Tankage, Blending and

Pipeline Transfer - I
Unit 945 : Oil Movement

Refinery Overview
A.

Overall relation with Process Units

B.

Material Balance and Production

Facilities in Tankage &

Blending
Crude Oil Storage & Process Charge
B.
Intermediate Storage and Charge
C.
Component Storage
D.
Finished Product Storage & Transfer to TLG
E.
Support Facilities
F.
Gasoline/Jet Fuel Blending
G.
Diesel/Fuel Oil Blending
H.
Crude Receipt and Finished Product
Transfer to Pipeline Systems
Note: Sulfur Storage is included in TLG area
A.

Tanks!

Tank Summary
Tank Types: Sphere, Cylindrical
Roof types & Structural Details of
Each Type
Why Floating Roof?
Why N2? and PCV Types
Why Tank Mixer? and Types
Breathers, PSVs, Vents
LI, TI, PI with alarms

Pumps!

Pump Summary
Pump Types (Centrifugal/PD)
Horizontal / Vertical
Why Spill Back
Pump Spill Back Type

A : Crude Oil Storage and

Process Charge

Crude Oil Storage

Receiving of mixed Crude from KMK

pipeline,
06 tanks with external floating roof
Receipt MOVs + Manual Valves
02 Mixers to prevent sludge, 04 Drains
Crude Receiving and Charging Plan by
TSD
Settling, Dipping, Water Draining,
Sampling and Mixing

Crude Charging

Example Results
Charging, SB MOVs and Manual
Valves
Attaching for Charging
03 Charge pumps with automatic
FC Spill back
Transfer Pump
PFD and P&ID

B : Intermediate Product
Storage and Process
Charge

Intermediates

3)

Heavy Naphtha
VGO
Stabilized Naphtha

Example Results

1)
2)

HN Storage and Charge

Excess HN rundown from NHT

02 Storage Tanks
Breathers
DR/IFR with N2 Self Regulators
Feed for NHT startup and PLAT
02 Vertical Hi Speed Sundyne
Pumps with Manual Spill Back
02 Blending Pumps with PDC Spill
Back for JP-4 and Gasoline

VGO Storage and Charge

Mixed VGO run down from VDU

One Insulated Storage
Breathers
4 loops of tubes with LP steam
N2 blanketing with Self Regulator
02 Feed Transfer Pumps with FC
Spill Back for DMX and Start up of
VDU

St.Naphtha Storage &

Charge

Run down from GCU

03 Storage tanks with CR/IFR
Inlet and Outlet MOVs + Manual
Valves
N2 Blanketing with Self Regulators
Breathers
02 Charging pumps with FC spill back
Charging to NHT

C : Blending Component
Storage and Transfer

Blending Components

3)

Heavy Naphtha
Light Naphtha
Reformate

Example Results

1)
2)

Light Naphtha

Run Down from NHT

LN has Hi RVP ~ 1.3 Kg/cm2 a
02 N2 double DR pressure tanks
N2 control with Split Range Control
Valves
PSVs
02 Blending Pumps with PDC spill
back
JP-4 and Gasoline Blending

Reformate

Run Down from PLAT

02 DR/IFR tanks
02 Blending Pumps with PDC spill
back
Gasoline Blending

D : Finished Product
Storage and Transfer to
TLG

MCR Products and Their

Use

LPG : House/commercial burner Fuel

Mogas: (Local + Export) :Motor Fuel for SI
engines
3) HOBC : Motor Fuel for SI engines
4) Jet A-1: (Local + Export) Aviation Turbine Fuel
Commercial Use
5) JP-8 Export: Aviation Turbine Fuel (US Military)
6) JP-8 PAF :Aviation Turbine Fuel (PAF)
7) Kerosene: House/ commercial Burner, Cleaning
8) HSD: Motor Fuel for IC (CI) Engines
9) LDO: Tractors, Generators, Engines
10) F.O: Burner fuel for Power Plants, Cement and
other industries, Furnaces, Boilers
11) Sulfur: Industrial use, Sulfuric Acid
1)
2)

Products Specifications

Specs of Each product by Lab

Example Test Certificate of Each

Product i.e. CQ

1) LPG

Run down from PLAT, LPG Merox

03 Spheres made of SS
Inlet and Outlet XVs + Manual LSVs
Operated at Equilib. VP ( 5~8 kg/cm2)
Vapor Equalizer Line, PSV
On line GC Analyzer at R/D line
Odorant Injection (Ethyl Mercaptan)
Off-Spec to Fuel Gas system
02 Vertical pumps with ARV

2) HOBC / 3) Gasoline

Blending of Components + RED Powder

Dye
03 + 03 tanks for each, Propeller Mixer
Inlet and Outlet LSVs + Manual Valves
DR/IFR, Vent
Mixing, settling before Sampling
Re blend if off-spec
02 + 02 pumps with PDC spill back
HOBC tanks used for Export Gasoline (undyed)

4) Jet A-1

Treated Kero from KMX + ASA (Stadis450) Chemicals thru Filter

Inlet and Outlet LSVs + Manual Valves
03 tanks with Propeller Mixer
CR, N2 with Self Regulator, Breather
Floating Suction, FFTs (QFDs)
Off-spec Reblend, to Kero or to Slop
02 pumps with PDC spill back
Filter/Separator

5) JP-8 for PAF

Treated Kero from KMX + Chemicals ASA,

CI (Hitec 580) thru Filter / Separator
Inlet and Outlet LSVs + Manual Valves
03 tanks with Jet Mixer, FFTs (QFDs)
DR/IFR, Vent, Floating Suction)
Off-spec Re blend or to Slop
02 pumps with PDC spill back
Filter/Separator
Prev. JP-4, Then Used for LN+HN, HOBC

6) Kerosene

Kero from KMX batch wise

03 tanks with Jet Mixer
Inlet and Outlet MOVs + Manual Valves
CR, Self Regulated N2 PCV, Breathers
Off-spec to Slop
02 T/L pumps with PDC spill back
JIMCO Delivery and MFM feeding
01 tank being used for other service
since long HSD, Ref, St. N. etc

7) HSD

Continuous blending at Process

03 tanks with Jet Mixer
Inlet and Outlet MOVs + Manual Valves
CR, Breathers
Off-spec Reblend or to H. Slop
02 T/L pumps with PDC spill back
To FLO and Fuel Oil tanks
JIMCO/Lal Pir Delivery and MFM feeding
01 Kero tank being used for HSD

8) LDO

Batch wise blending at Process +

F.O.
02 tanks with Jet Mixer
Inlet and Outlet LSVs + Manual
Valves
CR, Breathers
Off-spec Reblend from Process
02 T/L pumps with PDC spill back

9) Fuel Oil

Continuous blending at Process

03 Insulated & Heated tanks with
Propeller mixers
Inlet and Outlet MOVs + Manual Valves
CR, Breathers
Off-spec Reblend by HSD
02 T/L pumps with PDC spill back
To Refinery Fuel Oil tanks
02 Pumps for Delivery to Lal Pir

E : Support Facilities

Flushing oil

SR Diesel from CDU or HSD from

tanks
01 tanks, CR, Breathers
02 pumps with PDC spill back
Charge to Process for flushing and for
Startup of DMX
One is Motor and other turbine driven
Both Auto Stand by of Each other

LSL, HSL, Leaded Slop

From Process, ETP or off-spec tank

Light: Kero or Lighter, 02 pumps

transfer to Crude Oil
Heavy: Diesel or Higher: 02 pumps
transfer to Crude or FO blending

LSL tank design similar to LN tank

HSL tank: CR, Jet Mixer, Heating
Coil
Leaded Slop: Obsolete

F : Gasoline / HOBC / Jet

A-1 / JP-8 Blending

Gasoline / HOBC Blending

Reformat + LN + HN from component

tanks
Blending Recipe from TSD
+ Dye (opt.) +TEL (System Removed)
Separate Flow Meter of Components
Blending Master Controller on DCS
Online RON, RVP analyzer Feed back
to Blend Master
Correction is done manually

Blend Master Controller

Recipe input:
i.
ii.
iii.
iv.

Tank No. & Batch Size

Initial Component Ratio
Analyzer Selection & Set Points
Initial Flow and Qty.

Blender Checks following

i.

Correctness of Data i.e. Batch Size and ratio

etc.
ii. Component Pumps Running Status
iii. Product Tank Line up

The Dye Pumps are started manually after

flow is normal

Blend Master (Cont.)

Blender Checks/Controls during

Blending
i.
ii.
iii.
iv.

Results of Analyzers
Controls the flow rate of Components
Component Flow rates are within range
Tank Level is not Hi

When Batch Quantity reaches, the blending

is automatically completed.
HOBC is produced one batch / month on
manual mode (without selecting
analyzer).

Jet A-1 Blending

Treated Kero from KMX + Anti

Static Stadis-450
Control of Kero Flow rate from
Process
Ratio Control of Chemical Injection
according to Ratio Set Point
Jet Fuel Filter Separators

JP-8 Blending

JP-4(Obs.) =Kero+HN+LN+Chemicals
JP-8= Kero+Chemicals Anti Static, CI
Control all three Components flow
rates thru Master Controller
Ratio Control of Chemical Injection
according to Ratio Set Point
Jet Fuel Filter Separator
The JP-4 is not being produced.