S.

NO

TABLE OF CONTENTS

Acknowledgement

Byco in brief

Vision & values

Byco Organogram

Laboratory

Operations at ORC

Storage tanks

Single Point Mooring (SPM)

Integrated Product Distribution (IPD)

Oil & Gas movement and Logistics
Oil loading gantry
Decantation of product

10

Utilities

ACKNOWLEDGEMENT

First and foremost I would like to express my thanks to Almighty

Allah of His love and strength that He has given to me to finish
.this logbook as my internship report
I would like to thank my parents who supported me and allowed
.me to go to long distance
I also want to thank the whole Byco management and staff for
believing and granting me this golden opportunity to learn and
benefit myself to the utmost in both my academic and
.professional career
I would like to thank Mr.Fahad Hassan (Advisor Head) for his
support and guidance which helped a lot during the whole
.internship session
To accomplish whatever I have done in my internship, there were
many people along the way who have been responsible for
guiding me, advising me, encouraging me and for that I would like
to thank Mr.Irfan (IPD head at ORC) , Mr. Osama (Location in
charge at KESC) , all the shift engineers ,area operators , HR
department and all the staff who shared their time and
.knowledge
Raheel Masood Alavi
Internee (02 June 2014- 30
June 2014)

BYCO IN BRIEF

Byco is Pakistans emerging energy companies engaged in

the businesses of oil refining, petroleum marketing,
chemicals manufacturing and petroleum logistics.
Headquartered in Karachi, we are serving our mission to
fulfill the energy demand within and beyond borders.
Companies under Byco umbrella are:
Byco Oil Pakistan
Limited (BOPL)

Oil Refining &

Chemical
Manufacturing

Byco Petroleum
Oil Refining &
Pakistan Limited
Petroleum Marketing
(BPPL)
Byco Terminals
Petroleum
Pakistan Limited
Infrastructure &
(BTPL)
Logistics
Byco's operational refinery has a capacity to refine 35,000
barrels a day of crude oil into various saleable components
including Liquefied Petroleum Gas (LPG), Light Naphtha, Heavy
Naphtha, High Octane Blending Component, Motor Gasoline,
Kerosene, Jet Fuels, High Speed Diesel and Furnace Oil. BYCO

has expanded its refining complex by setting up another

refinery with the capacity of 120,000 barrels per day which is
completed.
BYCO take pride in having the largest capacity crude oil storage
tanks Pakistan.

VISION AND VALUES

Our vision is to be a leading energy company through
delivering the core business, achieve sustainable
productivity and profitability to deliver a superior
shareholder return.
Byco values are the guiding principles that define how it
conducts its business and what it stands for as a company.
This includes:

Setting high standards of care for environment, health and

safety.

Investment in human capital, offer competitive employment

terms and provide safe and congenial working environment
and an equal opportunity for all our employees.
Entail human resource development and promotes
openness, professionalism, teamwork and trust.
Enhancing value addition, implementing conservation
measures and growth up-gradation through addition of
newer generation technologies.
Credibility, goodwill and reputation earned through ethical
practices, honesty, integrity and respect for people.

 Safeguarding of shareholders' interest and providing them

with a consumerate return on equity is an integral part of our
business ethics.

BYCO'S ORGANOGRAM

LABORATORY
BPPL laboratory is very well equipped and well organized lab
where tests are performed after every 12 hours of the products
samples taken from the tanks before marketing to the customer. It

is the major source of reliance in the firm. Oil refineries require

laboratory tests of its products to confirm their reliability to be
trusted in the market and to meet the standards.
BPPL majorly produce kerosene, High Speed diesel, furnace oil
and LPG. Different tests are performed before their process to the
market, some of them are listed below:
Flash Point, cloud point and pour point
Doctor test by NaOH and lead acetate solution
Specific gravity test at 15.6 OC
Detection of sulphur in crude and products.
Distillation test
Colour Saybolt
Total sediments and metals in ppm
Reid vapour pressure (RVP) test at 37.8OC
Research Octane Number(RON)
Weathering of LPG
Cetane number test
Viscosity measurement at 50OC
Chromatography test
Initial boiling point(IBP) and Final boiling point(FBP)
Total acidity test

OPERATIONS AT ORC:
The refining of crude oil is done in following units:
1. Crude Distillation Unit (CDU)
2. Hydro-reformer unit
3. LPG separation unit
4. Merox unit
CRUDE DISTILLATION UNIT (CDU):
OBJECTIVE:
To distill and separate valuable distillate (naptha, kerosene,
diesel) and atmosphere gas oil from crude feedstock.
The Crude Distillation Unit consists of:
1. Booster Pumps
2. Desalter
3. Pre Flash Column
4. Pre heat by Exchangers & Furnaces
5. Crude Distillation Unit (C.D.U)
6. Naphtha Splitter
FINAL MARKETING PRODUCTS:
LPG
Furnace Fuel Oil
Motor Gasoline
High Speed Diesel
Jet Fuel Oil

HYDRO-REFORMER UNIT:

Hydro-Reformer Unit consists of:

1. Heat Exchangers, Furnaces and coolers
2. Product Seperator
3. DESULPHURIZER
4. Reformer
5. Product Separator
LPG SEPARATION UNIT:
LPG Separation Unit consists of:
1. Splitter Tower
2. DEETHANIZER, DEPROPANIZER, DEBUTANIZER
MEROX UNIT:
TYPES OF MEROX UNITS:
Conventional Merox for extraction of mercaptans from LPG,
propane, butanes or light naphtha.
Conventional Merox for sweetening jet fuels and kerosenes.
Merox for extraction of mercaptans from refinery and natural
gases.
Minalk Merox for sweetening of naphthas. This process
continuously injects just a few ppm of caustic into the feed
naphtha.

STORAGE TANKS:
Storage tanks are containers that hold liquids, compressed gases
(gas tank) or mediums used for the short- or long-term storage of
heat or cold. The term can be used for reservoirs (artificial lakes
and ponds), and for manufactured containers. The usage of the
word tank for reservoirs is common or universal in American
English and moderately common in British English. In other
countries, the term tends to refer only to artificial containers.
Byco has both types of storage tanks:

Fixed roof storage tanks:

Fixed roof tanks are common in production facilities to store
hydrocarbons with vapor pressures close to atmospheric pressure.
In this use, they should be equipped with pressure-vacuum valves
and purged with natural gas to eliminate air intake into the vapor
space. Product evaporative losses can be high especially when
crude is added to the tank and vapors are expelled through the
pressure vent valve.

Floating roof storage tanks:

An external floating roof tank is a storage tank commonly used to
store large quantities of petroleum products such as crude oil or
condensate. It comprises an open- topped cylindrical steel shell
equipped with a roof that floats on the surface of the stored liquid.
The roof rises and falls with the liquid level in the tank. As
opposed to a fixed roof tank there is no vapor space (ullage) in
the floating roof tank (except for very low liquid level situations).
In principle, this eliminates breathing losses and greatly reduces
the evaporative loss of the stored liquid. There is a rim seal
system between the tank shell and roof to reduce rim
evaporation.

SINGLE POINT MOORING

A Single point mooring (SPM) is a loading buoy anchored
offshore, that serves as a mooring point and inter connect
for tankers loading or offloading gas or liquid products.

Single Point Mooring (SPM) facility constructed by Byco

Terminal Pakistan Ltd, is the first of its kind in Pakistan. With
a clear draft of 25 m, the SPM can accommodate larger size
vessels carrying crude/ petroleum products in cargo sizes of
over 100,000 tons. The SPM has been set up on the coast of
Arabian Sea at a distance of approximately 14km from the
Byco's Mouza Kund site and is approximately 10 kilometers
from the sea shore at 25 meters depth. It is connected to the
storage tanks through 28 inch diameter offshore and
onshore pipeline
Benefits of SPM
:Key advantages of the facility are

Handling large vessels will result in saving of freight.

Capacity to handle over 22 million MT per annum of POL
products after Phase 2 expansion.
The location of the SPM will curtail the distance from the
Middle Eastern Ports by 100 nautical miles per trip thus
leading to further savings of freight.
Over 150 acres of sea front land forms part of the facility
which can be used to construct additional storage of up to
1,000,000 MT of POL products.
The SPM will be in 26 meters of water depth, with an ability
to handle vessels drawing upto 22 meters of draft.

 Dedicated POL products handling, which will lead to

significant time and cost savings for users.

:INTEGRATED

PRODUCT & DISTRIBUTION (IPD)

:Oil & Gas Movement

Provides with a complete and up-to-date overview of the oil

movements and storage operations in modern refineries,
marine terminals and oil plants
Acquire knowledge on oil production, recovery, dehydration
and desalting and be able to understand the description and
installation of a tank farm
Identify the different types of tank and review and improve
the operation of a tank farm
Illustrate the process of gas freeing of tanks and vessels and
be able to determine the various methods of gauging tanks
Describe marine terminal & SPM operation
Perform blending, tank mixing, meters and meter proving
and cleaning of crude oil and leaded gasoline tanks
Identify oil spill emergencies and be able to review the
operation and cathodic protection of gas transmission lines
Increase knowledge on pigging of crude and gas pipelines
and be able to demonstrate the process of ship loading
Recognize the role and importance of quality assurance,
control and work permit system

:Oil movement and logistics department deal with three areas

Decanting
Shipment

Tank Foam

:It can be explained as

Material in for processing

Transferring of products
.Transport of products

LOGISTICS

Logistics is the management of the flow of goods between the

point of origin and the point of consumption in order to meet
some requirements, for example, of customers or corporations.
The resources managed in logistics can include physical items,
such as food, materials, animals, equipment and liquids, as well
as abstract items, such as time, information, particles, and
energy. The logistics of physical items usually involves the
integration of information flow, material
handling, production, packaging, inventory,transportation, wareho
using, and often security. The complexity of logistics can be
modeled, analyzed, visualized, and optimized by
dedicated simulation software. The minimization of the use of
resources is a common motivation in logistics for import and
.export

OIL LOADING GANTRY AT ORC

IPD office at ORC receives loading plan from the head office on
daily basis which provides the details of the number of tank lorries
which will enter that day for filling. The tank lorries are brought to
weigh bridge for the measurement of the weight so that the net
weight of the filled product can be measured before the tanker
leaves ORC. After several tests are performed on the tankers, they
are then allowed to enter the oil loading gantry for the filling of
.the required product
:DECANTATION OF PRODUCT

:STORAGE TERMINAL AT KEAMARI (i)

Byco Terminals Pakistan Limited (BTPL) operates with storage
tanks facilities at Kemari and Byco refineries complex with total
.capacity of 140,000 MT
Terminal facility at Kemari has a total capacity of 10,000 MT and
will be utilized for import and export of petroleum products mainly
aviation fuel. Tank farm at Mouza Kund have a capacity of
.130,000 MT and is utilized for storing crude oil

:STORAGE TANKS FOR FURNACE OIL AT KESC (ii)

Byco is also supplying furnace oil to Karachi Electric Supply
Company (KESC) for the production of electricity at Port Qasim.
Byco has two storage tanks installed by KESC with the capacity of
.10,000 metric tons each
:WHITE OIL PIPELINE (WOP) (iii)

The US$ 480 million, White Oil Pipeline is the mega infrastructure
project implemented by PARCO. After conversion of PARCO's
existing pipeline network for Crude Oil transportation, the White
Oil Pipeline is catering to transport Refined Petroleum products to
the central and Northern regions of Pakistan; which account for
.almost 60% of the total Petroleum consumption in the country
For the implementation of the 786 km White Oil Pipeline Project
(WOPP) from Karachi to Mahmoodkot, a joint venture company,
Pak-Arab Pipeline Company Ltd. (PAPCO) was created. PARCO
holds a 51% majority share in PAPCO while Shell, PSO and
Chevron hold 26%, 12% and 11% shares in equity respectively.
The 26 dia White Oil Pipeline is designed for a capacity of 12
million tons per year, starting with 5 million tons in the initial
.years
Byco is also fulfilling the demands of several OMCs (Oil Marketing
.Companies) upcountry through WOP
PIPELINE FACILITIES:
One kilometer, 30 inches diameter pipeline connecting the
FOTCO oil jetty to Terminal and Pumping Station at Bin
Qasim.
786 Kms, 26" dia. Pipeline between Terminal and Pumping
Station at Bin Qasim and Terminal Station at Mahmood Kot
Terminal and Pumping station at Bin Qasim comprising of
main line pumps and storage tanks for seven days product
storage.
Pumping Station, Storage and off-loading Facility at
Shikarpur.
Terminal Station at Mahmood Kot with storage facilities and
connection to the OMCs at Gujrat and MFM-Pipeline system.

 Fibre Optic cable based communication system.

:SHIPMENT
Transportation of crude is a specialized economic activity, distinct
from that of other commodities. Some of the reasons for this are:
Hydrocarbon constituents in crude are highly inflammable
making the safety of the vehicle and operating environment
a significant feature.
Crude is mostly transported in large quantities thus requires
specialized containers.
Hydrocarbons are highly volatile and therefore suffer losses
during transit having financial and environmental impact.
There were different points for shipment of different products like:
Furnace oil(max. generation of electricity ,run heavy turbines
on ships), diesel
Furnace oil (diesel)
High speed diesel, fuel oil
Fuel oil
Naphtha, petrol and furnace oil
Naphtha, petrol and furnace oil
HSG(Normal, winterized, ultra winterized)
HSG(Normal, winterized, ultra winterized)
PMG, IODP 270, IODP 120, naphtha
Diesel(winterized, ultra winterized)
PMG, IODP 270, IODP 120, naphtha
Solvent (P-4076) , JP-1

UTILITIES:
Utilities are defined as the ancillary services needed in the
operation of any production process. These services are normally
supplied from a central site facility, and include:
Electricity
Fuel for fired heaters
Fluids for process heating
Steam
Process water
Compressed air
Inert gas supplies
The utility systems fall into three basic groups:
1. Those whose main purpose is energy transfer( fuel,
electricity, steam etc)
2. Water including process water, potable water, wastewater
and firewater
3. Compressed air and inert gases