander .This waste air is expanded
to a pressure of ~ 0.35 Kg/cm2 g and is warmed up to the room temperature again in the Main
heat exchanger after subcooling the LIN in subcooler(48-EP-103 and 48-EP-203) before leaving
the cold box. A part of it sent to an electric regeneration heater , as regenerating gas, for
molecular sieve & alumina, other part is passed through vaporisation cooler to chill the water
(which is used to chill process air in direct cooler),while if required is vented to the atmosphere
through a Waste nitrogen silencer.The gaseous nitrogen drawn from the top of distillation
column a part of this is warmed close to room temperature in the main heat exchanger and can be
delivered as a product at 7.5 Kg/cm2, while the other is condensed in bath type reboiler
condenser. A part of the Liquid nitrogen obtained is refluxed back to the distillation column
while the other is sent to the LIN sub cooler, The sub cooled LIN is expanded in a liquid-vapor
separator to a low pressure and Liquid is collected in the separator and finally send to the low
pressure storage system. The vapor stream is recycled back to the turbine outlet . The drains from
column, LIN line will be routed to waste disposal drum. Provision of gaseous nitrogen venting to
atmosphere is provided in case of drop in purity.
3.6 Captive Power Plant (CPP)
CPP is divided into 4 parts
1. Gas Turbine
2. Steam Turbine
3. HRSG –Heat Recovery Steam Generator
4. Utility Boiler

3.6.1 Gas Turbine:

There are 4 gas turbines each having a capacity to produce 33.75MW. Gas turbine consists of 3
parts : compressor, combustion chamber and turbine.
3.6.1.1 Compresssor- There is a 17 stage compressor in which the atmospheric air is
compressed upto 12 kg/cm2 and 300℃. The compressed air is passed to the combustion
chamber.
3.6.1.2 Combustion chamber- Combusion of natural gas takes place in this chamber. There are
2 spark plugs and 10 pilot burners. The flue gas produced is at 18.5kg/cm2 which passes to the
turbine.
3.6.1.3 Turbine- The flue gases are passed to the 3 stage turbine which increases the temperature
upto 400-500℃ and rotating the impeller which inturn roates the shaft . shaft is connected to the
gear box . gear box is connected to the generator which produces electricity.

3.6.2 Steam Turbine:

There are two steam turbines each having a capacity to produce 30 MW. Steam turbine is
operated by passing VHP(Very High Pressure) steam at 110 kg/cm2. Steam turbine system
contains turbine, condenser, ejector and gland steam condenser.
3.6.2.1 Turbine- It is a 19 stage turbine which is operated by VHP steam which rotates the
turbine and looses its pressure and can be extracted in the form of MP (Medium Pressure) and
HP (High Pressure) steam in the intermediate stages. From the last stage we get LP (Low
Pressure) steam which is condensed in the condenser.
3.6.2.2 Condenser- In condenser LP steam coming from turbine is condensed with the help of
cooling water. Then it is passed to the ejector.
3.6.2.3 Ejector- Ejector operates with the help of HP steam which creates suction which is
attached to condenser for taking out condensate from the condenser. And both the HPsteam and
condensate are mixed and passed to the gland steam condenser.
3.6.2.4 Gland steam condenser- It is used as a sealant for turbine. Sealant is HP steam which
prevents VHP steam from coming out of the turbine. After recirculation of HP steam ,the
condensate will form in gland steam condenser. Some amount of condensateis sent toETP and
some is recirculated to the condenser.
3.6.3 Balance Of Plant (BOP):
Scale formation in boilers is prevented by providing good makeup water to feed water
system and by avoiding condensate contamination. At higher pressures, the makeup must
be of condensate quality such as provided by evaporation or by demineralization. Corrosion of
metal surfaces in contact with water and steam constitutes the major maintenance expense to the
power industry. The condensate and feedwater must be free of dissolved corrosive gases and the
pH of the water must be properly adjusted to prevent the attack on metal surfaces.
3.6.3.1 Deaerator-
The oxygen content in the feedwater must be reduced to recommended levels by effective
deaeration in the condenser and in deaerating heaters. Make up condensate from storage tanks
should not be directly to the feed water system without deaeration. Minimum forced boiler
outage time has been realized where the oxygen has been reduced and held below 0.1ppm. It is
important to maintain a chemical reducing environment in the boiler water and chemicals like
hydrazine have been used to achieve this.
3.6.3.2 pH Maintaining Tank-
The pH of the feed water must be controlled to prevent the dissolution of the iron and
copper alloys in the system. These form corrosive products when introduced into the boiler and
will contribute to the corrosion of boiler steam generating surfaces. The pickup metals from
steam generating surfaces can be minimized by the addition of volatile alkaline chemicals that
raise the pH of the feedwater. The pH range of 9.1-9.8 have produced the best results. Volatile
controls should be used only when the dissolved solids content in the boiler is less than 2 ppm. If
a significant concentration of solids is present as a result of condenser leakage, solid treating
chemicals such as tri-sodium phosphate and ammonia should be available for immediate
injection for pH adjustment of the boiler water. Under no circumstances should a boiler be
operated with a pH value below 7.0. If the boiler water pH cannot be maintained above this value
with chemical feed and blow-down, the unit must be removed from service in an orderly fashion.

3.6.4 Heat Recovery Steam Generator-

There are 4 HRSG’s each having capacity to produce 110TPH of steam. HRSG is a heat
recovery system for the flue gases released from Gas Turbines. HRSG is divided into 4 parts:
Economiser, Steam Drum, Superheater, De-superheater, The entire system of HRSG is
maintaines at 160kg/cm2 pressure with varying temperature and BFW is counter-current with the
flue gases coming from Gas Turbine
3.6.4.1 Economiser- it is a type of heat exchanger in which heat is exchanged between Boiler
Feed Water (BFW) and Flue Gases. The BFW enters the economizer at 140℃ and leaves at
230℃ thus taking heat from flue gases. Since it is at 160kg pressure the water remains in liquid
state. The gases reduce its temperature to 160℃ and is vented off in the atmosphere before
controlling its SOx , NOx with steam .
3.6.4.2 Steam Drum- It consists a cylindrical drum attached to long tubes below the cylinder
filled with BFW. Steam Drum works on the principle of density difference. The cylindrical drum
is filled with 50% of liquid having low density w.r.t. water in the tubes. When the water gets
sufficient latent heat it changes its state from liquid to vapour phase and therefore is carried
upward due to density difference. Inlet water is at 230℃ and gets converted into vapour due to
density difference. Vapors from steam drum is passed to superheater.
3.6.4.3 Superheater I - Tt is a heat exchanger which is used to superheat the steam coming from
the steam drum. It converts steam to 500℃ and then it goes into the de-superheater for
controlling the temperature of the steam.
3.6.4.4 De-superheater- The main purpose of de-superheater is to control the temperature of the
superheated steam by spraying water. The steam coming at 500℃ is cooled to 300℃ and sent
back to the superheater.
3.6.4.5 Superheater II- The temperature of the steam is again increased to 500℃ from 300℃
using the flue gases with are entering at 500℃ .

3.6.5 Utility Boiler:

The structure is similar to HRSG with the only addition of combustion chamber. There are 2
utility boliers each having capacity of 220TPH . It directly produces VHP steam which is used is
Steam Turbine. Whereas in HRSG VHP steam is produced by exchanging it with High
temperature flue gases . Utility Boiler is divided into 7 parts : Forced Draft Fan ( FD fan), Air
preheater, combustion chamber, economizer, steam drum, superheater, desuperheater.
3.6.5.1 Forced Draft Fan – This is used for sucking the air form atmosphere which is then
cleaned with the help of mesh installed at the suction. The heavy dust particles present in the
atmosphere are removed in the mesh .
3.6.5.2 Air Preheater- The boiler requires certain inlet temperature of the air .Hence the
incoming air from the ID fan is preheated in the air preheater. Air is heated upto 197 ℃
with the help of flue gases leaving from the economiser at 253℃ and cooled to 130℃ and sent to
the stack.
3.6.5.3 Combustion chamber – The natural gas is burnt in the combustion chamber using
burners. There are 3 elevation with 4 corners and 1 burner in each corner of elevation (total=12
burners). The pilot burners are burnt with the help of spark plug present just below the pilot
burners. For complete combustion of the natural gases air is blown in the combustion chamber.
The flue gas generated is at 500℃ which is passed to the superheater and heat is exchanged with
the BFW. The flue gases are circulated 3-4 times to the combustion chamber to control the SOX,
NOX.
3.6.5.4 Economiser- The BFW enters the economizer at 140℃ and leaves at 230℃ thus taking
heat from flue gases. Since it is at 160kg pressure the water remains in liquid state. The gases
reduce its temperature to 160℃ and is vented off in the atmosphere and also some part of the
flue gases is recirculated in the combustion chamber.
3.6.5.5 Steam Drum- It consists a cylindrical drum attached to long tubes below the cylinder
filled with BFW. Steam Drum works on the principle of density difference. The cylindrical drum
is filled with 50% of liquid having low density w.r.t. water in the tubes. When the water gets
sufficient latent heat it changes its state from liquid to vapour phase and therefore is carried
upward due to density difference. Inlet water is at 230℃ and gets converted into vapour due to
density difference. Vapors from steam drum is passed to superheater.
3.6.5.6 Superheater I - Tt is a heat exchanger which is used to superheat the steam coming from
the steam drum. It converts steam to 500℃ and then it goes into the de-superheater for
controlling the temperature of the steam.
3.6.5.7 De-superheater- The main purpose of de-superheater is to control the temperature of the
superheated steam by spraying water. The steam coming at 500℃ is cooled to 300℃ and sent
back to the superheater.
3.6.5.8 Superheater II - The temperature of the steam is again increased to 500℃ from 300℃
using the flue gases with are entering at 500℃ .

3.6.6 Pressure Reducing Desuperheater System(PRDS) –

PRDS is used to reduce the pressure of VHP steam and converting it into HP, LP and MP steam
simultaneously using pressure reducing valves, which is used in the downstream plants.
 Chapter 4
Offsite Storage and Transfer Facilities

Offsite include storage area which is generally used to store, handle and transfer raw
materials, intermediate products and final products. There are 15 tank farms for storage of
material. They are generally supporting facilities for the plant which are actually not a direct
part of the primary or secondary process of the reaction train.

The overall storage and transfer available in the plant is as follows:

 Mixed Naphtha is brought to the plant from via pipeline and is stored in Floating
Roof tank provided for this purpose which is mainly feed to DFCU for various
purposes as its fuel via feed pumps provided for this purpose.
 Naphtha is fed to HGU when DFCU is shut down and hydrogen is needed for the
polymer units, where Hydrogen is produced by Steam Reforming of Naphtha
Process for which naphtha needed is delivered in liquid state using feed pumps.
 C2/C3/C4 which is also a fuel for DFCU is brought from nearby Hazira plant via
pipelines and is stored in Horton Spheres provided for this purpose and is then feed
to DFCU using feed pumps.
 C2/C3/C4 are lighter materials and require high pressure to be stored in the
liquid state and hence are stored in sphere where pressure inside is about 2-15
kg/cm2.
 The products of DFCU are Ethylene, Propylene, Off-spec Ethylene, Off-Spec
Propylene, Raw Pyrolysis Gasoline, C4 Mix, Off-spec C4 Mix, Carbon Black Feed
Stock, Hydrogen and Slop which are then used as feed for various auxiliary units
present in the plant.
 Ethylene obtained from DFCU is stored in DWST which is an insulated tank where
region between two tanks is filled with pearlite that acts as insulation to reduce the
heat loss so that ethylene can be stored in the liquid state and does not get vaporized.
 Also all the pipelines for the transfer of ethylene are insulated to eliminate heat
loss to prevent ethylene to convert into vapour.
 There is a pump present inside the DWST which will deliver ethylene up to the feed
pump which will further deliver it to the vaporizer and then it is further sent to
Swing HDPE/LLDPE unit where Polyethylene of various grades is being produced.
 Propylene from DFCU is stored in Horton Spheres provided from where it is
further sent to Polypropylene unit via feed pumps.
 There is also a provision provided for the loading of propylene directly into the
trucks from gantry and transfer pumps are present near the tank farm for the transfer
purpose.
 HPG is stored in Internal Floating Roof which is further sent via loading pumps to
the tankers which will be available in gantry area for loading purpose.
 C6 cut is stored in Internal Floating Roof which is transferred further as a feed to
BzEU (Benzene Extraction Unit) via pumps.
 C4 mix obtained from DFCU is used as a feed for BdEU (Butadiene Extraction
Unit) which is stored in a sphere and is transferred to the unit via pumps.
 1,3-Butadiene obtained from BdEU is stored in a sphere and is then sent to the
gantry area for loading purpose via loading pumps.
 1,3-Butadiene has a tendency of resonance above temperature of nearly 8⁰C and
hence it is very much necessary to store butadiene below 6⁰C.
 C4 Raffinate obtained from BdEU is stored in Sphere and then further sent to DFCU
as a feed via pumps.
 Carbon Black Feed Stock (CBFS) obtained as a product from DFCU is stored in a
cone roof tank which is then sent to gantry area for loading purpose via transfer
pumps provided.
 Slop produced in DFCU is stored in Cone roof tank and then sent to gantry area for
loading purpose via loading pumps.
 Hexane which is used as an additive in Swing HDPE/LLDPE unit is brought from
outside via tankers and unloaded into IFR tanks provided via pumps.
 Hexene-1 which shall also be used as an additive in HDPE/LLDPE unit is stored in
a cone roof tank being brought from outside via tankers and transferred via pumps.
 Pentane is stored in Horizontal Bullet which is brought from outside via tankers and
unloaded using pumps and further sent to HDPE/LLDPE unit as an additive.
 Hydrogen needed for polymerization reactions is produced in DFCU and is stored
in Vertical Hydrogen Bullet and is transferred using Compressors at desired
pressure.
 Butene-1 used as an additive is produced in Butene-1 unit by dimerization process
using ethylene as its feed which is then stored into sphere and then further fed using
pumps.
 C6+Oligomer is obtained as a By-product of Butene-1 reaction is stored in IFR
tank and is further sent to gantry area for loading purpose via loading Pumps.
 All the Off-spec Products i.e. Off-spec Ethylene, Off-spec Propylene, Off-spec C4
mix are stored in spheres and then again sent to their respective plants to produce
them again with required specifications.
4.1 Types of Storage
1. High pressure - Bullet (for propane, hydrogen)
2. Medium Pressure - Sphere (for propylene, ethylene, butadiene, C4 mix, CBFS, etc)
3. Low Pressure -
a) Dome roof tank - for cyclopentane, RPG, HPG, etc.
b) Atmospheric tank -
• Cone roof (for CBFS, Acid, Caustic storage etc)
• Cone roof & IFR tank with N2 blanketing (for Benzene, BEU feed stock etc)
• Cone roof & IFR tank without N2 blanketing (for New MS, imported Hexane, etc)
• External Floating Roof (for Naphtha, old MS, etc)

4.2 Requirement of Different Storages

1. Depending upon the vapor pressure of the liquid at atmospheric temp different types o
f storage is required.
2. If vapor pressure is >1kg/cm² liquid is to be stored in sphere or bullet.
3. If 0.5 kg/cm² < vapor pr <1kg/cm² liquid is to be stored in doom roof tank.
4. If vapor pressure <0.5 kg/cm² liquid is to be stored in atmospheric tank.

4.3 Over pressurization :

All the spheres /bullets are protected against the over pressurization by providing with
PSVs with different set points depending on the vapour pressure.

4.4 Over filling:

All the spheres/bullets are provided with high-high level alarm with level switch which
on actuation closes the SDV.

4.5 Gas leaking:

Gas detectors are provided at the top of the sphere, near the ROVs and in the pump house
to detect and inform to ECR through F&G panel about the leakage of hydrocarbon.

4.6 Fire case:

1. Spheres and bullets are coated with fire proofing material which will protect the
spheres/bullets for a period of two hours.
2. Over this layer there is one network of fire water system with sprinkler and one net
work of instrument air with quartzoid bulbs.
3. In normal position the instrument air is supplied to open the ROVs through SOV and
to close the Deluge Valve (DV) through a SOV.
4. Quartzoid bulbs are located at the tip of instruments air net work (pressure maintained
at 3.8kg/cm2 via PCV and RO) .

5. The bulb seals the network thus pressurizing the entire network to level of 3.8 kg/cm2.
6. When the bulb breaks at 79°c, instrument air leaks out causing a drop in air press. A
low pressure switch (PSL) located on instrument air line to each sphere is actuated when
pressure falls to about 2.5 kg/cm2g. This in turn actuates solenoid valve, thereby closing
ROVs of respective spheres and simultaneously opening SOVs and thus DV on fire water
line to the sphere. On actuation of this interlock the transfer pump will trip and the
respective sphere will be drenched at a rate of 10 lpm/m2 of sphere surface area.
7. Instrument air is supplied through a RO so that when a bulb breaks minimum amount
of air should enter into the system and leakage from one bulb should be sufficient enough
to actuate the PSL.
8. When a bulb breaks only PSL of the affected spheres is actuated while instrument air
network on other spheres remain pressurized.
9. When PSL of the sphere actuates, fire water deluge valve of the neighboring spheres
are also opened for cooling down the spheres.
10. In case of emergency, deluge system can be actuated from DCS with or without
actuation of interlock.
11. Manual actuation of DV can be done by mechanically releasing the air of SOV. In
this case PSL interlock will not actuate.
12. Manual actuation of sprinkler can be done by opening the bypass valve of DV.
13. Manual actuation of sprinkler can also be done by opening the manual valve at the
90° position of the DV. This should be actuated only in case of DV had been affected by
fire.