OM&S-R - Updated

OM&S
OPERATING MANUAL
RECEIPT
SEQ/PN/OMS/SI/7.5.1/V-I
PRODUCTION DEPARTMENT
INDIAN OIL CORPORATION LTD.

(REFINERIES DIVISION)
GUJARAT REFINERY
Revised by Checked by Approved by
SK VERMA,PNM S.SRIDHAR-SPNM SATYAWARTI KUMAR

DGM(PN)
REVISED ON Feb’18
CONTROLLED COPY
GUJARAT REFINERY
PRODUCTION DEPARTMENT
FOREWORD
Gujarat Refinery has come a long way from October 1965 when first processing
unit was commissioned with the distillation of Ankleshwar Crude. -one secondary
units including Hydro-cracker, FCC, FPUs, SRU, H2, N2, MTBE etc. units are
During the journey of 45 years five primary units and twenty commissioned. In
2004 LAB Plant & its Offsite Facilities were commissioned. In 2006 MSQ plant &
its offsite facilities were commissioned. KDPL was commissioned on 07th
December 2006 and KRPL was commissioned on 17.02.09. Viscosity grade
Bitumen which is a better quality was dispatched on 16.07.09. Personnel
involved in the activities in the offsite area were carrying on with the experience
they brought with them and what they gained on the new job. The Operating
manual is updated every two years; hence the exercise was taken up and
completed.
This operating manual gives general description and operating guidelines for
Gujarat Refinery off-sites facilities. Care has been taken to make it precise
without omitting the important details of operational value. The procedures
described here, in some instances, are not what is being practiced but what is
considered as correct. This operating manual for off-sites contains chapters
under different headings. For the sake of convenience separate manuls for
different sections in OM&S (Receipt, Tank Wagon, TTL. BITUMEN and LPG) has
been made.
It is expected that personnel involved in various activities in OM&S will study

and use the procedures and precautions contained therein for guidance in their
day-to-day work. It will be our endeavor to update this manual from time to
time and incorporate any valuable suggestions, which could be effectively made
use of in order to counter the market challenges of technological advancements
and safeguard customer satisfaction.
Some of the information contained in the manual is of a confidential nature and

the information should not be disclosed to non-company personnel.
[SATYAWARTI KUMAR]
DGM-PRODUCTION
2
O M & S MANUAL
Receipt
3
GUJARAT REFINERY
PRODUCTION DEPT (OM&S-1)
Sub: New Additions & Addendums in the Latest OM&S-1 (R&B) Operation
Manual.
OM&S-1’s Receipt &Blending operation

Manual was updated in Oct’2013. The details of
the New Topics / Modifications incorporated
while updation and the new additions added
thereafter are given below as addendums.
Addendum
S.No Addendum Manual Name
No
Data updation for TK-516 & 521 OM&S Receipt
1 01
new dome facility
2 BOD Scheme OM&S Receipt 02
3 Tk-99 Service change OM&S Receipt 03
4 List of TSV and testing date OM&S Receipt 04
Chapter-14.3 o 14.11 deleted OM&S Receipt
5 05
(Separate SOP prepared)
Scheme for feeding slop directly OM&S Receipt
6 06
from TK-201 / 202
4
GUJARAT REFINERY
INDEX
CHAPTER - 1 INTRODUCTION
1.1 OBJECTIVES
1.2 FUNCTIONS
CHAPTER - 2 SUB SECTION OF RECEIPT

2.1 GR – CRUDE CONTROL ROOM
2.2 GRE – CRUDE CONTROL ROOM
2.3 GR – PRODUCT CONTROL ROOM
2.4 GRE – PRODUCT CONTROL ROOM
2.5 BOD SUMP OR GR – GRE SUMP
2.6 MELTING PIT
CHAPTER – 3 CRUDE OIL HANDLING

3.1 GENERAL
3.2 RECEIPTS
3.3 AUTO SAMPLER
3.4 NG AUTO SAMPLER
3.5 PREPARATION OF TANK FOR FEED
3.6 BLEEDING
3.7 CRUDE BUSTER PUMPS
3.8 CRUDE FEED FAILURE
3.9 FRC IN CRUDE CONTROL ROOM
3.10 FLOW RECORDER
3.11 FLOW RECORDER CONTROLLER
3.12 SKIMMED OIL RECOVERY
3.13 RECEIPT OF CRUDE OIL IN GRE TANKS THROUGH SMPL
FROM VADINAR SHORE TERMINAL
3.14 BOMBAY HIGH CRUDE
3.15 SIDE MIXTURE OPERATION (CRUDE)
3.16 ROTARY JET MIXTURE
3.17 SIDE MIXER FOR LSHS & HSD OLD TANKS
3.18 EDUCTOR/SKONI MIXER IN HSD, LDO, FO TANKS OF
GREP
CHAPTER 4 STORAGE TANKS

4.1 TYPES OF TANKS
4.2 CONE ROOF TANKS
4.3 TANK PAD
4.4 STEAM COILS & INSULATED TANKS
4.5 HAMMERING
4.6 INLET, OUTLET, MIXER NOZZLES
5
4.7 STAIRCASE
4.8 DIP HATCH
4.9 REFERENCE POINT
4.10 DATUM PLATE
4.11 REFERENCE HEIGHT
4.12 FLAME ARRESTOR
4.13 PV VALVE (BREATHER VALVE)
4.14 AUTO LEVEL INDICATOR
4.15 TANK LEVEL AUTOMATION
4.16 TEMP-FLOW INDICATION
4.17 FOAM CHAMBERS
4.18 WATER DRAW
4.19 WATER DRAW IN ATF TANKS
4.20 EARTHING
4.21 LIGHTNING ARRESTOR
4.22 DYKE & FIRE WALL
4.23 OPEN SURFACE DRAINS
4.24 TANK MIXERS
4.25 SIDE ENTRY MIXERS
4.26 JET MIXER
4.27 ROTARY JET MIXER (TK-704, 703)
4.28 FLOATING ROOF TANKS
4.29 TYPES OF FLOATING ROOFS
4.30 PONTOON TYPE
4.31 WATER DRAW
4.32 FOAM CHAMBERS
4.33 TANK COOLING ARRANGEMENT
4.34 ROOF DRAIN
4.35 EMERGENCY ROOF DRAIN
4.36 ROOF SEAL
4.37 ROOF SHOES
4.38 ROOF SHOE VENT
4.39 FLOAT WELL
4.40 AUTO BLEEDER VENT
4.41 GAUGE PIPE
4.42 SKY LIGHT
4.43 ROOF LEGS
4.44 BREATHERS
4.45 INNER LADDER
4.46 CRITICAL ZONE
4.47 ACCESSORIES
4.48 COMMISSIONING OF TANK
6
4.49 SPECIAL INSTRUCTIONS
4.50 EXPLOSIVETER
4.51 WATER IN TANKAGE
4.52 DRAINING OF WATER FROM FEED TANKS
4.53 BASIC SEDIMENTS AND WATER (BS&W)
4.54 CHANGING OF FEED TANKS
4.55 WATER IN ATF TANKS
4.56 TANK FARM AUTOMATION
4.57 LIST OF STORAGE TANKS IN OM&S
CHAPTER 5 Pumps, Valves, Blinds

5.1 CENTRIFUGAL PUMP
5.2 STARTING A CENTRIFUGAL PUMP
5.3 ROUTINE CHECKING OF CENTRIFUGAL PUMP
5.4 CENTRIFUGAL PUMP TROUBLE CHECK LIST
5.5 ROTARY PUMPS
5.6 RECIPROCATING PUMP
5.7 PUMP HANDING OVER PROCEDURE
5.8 PUMP TAKING OVER/ COMMISSIONING PROCEDURE
5.9 PUMP DETAILS IN RECEIPT
5.10 VA L V E S
5.11 GATE VALVES
5.12 GLOBE VALVES
5.13 EEDBLE AND BUTTERFLY VALVES
5.14 CHECK VALVES OR NON-RETURN VALVES (NRV)
5.15 PLUG VALVES
5.16 MSQ CONTRO VALVES
5.17 FEW IMPORTANT POINTS ON OPERATING VALVES
5.18 HAMMER BLINDS
5.19 FEW IMPORTANT POINTS ON OPERATING OF HAMER

BLINDS
5.20 PRESSURE RELIEVING DEVICES
CHAPTER 6 RECEIPT, BLENDING & SUPPLY

6.1 RECEIPT AND BLENDING
6.2 Receipt
6.3 Piping Network of different products
6.4 Production of two grade of LSHS during GHP shut down
6.5 BLENDING
CHAPTER7 DESPATCH OF PRODUCTS

7.1 DESPATCHES BY PIPELINE
7.2 DESPATCHES BY TANK WAGON
7.3 DESPATCHES BY ROAD
7
CHAPTER 8 Measurement of Petroleum Products
1.0 DIP TAPE
1.1 METHODS OF DIPPING
2.0 PRECAUTIONS
3.0 CUP AND CASE THERMOMETERS
4.0 SAMPLING
5.0 SAFETY PRECAUTIONS
6.0 LABLELLING OF SAMPLES
7.0 AUTO TANK GAUGING
CHAPTER 9 Quality control

9.1 Product specifications
9.2 CRITICAL TESTS AND THEIR SIGNIFICANCE
CHAPTER 10 Chemical, Aditives & MSDS

10.1 ORANGE DYE
10.2 MFA
10.3 MDA ( METAL DE ACTIVATOR)
10.4 CAUSTIC SODA
10.5 ETHYL MERCAPTAN
10.6 MATERIAL SFETY DATA SHEET (MSDS) of METHANOL
10.7 LIME
CHAPTER-11 CLOSED CIRCUIT TV (CCTV)

11.1 CAMERA LOCATION (Dispatch, LPG, TTL)
11.2 CAMERA LOCATION (RECEIPT, TANK FARM)
11.3 MONITOR LOCATION
11.4 KEY-BOARD LOCATION
CHAPTER-12 SAFETY & EMERGENCY HANDLING IN OM&S

12.0 DEFINITIONS
12.1 AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS
OF SOME OF THE PETROLEUM PRODUCTS & THEIR
CLASS
12.2 FIRE PROTECTION FACILITIES ON STORAGE TANKS
12.3 LPG MOUNDED BULLETS
12.4 FOAM FLOODING SYSTEM FOR TANK WAGON
RAILWAY GANTRY
12.5 ACTION TO BE TAKEN ON NOTICING FIRE
12.6 EMERGENCY HANDING IN OM&S
CHAPTER-13 APPENDIX
13.1 CHECK LIST FOR FIXED ROOF TANK AFTER MA
13.2 CHECK LIST FOR FLOATING ROOF TANK AFTER MAINT.
8
13.3 CHECK LIST FOR FIXED CUM FLOATING ROOF TANK
AFTER MAINT
13.4 CHECKLIST FORMAT FOR HANDING OVER OF PUMPS
TO MAINTENANCE
13.5 CHECKLIST FORMAT FOR TAKING OVER OF PUMPS
FROM MAINTENANCE
13.6 ACTION TO BE TAKEN ON NOTICING FIRE
13.8 WATER AUTO DRAIN FACILITY
CHAPTER-14 SOP’s
14.1 TANK CLEANING PROCEDURE
14.2 DO’s AND DON’T’s OF TANK M&I
14.3 AUTO SAMPLER INSTALLATION AND REMOVAL
PROCEDURE
14.4 CRUDE RECEIPT AND FEEDING PROCEDURE
14.5 STARTING A CENTRIFUGAL PUMP
14.6 CHANGE OVER OF PUMP FOR FEEDING TO UNITS
14.7 LINE UP OF FINISHED PRODUCT TANK FOR RECEIVING
OF INTERMEDIATE STREAMS
14.8 LINE UP OF FINISHED PRODUCT TANK FOR
CIRCULATION
14.9 TANK TO TANK TRANSFER
14.10 LINE UP OF FINISHED PRODUCT TANK FOR PIPE LINE
TRANSFER
14.11 CHANGE OVER OF FINISHED PRODUCT TANK FOR
DISPATCH (R/R)
CHAPTER-15 List Of TSV’s
9
MANUAL REVISION DETAILS
REV DATE DOC Prepared Checked by Approved

by
by
UPDATED, ISSUED SL NIRANTAR RS PATEL

1 June’05 AK KAPADIA
FOR RECORDS
(MSQ FACILITIES),
BS Pachahara AK Srivastava
2 June’07 KOYALI DAHEJ THANIGAIVELU.M
PIPELINE
RUP related piping in MM Parmar AK Srivastava
3 Feb’10 BS Pachahara
part
RUP
MM Parmar RS PATEL
4 MAR 11 SLOP,ISOMARATE BS Pachahara
TK
SOP / SAFETY
RELATED MM Parmar N U PATEL
5 OCT’13 PANKAJ PATIL
INSTRUCITONS /
Auto drian valves
PANKAJ PATIL AK BISWAS
6 OCT`15 UPDATED SK Verma
SATYAWARTI
S.SRIDHAR
7 Mar`17 UPDATED SK Verma
KUMAR
SATYAWARTI
S.SRIDHAR
8 Feb`18 UPDATED SK Verma
KUMAR
10
DISTRIBUTION LIST
Sr. No. ISSUED TO CONTROLED COPY NO.

1 DGM PN 1
2 CPNM 1
3 PNM 1
4 RECEIPT 3
11
O M & S MANUAL
Chapter – I
Introduction
GUJARAT REFINERY
12
CHAPTER – 1
1.0 INTRODUCTION
Gujarat Refinery of Indian Oil Corporation Limited has a capacity to refine 12.75
million Mts. per annum of Crude Oil. Four types of Crude Oil viz. Bombay high,
Pursian Gulf, North Gujarat & South Gujarat are processed.
The Oil Movement & Storage (OM&S) is a part of Production Department which
is headed by Chief Production Manager. OM&S is supported by Senior
Production Manager.
The offsite facilities play an important role in maintaining the smooth and
continuous operation of the refinery. OM&S is mainly responsible for activities
in offsite area.
The Objectives and functions of OM&S are as follows: -
1.1 OBJECTIVES
01. To receive crude oil and uninterrupted supply to processing units after
proper accounting and tank operations, in environment friendly manner,
keeping internal customer’s satisfaction.
02. To receive intermediates and finished product streams ex units to
prepare quality product in a safe & environment friendly manner.
03. Timely supplying the quality products to Marketing as per planning and
schedule to meet the market demand.
04. To meet the statutory requirements of Central Excise & Customs w.r.t.
Crude & Petroleum Products storage and movement.
05. To maintain safe and pollution free environment. To strive for internal
and external customer satisfaction.
06. To conserve energy by controlling losses.
07. To ensure safety of personnel & equipments by adopting safe practices.
08. To continuously upgrade and assess the knowledge and skills of
operating personnel.
1.2 FUNCTIONS
1. Receipt, storage, accounting, sampling of crude oil.
13
2. Crude & LABFS tank preparation and uninterrupted feeding to processing
units.
3. Receipt, storage, accounting of finished products and intermediates ex.

Units and blending of intermediates and blending of MS at blending station
to make HIGH QUALITY as EIV MS finished products with minimum quality
give away and to delight customer and to protect environment..
4. Supply of intermediates (feed) to processing units.
5. Preparation of finished products tanks for dispatch. Sampling for Quality

Certificate and accounting.
6. Product dispatch by pipeline, T/W & TTL.
7. Excise & Customs formalities and co-ordination with central excise & custom
officials for carrying out day to day operations.
8. Unloading the rail wagons declared either sick by railway or contaminated

by Marketing.
9. Unloading of Truck of different chemicals. e.g Benzene.

10. Slop recovery and reprocessing to units.
11. Preparation of Tank for cleaning, inspection, repair & maintenance.
12. Co-ordination with Technical Services & Marketing for planning and supply
of finished products.
13. Co-ordination with Railway and Marketing for availability and placement of
rail wagons as per planning schedule.
14. Co-ordination with service departments (Maintenance /inspection/ Technical

services) for maintaining good house keeping and health of equipment,
gantry area, and facilities, safe and in healthy condition for operation.
The Oil Movement & Storage Division consists of various sections like
a) Receipt and Blending

b) Tank Wagon Handling
c) Tank Truck Loading
d) LPG
e) Bitumen
14
Gujarat Refinery has following units: -
PRIMARY UNITS
a) Atmospheric Distillation Unit-I (AU-I)

b) Atmospheric Distillation Unit-II (AU-II)
c) Atmospheric Distillation Unit-III (AU-III)
d) Atmospheric Distillation Unit-IV(AU-IV)
e) Atmospheric Distillation Unit-V (AU-V)
SECONDARY UNITS
Catalytic Reforming Unit (CRU)

Udex
Merox
Visbreaker Unit (VBU)
Vacuum Distillation Unit (VDU)
Bitumen Blowing Unit
Feed Preparation Unit-I
Fluid Catalytic Cracking Unit
Food Grade Hexane Plant
MTBE
DHDS
LAB PLANT
MSQ
Plant commissioned uder RUP.
DHDT
ISOM
VGO-HDT
SRU-III
DCU
LPG MEROX
ATF MEROX
15
The intermediate products are as follows:
a) Light Charge Stock - 700 C - 900 C cut

b) Heavy Charge Stock - 900 C - 1200 C cut
c) Reformate for motor sprit blend
d) Feed stock for Udex
e) Raffinate ex Udex to motor spirit blend or in the Naphtha pool
f) C5-70 naphtha cut. For blending station
g) 90-140 naphtha cut for blending station
h) Light Gas Oil (LGO)
i) Heavy Gas Oil (HGO)
j) Reduced Crude Oil (RCO)
k) Light Vacuum Gas Oil (LVGO)
l) Heavy Vacuum Gas Oil (HVGO)
m) Vacuum Residue (VR)
n) Visbreaker Gasoline
o) Visbreaker Gas Oil
p) Visbreaker Tar
q) VB Naphtha
r) ISOMARATE
s) REORMATE
Various feeds to units for which offsite are required to receive, prepare and
supply are as follows:
Crude Oil to AU-I, AU-II, AU-III , AU-IV and AU-V
The different types of crude oils received and processed are as follows:
South Gujarat crude

North Gujarat crude
Bombay High crude
Low sulfur crude
High sulfur crude
The modes of dispatches of finished products are as follows
a) BY ROAD :-
In Tank Truck Lorries, specially designed containers for bulk LPG, packed LPG
and Bitumen in trucks.
a) BY RAIL :-
In Tank Wagon, packed LPG and Bitumen in Railway wagons.
16
c) BY PIPELINES: -
To Sabarmati IOC installation near Ahmadabad, to GSFC, to IPCL, to HPCL and

BPCL installation at Nandesari, BPCL (OMC), and to GIPCL. The last four are
next door to Gujarat Refinery. LSBFS to NIRMA, HSD/MS to IOTL (Dumad) HSD,
MS, SK to KNPL, KVSSPL and KDPL & KRPL.
Waste Water from process area, Oily water and Oil spillages from loading areas,
pump slabs and tank farms is brought through different collection pipe net-
work to the GR/GRE effluent sump where oil is removed by Roto pump and is
pumped to slop tanks 201 to 202. These slop tanks are under OM&S. The
responsibilities of OM&S include receipt, preparation and feed of slops for
reprocessing to GRE slop tanks.
Scheme has been prepared for directly feeding this slop to crude units via GRE
unit slop transfer pumps.
SLOP 6" 6"

TANK-201
WET SLOP
TANKS AT OM&S
10" DRY LIGHT 6" 6"

10"-P-2115-7301-A9A SLOP TANK- SLOP 6"
1516 SLOP SLOP
COMBINED LIGHT (UNDR RUP) TANK-202 PUMP-1 PUMP-2
SLOP STREAMS(RUP) 4" 4"
TO AU-3
10" TO ISOMERATE TANKS 10" 10"
4" 4"
4" 4"
PUMP SUCTION
751-11A 751-11B
18"
NG CRUDE TO AU-3
PUMP SUCTION 4" NOTE:
(AT GRE CRUDE AREA) 1) THIS PROCESS SCHEME ENVISAGES SLOP REDUCTION BY
4" REPROCESSING SLOP EX TANKS- 201 & 202 (AT OM&S) IN VBU, AU-3 &
DCU UNITS.
PUMP SUCTION
TO VBU
2) ACTUAL PIPING ROUTING TO BE DECIDED AS PER SITE CONDITION.
4" 3) PROPER APPROACH PLATFORM NEEDS TO BE PROVIDED FOR THE

SLOP EX TKS-735/736 TO GRE OPERATION OF PROPOSED VALVES
TO PUMP SUCTION OF VBU SLOP WET SLOP
REPROCESSING PUMP-07A TKS-735/736 4) REDUNDANT 4" PIPINGS AVAILABLE ( APPRX 50 MTRS) FOR
REDUNDANT 4' LINE PROPOSED MODIFICATIONS FOR ROUTING SLOP TO AU-3/VBU UNITS.
4.0
3.0
2.0 VALVES/NRV 4" 06 NOS /1 NO
1.0 CS PIPING 4" 650 MTRS
S.NO DESCRIPTION SIZE QTY
APPROXIMATE BILL OF MATERIAL
OPERATING CONDITIONS : LEGEND

OPERATING
TEMPERATURE : 45.0 DEG C EXISTING
PRESSURE: 4.0 KG/CM2G
SERVICE : WET SLOP PROPOSED
LEGEND
SLOP REDUCTION BY REPROCESSING
SLOP EX TANKS- 201 & 202 IN VBU, AU-3 &
DCU UNITS.
EXISTING FACILITY
INITITAOR CHECKD BY: APP BY SIZE FSCM NO SCHEME NO. REV
PROPOSED FACILITY GUJARAT REFINERY
TS/PS/OM&S/09/18 0
A.K.AGARWAL DATE:22/10/09 ISSUED FOR COMMENTS SCALE 1:1 SHEET 1 OF 1
DMPS PSM
17
Accounting relating to receipt and processing of crude oil, production of various
intermediate and finished products, dispatches, billing, payment of excise duty
are maintained by oil accounting section of Finance Department.
They also maintain upto-date records, pertaining to above activities, as required

by other agencies like Central Excise. All the accounting in this section as done
on the basis of relevant data supplied by OM&S. Hence, the primary
responsibility in this regard rests with OM&S Division.
Customs duty has to be paid on imported crude Oil. All finished petroleum
products are excisable and as such formalities as stipulated by the Central
Excise Department shall have to be completed prior to effecting movement of
oil and dispatches of any finished products.
18
O M & S MANUAL
GUJARAT REFINERY
Chapter-2
SUB SECTION OF
RECEIPT
19
Chapter-2
The receipt section is controlled by one shift in charge who is stationed at OM&S
Building. The area of receipt is very large and hence there are pump houses in
field in which operators seat. The different sections under receipt are:
GR- crude control room

GRE- crude control room
GR- Product control room
GRE- Product control room
BOD sump
Melting pit
2.1 GR- crude control room

GR crude control room in manned by 4 operators per shift. The operators look
after South Gujarat crude receiving and pumping to units, HSD tanks 906,
907,909, 910, Ntaptha tanks 905 & 908 and slop tanks 201& 202. The details
of different tanks and pumps cming under GR- crude are given herewith.
When the feed tank reaches a dip of 4 meters, the bleeding (slow starting of a
new full tank into feeding system) should be started from the next feed tank.
Great care must be taken and a close check to be maintained on the bleeding
tank to ensure that it is not gravitating to the main feed tank and that the rate
of bleeding is maintained at 20 % to 25 % of the total feed after an initial slow
bleeding which is increased gradually. In the initial stage of bleeding, ensure
that the oil is moving out from the tank. This is to ensure that the flow to
Booster pump is not interrupted when feed tank is switched over. Before
starting bleeding from a tank, keep concerned unit informed and if any sludge
or water is noticed by units, stop bleeding and check the tank for water conent.
2.2 GRE- crude control room

GRE crude control room in manned by 4 operators per shift. The operators look
after Nouth Gujarat crude and imported crude receiving and pumping to units.
The details of different tanks and pumps coming under GR- crude are given
herewith.
20
or water is noticed by units, stop bleeding and check the tank for water content.
2.3 GR- product control room

GR product control room in manned by 4+4=8 operators per shift. The
operators look after product stream coming under this area such as MS, HSD,
FO, LSHS, BH Naptha tanks 203 & 204. Receiving of streams from units and
preparation of tanks for sampling and dispatch of product for pipeline or tank
wagon is done by these operators. These operators also lookafter FO & Bunker
FO tanks 301, 302,303 & 304, which are near TTL. The details of different tanks
and pumps cming under GR- crude are given herewith.
2.4 GRE- product control room

GRE product control room in manned by 4 operators per shift. The operators
look after product stream coming under this area such as MS, HSD, Naptha,
LSHS, LSHF, LDO, FO, PCK. Receiving of streams from units and preparation of
tanks for sampling and dispatch of product for pipeline or tank wagon is done
by these operators. The details of different tanks and pumps coming under GR-
product are given herewith.
2.5 BOD sump or GR/GRE Sump

BOD sump is managed by one operator per shift. OWS from different area of
tank farm come to BOD sump. The purpose of this sump is to pump water to
CETP and oil to slop oil tanks 201 and 202. There are 7 pumps for transfer of
water to CETP and two Rota (Scew) pump to transfer oil to slop tank. The
details of different pumps coming under GR-GRE sump are given herewith.
There is a sump provided to gather the slop a provision of level indication is

done in order to monitor the sump level.
It is understood that the oil layer rests on the upper side while the water portion
in the lower side. Hence in order to pump out the oil from the oil layer, a hose
pipe with elevator provided to suck the oil from the sump. The height of the
hose pipe can be adjusted as desired. Two roto pumps [P-128A&] are provided
21
in order to pump out oil via the hosepipe, which becomes the suction of the
roto pumps. suction hose pipe.
The oil can be pumped to two following places:
1. Slop tanks 201 and 202 directly.

2. GRE slop tanks 735 and 736.
The water portion can be pumped to CETP via water removing pumps
PM-101A, B, C, D, E, F. At CETP, oil is recovered from this effluent.
SCHEME FOR PROVISION OF FACILITY FOR CARRYING OUT MAINTENANCE OF

DISCHARGE VALVES AT GR/GRE SUMP SUCESSFULLY COMMISSIONED IN JUNE’14 .
BACKGROUND:
There are 07 numbers of effluent pumps each of capacity 400 m3/hr at BOD for pumping
effluent to CETP. Currently, discharges of all effluent pumps at BOD go to a common header
of size 30” which finally goes to CETP.
CURRENT PROBLEM:
Currently, the seat of two numbers of valves at pump discharge is dislodged. Also, no
provision exists to isolate these discharge valves for carrying out maintenance jobs.
All the effluent pumps have to be stopped, discharge header needs to be isolated and drained
for attending the valves which is practically not possible as level in the sump rises very fast.
One pump has to run continuously to maintain BOD sump level.
PROPOSED FACILITY:
In view of the above, it is proposed to provide a facility for carrying out the maintenance of
valves at pump discharge without affecting the normal operation at BOD.
In the rainy season, all seven numbers of effluent pumps needs to be run simultaneously for
maintaining sump level. If two numbers of pumps remain out of service due to problem in the
discharge valve seat, sump level cannot be maintained which may lead to spillage of oil in
open channel which is undesirable. Hence the discharge valves also need to be changed at
the earliest.
1. About 200 m piping of 12” with 12” gate valve (2 nos) from the discharge header of pumps
P-101 A & B.
2. Piping to be routed through the sump wall.
3. Piping of 10” to be provided for open draining with the provision of valve.
Accordingly, Process scheme no HSE/2014/03 is being issued for comments from all
concerned departments. Form I furnished by PN-OM&S is also attached herewith.
Scheme reproduced below:
22
Melting pit
There is one melting pit near slop tank 201 & 202 on road no 6. This is
operated in general shift.
Melting pits are provided with steam coils, pump for water and pump for sludge.
The sludge is heated here, water is separated and pumped out to OWS while
oily part is pumped to tank 201 and 202. The sand and mud gets settled at the
bottom of the melting pit which is removed by manual labor whenever required.
23
O M & S MANUAL
CHAPTER – 3
Crude Oil Handling
GUJARAT REFINERY
24
CHAPTER - 3
CRUDE OIL HANDLING
3.1 GENERAL
Gujarat Refinery receives crude oil through three different pipelines, from
different sources, directly into the crude oil tanks in the refinery.
a) A 98-km long pipeline brings South Gujarat Crude oil from fields in
Ankleshwar, Gandhar, Nada etc. which is situated south of Gujarat
Refinery.
b) A 135-km long pipeline brings North Gujarat crude oil from oil fields in
the Cambay, Mehasana, Kalol, Navagam etc. region which is situated
North of Gujarat Refinery.
c) A 416-km long Salaya-Viramgam-Koyali pipeline brings crude oil

unloaded from oil tankers at Salaya -
The section between Salaya and Viramgam of pipeline is 275 km having 28”
pipe dia and section between Viramgam and Koyali pipeline is 141 km having
18” pipe dia.
Crude oil from Bombay High and crude oil imported from various sources comes
through this pipeline in batches per the planning for procession.
3.2 RECEIPTS:
a) The opening dip before the receipt of crude will be taken jointly by the
representatives of crude oil pipeline and refinery. Refinery will be
represented by an operator normally the rank of grade “B” level. The dip
details will include gross dip, water cut and the temperature.
At the time of dipping, one average sample of crude is drawn for density before
receipt of fresh crude.
Dip memos will be prepared and signed by both the representatives. A copy
each of dip memos will be handed over to the representatives of ONGC/SMPL/
Custom.
b) Since all the crude oil tanks are floating roof tanks, it must be ensured
at all times that the roof is not in a semi-float condition when taking the
dip for receipt.
25
c) Between the opening and closing dips, the tank will remain isolated. i.e.
transfer of oil will not take place to/from the tank, no draining operation
to be done and steam to heater coil will remain cut off.
d) Normally, the closing dip should be taken 24 hrs after the receipt is over.
The dip (gross dip, water cut, and temperature) will be taken jointly as
in case of opening dip.
e) Dip memo will be prepared for the closing dip and signed by all the
representatives, as stated above. After this, the tank remains with
operations for any operation like water draining, steaming, transfer and
feeding that may be required.
f) Along with the closing dips, the temperature will be taken from middle
level and reported in the dip memos.
g) No opening or closing dip should be taken when rainwater is standing

on the floating roof. Get rid of all rainwater from the floating roof before
taking the dip. If this care is not taken, it will lead to serious oil
accounting problems, which involves payment for crude.
h) While lining up the tanks for receipt or for feed to the unit, please ensure
that the valves on the tanks as well as on manifolds are full open as per
the requirement of operations.
I) Flying switches (fast change over) are required to be carried out while
changing the receipt tank. These operations may involve opening and
closing of valves on the tanks itself or on manifolds. Extreme care should
be taken not to shut against the source of pumping. In case of SMPL,
before flying switch over, ensure from SMPL that MOV of empty tank on
manifold is open.
3.3 AUTO SAMPLER:

N/G and ANK crude oil lines are provided with auto samplers. When the crude
is under pumping, the sample gets collected in the container provided with auto
sampler. These are used for determining the BS&W. From the total quantity of
crude received the percentage of BS&W is subtracted, the resultant quantity is
called “dry crude”. The payment is made for the dry crude supplied. Sample
from SMPL is collected manually by
SMPL personnel.
The Auto sampler is designed to collect samples, from the line and sampling
time is set in such a way that about 5 liter line sample is collected during receipt
26
in each tank. These samples should be duly labeled with following information:
date, starting time, tank no., type of crude, and sent to lab. for Testing density
and BS&W.
When Auto sample is out of order, or under maintenance or by-passed, samples

of NG crude should be taken from KNK terminal of ONGC every two hours.
3.4 NG AUTO SAMPLER:

Auto sampling system is located on a loop line of NG Crude receiving line. It
comprises of the following features.
1. Turbine meter
2. Automatic sample grabber
3. Sample collection unit
4. Jet mixing pumps (two nos.)
5. Digital display panel located in GR Crude Control Room
Depending upon the incoming NG Crude flow rate which is sensed by the
turbine meter and signal sent to the grabber which automatically adjusts the
flow of sample to the sampling cane.
The jet mixing pumps draws a slipstream from the loop line and injects it back
at the location upstream of grabber to make the sample homogeneous.
For each NG Crude tank receipt, separate cane is used. The filled sample can
is then sent to laboratory for density and BS&W content.
Description & functioning of SG auto sampler is same only the difference is it is

installed in process unit feed line.
3.5 PREPARATION OF TANK FOR

FEED:
After the closing dip, drain off all the possible water, if any.
3.6 B L E E D I NG:
27
or water is noticed by units, stop bleeding and check the tank for water.
3.7 CRUDE BOOSTER PUMPS:

Originally the supply of crude from storage tanks to the distillation units was by
gravity feed. This caused limitation in increasing the throughput. So crude
booster pumps were added which pump the crude to units at a pressure of
about 3 Kg/cm².
For Crude booster pumps presently in operation alongwith their service and
capacity. Please refer pump summery sheet 1.6 chapter IV.
PRESSURE DROP AT BOOSER
Crude Oil Booster pumps are provided with strainers. The fall in pressure on
pump is indication of choking of these strainers. They should be cleaned at
regular intervals. Should a booster fail and if a standby is not available, open
the bypass immediately. So that the feed tank if lined up directly to the
processing unit. Simultaneously, inform the processing unit of the change in
line up.
3.8 CRUDE FEED FAILURE

What happens when crude feed supply to the unit is interrupted?
1) It causes rapid drop in K-1 bottom level.

2) Furnace feed pumps will lose suction and there will be no flow to
the furnace.
3) Coke formation in the furnace tubes may take place.
4) Off-spec products are sloped.
What action crude control section should take?
1. Restore the supply with least possible delay.

a. By starting the standby booster if readily available of
b. Put the feed tank directly on line to unit by- passing the
booster.
2. Check the line up if the switch over of tanks has just taken
place.
3. Get the strainer of Booster cleaned.
28
4. Get Motor/pump attended if it is electrical/mechanical failure of
the booster.
3.9 FRC IN CRUDE CONTROL

ROOM:
It is necessary to have steady and smooth supply of measured quantity of crude
oil to the processing units. This ensures the steady and smooth operation of
processing units, which in turn can give better quality of production at optimum
level. The steady and smooth supply of crude oil to the processing units is
controlled at the crude control room. The rate of supply of crude oil is measured
in metric tons per hour.
To achieve this two instruments are installed in the crude control room, They’re:
a) Flow Recorder (FR) and

b) Flow Recorder Controller (FRC)
3.10 FLOW RECORDER:

It is based on Bernoulli principle that at any point of time an incompressible
flowing fluid, the total energy will remain unchanged.
Here, deliberately a restriction is introduced by installing one orifice plate on

the line where flow is to be recorded. Because of the restriction, the velocity of
fluid increases. Now as the energy is balanced by a decrease in the static
pressure of the fluid. Pressure at upstream and downstream of the orifice plate
is measured. The differential pressure is proportional to flow. This flow is
recorded on the square roof chart in the control room. Care must be taken to
see that correct type of the chart is provided in the recorder.
3.11 FLOW RECORDER

CONTROLLER
A control valve is mounted on the down stream of flow recorder, which
controls the fluid flow as per the requirement. There are two types of
controls
a). Manual
b). Auto Control
29
Pneumatically based instruments are replaced by microprocessor based
electronic instruments. Primary instruments remain same.
EXAMPLE
One distillation unit is processing 4000 MT/D of mixed crude consisting

of 3000 MT/D of Ankleshwar and 1000 MT/D of North Gujarat Crude.
The processing unit on its FRC control will control the total quantity of 4000
MT/D.
In the crude control room, 3000 MT/D of Ankleshwar crude will be on FR

and 1000 MT/D or North Gujarat crude will be controlled on FRC.
Now, take two cases where an increase of 200 MT/D in the feed is required.
a) AN INCREASE OF 200 MT/D IN ANKLESHWAR CRUDE :-
Receiving unit will increase its in take from 4000 MT/D to 4200 MT/D by making
necessary adjustment on units FRC. This will result in an increase of 200 MT/D
in Ankleshwar crude. Since Ankleshwar crude is on FR in Crude control room,
no adjustment is required at this end. Flow recorder of Ankleshwar crude in
control room of crude will show rise of 200 MT/D.
b) AN INCREASE OF 200 MT/D IN NORTH GUJARAT CRUDE :-
Necessary adjustment on FRC in crude control room to increase North Gujarat

crude from 1000 MT/D to 1200 MT/D will be done. Simultaneously, receiving
processing unit will make necessary adjustments to raise intake from 4000
MT/D to 4200 MT/D.
3.12 SKIMMED OIL RECOVERY:

We have three types of effluent/oil/water drainage system:
1. Open channel/ surface drain/ storm water drain
2. OWS
3. CRW (Contaminated rainy water )
3.12.1 OPEN CHANNEL:
All the water either from the surface of tank farm, rainy water, service water,
and drinking water drained goes to open channel.
3.12.2 OWS:
30
OWS is a closed drain system meant for transportation of oily water from
different sections of OM&S by gravity to the GR-GRE sump.
The different sections are:
✓ Crude & product tank siphon drains

✓ T/w flushing oil
✓ T/w draining material
✓ T/t flushing oil
✓ T/t draining oil
✓ Pump casing drain material
✓ Pump suction vent line material
All the oily water goes to GR-GRE sump through under ground piping network.
3.13 RECEIPT OF CRUDE OIL IN

GRE TANKS THROUGH SMPL
FROM VADINAR SHORE
TERMINAL
Imported duty on imported crude is paid at GR, as and when imported crude is
withdrawn from the bonded crude tanks, for processing on day to day basis.
Separate PLA for imported crude is maintained. P&C plans imported crude
processing and on their advice finance dept. is maintaining balance in PLA.
The crude is received by tanker at Vadinar. Hence imported crude receipt is

accountable, to Excise and there is a physical control of Excise on operations.
At interface of Bombay-high-imported crude is received in the imported crude

tanks, the quantity of B/H crude received as interface in imported crude is
separately worked out quarterly in the joint reconciliation meeting and same
quantity is processed with NIL rate of duty with proper documentation.
The representatives of SMPL/OM&S do the dipping and sampling of tanks jointly

before and after the receipt of crude oil in each tank. The dip memos will carry
the signatures of the above representatives.
After (before receipt) dip and lining up (for receipt), the tank will be handed
over to SMPL representatives who will ensure that the tanks are not taken much
in advance. After the receipt in the tank is over, a settling time of 36 hours will
be given. This settling time can be reduced, if the refinery operations require,
by mutual consent of the parties concerned.
31
The MOV on crude oil manifold will be operated by SMPL while OM&S personnel
will operate the valves on tank and inside tank farm
If the SMPL personnel desire they can seal the following valves:
a) Inlet valves of other tanks falling on the same system.

b) Water draws valves and main outlet valve on the receiving
tank.
Double block valves will ensure isolation. It is the joint responsibility of SMPL
& OM&S to ensure -
a) Timely switch over of rundown tanks,

b) The receiving tank does not overflow,
c) There is no shut-off against pumping from Vadinar.
OM&S will take two hourly dips when the tank is under receipt.
SMPL will keep OM&S informed of the time pumping commence, the time when
pumping is over and of interruptions in pumping, if any.
SMPL will keep track of interface when two different crude viz. Bombay High
and imported are in the line and ensure that the interface is not fed into
undesired tank.
After receipt dip and TMB samples are taken after 36 hours settling time and
thereafter SMPL Thereafter hands the tank over back to OM&S, preparation of
tank for feeding to unit should be started.
3.14 BOMBAY HIGH CRUDE:

The length of the parcel of Bombay High crude should be as big as possible
taking into consideration the limitation at the refinery in order to minimize the
number of interfaces. Because of high pour point of Bombay High Crude, it is
not advisable to keep this crude static in the line for long periods. The interface
of Bombay High, imported crude will be received in the imported crude tanks.
3.15 SIDE MIXER OPERATIONS

(CRUDE)
The new tanks having side mixers under the control and operation of Production
operators. It is run as and when required. After crude receiving is over in a
particular tank settling time of 36 Hrs. is required.
32
Water draining operation is carried out and then dipping of tank with C. Excise
& customs and SMPL representative is being done, mixer is started after
ensuring the gland leak and lube oil level.
After draining out the settled water, the mixers run for 8 hrs. Again it is run
when bleeding operation starts, this continues upto 3 mtrs. level of the tank.
Tk-701, 702, 703, 704, 771, 772, 781, 782, 783, 901 to 904 and 911 are having
2 mixers in each tank, whereas Tk-770 is having 3 mixers.
3.16 ROTARY JET MIXER :

Rotary jet mixers are operated after taking the following measures.
i) Roof of the tank should never be fixed at lower leg height. This is
to avoid any damage to the centrally mounted mixer assembly as
well as to the roof, therefore the roof should always be fixed at
upper leg height.
ii) In coordination with SMPL start the mixer at 600 cms. of oil level
with the help of necessary block valve operation.
iii) Mixer should be isolated when receiving is over.
3.17 SIDE MIXER FOR LSHS &

HSD OLD TANKS:
Side mixers are provided in all LSHS/FO tanks and HSDLDO tanks for making
the product homogeneous. After checking the gland leak and lube oil level, the
operator starts it at 3 meter level during receiving of tank and stops before
sampling for quality certificate.
3.18 EDUCTOR/SKONI MIXER IN

HSD, LDO, FO TANKS OF
GREP
Operation of SKONI mixer is simple, pumps for mixer circulation is run during
receiving of tank and stopped before sampling of tank.
33
34
O M & S MANUAL
CHAPTER – 4
Storage Tanks
GUJARAT REFINERY
CHAPTER -4
STORAGE TANK
35
All petroleum stocks from crude oil to its lightest volatile fraction must be stored
during the intervals between production, transportation, refining, blending and
Marketing. Hence, for this purpose, different types of tanks and vessels to suit
the characteristics of the product to be stored are provided.
4.1 TYPES OF TANKS:

The storage tanks are mainly of three types.
1. Cone roof or fixed roof tanks for storing heavy products.
2. Floating Roof tanks for lighter products.
3. Floating cum fixed roof tanks.
Less volatile petroleum stocks are stored in Floating Roof tanks, highly volatile
liquids like LPG, 80 MT are stored in pressure vessels like spherical ( horton
sphere) or cylindrical (also known as bullets) Mounded Bullets.
4.2 CONE ROOF TANK:

This is a vertical cylindrical vessel made of welded steel plates. The fixed roof
is supported on internal structure. The shell at the bottom is thick while at the
top it is thin.
4.3 TANK PAD:

The tank is erected on a specially prepared hardened pad. It is called tank pad.
4.4 STEAM COILS & INSULATED

TANKS:
If the liquid is to be stored at a higher temperature, than the ambient
temperature, the shell of the tank is covered with insulation to prevent loss of
heat and/or is provided with steam (heating) coils inside the tank, which are
placed 500 mm approximate above the tank floor. The number of coils provided
will depend on the size of the tank and the amount of heating required. Each
coil has an independent inlet of steam with a valve to control. The valve is
placed outside the tank close to the shell. Each coil has an independent outlet
36
for the flow of condensate. The outlets are fitted with steam coils inside the
tank.
4.5 HAMMERING:
If for any reason the condensate in the steam coil is not moving freely, the loud
banging report will indicate this. It can be heard from a distance. The
phenomenon is called “Hammering”. The remedy is to take immediate steps to
drain out and establish flow of condensate. Till this is done, the steam inlet can
be closed temporarily. In order to protect the coils against damage due to
hammering and to take care of expansion due to variation in temperature, the
supports on which coil is resting are not welded to the tank floor.
4.6 INLET, OUTLET, MIXER

NOZZLES:
Each tank may have two or three nozzles in the shell. They are normally placed
at about (300 to 600 mm) above the tank floor. This distance may vary from
tank to tank depending upon its design. One nozzle is inlet for receiving oil, one
nozzle is outlet for taking out oil from the tank. Since the outlet invariably leads
to a pump, it is also commonly known as suction line. The third nozzle will be
found in those tanks where provision is made for mixing the contents to a
uniform density.
The tank is provided with a drain point also known as water draw through which
water from the tank is drained. This water draw opens in a pit or in a funnel
which is connected to an underground network known as oily sewer system
which eventually leads to effluent or waste water treatment plant of the
refinery. Thus any oil that may come out along with water is drained from the
tank is not all wasted and can be recovered.
4.7 STAIRCASE:
There is a ladder to go on the roof of the tank. The ladder may be an
independent structure or welded to tank shell itself. Where the height of the
tank is more, two inter- landing platforms are provided. A platform is also
provided at the landing, where the ladder ends at the top.
4.8 DIP HATCH:
37
Near this platform dip hatch is situated. This hatch is used for dipping, sampling
and taking temperature. Other than this operation dip hatch cover should be
closed to reduce vapor loss from tank.
Normally, at the mouth of the perforated pipe of dip hatch, a ring of non-ferrous
metal is fixed. This is to avoid the generation of static electricity that may be
produced when the steel tape of dip tape slides over the edge of the pipe. The
pipe should be perforated so that material inside this pipe is representative of
the bulk of the material inside the tank.
4.9 REFERENCE POINT:

A guide made of non-ferrous metal with a sloping notch wide enough to
accommodate the tape of dip tape is fitted. This guide or a marking on the rim
of the above said ring indicated as the reference point.
4.10 DATUM PLATE:

Exactly below and corresponding to the dip hatch a steel plate is provided on
the floor of the tank. It is called datum plate. When a dip is taken, it is here on
this plate the bob of the dip tape rests. This is the reason why dip tapes are
provided with a brass bob. Should bob come down heavily and strike the datum
plate with force no spark can be produced. Datum Plate may be circular or
square in shape, It is considered as zero reading of the tank level for
measurement purpose. The liquid below the datum plate is dead stock and is
mentioned in calibration chart.
4.11 REFERENCE HEIGHT:

Reference height is the distance between the marking on the rim of the pipe
(nozzle) of dip hatch and the datum plate.
4.12 FLAME ARRESTOR:

There is an opening in the center of the roof on which flame arrestor is fitted.
This is to arrest any flash back of spark or flame.
4.13 PV (BREATHER)VALVE:
Fitted on the roof is a pressure cum vacuum relief valve. It has a dual function.
When the liquid is coming into the tank, the air, gases from inside tank are
38
expelled out through this and no pressure is allowed to be built inside. Similarly,
when the liquid is going out from the tank, the air is allowed to enter through
this valve into the tank thus not allowing the creation of vacuum. If for any
reason a vacuum is created inside the tank, the shell of the tank will buckle.
This happens due to condition created wherein the pressure inside tank
becomes less than the atmospheric pressure outside, which pushes the shell
plate inside, and the tank collapses.
If the PV Valve does not function, the chances are that the pressure inside may
not get regulated and the build up pressure which will be more than the
atmospheric pressure outside, cause a blow up. In such a case to minimize the
damage to shell the joints where roof is welded to shell are kept comparatively
weak so that it is the roof where the blow up occurs.
It is therefore of utmost importance that PV valves are regularly checked and

periodically serviced as per schedules to ensure their smooth functioning all the
time.
4.15 TANK LEVEL AUTOMATION:

Servo gauge and Radar gauges are the two auto tank gauging systems
commonly used. Servo gauge is located at tank top. A small Displacer is
accurately positioned in the liquid medium using stainless steel wire and a
servomotor. At operator’s command, the Displacer is lowered and as it touches
the liquid, the weight of the Displacer is reduced because of the buoyant force
of liquid. As a result the torque in the magnetic coupling changes. This change
is measured. The signals, an indication of the position of the Displacer is finally
converted to digital values of oil level and displayed on computer screen.
Radar level gauge is mounted on tank roof. An antenna inside the gauge
projects a microwave beam into the tank towards the surface of the oil in the
tank. The microwave beam travels down towards the surface of oil which
reflects it back to the antenna unit on top of the tank upon re-entering the
gauge unit, it is sensed by the antenna and level measured. The signals are
converted to digital values of oil level and displayed on computer screen.
4.16 TEMP-FLOW INDICATION:

Multi Thermocouple Temperature (M.T.T) measurement probe will indicate the
average temperature as well as temperature profile of the tank. The M.T.T.
consists of twelve thermo couple elements for measuring temp. Flow, density
and water-cut measurements are also incorporated and shown on computer
screen.
39
4.17 FOAM CHAMBERS:
This is a fire fighting equipment fitted on the tanks. Their number varies
according to the size of the tank. These are fitted on the opening in the tank
shell nearer the roof and connected to a pipe which runs along the shell and
leads away from the tank. In some cases, this pipe comes right upto the nearest
road. In new tanks, these pipes coming from the same tank are hooked up in
a single manifold situated on the roadside. The end of the individual pipe or
manifold is fitted with 2.2/12” dia, quick fit male coupling. The foam chamber
is fitted with a diaphragm inside it. It is a coated thick paper, which can rupture
under pressure. It prevents the gases from inside tank from coming out.
Periodic checks should be carried out to ensure that the diaphragm is intact. If
it is damaged, the escaping gases will constitute fire hazard and add to losses
of petroleum products. For additional safely, each pipe end is capped at
roadside.
In the event of fire, the fire hoses are connected to said device and foam is
pumped into the tank. Thus, a foam blanket is produced over the liquid surface
cutting off the oxygen and thus the fire gets extinguished. After the use of foam
chamber, the diaphragm must be replaced with a new one.
This facility is incorporated in all class-A product tanks and in `B’ class product
having tank dia 30m for Floating Roof tank & 20m for fixed roof tank.
4.18 WATER DRAW:

1. In Russian design the conical saucer shaped tank floor with a depression
ending in pit in the center. Since the slope is towards center, all the
water flows towards impression in the center and gets collected in the
pit. The water pipe, which enters the tank shell through a gland, extends
right upto the central pit. The clearance between the inverted open end
of pipe and the floor of pit is about 300mm. When the water draw valve
is opened outside tank, the pressure of the column of liquid inside the
tank on the water collected in the pit force it into the pipe and it rushes
out. The pipe inside tank rests on supports and can be rotated from
outside.
2. In other designs, the bottom of the tank (tank floor) is convex i.e. like
an inverted saucer shape. Here, the water in the tank gets collected
towards the periphery. Hence, the water draw pipe in such tanks is short
(about 750 mm) and is turned towards the floor forming an angle of 450
with tank floor. The clearance between open end of pipe and tank floor
is 150 to 200 mm. This water draw is also called as siphon drain.
In some tanks with convex tank floor, a hole of 80 mm or 100 mm dia

is made in the tank floor near the shell and a pipe is welded to it from
the bottom of the tank and drawn out. This water draw is called as
40
Bottom drain. This type of provision of bottom drains is not desirable
and leads to spillage of products in case pipe gets corroded. Hence,
these drain lines from the tank are being blanked off whenever tank is
handed over to repairs/ internal inspection.
4.19 WATER DRAW IN ATF

TANKS:
Such arrangement is of immense help in ATF tanks where no water however
small is tolerable. That is the reason why a medium sized ATF tank is supposed
to have 4 water draws while other tanks of comparable size has only one water
draw. Stagnant water at the bottom (no matter how small in qty.) in ATF tank
gives rise to a kind algae which multiples fast and forms colonies. Organic
chemical produced by colonies reacts with ATF and renders it off specification.
ATF fails the test of silver strip.
In tanks with concave flooring there may be more than one water draw, if the
size of the tank is big.
When ATF tank is required to be released to mandatory cleaning every year,

the water draw is connected to a suction line of Transfer Pump specially
installed for ATF. One of the siphon drains is connected with a 4” hosepipe to
the suction pipe of the pump. Water is received in the ATF tank and oil and
water is pumped out by means of the pump to SK tank No. 92.91. sko run
down line.
When an empty tank is to be commissioned, the risk of generation of static

electricity is very high and this may cause explosion. Since the nozzle of inlet
line is situated at a height, the liquid will fall on dry steel plate (tank flooring)
generating tremendous amount of static electrical charges. If the liquid is
introduced in an empty dry tank from the lowest point, at a slow rate till the
inlet nozzle is fully covered, this risk can be eliminated.
4.20 EARTHING
The tanks are grounded through Earthing strips welded to the shell of the tank.
In all tanks Earthing network have been reviewed & whenever required new
Earthing system installed.
41
Whenever hydrocarbons move in steel pipe static electrical charges are
generated. The quantum of charges produced will depend on the velocity of
the moving hydrocarbon and its purity. For example, Kerosene or ATF
containing water moving at considerable velocity will produce much more
electric charges than the dry kerosene or ATF.
4.21 LIGHTNING ARRESTOR:

These are provided on the top of the tank itself. They are welded to the tank
shell. The other method is to provide a common lightning arrestor to group of
tanks. (normally 4 in number). Now as per CCE all the lightning arrestors from
tank are to be removed. Job of lightning arrestor removal is in progress.
4.22 DYKE & FIRE WALL:

Situated at calculated distance on all the sides of a tank farm are called Dyke,
made of earth/concrete. The height of the dyke is maximum 2.0 Mts. and the
area enclosed by them should have a capacity to hold the contents of the
biggest tank. There are small dykes of 0.6 Mts. height between two tanks inside
the main dyke. These are called firewalls.
4.23 OPEN SURFACE DRAINS:

On one side in the tank farm of each tank, an open channel is provided. The
grading of the tank farm is such that the rainwater or water from other sources
that may come in the tank farm should flow into the open channel. In old tanks,
the channel is connected the underground oily sewer (industrial) drain inside
the tank farm only. In recently constructed tanks, a pit with two outlets is
provided inside the tank farm. Whatever comes through the open channel, it
has to pass through this pit which has a strainer to hold back solid material and
a sand trap. If the contents of the water flowing through channel is free from
oil, it can be routed to main open surface drain outside the tank-farm. If it
contains oil then it can be routed to underground (industrial) oily sewer.
Before every monsoon, it should be checked that the gradient of tank farm is
all right, the strainer, sand trap, the pit and the open channel is clean. Never
route oil free rainwater to industrial sewer as it will unnecessarily increase the
load on waste water treatment plant which has a calculated capacity and caters
to the entire refinery.
4.24 TANK MIXERS:
42
The three different types of mixing arrangements provided in different tanks in
Gujarat Refinery are as follows:
Whenever a product is to be prepared by blending i.e. by mixing two or more

components that may vary in densities, the components are required to be
mixed up thoroughly to make a single homogenous mass of uniform density.
For this purpose, the required tanks are provided with mixing arrangements.
4.25 SIDE ENTRY MIXERS:

Although a crude oil storage tank contains only one type of crude at a time
even then it requires mixing. This helps in the disposal of sludge forming
constituents in the crude oil and reaches processing unit in tolerable limits.
Thus, the settling and accumulation of sludge and sediment on tank floor is
considerably minimized and the tank may not require cleaning at short intervals.
It consists of a long shaft at the end of which three curved blades are fitted.
The other end is brought out of the tank through a gland in the reinforced part
of the shell. This end of shaft is connected either directly to a motor drive
or through a gearbox. The motor drives this fan like structure inside the tank.
If the rotation is in correct direction, it throws the heavy liquid, which has a
tendency to settle on tank bottom, toward the top, thus setting in motion a
circular movement in the vertical plane. In this way, the mixing takes place and
the contents become homogeneous.
This mixer is not to be operated when the level of liquid in the tank is below 3
meters.
Crude oil, FO, LSHS & HSD storage tanks are provided with such mixers in
Gujarat Refinery. Such mixers can be used in any other product also.
4.26 JET MIXER:

Heavier portion of oil has tendency to settle down. Thus, heavier liquid is drawn
through tank outlet by a pump of adequate capacity and discharge pressure
and is returned to the tank through a comparatively smaller dia line, which
enters the tank through a separate nozzle. About one meter from the shell
inside the tank the line turns about 45º tapering into a narrow open mouth of
an ID of about 50mm. This nozzle is usually pointing towards the center of the
tank roof. Thus, the heavier portion drawn from bottom is thrown with force
towards the top the liquid column. The heavier portion thus mixes with tank
contents while going up as well as when it tries to come down. A circulation is
set in motion, which results in through mixing. The time required to make a
given mass of oil homogeneous will depend on its density and quantity. For
example, a full tank of MS of 5000 M³ capacity will require circulation for six
hours. This type of mixers can be fitted on both the type of tanks i.e. cone roof
43
as well as Floating Roof. Jet mixers should not be operated if the liquid level in
the tank is below 3 meter, otherwise, there will not be sufficient bulk of oil to
offer adequate resistance to the jet and the jet of oil may go through layer of
oil and hit the roof causing damage. Also generation of static electricity charges
due to free fall of oil may damage the tanks. MS, GR Naphtha, GOP Naphtha,
HSD (GRE) and Bitumen tanks are provided with such mixer in Gujarat Refinery.
4.27 ROTARY JET MIXER (TK-

704, 703)
To prevent localized sludge deposition inside crude tank, this mixer is most
useful. The mixer can be mounted at the center of the tank or on shell. The
inlet pipeline is connected to the jet mixer. As the incoming inlet crude passes
through the mixer, the outlet nozzle rotates distributing the crude and sludge
evenly all over the tank. The mixer is to be isolated when receiving as is over.
4.28 FLOATING ROOF TANKS:

These are vertical cylindrical welded steel tanks with open tops equipped with
Floating Roof which cover and ride up and down, on the liquid stored in the
tank. The Floating Roof reduces evaporation loss.
In Floating Roof tanks also, the following accessories will be found and these
are discussed in detail in the preceding pages.
- Tank pad
- Tank insulation
- Steam coils
- Inlet, outlet and Mixer nozzles
- Staircase
- Reference height
- Earthing
- Lightening arrestor
- Dykes
- Open surface drains
- Swing arm
- Tank mixers
- Side mixer
- Jet mixer
44
4.29 TYPES OF FLOATING
ROOFS:
There are three types of Floating Roofs:
1. Pan Type
2. Pontoon Type
3. Double deck type
Here, only one type (pontoon type) is discussed in details.
4.30 PONTOON TYPE:

The roof has an annular pontoon around the outer edge of the roof and a deck
of single thickness at the center. The top of the pontoon is sloped downwards
to the center of the tank. In addition to buoyancy the pontoons provide air-
space insulation from the sun’s heat, thus reducing evaporation losses. The
pontoon is divided into several compartments with redial bulkheads, which
allow the roof to remain afloat even if the center deck or any of the
compartments develop leakage. Each compartment is provided with a manhole
or inspection hatch. In some cases, the cover is bolted while in others, loose
covers are provided.
4.31 WATER DRAW:

Floating Roof tanks have convex shaped tank floor. Hence, the water draws are
either of siphon drain type or direct gravity type. Both these types are discussed
in detail in preceding pages.
4.32 FOAM CHAMBERS:

As a part of fire fighting equipment, foam chambers are provided. Here, the
foam from foam deflectors falls on the roof seal and spreads along the
periphery. Baffles are provided on the roof to contain the foam in the zone of
roof seal. These baffles are also known as foam dam or foam rate.
4.33 TANK COOLING

ARRANGEMENT:
A circular ring of pipe is provided towards the top of the shell. Spray nozzles
are fitted into this ring, which is connected, with pipes to supply water through
fire water system. The valve(s) are situated outside dyke of the tank. By simply
45
opening these valves, the entire system can be put in operation. In case of
fixed roof tanks at GREP area, deluge system is provided where water spray is
on Center of top of the roof.
4.34 ROOF DRAIN:

The pan slopes towards center where a pit is provided. The pit is covered with
a perforated loose cover. It thus acts as a strainer. The pit opens through a
check valve (NRV) into a short pipe, which in older design is connected to hose
the other end of which is connected to a nozzle in the shell at the bottom. A
valve is provided outside on this outlet. The length of the hose is sufficiently
long to take care of the movement of the roof. Thus, the rainwater from the
roof passes straight outside the tank. One disadvantage in this system is that
the life of hose is short and need replacement for which the tank has to be
decommissioned and gas freed. If the damaged hose is not replaced, the water
from the roof will fall into the tank and mix with the oil. Oil will start coming
out from outlet whenever the valve is opened.
In later designs, the hose is replaced by assembly of steel pipes. This assembly
folds like a jack-knife when roof comes down and unfolds when the roof goes
up. This assembly is therefore also called as jack-knife drain. There are 4 swivel
joints should the system develop leak the check valve prevents oil coming on
the roof, but it will start coming out from the outlet outside tank. It is, therefore,
for this reason that the roof drain valves should be kept close except when
raining.
4.35 EMERGENCY ROOF DRAIN:

These are provided in the new design. A short length of about 50 mm dia pipe
passes through the pan. The height of this pipe above the pan is less than the
height of pontoon boxes. The other end of the pipe terminates in a hanging
tray, which is always kept filled with water to form a water seal. If this seal is
broken or the tray runs dry of water, the oil from inside the tank will come on
the roof when the roof is moving.
The portion of the pipe on the roof is provided with a cover fitted with metallic
knot, which acts as a strainer. Should the regular roof drain fail for any reason
or due to heavy rain or cloud burst the regular drain is not able to cope with
the load, the water starts going through these emergency roof drains and falls
into the tank thus not allowing water to enter pontoon boxes and the roof is
saved from sinking.
4.36 ROOF SEAL:
46
The gap between the roof and the shell is closed by providing a loop of rubber
or neoprene sheet.
Enclosed in the loop is foam rubber.
4.37 ROOF SHOES:

The metallic cover over roof seal made of nonferrous metal is called roof shoe.
It is kept in position by cantilever arrangement which can be seen from inside
the tank.
4.38 ROOF SHOE VENT:

Rim vents are provided for venting the dead space between the stores liquid
and shell seal.
4.39 FLOAT WELL:

To accommodate the float of auto level indicator, a well is provided through
one of the pontoon compartments. The well is covered with a loose cover and
through the center of which the tape of auto level indicator passes. A ring of
non-ferrous metal is fitted into this hole.
4.40 AUTO BLEEDER VENT:

Automatic bleeder vents open before the roof reaches its lowest position and
close when the roof rises above this point.
When the roof loses contact with the liquid, a space is created between roof
and surface of liquid, which is filled with vapour and air mixer. To vent it out
automatic bleeder vents are provided in the later designs.
On a hole in the pan, a short pipe is welded above the roof. Through this pipe
slides smaller dia long pipe of calculated length. This pipe closed at both ends
with welded plates. The plate on top rests on the open end of outer pipe when
the roof is floating. When the roof starts landing on its legs, the inner pipe rests
on the floor below thus opening the upper end of the fixed outer pipe. The
gases pass through this opening via the gap between two pipes. The height of
the cover fitted on sliding pipe can be adjusted at two positions corresponding
to the two different positions of the roof legs.
4.41 GAUGE PIPE:
47
It is a pipe normally of 150 mm dia running through the roof from near the
gauging platform upto the bottom of the tank. It is secured at both the ends.
Inside it stops short of reaching tank floor by about 600 mm. Both the ends of
pipe are open. Situated below this pipe on the tank floor is datum plate. The
top end is fitted with gauge hatch. Sampling and gauging is done through this
pipe. This pipe has two vertical rows of perforated holes to break the rise of
liquid in pipe due to capillary action; otherwise the surface of liquid in the pipe
and in the tank will not be in the same level and erroneous liquid level of the
tanks will be recorded. To accommodate gauge pipe. A well is provided in one
of the pontoon compartments The cover of this well is fixed and fitted with two
moveable brass rollers. During the movement of roof these rollers are in contact
with steel pipe and thus no sparks are produced.
Gauge pipe also serves as antirational anti-rotational device. There are two
more such pipes fitted in bigger dia tank, which serve as anti-rotational device.
They prevent the rotational movement of the roof.
4.42 SKY LIGHT:

The roofs of tanks (both the fixed roof and floating) are provided with manhole
size openings. These have bolted covers.
4.43 ROOF LEGS:

Arranged in circles on the roof are roof legs on which the roof rests when not
floating on the liquid. A roof leg consists of a moveable pipe with two different
positions for adjusting the height. It passes through the roof and a sleeve
welded on the roof. After the roof floats, the legs are pulled up on the roof and
fixed in low position. So that the portion inside the tank is minimum (about
1/3rd of the total length of the leg). So that roof can be taken down to
the maximum possible lower dip, thus keeping the hold up of contents inside
the tank to the minimum possible. When a tank is to be taken out of service
with the intent of entering inside, the legs are lowered into the tank, when the
roof is still floating, and fixed in higher position. So that when roof rests on
legs, there is enough room inside tank for men to walk freely.
4.44 BREATHERS:
Provided on the Floating Roof are three to four 50mm dia about 500 mm long
open-end pipes. Where the liquid stores has high vapour pressure the escaping
vapour is likely to bring liquid on the roof. To correct this situation, goosenecks
are fitted on the vents/breathers.
4.45 INNER LADDER:

48
The outer/spiral ladder terminates at the top on a landing platform, which also
serves as gauging and sampling platform. From this platform, leads an inner
ladder to the Floating Roof. The other end of this ladder rests on two wheels,
which move on the rails. Near the heels a small landing platform is provided to
which one or two steps may be connected if the platform is placed at an
inconvenient height. With the movement of the roof, the inner adder moves on
hinges at one end and on wheels at the other end. The ladder is grounded
through flexible earthing wire to the shell at the top and to the roof at the other
end.
4.46 CRITICAL ZONE:

The zone where liquid starts touching the roof and till it is completely floating
is called critical or inaccurate zone. Any dip taken when the roof is in this zone
will give misleading quantities.
Once the Floating Roof is put in operation, it should not be landed unless and
until the tank is required to be taken out of service for cleaning or repair. Every
time a Floating Roof is landed or lifted the risk of damage to the roof is involved.
Hence, it is forbidden to land a Floating Roof during day to day operations.
4.47 ACCESSORIES:
Each vessel is normally provided with at least one of each of the following
fittings all of which is suitable for use with the LPG at pressure not less than
the design pressure and for temperature appropriate to the characteristics of
the LPG and working conditions:
a) Manhole
b) Pressure relief valve connected directly to the vapour space
c) Drain
d) Means of determining the liquid level (Local indicator as well as
remote display)
e) Pressure gauge connected to the vapour space.
f) Means of measuring terature of contents of the storage
Vessel
g) Sampling points.
h) Water draining facility.
4.48 COMMISSIONING OF TANK:

When a new tank is ready after the completion of mechanical job, it is filled
with water up to safe filling height and kept standing for a week. This allows
the settlement of floor and even distribution of pressure on the shell. Necessary
49
strapping of the shell are taken for leaks. In case of Floating Roof tanks, the
lifting of roof is observed for smooth lift off. Like wise when water is drained
from the tank, the landing of the roof is observed for smooth operation. The
tank is opened again for cleaning and final inspection. While the tank is
absolutely free from water and open, water is introduced through meter, till the
highest point in tank floor is just covered. The height of datum plate
corresponds to this point on the floor and the quantity of water thus introduced
is recorded in the calibration chart. This is called the zero hold up or hold up
below the datum plate. This means when the dip reading on the dip tape is
zero, the stock in the tank is not nil. That is why on the calibration chart of the
tank, some quantity is shown against zero reading.
After the tank has been cleaned and dried, it is boxed up. All the blinds from
various Inlet and outlet nozzles are removed. The tank is now ready to receive
oil. If the oil is introduced at high velocity in an empty tank, it will rapidly
produce and explosive mixture of air and vapour (hydrocarbon) which may
surpass the safety limit. Hydrocarbons falling heavily from height on dry steel
plates of tank floor can generate enormous amount of static electric charges at
a rate much faster than the rate of dissipation and ultimately result in a flash
and that is how an explosion can take place.
To safeguard against this, liquid (hydrocarbon) should be introduced from the

lowest entry point into the tank, preferably through water draw at a very slow
rate till the inlet nozzle is fully covered. Thereafter the rate of receipt can be
increased. Receive by gravitation as far as possible, till the level in the tank
reaches 1.8 meters. This will cover all the nozzles/manholes fitted in tank shell.
Check for leaks. Now the tank can receive from pump or directly from
processing units.
In case of Floating Roof tanks, control the rate of intake till the roof is fully
afloat. While the roof is lifting an experienced operation man will standby on
the gauging platform to watch the uniform and smooth lift off of the roof. At
the slightest sign of a twist or uneven lifting of the roof, the inflow of liquid
must be stopped /diverted to other tank.
4.49 SPECIAL INSTRUCTIONS:

1. Water draw-off on tanks should never be left running unattended.
2. Floating Roof of the tanks must be checked after each rain for
accumulation of water and if any, steps must be taken to drain
out completely.
3. Emergency roof drains where provided should be checked

regularly for water. They require topping up with water at short
intervals in order to ensure that water seal is not broken otherwise
the oil will start coming out on the roof.
50
4. Inspect the inner side of the dip-hatch cover and Automatic
bleeder vent cover for rubber/neoprene gasket. Missing,
damaged gaskets should be replaced immediately.
5. Gauge and sample hatches should be kept closed except when in

use.
6. Roof vents (Breathers, relief valve, fire arrestor) should be

observed regularly for evolution of vapours. Excess vapours
indicate that the tank is receiving a liquid that is too light or too
hot. This can spell disaster. Completely non-evolution of vapour
is also a danger signal.
7. Internal mixing nozzles should not be used for any other purpose
except for mixing and that too above the specified level of liquid
in the tank. Filling the tank through mixing nozzle entry will
generate static electrical charges.
8. At the slightest indication of steam coil developing leak, cut off

the steam as it will build up a pressure much beyond the point of
tolerance and the tank will explode.
9. Tank fitted with steam coils should never be pumped low enough
to expose the heating coils while the steam is on.
10. Never leave dyke valves where provided, open and unattended.
11. Never walk on the roof of a tank containing high Sulphur

products.
4.50 EXPLOSIMETER:
The explosive meter is an instrument by means of which environmental air may
be quickly and conveniently tested for concentration of flammable gases and
vapours, which it may contain.
PRINCIPLE OF OPERATION
Tests are made with explosive meter by drawing a sample of the environmental
air to be tested over a heated catalytic filament, which forms part of a balanced
electrical circuit.
Atmospheric combustibles in the sample are burnt on the filament, which raises
its temperature and increases its resistance in proportion to the heat developed
by combustion of the combustible gases. The resulting imbalance the electrical
51
circuit causes a deflection of the meter pointer, which indicates on the scale,
the concentration of the combustible gases. This scale is graduated in percent
of the lower explosive limit.
HOW TO USE THE EXPLOSIMETER
The explosive meter normally used in our Refinery is an M-S-A explosive meter,
Model 2A. The operating instructions for this type of instrument are as follows:
a) To make the instrument “ON” lift the bar on Rheostat knob named
“ON” - “OFF.
b) Turn this knob one quarter of a turn clockwise. This operation

closes the battery circuit. Because of unequal heating, there will
be an initial deflection of the pointer. The meter pointer may
move rapidly upscale and then return to a point below zero or
drop directly below zero.
c) Flush air through explosive meter by the aspirator to remove all

combustible gases initially.
d) Adjust Rheostat knob until meter pointer resets at zero.
Clockwise rotation of the Rheostat knob causes the meter pointer to

move upscale. A clockwise rotation sufficient to move the meter pointer
considerably above zero should be avoided as this subjects the detector
filament to an excessive current and may shorten its life.
e) Connect the sample connection to the Explosive meter.
f) Re-adjust zero of the meter if required by turning rheostat knob.
g) Aspirate sample through the explosive meter until highest reading

is obtained.
PRECAUTIONS:
a) If the pointer remains below zero, and cannot be brought to zero

even by adjusting the Rheostat to its extreme clockwise position,
the cells are exhausted and must be replaced.
b) If the pointer of the meter moves to the extreme right side of the
scale when the explosive meter is turned “ON” and cannot be
adjusted to zero, the detector filament is burnt out and must be
replaced.
52
The above precautions must be taken for handling the instrument.
4.51 WATER IN TANKAGE:

Types and sizes of storage tanks comprise much of the refinery investment,
however, contents are of even greater value. The primary function of these
tanks is to hold petroleum products before, between and after various refinery
operations. Since the tanks are essential to the operation of process equipment,
a look at how they may affect the water problem and how such problems can
be minimized or eliminated is in order.
4.52 DRAINING OF WATER FROM

FEED TANKS:
Water level in feed tanks must always be kept well below the suction line,
Checking for water frequently and draining it regularly are extremely important.
When water is drawn from Naphtha or gasoline tanks oil can easily be mistaken
for water unless some special means of detection is used. Wood tends to stand
on the surface. Therefore frequent testing of the stream with a stick or small
board prevents of the stream with a stick or small board prevents wasting oil.
The use of detection paste is another method for checking water drawn from
tanks. The paste changes colour in the presence of oil.
Water can enter tanks in many ways:
a) Through open hatches

b) Gauge board cable openings
c) Leaking steam heaters
d) Leaking roofs
e) By circulating oil through unit and back to feed tanks during
starts ups.
f) From process units due to -
1) Poor separation of water from hydrocarbon in reflux drum

2) Stripping steam water partially carried to
SK/ATD/HSD/NAPHTHA
53
4.53 BASIC SEDIMENTS AND WATER
(BS&W)
a) Fouling in heat exchangers causing increase in pressure drop and
poor heat transfer.
b) As the specific heat of water is higher than that of crude oil, the feed
temperature to the main column drops down causing increase in fuel
consumption.
c) Excess BS&W can even lead to emergency shutdown of the
processing unit
d) Accumulation of sludge in the storage tank.
A water and oil emulsion of water in small amounts from tank creates a steady
pressure rise through the unit. If this occurs, a sample of the incoming stock
should be taken and checked for water and BS&W. If either is excessive, the
pumping station should be notified immediately and the situation corrected.
Normally, feed should not be charged to unit if the BS&W content is greater
than 0.4 %. Feeds with amounts higher than 0.4% can be charged safely only
under carefully controlled conditions.
Some emulsions can be and are broken by special emulsion treating facilities
and the water may thus be eliminated. Other emulsions are difficult or
impossible to break. Such type of emulsions can be formed when viscosity of
oil is high and oil is having the gravity near to water (API gravity 10). When the
API gravity of the oil is higher than 10, this usually can be corrected by heating
the oil so that the water settles to the bottom. Tank mixers will also help
eliminate this problem.
4.54 CHANGING OF FEED TANKS:

Two of the critical points in the operation of a unit are the change-over from
one feed tank to another and the use of a new suction line up. Water may be
found in either the new stock or the new suction line-up. If feed lines, which
have been inactive, are to be included in the line-up, they should be flushed
out just prior to being put in service.
When changing feeds or when making a new suction line up, the person making
the change must notify the unit operator well before the change is made. The
operator must then be alert to any pressure and temperature irregularities or
any change in the colour of distillates. Of particular importance is the feed
pump. Here any increase above the normal discharge pressure may indicate
that water has reached the furnace. The feed rate can be decreased to help
overcome the pressure increase.
54
4.55 WATER IN ATF TANKS:
MICROBIOLOGICAL TESTS - METHODS & SIGNIFICANCE :
Microorganism is microscopic, unicellular organism found in nature in dormant

state. The most common microorganism encountered by hydrocarbon fuel is
fungus. Whenever water is present in fuel in traces, the dormant fungus gets
the ideal surrounding to grow at the interface of fuel and water. One of the
very common sources of bacterial contamination is storage over or contact with
seawater. The principal deteriorative effects of this microorganism are: -
a) Emulsion of fuel
b) Accumulation of large quantity of slime and other materials which

can clog filters and separators.
c) Increased corrosive nature of the stored fuel, which will result in

corrosion of storage and aircraft wing tanks.
Hence, we find it very important to check the quality of fuels or any presence
of fungal pores.
This is done in the laboratory by conducting a microbiological analysis of fuel
sample. After growing fungus in suitable funnel over a Millipore membrane of
0.45 micron porosity. By counting the number of colonies, one can judge the
suitability of fuel for Aviation use.
4.56 TANK FARM AUTOMATION: -

(Do’s and Don’ts)
• Displacer in auto gauge pipe to be lifted before any dipping, sampling of the
tank.
• Use auto gauging computer for round the o’clock monitoring of tank level/
temp. & Ullage.
• Do not rely on auto gauging system 100%, ensure actual physical dips,
particularly when tank is at higher level.
• Generate reports as and when required from DCS & ENRAF system.
• Do not switch off power of field.
• Do not temper with Displacer.
• Do not temper Instrument and its accessories.
• Except auto-gauging system, no other function of computer to be opened.
• No copy of tank gauging language system or external in put of language by
floppy is allowed.
• Do not take any kind of eatables in control room.
• Do not switch off control room power.
55
56
4.57 LIST OF STORAGE TANKS IN
OM&S :-
CAL FACT CRITI
Tan Tank
Prod RH SFH CAP CAL R/C Tank Ty
k MT/C Ht
uct cm cm KL KL/CM ZONE, cm Dia M pe
no. M cm
cm
85 ATF 1265.7 1050.0 5000 3.170 4.076 - - 22.8 1210 FIX
86 ATF 1265.6 1050.0 5000 3.170 4.076 - - 22.8 1210 FIX
90 ATF 1263.0 1050.0 5000 3.170 4.076 - - 22.8 1210 FIX
91 ATF 1268.7 1050.0 5000 3.250 4.076 - - 22.8 1210 FIX
92 ATF 1267.2 1050.0 5000 3.250 4.076 - - 22.8 1210 FIX

160.0- FCF
64 BENZ 776.0 630.0 400 0.500 0.570 184.0 11.5 8.5 760 R
160.0- FCF
65 BENZ 770.0 630.0 400 0.500 0.570 185.0 11.5 8.5 760 R
174.0- FCF
67 BENZ 913.0 650.0 1000 1.030 1.190 230.0 11.1 12.3 900 R
174.0- FCF
68 BENZ 915.0 650.0 1000 1.030 1.190 230.1 11.1 12.3 900 R
174.0- FCF
69 BENZ 919.0 650.0 1000 1.020 1.190 230.0 11.5 12.3 900 R
078.0- FCF
511 BENZ 1042.0 750.0 1000 1.030 1.190 095.0 6.5 12.3 900 R
078.0- FCF
512 BENZ 1042.0 750.0 1000 1.030 1.190 096.5 6.5 12.3 900 R
160.0-
203 BHnap 1440.0 950.0 5000 2.900 4.076 190.0 13.6 22.8 1210 FL
155.0-
204 BHnap 1432.0 950.0 5000 2.900 4.076 185.0 13.6 22.8 1210 FL
CRUD 084.0-
517 E 1192.0 827.0 10000 8.610 9.899 105.0 9.0 35.5 1020 FL
CRUD 080.0-
518 E 1199.7 827.0 10000 8.610 9.899 110.0 8.4 35.5 1020 FL
CRUD 114.5-
519 E 1526.8 1250.0 16000 10.920 12.550 138.1 6.6 40.0 1413 FL
CRUD 110.5-
520 E 1525.3 1250.0 16000 10.920 12.550 134.1 6.6 40.0 1413 FL
CRUD 164.5-
701 E 1556.1 1220.0 30000 20.140 24.650 230.0 8.0 56.0 1430 FL
CRUD 149.7-
702 E 1557.3 1220.0 30000 20.150 24.650 173.8 8.0 56.0 1430 FL
CRUD 149.7-
703 E 1552.0 1220.0 30000 20.140 24.650 173.8 8.0 56.0 1430 FL
CRUD 149.7-
704 E 1559.0 1220.0 30000 20.400 24.650 173.8 8.0 56.0 1430 FL
CRUD 132.0-
770 E 1438.0 1220.0 65000 41.900 49.000 180.0 35.5 79.0 1433 FL
57
CRUD 155.2-
771 E 1507.5 1220.0 30000 21.150 24.650 177.5 8.0 56.0 1430 FL
CRUD 155.2-
772 E 1526.5 1220.0 30000 21.150 24.650 177.5 8.0 56.0 1430 FL
CRUD 220.0-
781 E 1769.0 1250.0 20000 14.300 15.900 250.0 10.9 45.0 1600 FL
CRUD 150.0-
782 E 1700.5 1230.0 20000 14.300 15.900 186.0 8.0 45.0 1600 FL
CRUD 150.0-
783 E 1694.0 1230.0 20000 14.300 15.900 186.0 8.0 45.0 1600 FL
CRUD 131.5-
901 E 1548.1 1181.4 30000 20.900 24.600 141.9 10.4 56.0 1430 FL
CRUD 131.4-
902 E 1556.0 1181.0 30000 18.800 24.600 141.8 10.4 56.0 1430 FL
CRUD 131.6-
903 E 1554.2 1181.2 30000 20.900 24.600 142.0 10.4 56.0 1430 FL
CRUD 135-3-
904 E 1549.8 1185.4 30000 20.900 24.600 145.7 10.4 56.0 1430 FL
CRUD 180.0-
911 E 1667.5 1360.0 20000 13.960 15.900 218.5 9.7 45.0 1600 FL
154.0- FCF
516 FGH 1093.0 700.0 1000 0.900 1.190 200.0 12.5 12.3 905 R
95 FO 1265.5 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX
96 FO 1250.2 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX
219 FO 1236.7 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
220 FO 1236.4 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
302 BFO 1238.0 1050.0 3000 2.380 2.550 - - 18.0 1330 FIX
303 FO 1242.0 1050.0 1500 1.190 1.270 - - 12.7 1245 FIX
304 FO 1242.0 1050.0 1000 0.660 0.705 - - 12.7 1245 FIX
733 FO 1445.5 1370.0 16000 11.600 12.550 - - 40.0 1432 FIX

124.1-
557 HAB 910.0 650.0 1500 0.625 0.784 138.3 18.9 10.0 780 FL
124.1-
558 HAB 910.0 650.0 1500 0.625 0.784 138.3 18.9 10.0 780 FL
98 HMW 1268.4 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX

120.0-
723 HSD 1593.4 1250.0 16000 10.3 12.550 129.5 9.2 40.0 1440 FL
098.0-
724 HSD 78 1250.0 16000 10.3 12.550 107.0 8.2 40.0 1440 FL
120.0-
725 HSD 1593.0 1250.0 16000 10.3 12.550 129.2 8.6 40.0 1440 FL
100.0-
726 HSD 1592.2 1250.0 16000 10.3 12.550 160.0 8.6 40.0 1440 FL
107.0-
731 HSD 1576 250.0 16000 10.3 12.550 115.3 8.0 40.0 1440 FL
97.0-
732 HSD 1585 1250.0 16000 10.3 12.550 105.0 8.0 40.0 1440 FL
96.2-
906 HSD 1582.5 1235.0 25000 15.9 19.630 107.5 9.8 50.0 1440 FL
58
96.5-
907 HSD 1582 1235.0 25000 15.9 19.630 106.3 9.8 50.0 1440 FL
96.5-
909 HSD 1582.4 1230.0 25000 15.9 19.630 106.7 9.8 50.0 1440 FL
97.0-
910 HSD 1581 1230.0 25000 15.9 19.630 107.2 9.8 50.0 1440 FL
126.0- FCF
205 LABFS 1741.4 1330.0 12000 6.900 8.514 144.5 18.5 32.9 1650 R
125.0- FCF
206 LABFS 1741.6 1330.0 12000 6.900 8.514 143.5 18.5 32.9 1650 R
120-0- FCF
207 LABFS 1731.4 1330.0 12000 6.900 8.514 138.4 18.4 32.9 1650 R
125.0- FCF
208 LABFS 1729.9 1330.0 12000 6.900 8.514 143.4 18.4 32.9 1650 R
97 LDO 1233.8 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX
99 LMW 1264.4 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX
100 LDO 1268.4 1050.0 5000 3.45 4.076 - - 22.8 1210 FIX
727 LDO 1518.5 1430.0 7000 4.200 4.900 - - 25.0 1505 FIX
728 LDO 1507.0 1430.0 7000 4.200 4.900 - - 25.0 1505 FIX
729 LDO 1518.5 1430.0 7000 4.200 4.900 - - 25.0 1505 FIX
730 IFO 1521.0 1430.0 7000 4.200 4.900 - - 25.0 1505 FIX
FCF
87 LMW 1264.8 1050.0 5000 3.170 4.076 - - 22.8 1210 R
FCF
88 LMW 1267.3 1050.0 5000 3.170 4.076 - - 22.8 1210 R
FCF
89 LMW 1267.5 1050.0 5000 3.170 4.076 - - 22.8 1210 R
93 IFO 1264.9 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
94 HVFO 1261.1 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
101 HVFO 1235.8 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
102 HVFO 1252.0 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
103 HVFO 1239.1 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
218 HVFO 1237.8 1050.0 5000 3.800 4.076 - - 22.8 1210 FIX
301 FO 1235.5 1050.0 3000 2.380 2.550 - - 18.0 1330 FIX
734 LSHS 1446.5 1370.0 16000 11.600 12.550 - - 40.0 1432 FIX
777 LSHS 1802.5 1574.0 20000 11.700 12.550 - - 40.0 1790 FIX
HCU
LT 194.0-
63 NAP 1404.0 950.0 5000 2.900 4.076 221.0 15 22.8 1210 FL
109.0-
59 MS 1807.4 1487.0 12000 5.700 8.038 122.2 12.3 32.0 1654 FL
194.0-
60 MS 1432.0 950.0 5000 2.900 4.076 221.0 14.0 22.8 1210 FL
59
195.0-
61 MS 1444.0 950.0 5000 2.900 4.076 225.0 14.3 22.8 1210 FL
120.0-
76 MS 1818.0 1400.0 12000 5.700 8.038 148.0 12.4 32.0 1654 FL
120.0-
78 MS 1818.0 1400.0 12000 5.700 8.038 148.0 12.4 32.0 1654 FL
109.0-
82 MS 1807.4 1487.0 12000 5.700 8.038 122.2 12.3 32.0 1654 FL
109.0-
83 MS 1807.4 1487.0 12000 5.700 8.038 122.2 12.3 32.0 1654 FL
110.0-
84 MS 1806.0 1487.0 12000 5.700 8.038 123.2 12.3 32.0 1654 FL
115.0- FCF
1101 MTBE 1451.5 1180.0 2655 1.690 2.250 138.0 25.0 16.9 R
114.0- FCF
1102 MTBE 1458.1 1180.0 3000 1.690 2.250 137.0 25.0 16.9 R
190.0-
108 MTO 918.0 650.0 1000 0.900 1.190 220.0 13.5 12.3 904 FL
190.0-
109 MTO 916.0 650.0 1000 0.900 1.190 220.0 13.5 12.3 904 FL
194.0-
73 NAP 1440.0 950.0 5000 2.950 4.076 221.0 15 22.8 1210 FL
190.0-
74 NAP 1436.0 950.0 5000 2.950 4.076 216.0 14.8 22.8 1210 FL
194.0-
75 NAP 1439.5 950.0 5000 2.950 4.076 221.0 14.8 22.8 1210 FL
190.0-
77 NAP 1440.0 950.0 5000 2.950 4.076 225.0 15 22.8 1210 FL
Reform 147.5-
513 ate 1441.1 1050.0 3000 1.900 2.550 193.5 10.7 18.0 1245 FL
100.0-
711 NAP 1514.7 1150.0 10000 5.770 8.600 140.0 9.6 33.1 1380 FL
095.0-
712 NAP 1508.6 1150.0 10000 5.770 8.600 140.0 9.6 33.1 1380 FL
095.0-
713 NAP 1513.5 1150.0 10000 5.770 8.600 140.1 9.6 33.1 1380 FL
095.0-
714 NAP 1511.0 1150.0 10000 5.770 8.600 140.0 9.6 33.1 1380 FL
096.0-
905 NAP 1582.5 1236.0 25000 14.320 19.630 107.5 11.5 50.0 1440 FL
096.8-
908 NAP 1581.4 1230.0 25000 14.320 19.630 108.1 11.5 50.0 1440 FL
118.0- FCF
514 N-para 1299.1 930.0 3000 1.890 2.550 129.3 11.3 18.0 1250 L
HyREF 194.0-
62 OR 1415.5 950.0 5000 2.900 4.076 221.0 15 22.8 1210 FL
95.0-
715 SKO 1489.5 1200.0 12000 8.100 10.200 145.0 9.0 36.0 1385 FL
90.0- 1385
716 SKO 1486.2 1200.0 12000 8.100 10.200 145.0 9.0 36.0 FL
90.0- 1385
717 SKO 1484.5 1200.0 12000 8.100 10.200 145.0 9.0 36.0 FL
95.30- 1385
718 SKO 1489.2 1250.0 12000 8.100 10.200 145.0 9.0 36.0 FL
120.0-
738 PCK 1310.3 950.0 7000 5.600 7.056 140.0 9.6 30.0 1195 FL
120.0-
739 PCK 1310.3 950.0 7000 5.600 7.056 140.0 9.6 30.0 1195 FL
60
096.5-
914 LABRS 1485.7 1087.4 12000 8.520 10.730 106.3 11.8 37.0 1352 FL
155.0-
201 SLOP 1459.0 950.0 5000 3.170 4.076 185.0 13.6 22.8 1210 FL
155.0-
202 SLOP 1443.0 950.0 5000 3.170 4.076 185.0 13.6 22.8 1210 FL
162.0- FCF
66 TOL 770.0 630.0 400 0.490 0.570 186.0 11.5 8.5 760 R
160.0- FCF
70 TOL 772.8 630.0 400 0.490 0.570 185.0 11.5 8.5 760 R
160.0- FCF
71 TOL 772.5 630.0 400 0.490 0.570 185.1 11.5 8.5 760 R
163.0- FCF
72 TOL 772.5 630.0 400 0.490 0.570 187.0 12.5 8.5 760 R
101.0- DO
521 FGH 1180.4 790.0 3000 2.520 3.140 129.0 12.5 20.0 962 ME
101.0-
522 FGH 1186.4 790.0 3000 2.520 3.140 129.0 12.5 20.0 962 FL
LT.
1516 Slop 1117 715 2000 2.137 - - 16.5 960 FL
Hy.
1517 Slop 1004 811 2000 2.137 - - 16.5 960 FL
Isomer Do
1508 ate 1393 1080 1000 0.785 - - 10.0 1275 me
Isomer Do
1509 ate 1394 1079 1000 0.785 - - 10.0 1275 me
515 PGH 1091 700 1000 0.785 1.19 152-198 FL

DO
516 PGH 1093 700 1000 0.785 1.19 154-200 ME
61
O M & S MANUAL
CHAPTER – 5
Pumps, Valves,
Blinds
GUJARAT REFINERY
62
Chapter - 5
PUMPS, VALVES, BLINDS

5.0 PUMPS:
Pump is an equipment for transferring liquid from one place to another.
CLASSIFICATION OF PUMPS:
Pumps are generally classified in three types

a) Centrifugal
b) Rotary
c) Reciprocating
The last two are also called positive displacement pumps. Each class is again
sub-divided in a number of different types suitable for different purposes.
5.1 CENTRIFUGAL PUMP

The name of this type of pump comes from the force, which is exerted by body
moving in a circular path-centrifugal force. In the pump, the liquid is forced to
revolve and therefore exerts a centrifugal force on the liquid in the case around
the revolving wheel or impeller, which is equal to the discharge pressure or
head.
The theory of action of a centrifugal pump may be illustrated by the simile of

the boy and the bucket. The boy whirls the pail of water about his head and
not a drop is spilled provided the pail is moving fast enough. The force that
holds the water against the bottom of the pail is centrifugal force.
Now suppose a hole is punched in the bottom of the pail. A stream will flow
out. The stream would be continuous if the boy’s arm were a pipe supplying
water to the pail. The boy’s arm is a suction pipe, the pail is the impeller
throwing a stream and the casing of the pump has been introduced to guide
the stream in one particular direction to the discharge outlet.
With no pistons, valves or close clearances, a centrifugal pump is not positive

action. In other words, a particular impeller is good for so much pressure of
head and if the actual pressure or head is higher than this, the impeller will
merely churn the liquid.
The liquid forced out of the casing creates a partial vacuum permitting
atmospheric pressure to force more water into the pump suction and the
operation is continuous. This class is widely used in process industry.
63
TYPES OF CENTRIFUGAL PUMPS:
The various types of centrifugal pumps are as follows:
i. Volute
ii. Diffuser
iii. Vertical Turbine
iv. Mixed flow or Axial flow
Centrifugal pumps are available in a large range of capacity and pressure; from
1M³/hr to 700M³/hr and from 0.3kg/cm²to 200kg/cm². In this class, pumps
are available for handling liquid at temp upto 4500 C.
ADVANTAGES OF CENTRIFUGAL PUMPS:
Main advantages of the centrifugal pumps are as under:
i) Simplicity of operation
ii) Low initial cost
iii) Uniform non-pulsating flow
iv) Low maintenance expenses
v) Smooth operation
vi) Simple construction
vii) No close clearance
viii) No excess pressure even with discharge valve closed
ix) Impeller and shaft only moving parts
x) Quiet
DIFFERENT PARTS OF CENTRIFUGAL PUMPS:
STUFFING BOX:
When pressure at its inner end is below atmospheric, the stuffing box prevents
air leakage into the pump. When pressure at the inner end is above atmospheric
pressure the stuffing box prevents liquid leaking out of the pump.
MECHANICAL SEAL:
A Mechanical seal provides a leak proof design with low power losses for a wide
range of liquids.
BEARING LUBRICATION AND COOLING :
Ball bearings are generally grease lubricated, although in large size bearing oil
lubrication is frequently used. If the amount of heat generated in the bearings
is too much to be dissipated by air cooling, water-cooling becomes necessary.
PRIMING OF PUMPS:
64
Priming means removal of air, gas or vapour from the liquid ways of the pump
by filling them with liquid to be pumped.
When first put in service or after maintenance, the liquid ways of the pump are
filled with air. When the liquid is introduced under pressure, the air is trapped
in the pump. This air is vented out through a valve meant for this purpose.
WARMING UP OF HOT SERVICE PUMPS:
For any emergency the hot service pump should always be kept warm. Keeping
the valves on pump drain and bleeder lines in closed position, crack open the
delivery valve with suction wide open. Care should be taken to see that the
pump impeller does not rotate in the reverse direction.
5.2 STARTING A CENTRIFUGAL PUMP:

The following steps are followed in starting a pump:
a) Prime the pump and check for free rotation of the shaft.
b) Open the valve in bearing cooling water supply line, if any
c) Open the valve in stuffing box cooling water supply line, if
any.
d) Open the valve in sealing liquid supply line.
e) Open the suction valve/close the discharge in case it is kept
open for warming up.
f) Check the lubrication and grease points where provided. Ensure
that there is correct quantity of lube oil/grease. Lube oil/grease
should be clean and free from water and dirt.
f) Start the motor, and check for correct direction of rotation of

the motor
g) Open discharge valve slowly taking care to maintain required
discharge pressure.
h) Observe leakage from stuffing boxes and adjust gland position
where packing is provided in case of leakage.
j) Check mechanical operation of pump and motor. Check the
current drawn by the pump if ammeter is provided.
k) Check the bearing and gland temperatures.
65
5.3 ROUTINE CHECKING OF CENTRIFUGAL
PUMP:
a) Check all oil reservoirs for proper level and appearance of oil.
b) Check for temperature around bearing housing, stuffingbox

and motor (if motor driven)
c) Look for abnormal leakage at packing gland and/or

mechanical seal.
d) Check for abnormal vibration
e) Check pressure gauge for unusual pulsation
STOPPING A CENTRIFUGAL PUMP:
a) Close discharge valve slowly.
b) Stop motor
c) Close suction valve
d) Stop cooling water, seal oil etc.
e) Drain pump case if repairs are to done
5.4 CENTRIFUGAL PUMP TROUBLE CHECK

LIST:
A) NO LIQUID DELIVERED:
1. Priming-casing and suction pipe not completely filled with liquid.
2. Speed too low.
3. Discharge head too high check total head (particularly friction

loss)
4. Suction lift too high (suction pipe may be too small or long,
causing excessive friction loss). Check with vacuum or compound
gauge.
5. Impeller or suction pipe or opening completely plugged.
66
6. Wrong direction of rotation
7. Air pocket in suction line.
8. Stuffing box packing worn or liquid seal plugged allowing leakage

of air into pump casing.
9. Air leak in suction line
10. Not enough suction head for hot or volatile liquids. Check carefully
as this is a frequent cause of trouble on such service.
B) NOT ENOUGH LIQUID DELIVERED:
1. Priming-casing and suction pipe not completely filled with liquid.
2. Speed too low.
3. Discharge head higher than anticipated. Check total head

(particularly friction loss)
gauge.
5. Impeller or suction pipe or opening completely plugged.
7. Air pocket in suction line.
8. Stuffing box packing worn or liquid seal plugged allowing leakage

of air into pump casing.
9. Air leak in suction line
10. Not enough suction head for hot or volatile liquids. Check carefully
as this is a frequent cause of trouble on such service.
11. Foot valve or suction pipe not immersed deeply enough
12. Mechanical defects:
Impeller clearance too great

Impeller damage
C) NOT ENOUGH PRESSURE:
67
1. Speed too low
2. Air or gases in liquid
3. Impeller diameter may be too small
Impeller clearance too great
Impeller damage
6. Be sure pressure gauge is in correct place on discharge nozzle or

discharge pipe.
D) PUMP WORKS A WHILE AND THEN QUITS:
1. Leaky suction line

2. Stuffing box packing worn or liquid seal plugged-allowing leakage
of air Into pump casing.
3. Air pocket in suction line
4. Not enough suction head for hot or volatile liquids. Check
carefully as this is a frequent cause of trouble on such service.
5. Air or gases in liquid
gauge.
E) PUMP TAKES TOO MUCH POWER :
1. Speed too low
2. Head lower then rating, pumps too much liquid
3. Liquid heavier than anticipated. Check viscosity and specific

gravity
Shaft bent
Rotating element blinds
Stuffing box too tight
Pump and driving unit misaligned
F) PUMP LEAKS EXCESSIVELY AT STUFFING BOX:
68
1. Packing is worn or not properly lubricated
2. Packing is incorrectly inserted or not properly run in.
3. Packing is not right kind for liquid handled.
4. Shaft bent.
G) PUMP IS NOISY:
1. Hydraulic noise - Cavitation, suction lift too high. Check with
vacuum or compound gauge.
2. Mechanical defect:
Shaft bent
Rotating parts are loose or broken
Bearing worn out.
Pump and driving unit misaligned.
When connected to electric motors, check whether motor wiring is correct and
receives full voltage.
5.5 ROTARY PUMPS:

A rotary pump is simple in design, has few parts and like a reciprocating pump,
is positive acting. It consists primarily of two cams or gears, spur or
herringbone, in mesh, the so called “IDLER” gear driven by the “DRIVING” gear
which later is rotated from an outside source of power. A close fitting casing
surrounds the cams and contains the suction and discharge connections. Liquid
fills the spaces between the cam teeth. The cam rotates in the direction shown
and as they mesh, the liquid is literally squeezed out of the discharge. Following
this, the cam teeth separate, create partial vacuum and the liquid flows into the
spaces between the teeth from the suction. Such operation produces a very
even and continuous flow. As in the case of reciprocating pump, the capacity
delivered is constant, regardless of pressure. Due to the necessary close
clearance and metal to metal contact, such units naturally work best and last
longest when pumping liquids having lubrication qualities.
Rotary pump consists of a fixed casing and moving part like gears, screw,
vanes, cams, etc. having minimum clearance between the fixed and moving
parts.
STARTING OF ROTARY PUMP :
a) Check the shaft for free rotation

b) Line up cooling water system
69
c) Check lubrication system
d) Open suction and discharge valves
e) Check that the system on discharge side is through all the way.
f) Start the motor
g) Check
i) For leakage through glands
ii) Bearing temperature
iii) Amperage if Ammeter is provided
STOPPING OF ROATRY PUMP :
a) Stop the motor

b) Close discharge and suction
c) Stop cooling water system
5.6 RECIPROCATING PUMP

A reciprocating pump is a positive acting type, which means it is a displacement
pump, which creates lift and pressure by displacing liquid with a moving
member of piston. The chamber or cylinder is alternately filled and emptied by
forcing and drawing the liquid by mechanical motion. This type is called
“positive” in as much as the only limitation on pressure, which may be
developed, is the strength of the structural parts. Volume or capacity delivered
is constant regardless of pressure, and is varied only by speed changes.
The double action cylinder has two separate chambers, each with its own
suction and discharge valves, with the piston operating through the center of
both. Movement of the piston forces liquid out of the right-hand chamber into
the discharge pipe through discharge valve causing the left-hand chamber to
fill. On the reverse stroke, water is forced out of the left-hand chamber through
discharge valve and suction valve is opened, casing he right-hand chamber to
fill. This construction allows pumping on both directions of the piston stroke
hence the same “Double acting”.
It discharges a definite quantity of liquid. The pump discharge is not steady. A

simplex reciprocating pump gives more pulsation than a duplex.
STARTING OF RECIPROCATING PUMP :
a) Check and start cooling system.
b) Check lubrication system
c) Open suction, discharge and by-pass connecting suction to

discharge
d) Start the pump
70
e) Close by-pass slowly keeping a watch on discharge pressure
STOPPING OF RECIPROCATING PUMP :
a) Take discharge on by-pass if necessary

b) Stop the pump
c) Close suction and discharge
d) Close cooling system
IMPORTANT NOTES ON PUMP OPERATION:
1. Never start a pump without lining up the system properly
2. Never start a positive displacement pump without opening the

discharge valve or bypass valve.
3. Before starting a pump, ensure that there is correct quantity of

lube oil/ grease where such points are provided.
4. Before starting a pump, rotate the shaft by hand to check its free
rotation.
5. Before starting a pump, ensure that the discharge valve is loose

enough to be opened by hand.
6. Check for availability of utility before starting a pump
7. Before starting any system driven pump, care is to be taken to

drain off condensate from the line and warm-up pump side
properly.
8. In case of turbine driven pump, ensure that over speed tripping

device is set correctly.
9. Check for correct direction of rotation of the motor after starting

a pump.
10. After starting the pump, ensure that pump is discharging at

normal pressure and rate. Otherwise, stop the pump and
investigate the cause and rectify and re-start.
11. Check the ammeter reading if provided in case of motor driven

pump to see that motor is taking correct amperage. Otherwise
stop the pump and investigate the reason and rectify and re-start.
71
12. For initial commissioning of any pump, suction line must be provided
with suitable strainer. This is to protect the pump for any damage of
the pump due to carry over of foreign matters (welding rods, metal
chips etc.) into the pump.
5.7 PUMP HANDING OVER PROCEDURE:

1. De-pressuring the pump:
Following steps are to be followed for pump de-pressuring.
a) If mech. Seal flush line is their, close seal flush line valve.
b) Close suction, discharge warm up (quenching steam) block valves
c) Cool to self draining temperature
d) Avoid overcooling, congealing
e) Close all discharge & suction valves of the pump.
f) Pumps casing liquid drain in to ows (for lpg & high rvp product service
pump casing liquid to be vent into flare and after de-pressuring the pump
vent to flare valve to be closed).
g) If pump service is for heavy product, take FLO and drain into OWS (for
flushing the pump casing).
h) If pump service for caustic, amine, anti-oxidant or other chemical drain
pump casing liquid into chemical drum and then flush with water two or
three times.
2. If mech. Seal and pump bearing cooling water line is there, close cooling
water line valve.
3. Isolate power supply of pump motor & its auxiliary motors from sub-
station.
4. Ensure that “man at work” board is displayed at the pump
5. Now pump is ready for handling over to maintenance.
5.8 PUMP TAKING OVER/ COMMISSIONING

PROCEDURE:
1. Confirm from concerned maintenance deptt about completion of
maintenance work.
2. Pumps piping are properly connected & supported
3. Lube oil, seal oil systems have been flushed
72
4. Instrumentation like pressure gauge, temperature gauge, vibration
meters, safety valves and electrical ammeters are installed.
5. Motor has been revisioned & its no load test has been completed.
6. Rotation is checked & ok
7. Double earthing is provided to motor
8. Motor pump is properly bolted with foundation
9. Coupling guard is properly fixed
10. Pump & pipings are thoroughly flushed
11. Mech. Seal flushing line is clear
12. Connected valves are easy to approach & operable
13. Suitable gaskets have been fixed
14. Motor/pump cold alignment has been completed
15. Proper size of strainer is provided
16. Lube oil is topped up
17. Cooling water is on
18. Steam quenching line is clear
19. There is no blind in suction or discharge line
20. Priming is done after opening suction valve and supply of fluid is assured.
21. Shaft is free
22. Get the pump motor energized from the sub-station
23. First trial to be done in presence of maintenance
24. Start the pump and open the discharge slowly maintaining the pressure
in the discharge line & amperage load of the motor.
25. Check the temperature of the bearing house, and observe for any
leakage developing in pump body.
26. Check the sound of the motor/pump.
27. Check for the vibration.
28. Hot bolting is done in case of hot pump
73
5.9 PUMP DETAILS IN RECEIPT
5.9.1 GR CRUDE
SN PUMP NO Service KL/HR Head KW AMP.

1 65-P-01 SG Crude 350 75 125 220
2 65-P-01A SG Crude 350 75 125 220
3 65-P-01B SG Crude 350 75 125 220
4 65-P-01C SG Crude 350 75 125 220
5 65-P-02 SG Crude 350 75 125 220
6 65-P-05 0ffspec MS to Crude 60 40 20 28
7 65-P-06 0ffspec MS to Crude 60 40 20 28
8 65-1502-P03A/B 90 – 140 Naphtha 42 40 30 153
9 65-1502-P06A/B LT/HT FCC Gasoline 97 40 37 62
10 65-1502-P10A/B Hy. Reformate 68.4 40 30 51.6
11 65-P-13 A/B B/H Naphtha 90 138 55 93
12 65-P-14 A/B Naphtha 220 145 45 55
13 65-P-21 A/B ATF Transfer Pump 140 145 90 148
14 65-P-103 A/B Naphtha 140 145 90 153
15 65-P-104 A/B HSD 400 49 75 126
16 65-P–15/16 Slop transfer pumps 60 31
17 65-P-03 CRUDE 350 75 125 211
18 65-P-10 FGH
5.9.2 GRE CRUDE

5.9.3
1 751-P-01 B/H & IMP crude 360 49.3 55 98
2 751-P-06A B/H & IMP crude 237 49 67 114
3 751-P-06B B/H & IMP crude 237 49 67 114
4 751-P-06C B/H & IMP crude 237 49 67 114
5 751-P-11A NG Crude 375 56.4 110 84
6 751-P-11B NG Crude 375 56.4 110 84
7 751-P-11C NG Crude 375 56.4 110 84
8 15-P-101A B/H, IMP & SG Crude 400 143.7 300 33
9 15-P-101B B/H, IMP & SG Crude 400 143.7 300 33
10 15-P-101C B/H, IMP Crude 400 143.7 300 33
11 15-P-101D B/H, IMP Crude 400 143.7 300 33
12 15-P-101E B/H, IMP Crude 400 143.7 300 33
5.9.3 GR PRODUCT / DUMAD
SN PUMP NO Service KL/HR Head(M) KW AMP.

1 2200-P-01A LABFS 250 227.6 255 25
2 2200-P-01B LABFS 250 227.6 255 25
3 2200-P-02A MS 236 344 260 27
4 2200-P-02B SKO 236 344 260 24
5 2200-P-03A HSD 258 344 300 31.5
6 2200-P-03B HSD 258 344 300 31.5
7 2200-P-03C MS/SKO/HSD 258 344 300 31.5
74
8 2200- FO/LDO 200 163 200 21.8
P04A/B
GR PRODUCT / MFA ADDITION
SN PUMP NO Service KL/HR Head(M) KW AMP.

1 13-P-2A MFA unloading 5 75
2 13-P-2B MFA unloading 5 75
3 13-P-1A MFA transfer 25
4 13-P-1B MFA transfer 25
5 13-H-1 Dye addition 25 25
6 13-H-2 MS/Nap. circ. 450 50 75 130
13-H-3 Dye addition 25 10 25 46
7 13-H-2A MS circulation 500 132
8 13-H-2B MS circulation 500 132
9 1502-PA- MS cir. ( new) 500 45 59 155
CF-8A
10 1502-PA- MS cir. ( new) 500 45 59 155
CF-8B
11 1100-P-101A MTBE tr to MS 220 100 75 133
12 1100-P-101B MTBE tr to MS 220 100 75 133
13 1502-PA- MTBE tr to MS 13.5 75 9.3 17
CF-7A
14 1502-PA- MTBE tr to MS 13.5 75 9.3 17
CF-7B
5.9.4 GRE PRODUCT

1 751-P-03 HSD/SKO/LDO Circ. 200 61.7 75 125
2 751-P-04 SKO to FO rundown 200 69.0 75 125
3 751-P-04A FO/LSHS Circulation 200 54.2 75 150
4 751-P-05 HSD Circulation 200 54.2 45 74
5 751-P-08A HSD CIRN PUMP 380 52 85 32
6 751-P-08B HSD/ CIRN PUMP 380 52 85 32
7 751-P-09A NAPHTHA circ. & booster 360 52 75 130
8 751-P-09B NAPHTHA circulation 360 58 75 130
9 751-P-09C NAPHTHA circulation 360 58 75 130
10 751-P-05 A E-IV HSD Circulation
GRE PRODUCT (OMC PUMP HOUSE)

1 2071-P-8A n- Paraffine 18 50 55
2 751-P-21A LABFS 140 88 55 89
3 751-P-21B LABFS 140 88 55 89
4 751-P-22A Hy. Alkylate 50 107 30 51
75
5 751-P-22B Hy. Alkylate 50 107 30 51
6 751-P-H2 FGH 50 72 18.5 33
7 751-P-H3 FGH 50 72 18.5 33
8 751-P-10A SKO 300 125 132 215
9 751-P-10B HSD 300 125 132 215
10 751-P-10C HSD 300 180 132 260
11 751-P-10D MS 300 180 132 260
NEW P/H UNDER RUP: OUT SIDE DYKE OF 777

1 2115-P-105A/B Isomerate 60 - - 53
2 2115-P-109A/B Lt Slop 40 - - 88
3 2115-P-110A/B Hy Slop 20 - - 174
5.9.5 BOD / GE-GRE SUMP

1 PM-101 A EFF 450 42 96 156
WATER
2 PM-101 B -DO- 450 42 96 156
3 PM-101 C -DO- 450 42 96 156
4 PM-101 D -DO- 450 42 96 156
5 PM-101 E -DO- 450 42 96 156
6 PM-101 F -DO- 450 42 96 156
7 PM-101 G -DO- 450 42 96 156
8 PM-128 OIL 666 43.6 11 22
A(ROTA)
9 PM-128 OIL 666 43.6 11 22
B(ROTA)
10 PM-102 A DE- 101 20 1.5 3.2
WATERING
11 PM-102 B -DO- 101 20 1.5 3.2
12 MK 101 A AIR 15000 50 3.7 8.2
BLOWER MMWG
13 MK 101B -DO- 15000 50 3.7 8.2
MMWG
14 MK101C -DO- 15000 50 3.7 8.2
MMWG
5.10 VA L V E S :-
In the process industry, different types of valves are used. They are mainly –
a). Gate valve

b). Globe valves
c). Needle and Butter fly valves
d). Check valves
e). Audco Plug valves
76
5.11 GATE VALVES: -
There are basically two types: -
a). Wedge type

b). Disc type
5.12 GLOBE VALVES :-
They are extensively used for the control of flow where positive shut off is
required.
Angle valve is a variation of globe valve.
5.13 BUTTERFLY VALVES :-

They offer accurate throttling even at high pressure and temperature.
Extensively used in instrumentation and at sampling points.
5.14 NON-RETURN VALVES (NRV) :-
These are provided in the system to avoid back flow.
5.15 PLUG VALVES :-

All plug valves have pressure-balanced plugs as a standard feature. It gives the
benefit of the elimination of any possibility of unbalanced forces causing taper
locking of the plug. In pressure balanced design live line pressure is used. By
allowing the line to pressurise the small end chamber a balancing force is
produced which prevents taper lock. For effective leak tightness, however,
sealant injection becomes necessary.
The line pressure is allowed to equalise the pressure acting on each end of the
plug. The pressure balance system consists of two holes in the plug connecting
the chambers at each end of the plug with the port, which contains line
pressure. The hole in the large end of the plug is a simple connecting passage
whilst the hole in the small end of the plug contains a non-return valve. This
enables sealant pressure to be built up if necessary, whilst allowing access of
the line pressure to the small end chamber. Thus the pressure in the large end
chamber always equals line pressure and the pressure in small end chamber is
always equal to or greater than the line pressure.
BENEFITS:
❖ Certainty of operation. Freedom from seizure
❖ Consistent torque which is stable over long periods
❖ Freedom from regular maintenance
❖ Assured sealing to atmosphere, even in emergency, a system for injecting
stem sealing compound is available
77
❖ Certainty of sealing down the line. Even with slightly damaged seats, sealant
injection will be effective.
❖ Ensures lever indicates open/closed positions
❖ Increased overall reliability and safety
FEATURES
❖ Pressure balanced plug
❖ Super LoMu (PTFE based antifriction agent) treatment on plug & stem
❖ Large area metal-to-metal seats fully protected as line fluid flows
❖ Fire safe graphite stem seal
❖ Externally actuated emergency stem sealing system
❖ Lapped taper surfaces for precise seat mating
❖ External provision for plug sealant injection
❖ Blow out proof stem
❖ Double ‘D’ stem drive
❖ Fire tested performance.
5.16 MSQ CONTRO VALVES:-

S.NO CONTROL SERVICE FLOW
VALVE RATE(MAX)
1. 1501FIC0101 C5- 70 NAPHTHA BSII 27
2. 1502FIC0102 “ EIII 18
3. 1502FIC0103 90-140 NAPHTHA BSII 34
4. 1502FIC0104 “ EIII 30
5 1502FIC0105 H R BSII GRADE 48
6. 1502FIC0106 H R EIII GRADE 60
7 1502FIC0107 MSQ MEROX R/D 79.22
8 1502FIC0108 MSQ MEROX R/D 58.07
9 1502FIC0109 MTBE BSII GRADE 5.87
10 1502FIC0110 MTBE EIII GRADE 5.87
11 1502FIC0111 BSII COMBINED FLOW 117
12 1502FIC0112 E III HAEDER COMBINED 104.3
FLOW
5.17 IMPORTANT POINTS ON OPERATING

VALVES :-
a) Valve should be hand tight only when closed. Never use
excessive force. It will hold no-matter how much force is applied.
b) Likewise when the valves is in full open position, it should not be

tight open. The wheel should be free.
c) If the valve is hard to operate, cleaning and lubrication of stem,

lubrication of gland and/or loosening of gland will make it easy to
operate. In spite of these preliminary attempts, if the valve
78
continues to operate hard, get the help of mechanical
maintenance. Do not use force to operate it.
d) If any easy operating hand tight valve is suspected or passing get

it serviced by opening through mechanical maintenance. The
main causes for the passing of the valve can be any one or
cumulative of the following :-
i. Accumulation of rust, dust, foreign matter in the seat.
ii. Damage to the seat due to use of excess force in

operating valve or due to erosion.
iii. Damage or pitting on the rings/ball/needle or

erosion
e) When the glands of valves develop leak, get the gland packing
changes.
f) Keep the exposed steam clean. Dirt, sand mixed with grease work
as abrasive and does lot of damage.
g) A passing valve can cause
i. Migration of products creating discrepancy in the oil

accounting
ii. Contamination by mixing with other products.
iii. Losses if the end of line is open, like loading points on
Truck and Wagon loading gantries. Besides, this will
constitute serious fire hazard. A passing valve must be
immediately repaired/ replaced more especially so on
loading points of trucks and wagons and in LPG.
5.20 PRESSURE RELIEVING DEVICES:

DEFINITIONS:
OPERATING PRESSRE:
It is the pressure to which the system is normally subjected to in operation
MAX ALLOWABLE WORKING PRESSURE:
It is the pressure to which the system is designed.
79
DESIGN PRESSURE:
It is the normally 10 % more than the normal operating pressure.
SET PRESURE:
It is the pressure at the inlet of safety or relief valve at which there is a

measurable lift.
RELIEVING PRESSURE
The operating pressure increased by the over pressure at full lift of relief
valve.
RESET PRESSURE :
The pressure at which the valve closes after discharging.

SAFETY VALVES
These are automatic spring loaded pressure relieving devices actuated by static
pressure on upstream of a valve. These are generally used in air and steam
services.
RELIEF VALVES:
They are like safety valves only with a differences that here the lift is in
proportion to the increase in pressure over opening pressure. Whereas safety
valves are characterized by rapid full opening or pop action. Generally used in
Gas, air or liquid services.
PRESSURE CUM VACUUM RELIEF VALVE:
These are automatic pressure or vacuum relieving devices actuated by pressure

or vacuum in the storage tanks. These are weight loaded on both the pressure
and vacuum side.
80
Chapter- 6
RECEIPT, BLENDING
&
SUPPLY
81
Chapter-6
Receipt, Storage, preparation and supply of feed to the primary and secondary
units is one of the important functions of OM&S. Uninterrupted supply of feed
to the units is the responsibility of OM&S.
6.1 RECEIPT AND BLENDING

Product transfer and blending is one of the major operations of off-sites.
Adequate storage space (ullage) is created in the off-site tanks for receiving
products from processing unit by transfer/despatch of products already stored.
Finished products are obtained by inline blending of various intermediate

products or by transfer and blending of different components.
Utmost care should be taken in carrying out transfer operations so that the
products are not contaminated.
The following facts should be born in mind while lining up of the tanks. Most
of the tanks in Gujarat Refinery as well as GREP off-site have a single nozzle
and hence single line serving as inlet/outlet. This line comes out of tank bund
and terminates in a manifold. It is in this manifold, the rundown, suction and
sometimes return line tie up.
6.2 Receipt
Off-sites receive following categories of products from the operating units:
a) Intermediate products (to be supplied as feed to other processing units)
b) Semi-finished products to be properly blended as finished products.
c) Finished products to be despatched
Following key points should be born in mind while receiving products from the
units:
a) At no time the valve on the rundown line be closed without obtaining

prior approval of the concerned processing unit.
b) Lining up of the receiving tanks should be done carefully to avoid

pressure surges, contamination or overflow.
c) While receiving product in a tank/vessel care should be taken NOT

to EXCEED safe filling height.
82
d) All records of product movements should be maintained for
proper accounting.
e) During storage of products ensure that:
1) Proper temperature of the products is maintained by steam heating coils,

if provided.
2) All the tank accessories e.g. breather valve, flame arrestor, dip hatch,
ladder etc. are in proper condition.
6.3 Piping Network of different products:
Naphtha
Line No.44 (150-mm dia) is the main rundown line for Naphtha in GR Offsite.
A Naphtha rundown line from AU-3 joins line No.45 near job 51 (intermediate
pump house of CRU). Naphtha rundown from AU-1 and AU-2 comes and joins
line No.44 opposite laboratory. Line No.44 then runs along road nos.4 and 5
and terminates in the naphtha tanks 73,74,75 and 77 of GR after joining
Naphtha tks 905 & 908.
An independent (200 mm dia Bombay High) Naphtha rundown from AU-IV

units runs along road no.1 and ultimately terminates in the manifold of GREP
naphtha tank 714. A 200 mm branch takes off from this rundown line near
crossing of road no.1 and 8 and runs along road no.8 into sector XXVI from
where it turns towards GR Naphtha tanks 73, 74, 75 and 77 and the same line
is extended upto tanks 203/204 for receiving B/H Naphtha in these tanks. At
the manifold of GR Naphtha tanks the two naphtha rundown viz. one from GREP
and another from GR (Line No.44) meet.
Tank 714 is taken out of service from B/H Naphtha and tank 203 and 204 are
converted to B/H Naphtha service. Two new pumps Nos. P-13A and P-13B in
GR crude Booster Pump House are installed to supply B/H Naphtha from Tank
203/204 is passing road no. 5 to P-13 A/B. The 150 mm dia discharge line from
P-13 A/B passes road no.6, 3, 4 and enters AU-1/AU-2. A provision is made on
West side of road no.5 to transfer B/H naphtha from tank no.203/204 to MS.
200 mm dia line is drawn from outlet of TK 203/204inside the tank farms and
connected on suction line of P-19 (job-55) which is coming from tank 515/516.
Thus B/H Naphtha ex 203/204 by P-19 may be transferred to MS tanks.
B/H Naphtha 203, 204
The 80-mm Light Charge Stock rundown going to tanks 207,208 [before
reconstruction of tks 207-208] is connected to line no.44 in front of tanks 207,
208 on road no.5 in Sector-II.
83
A separate 150 mm rundown for GOP Naphtha for supply to IPCL, originating
in AU-1/AU-2 running along road no.4 towards west and turning to north from
road no.1 and 4 crossing. While running along road no.4 this line is increased
in size to 200-mm dia just before the point where AU-4 naphtha rundown
branch meets it (north of GREP Merox Units). This line is taking GOP Naphtha
to tanks 711 to 714. A 350-mm dia outlet from these three tanks goes to
Naphtha pumps P-09 A/B/C situated in the pump house on road No.8 near the
crossing of roads 3 & 8 250 mm
dia discharges from these pumps goes to IPCL via road 8 and 5. A separate Dia
150 line is laid from GHP to Tks 711,712,713 and 714 manifold for receiving
Naphtha.
A separate line ex AU-V comes to OM&S and terminates at tank 205/206 [before
reconstruction of tks 207-208] and 711-714 and 73,74,75 and 77.
A modification in AU-V naphtha line is made at manifold of nap tk 905, from

where AU-V naphtha is diverted to manifold of BHNaphtha tks 203-204 manifold
at junction of road no. 6 and road no. 5, which enables to receive only AU-V
naphtha in BH Naphtha tks 203 and 204.
Two new tanks are added for Naphtha service i.e tank 905 and 908 of 25000
M3 capacity, Naphtha rundown Ex GR Units and AU-V is connected to these
tanks.
Light Charge Stock :
An independent rundown 80-mm dia line brings light charge stock from AU-1
and AU-2 to tanks 207, 208 [before reconstruction of tks 207-208]. This line
runs along road no.5 and is also connected to tanks 62 and 63. This line runs
along road no.5 and is also connected to tanks 62 and 63. To handle increased
quantity of light charge stock, second line from AU-1/AU-2 to OM&S is laid. For
this purpose C-6 Ret. Line from P-07 to AU-1/AU-2 is used. Tank 62 can be
used in SK service after de blinding SK line.
From AU-5 dia 6” Naphtha header joint to tank 73-77, tank 711-714 and new
tanks 905 & 908 line no. 44,45 connection also done to tank 905/908.
Heavy Charge Stock :
An independent 100-mm dia rundown line running along roads 4 and 7, serves
tanks 62 and 63. Tanks 62 and 63 are connected to this line at tank manifolds
situated near the junction of roads 6 and 7.
IBP-70
84
IBP-70 of AU-1 and AU-2 can be sent jointly or independently to reformat
rundown line no.45 and to Naphtha rundown line no.44.
IBP-70 line joins no.45 near job-51 while it joins line no.44 opposite to
laboratory.
Production of IPCL GAP Naphtha is discontinued and tank 513 is empty & tk
514 service changed to n-Paraffin.
Visbreaker Gasoline (Naphtha)
After treatment in Merox it leaves through a 80 mm dia line from the eastern
battery limit of AU-IV, crosses road no.1 and then proceeds along road no.4
towards east. It crosses road no.4 in front of Job-51 and joins lines 44 and 45
near Job-51 pump slab.
Visbreker Naphtha can be routed to the pump suction header of crude tks
72,701,702. This is the new modification which is carried out near GRE Crude
Pump house.
Benzene
An 80-mm dia line originating in Udex intermediate pump house proceeds

towards CRU intermediate pump house in Sector VII and comes out on road
no.4. From the junction of road no.3 and 4 it turns towards north and runs
along side road no.3 through sectors V and II between the tank bunds and road
no.4, terminating in the Benzene Storage tanks of OM&S.
Toluene
An 80-mm dia line carrying Toluene runs alongwith Benzene piping network
and follows the same as Benzene piping.
LABFS
LABFS (M/s. Nirma) Grade is received in tank 207 & 208 and pumped out to
Nirma plant through IOTL pump house No.s P01A/B of 255m3/hr capacity each.
LABFS for GR-LAB plant is received in tank 205 & 206 from a new extended
line which is hooked up to 8” SKO line at junction of Road no. 4 and 3, this line
is coming out of AU-IV along with AU-III SKO. This 8” line meets with 8” AU-1
and AU-II SKO lines which ultimately opens in Nirma tanks 91 and 92. AU-I and
AU-II LABFS line is also hooked up at this junction. The new modified line
extends upto AU-V west side battery limit area.
Superior Kerosene
85
There are two independent loops of piping for SKO, one for GR Off-site and
another for GREP off-site. These two loops are connected with each other in
the pipe trench opposite to laboratory.
GR Loop of Kero Piping
SK from units AU-1 and AU-2 join in a common 200-mm dia rundown just
outside western battery limits of AU-2. This line crosses road no.4 near
Laboratory where an independent SK rundown from AU-3 joins it. This line then
proceeds along road no.4 towards east and turns to north near junction of road
no.4 and 7 and continues along road no.7 and terminates in the SK manifold of
GR SK storage tanks. In GR SK tank farm tank 91, 92 is in SK service. This SK
rundown header is kept blinded for tanks 85 to 90 as these tanks are in ATF
service. From SK manifold a common suction line of 350-mm dia serve SK
pumps in Job-55 for wagon loading and TTL loading. A return line of 250-mm
dia from these pumps goes back to SK manifold. From tank 90, 91 and 92
another header of 250-mm dia is drawn which runs along road no.7 and turns
to TTL from the crossing of road 4 and 7 to TTL SK pump slab. This provision
is made to facilitate TTL SK loading. In another words tank 90,91,92 can
despatch SK to TTL only for separate accounting purpose. At tank 90 this
header is blinded only tank 91,92 can feed to TTL now. Tank 62 can be taken
into SK service separate suction and rundown headers are laid upto tank 62,
which are blinded at present. A single outlet of 250-mm dia from Tanks 85 to
90 runs long road no.7 and joins KAPL manifold opposite TEL Plant. This header
is in service of ATF to supply to ATF to KAPL from tanks 85 to 90.
After arrival of LAB plants, TKS 87, 88 and 89 are converted to dual service of
LMW / HMW. A dedicated header of 3“ coming along road no. 7 meets the
manifold for receiving LMW and HMW in these tanks. In order to facilitate new
operation, all the old receiving lines have been blinded and on the manifold,
the outlet lines used for hooking up of dispatch lines of LMW and HMW dispatch
lines separately for all the 3 tanks. ATF RR lines and KAPL lines are blinded at
the manifold.
In addition to the above, tk 90 converted from LABFS NIRMA service to ATF

Service.
GREP Loop of Kero Piping
A 200-mm dia line carries Kero from AU-4 to GREP Kero storage tanks. It comes
out from the northern battery limits of Merox Plant of GREP and runs along
road no.8 it turns to GREP Kero tanks. A take off from this bend runs along
road no.8 towards east and meets the suction manifolds of LDO blending pump
P03 and FO blending pump P-04 on pump slab no.2 of GREP.
In the battery limits of AU-4 the same line is extended back and brought and
from eastern battery limits of AU-4 from under road no.1 which travels along
road no.4 and meets with GR Kero rundown in front of laboratory.
86
From the Kero manifold of GREP storage tanks a 450-mm dia header goes to
Kero despatch pumps on job-55. This line runs along road no.8 then along road
no.7 nr IOTL pump house.
Another suction header is provided from GREP storage tanks to job-55 as BTPN
header for R/R loading.
A 250-mm dia header from Kero manifold of GREP Kero tanks comes along road
no.8 and joins KAPL manifold. This header of SK is KAPL transfer from SK tanks
715,716,717,718 and tank 738 and 739.
An independent dia 150 line is laid from GHP to above tanks manifold. This new
line is also having interconnection with SK loop going to GR Tanks.
Tank 738,739 are converted to SK service same piping facilities are provided to
receive and despatch product in these tanks. For transferring SKO to OMC a
suction header is provided as each tank which joins at manifold and one single
line goes to OMC P/H near GREP control room as suction header. At present
tank 714 is converted to Naphtha service, hence all SK headers are blinded at
the manifold.
SKO header dia 6” from AU-5 also joins to SKO manifold of tank 738/739 and
tank 715-718 and sko tk 914.
SKO tk 914 at present is being used for receiving LAB Return stream ex Nirma
[LABFS], which is then sampled in GR QC Laboratory and dispatched as normal
SKO for PDS.
It is to be noted that AU-V SKO can be routed either to SKO Pool or LABFS
pool from the unit itself near west side battery limit area.
All the SKO tks (715,716,717,718,738,739,914) are connected upto

KNPL/KVSSPL manifold opposite IOTL pump house.
ATF
a) ATF produced in AU-1 & AU-2 is pumped via 200-mm dia ATF rundown line,
which comes from job-50, crosses road no.4 near laboratory and then runs
along road no.5 terminating in GR ATF tanks (85 to 90).
b) ATF produced in AU-3 is pumped through an independent line which meets

AU-1/AU-2 ATF rundown near job-50.
c) ATF produced in AU-4 is treated for removal of Mercaptans and sent down
through 150 mm dia line running along road no.4 and turning near
87
laboratory to go to AU-1/AU-2. This line is also connected to a 200 mm line
crosses road no.4 near laboratory then runs along road no.4 then turning
on to road no.5 going to north side, serving all the ATF storage finished
product tanks.
d) ATF produced in GHP is sent or directly to OM&S via new Dia 150 rundown
line.
AU-5 ATF rundown is coming thru’ GHP line
At present, Tks 85,86, 90,91 & 92 are in ATF Service.
Tks 85,90,91,92 have separate R/R & KAPL headers, while Tk 86 has got only
R/R header, its KAPL header spool piece is taken out.
Tks 85,86,91,92 & 90 syphon drains are connected to a pump located between
ATF manifold and MS manifold on Road no. 7 in order to transfer left over
material to SKO tanks before M&I.
High Speed Diesel
A 150-mm dia HSD rundown header from Job-50 takes High Speed diesel from
AU-1 and AU-2 to GR diesel storage tanks. This line runs along road no.4 and
7. A 100 mm dia rundown from AU-1 and AU-2 can take HFLS or HSD army
grade if any when produced to tanks 97,98,99 and 100 only. A 100-mm dia
rundown from AU-3 comes and meets this 100-mm dia and 150 mm dia
rundown line described above, in front of laboratory. Either High Speed diesel
HFLS or HSD Army Grade Ex AU-3 can be sent from AU-3 through this line.
A 200-mm dia diesel rundown from AU4 comes and meets 150-mm diesel
rundown of AU-1/AU-2 in front of laboratory. This 200-mm dia diesel line of
AU-4 continues through the processing units of GRE and comes out from
northern battery limits and proceeds as 250-mm dia rundown header is further
extended to tanks 723-726,731 & 732.
A new 150-mm HSD rundown is laid from GHP and meets with existing HSD
rundown line going to GR [opposite Laboratory] and GRE tanks manifold.
A new DHDS header dia 16” (Sweet Diesel) is connected to manifold of tank
723-726, 731,732 and tank 906, 907,909,910.
A separate line is laid to receive AU-5 HSD in GRE tanks
HSD rundown line Ex DHDS is laid upto GRE tanks and New tank. All units
rundown is connected to DHDS rundown to have operation flexibility.
88
The 200-mm dia diesel header is connected to 400-mm DHDS run-down
header. A 250-mm HSD header from northern battery limit goes to GREP HSD
tks. The 400-mm DHDS run-down header is connected to all GREP HSD tanks
and to TKS 906,907,909 and 910.
An INLINE-HSD BLENDING SYSTEM has been incorporated in the DHDS HSD

rundown line near junction of road no. 4 and 3, which calls for entire HSD
streams to pass through the DHDS Header that is why 200-mm HSD header ex
AU-IV must be always lined up to DHDS Header.
A new 10” header is commissioned meant for EURO III HSD rundown. It is
connected to HSD tks 906,907,909 & 910 and tks 723-726,731,732 with plug
valve.
At GRE manifold two suction headers are provided for T/W loading which are
going to HSD pump at job-761. Also two different suction headers are provided
for KAPL &,OMC transfers.
For dispatch to IOTL, no separate header is provided. Provision is made both

from R/R & BTPN headers. At present, BTPN header is blinded near GR LSHS
manifold on road no. 7, hence BTPN header is dedicatedly used for pumping to
IOTL.
HSD tks no. 906,907,909 & 910 via a dedicated header can be pumped to
KNPL/KVSSPL, while Tks 723-726,731,732 are connected via BTPN header to
KNPL/KVSSPL manifold nr Junction of Road no. 8 & 7.
At GR manifold facilities are provided for T/W, TTL, KAPL despatches of

Normal/HFLS/Army grad HSD.
LDO
In the battery limits of the processing units of GRE there is a common manifold
in which following lines tie up :
Kero LGO/HGO.RCO, LVGO, Vac.Residue. A 150-mm dia from the manifold

comes out from northern side of GRE units and goes to LDO tanks. 250-mm
suction header from LDO tanks goes to blending pump P03 in No.2 Pump
House. A 200-mm dia return (recirculation) line from P03 goes back to FO tanks.
A 450 mm dia suction header goes to Job-56 Rail/Loading/Transfer pumps via
road 8 and 7.
Furnace Oil
A 200 mm dia fuel oil rundown header from VBU comes out from northern
limits of Merox Plant runs along road no.1 upto the crossing of roads 1 and 8,
then turns east and proceeds along road no.8 and 5, terminating in FO tanks
manifold. 450-mm dia suction from FO tanks goes to blending
89
pump P-04 in no.2 Pump House. A 200-mm dia recirculation line goes back
from the discharge of blending pump to the FO tanks. 450-mm dia suction
from FO tanks goes to job-56 Rail loading/transfer pumps via road no.6 and
7.
LSHS
a) A 150 mm independent rundown from AU-3 runs along road no.4 and
terminates in LSHS manifold of GR on road no.7 opposite job-56.
b) A 150-mm independent rundown from AU-1/AU-2 comes out on road no.4

near laboratory and runs along road no.4 and terminates in LSHS manifold
of GR on road no.7 opposite Job-56.
c) A 300 mm independent line ex-FPU carrying FPU-VR comes out on road no.4
from FPU and runs along road no.4 and terminates at the crossing of road
no.4 and 5, near LSHS Tk no. 94. CLO ex FCC joins this header at the battery
limit of FCC. There is a provision to route FPU VR from 300-mm header to
150-mm header of LSHS from AU-1, AU-2 and AU-3 at the crossing of road
nos.4 and 5.
d) A 500 mm take off from above 450 mm header is taken and runs along road
no.5 (east side), turns on road no.8 at the crossing of road nos.5 and 8,
crosses road no.8 opposite Benzene tank 511 and terminates on new LSHS
manifold of LSHS tanks 777.
e) A 200 mm LSHS rundown from AU-4 comes out from northern battery
limit of CDU and runs along road no.1 and turns on road no.8 and
terminates on tank-731 to 734 manifold. Tank 731 & 732 are now
converted to HSD service,& Tk 733 into FO service, and Tk 734 is in
LSHS Service.
f) A 200 mm branch from AU-1/AU-2/AU-3 rundown header from the

crossing of road nos. 4 and 5 is taken and runs along road no.5 and 8
and gets connected on manifold of tank 731/734 in the header
mentioned in (e) above.
g) A separate 250 mm FPU (VR) rundown line is being laid for split routing
of FPU(VR). The production and routing of both grades of LSHS will be
as under :
6.4 Production of two grade of LSHS during

GHP shut down
90
Production of High Viscosity Grade LSHS
The required quantity of H.V Grade LSHS is to be made by blending total CLO
ex FCC and part of VR production from FPU. The mix contains around 17% CLO
and 83% Mix. VR.
As the split routing of Mix AR ex FPU is not possible from the existing VR
rundown circuit it is necessary to augment this by laying and additional
rundown line from FPU to AU-II corner.
The above HV grade components are to be routed via this new (10”) line upto
AU-II corner and further routing upto tanks by 20” header to GRE tanks and
by(1 x 0.8” + 2 x 0.6”) line to GR tanks
Production of Low Viscosity Grade LSHS
The balance production of LSHS will be only LV Grade. This quantity of LV Grade
is to be made by blending total quantity of VBU LSHS, balance Mix VR ex FPU,
balance near N/G RCO or Mix RCO ex AUs and SK as cutter stock if required.
The above components are to be routed to tanks via existing 12” VR rundown
line from FPU to AU-II corner and further routing via 18” line to GR tanks and
via 20” line to GRE tanks.
Production of two grades of LSHS after commissioning of GHP
The production of both grades of LSHS is feasible by blending resultant VBU,

LSHS ex VBU (which is to be operated on 100% Mix VR), CLO ex FCC, slop
distillates ex FPUs (New and old) and SK as cutter stock if required. The routing
of different LSHS components in different grades of LSHS is as under:
Production of High Viscosity Grade LSHS
As per the recent indications from IFP the resultant VBFO from VBU by
Visbreking N/G VR will meet the HV grade specification. The required quantity
of HV grade LSHS can be made by directly routing of VBFO (partly) to tanks via
8” new R/D line ex VBU and 10” new R/D line ex FPU to AU-II corner & further
Routing via 18” line to GR tank sand 20” line to GRE tanks. If VBFO viscosity is
not meeting HV grade LSHS quantity then CLO can be blended in the above.
Production of Low Viscosity Grade LSHS
In view of low demand of HV grade LSHS the split routing of VBFO is necessary.
The above quantity of LV grade can be made by blending balance quantity of
VBFO, CLO ex FCC slop distillate ex FPUs and SK injection for viscosity cutting
if required.
91
The above components to be routed to tanks via 12” R/D line ex FPU. 8” VBU
R/D line (being provided in pre GHP stage) and new (VR + Slop) distillate R/D
line ex new FPU to the crossing of road no.4 and 5. The further routing is to be
done by 18” / 20” lines to tanks.
Raffinate
Raffinate ex Udex Plant comes to CRU intermediate tanks. The rundown line
also connects to reformat. Thus Raffinate ex Udex ultimately ends up in MS
blend. Raffinate can also be routed to line no.44 or in GOP Naphtha pool from
the units. Raffinate can also be the feed for FGH Plant.
MTBE
A separate rundown line is coming Ex MTBE Unit upto this tank 1101 & 1102.
MTBE is being used as a blending component in MS to boost up the Octane
Number and it is also dispatched through T/T. For this purpose 2 Nos of pumps
1100-P-101A/B are provided alongwith pump suction & discharge headers.
Apart from this these two tanks have got circulation line too.
LAB:
The LAB project, a Petrochemical plant, is being put up at Gujarat Refinery with
a capacity of 120000 TPA LAB production. The process licensor for the plant is
M/s UOP of USA. It is only fourth in the world of its kind. It is envisaged to
product two grades of LAB products, Low Molecular Weight (LMW) and High
Molecular Weight (HMW). LAB is the most common raw material for the
manufacture of premium quality biodegradable detergents that is 95%
biodegradable and hence detergents from LAB are superior in quality. The LMW
grade has the indigenous consumer market and HMW grade has the export
market. The detergent characteristic of HMW is more compared to that of LMW
grade LAB product.
The LAB is produced by the alkylation of Benzene with the linear mono olefins
of C10-C13 Hydrocarbons. The main raw materials for production of LAB,viz
LABFS grade kerosene for deriving normal paraffin, Benzene and Hydrogen,
shall be made available from existing units only.
LABFS grade kerosene is derived from atmospheric units AU-IV/V, AU-I, AU-II
and AU-III. The kerosene heartcut (contains C10-C13) is separated in
Prefractionation unit (2060). The heartcut is desulfurised and denitrified in
unionfining unit (2061). The product from unionfining unit is routed to the
92
MOLEX unit (2063). The hydrogen required in the unionfining unit is supplied
from the PACOL Unit and the existing hydrogen units. In the MOLEX unit the
N-paraffins are separated from the Non-Normal paraffins by molecular
adsorbents. The N-paraffin Stream can be routed directly to the PACOL unit
(2070) or to the N-paraffins tank Tk 514. The N-paraffins are converted to N-
olefins in the PACOL unit and the aromatics that are formed together with the
N-olefins are removed in the PEP unit (2071). The N-olefins from the PEP unit
(after aromatics removal) is reacted with Benzene in the DETAL unit (2073) to
produce Linear Alkyl Benzene-LAB product. The byproduct produced together
with the LAB product is Heavy Alkylate, which is routed to storage tanks Tk
557-558.
The offsite facilities are envisaged with the available initial inputs and shall be
met from modifications of existing offsite facilities with addition of new pumps
and piping. The storage requirements are met by reallocation / capacity
augmentation of the existing tanks.
LABFS, a special cut kerosene, is one of the feed for LAB complex. Three tanks Tk 205,
206 and 207 of capacity 12000 KL each (Dia X H : 33 X 16.5 Mtr) are provided for
storage of LABFS. The capacity of these tanks is augmented by constructing the tanks
in place of existing 5000 KL tanks. Tk 207 has the facility to use it in dual service of
LABFS as well as ATF. These tanks are provided with nitrogen blanketing facility, local
as well as DCS level indications; DCS pressure indication and local temperature
indicator.
A new 10” dedicated header is being laid from AU-5 to the manifold of these tanks. An
8” jump over from AU-4 LABFS to Nirma tanks header is provided to the new 10”
header ex AU-5 as South West corner of Tk 908. Similarly, A 4” jump over from AU-
1/2 LABFS header is provided to the new 10” header ex AU-5 at south west corner of
Tk 908.
LABFS from tanks Tk 205,206 and 207 shall be pumped to LAB Complex by new pumps
751-P-0021A/B provided in OMC pump house. The capacity of the pump is 140m3/hr.
The requirement for the LAB plant is 89.436MT/hr i.e.112m3/hr. Two separate suction
/ discharge headers (10” and 6” respectively) are provided.
• One for LABFS to LAB complex and

• Another for off spec LABFS to LABRS header for routing it to SK pool
The pumps are provided with minimum flow line with restricted orifice.
Benzene
Benzene is also one of the feeds for LAB complex. The existing storage tanks
Tk-64, 65 (400KL each), 67,68,69,511,512 (1000 KL each) shall be utilized for
storage of Benzene. A buffer tank Tk 768 (Capacity 1600KL) is being provided
after modification for providing fix roof in addition to the existing floating roof.
93
A nitrogen blanketing system is also being provided to this tank. The Benzene
shall be received in Tk 768 from OMS pumps. Also, a 2” line is provided to
receive Benzene directly from UDEX run down line.
Benzene from existing Benzene tanks shall be pumped by existing Benzene

loading pumps H-37/38 (capacity 50 m3/hr each) to the buffer tank (Tk 768 at
Job-50). A new 6’ line is laid from OMS to the inlet of Tk 768. New pumps 50-
P-21A/B (Capacity 8 m3/hr) provided at job 50 shall have two discharges.
• To pump Benzene from Tk 768 to LAB complex (2”header)

• To pump off spec Benzene from Tk 768 to UDEX along with CRU
rundown line (2” header)
Benzene unloading system
In addition to above, a Benzene unloading facility is also envisaged to meet the

exigencies. The facility shall include 4 unloading points from Tank trucks and a
Benzene unloading pump. From the Benzene unloading pump Benzene is
routed to the Benzene tanks Tk 64,65,67,68,69,511 and 512 (located at OMC
pump house) or directly to the Benzene tank Tk-768 located at Job-50 from
where it is routed to LAB unit.
N-paraffin (Production Rate: 12 MT/hr)
Normally N-paraffin produced in Molex unit of LAB complex is routed directly to

the next processing unit PACOL. However, a buffer tank between the two units
has been provided. Tk 514 (capacity 3000 KL) is earmarked for this service
after modification for providing fixed roof in addition to the existing floating
roof. A nitrogen blanketing system is also being provided to this tank. A 4” new
line is being laid from LAB battery limit to the inlet of Tk-514.
N-paraffin from Tk-514 is pumped by new pump 2071-P-008 provided in OMC

pump house. The capacity of the pump is 16.5 m3/hr. Three discharge headers
are provided to this pump.
• 4” header to LAB complex

• 6”/4” header to TTL tank 755
• 3” header to LABRS line for emptying out as well pumping off spec
material to kerosene
Unloading
To meet the initial commissioning requirements it is envisaged to have a N-
paraffin unloading facility. The unloading facility includes 2 unloading pints from
the Tank Trucks and an unloading pump 761-P-11. N-paraffin from the tank
trucks is pumped by 761-P-11 and routed to the discharge
94
header of the pump 2071-P-08 back to the N-paraffin tank Tk-514. From Tk-
514 N-paraffin is routed through the pump 2071-P-08 to the PACOL unit.
As N-paraffin is a specialty product, dedicated TT dispatch facilities are

envisaged. N-paraffin from pump 2071-P-008 shall be received in TTL tank 755
(capacity 1000 KL). N-paraffin from Tk 755 shall be pumped by pump 761-P-
011 (capacity 50 m3/hr) to loading bay no. 8 and 9 of white oil TTL gantry. A
new line of 3” shall be laid which shall join the white kero header. A separate
mass flow meter and loading arms are envisaged for the same.
LAB Product (Production Rate: 15 MT/hr)
LAB complex shall produce two types of LAB product:
• Low Molecular Weight (LMW) for indigenous market

• High Molecular Weight (HMW) for export market
The production rate shall be 15 MT/hr. LAB complex can produce one grade at
a time only. LAB from the unit shall be first received in the day tanks Tk
26,27,28,29 (Capacity 300 KL each) and 767 (capacity 1600 KL). After due
certification the product shall be pumped to final product tanks Tk-87, 88,89
(Capacity 5000 KL each). Tk 767 (Capacity 1600 KL) is being provided after
modification for providing fix roof in addition to the existing floating
roof. A nitrogen blanketing system is also being provided to this tank.
Dispatch
LAB product from day tanks shall be pumped by new pump 50-P-22A/B
provided at Job-50 pump house. The capacity of the pump is 90 m3/hr each.
Two discharge headers are provided to this pump.
• 6” header to LAB final product tanks 87,88,89 at OM&S

• 3” header to off spec LAB tanks Tk 1 and Tk 2 at Job-50
Provision has been kept to route LAB product directly from LAB unit to the final
product tanks 87,88 and 89. This bypass line has been provided in Job-50 area.
LMW dispatch facility

A 10” header shall be laid from Tanks 87,88 and 89 manifold to the existing 18”
TTL SK header going to the suction of existing TT loading pumps H-33/33A
(capacity 50/150 m3/hr respectively). The existing discharge header of these
pumps shall be utilized for loading of LMW grade LAB product. Three loading
bays no. 4,5 and 6 of white oil TTL gantry are allocated for this service. A
separate mass flow meter and loading arms are envisaged for the same. One
discharge is also provided to off spec LAB receiving line to Tk-104.
95
HMW dispatch facility
A 10” header shall be laid from Tanks 87,88 and 89 manifold to the existing 12”
TTL HSD header going to the suction of TT loading pumps H-35A/B. These
pumps are new pumps of capacity 80 m3/hr each. The existing discharge
header of these pumps shall be utilized for loading of HMW grade LAB product.
Two loading bays no. 9,10 of white oil TTL gantry are allocated for this service.
A separate mass flow meter and loading arms are envisaged for the same. One
discharge is also provided to off spec LAB receiving line to Tk-104.
Off spec LAB
A new pump 2073-P-016 of capacity m3/hr is provided at job-50, which shall
take suction from off spec tanks 1 & 2. Two discharge headers are provided to
this pump.
• 3” header to LAB complex for reprocessing

• 3” header to TTL off spec LAB tank Tk-104.
The existing n-Heptane TT loading pumps P-015A/B of capacity 80 m3/hr shall

be utilized for loading of off spec LAB. One loading bay no. 7 of white oil TTL
gantry is allocated for this service. A separate mass flow meter and loading
arms is envisaged for the same.
HEAVY ALKYLATE
Storage
A valuable side product named Heavy Alkylate is also available along with the
LAB product. It shall be routed to Tk-557, 558 (Capacity 500 KL each) via
dedicated 2” header from LAB battery limit.
Dispatch
Heavy Alkylate from Tk-557/558 shall be pumped by new pump 751-P-22A/B
provided in OMC pump house. The capacity of these pump is 50 m3/hr. Two
discharge headers are provided to this pump.
4” header to bay no. 7 of white oil TTL gantry LAB complex

4” header to FO receiving line for blending as cutter stock
As Heavy Alkylate is a specialty product, its TT dispatch facilities are envisaged

at bay no. 7 of white oil TTL gantry. A separate mass flow meter and loading
arm is envisaged for the same.
LABRS
A Prefac stripper top, Re run column bottom, Non normals from MOLEX unit
and off spec material are combined outside north side battery limit in a 6”
header. Off spec ATF, off spec LABFS and off spec N-paraffin are also routed
to this header and combined 8” header joins the AU-V Kerosene run down
header at East of GRE product pump house.
96
OTHER PROCESS LINES:
SL SERVICE DESCRIPTION
1 Hydrogen 3” line is taken from Hydrogen line going to Butene 1
unit at South of LAB battery limit.
2 Hydro carbon 3” CBD discharge from South side LAB battery limit
slop joins GHC slop line going to GRE at South of LAB
battery limit
3 Aromatic slop 3” ABD discharge from South side LAB battery limit
joins reformat line going to UDEX at South of LAB
battery limit
4 Net over head 2” line from South side of LAB battery limit is routed to
liquid AU-V stabilizer.
(Unstabilised Similarly, 2” line from North side of LAB battery limit is
naphtha) routed to AU-IV stabilizer.
5 Net over head 2” line from North side of LAB battery limit is routed to
vapors AU-IV Amine absorber along with FCCU gas.
6 Caustic 2” line is taken from 2” line going to AU-III/IV at south
side of LAB battery limit
7 Spent Caustic 2” line is going from South side battery limit to 2” spent
caustic line going to AU-IV from AU-I/II at south side
of LAB battery limit.
8 Sour water 2” line is going from south side battery limit to 4” sour
water line going to SRU from DHDS at south side of
LAB battery limit.
9 Aromatic rich 2” line is going from south side battery limit to AU-III
fuel and AU-V and joins crude inlet line for reprocessing
6.5 BLENDING :
When two or more different components are mixed together to produce a
finished product, the process is called is called blending.
Blending involves
a) receiving of calculated quantities of components of known quality
b) Mixing of these components to produce a homogeneous product of

uniform density, satisfying all the required specifications.
Mixing of components can be done in the pipelines while eceiving/transferring

components into a tank. This is called in-line blending. Another method
generally employed in receiving/transferring of known quantities of different
components in to a tank. The final mixture is made homogeneous with the help
of tank mixing arrangement.
97
The quantities of components can be ascertained by:
a) Processing units while sending them through rundown;
b) On the basis of receiving tank dips if components are transferred one at a

time.
General Procedure
a) Prepare the tank for transfer i.e. drain water/sludge/caustic etc. from the
tank. Heat the tank contents to the required temperature, if and where
necessary. Take correct temperature and dip.
b) Take correct dip and temperature of receiving tank.
c) Line up the system correctly.
d) Check the quantity to be transferred. Calculate the stop dip i.e. the dip at
which the transfer has to be stopped.
e) Calculate the approximate time required for the transfer.
f) After starting the transfer, check the dip of receiving tank and the tank
under transfer to ensure that there is no mix up in lining up the tanks.
g) Take hourly dips on both the tanks.
h) Note down the expected time of finished.
i) Towards the end of transfer stay on the tank under transfer and take dips
every few minutes.
j) Just before the calculated stop dip is reached give single to operator, who
will be standing by the transfer pump, to stop the pump.
k) The pump operator will close the discharge valve on the pump, thereafter
take the final dip of the tank to ensure that the transfer has been stopped
at the calculated dip. In case some quantity is left out, restart the transfer
and repeat the above said procedure.
l) Allow the receiving tank to settle for half an hour (light oils) two hours
(heavy oil), then take the dip of the receiving tank. Cross check the
quantities transferred and received.
m) Closed all the valves on the system, if there are no more transfers to follow
immediately.
98
n) After all the components are received start the recirculation of the tank or
tank mixer as the case may be.
o) Heavier oils take longer time for mixing. A tank of 5000M3 capacity filled
upto safe filling height with heavy oil will take 6-8 hours of mixing to attain
uniformity of its contents.
p) After stopping the tank mixer/recirculation allow the tank to settle for two
hours (heavy oil), half an hour (light oil), then ask laboratory to collect
samples for quality certificates.
q) If the densities of TMB are not uniform laboratory will ask for more
circulation of the tank, which should be done. Thereafter laboratory will
collect fresh samples.
r) In case the laboratory results fail, the tank is to be corrected by re-blending.

s) If the tank contents are certified as OK, it is ready for despatch.
t) Make appropriate entries of all the transfers/receipt in the pumping report.
Inline Blending [Manually]
The network and inter-connections of rundown lines from GR and GREP offer
the flexibility for inline blending. Moreover in the battery limits of GREP
processing units itself manifolds are provided where various different streams
can be grouped together and sent down through a common rundown line to
storage tanks. When two or more different streams from different processing
units are thus mixed in a common line and sent down to a receiving tank, it is
called in line blending. The quantities of different streams can be controlled.
In line blending is normally done in the case of following products.
a) High Speed Diesel - HSD/LCO/Hy.Naphtha

(Normal grade)
b) Light Diesel Oil - Heavy HSD/LVGO/VR
c) Furnace Oil - FO/KERO/HVGO/LVGO
d) GOP Naphtha - IMP Naphtha/IBP-/Raffinate/
Heavy Charge Stock (90-12oC) Cut
MS Blending
The total capacity of new MS blending station is 850 TMTPA. It is capable to

produce 450 TMTPA of BS-II standard MS and 400 TMTPA of Euro –III standard
MS. The blending station can run independently to produce both BS-II and
EURO-III standard MS. There is a bypass facility of the blending station. The
BS-II and EURO-III grade motor sprit will be produced in Automatic blending
station by blending the following streams:
99
C5 – 90 Naphtha cut directly from AU – 1 Unit (3” line).
Straight Run Naphtha (90 – 140 Cut) from Tank – 63 through Pumps 1502 –
PA – CF – 003A/B located in GR Crude Pump House (4” line).
MTBE from existing Tanks – 1101 / 1102 through Pumps 1502 – PA – CF –

007A/B located near MTBE tanks.
Heavy Reformate from Tank – 62 through Pumps 1502 – PA – CF – 010 A/B

located in GR Crude Pump House (6” line).
Light Cut + Heart Cut Gasoline (Merox Treated) directly from MSQ unit (6” line).
The above MS components are routed to 10” BS II Blend header (Connected to

L45) and 10” Euro III Blend Header (Connected to FCC Gasoline Line) through
control valves which control flowrates of individual components in order to
maintain quality. The above MS components can be bypassed to Bypass Header
whenever required.
Existing MS circulation pumps H2 / 2A and New MS Circulation pumps 1502-

PA-CF-008A/B will be used for circulation of BS – II and Euro – III tanks
respectively.
Offspec Handling:
Offspec material if any from MSQ plant can be routed to Tank – 513 via 8” line.
Provision is also given for routing offspec material in BS – II and Euro – III
header to Tank – 513 through 10” Offspec header. Offspec material from Tanks
513 can be pumped to GRE crude booster pump suction via pumps 65 – PM –
05/06.
List of Control Valves in MS Blending Station:
Details of Control Valves on BS - II Header

Sl Line Size Valve Size Flow cu.m/hr
Tag No. Service
No. in inches in inches Min Normal Max
C5 - 70
1 1501-FV-101 Naphtha 3" 2" 6.00 14.02 27.00
90 - 140 SR
2 1501-FV-103 Naphtha 3" 2" 7.60 20.85 34.00
Heavy
3 1501-FV-105 Reformate 4" 2" 6.40 18.36 34.68
100
LT,HT FCC
4 1501-FV-107 Gasoline 6" 3" 17.60 45.58 79.22
5 1501-FV-109 MTBE 2" 1" 1.30 1.41 5.87
Details of Control Valves on Euro - III Header

Sl Line Size Valve Size Flow cu.m/hr
Tag No. Service
No. in inches in inches Min Normal Max
C5 - 70
1 1501-FV-102 Naphtha 2" 2" 4.00 12.73 18.00
90 - 140 SR
2 1501-FV-104 Naphtha 3" 1.5" 3.80 17.16 17.17
Heavy
3 1501-FV-106 Reformate 4" 2" 8.60 35.87 39.00
LT,HT FCC
4 1501-FV-108 Gasoline 4" 3" 12.90 21.57 58.07
5 1501-FV-110 MTBE 2" 1" 1.30 2.02 5.87
Details of Orifice Plates on Bypass Header

Sl Line Size in Flow cu.m/hr
Tag No. Service
No. inches Min Max
C5 - 70
1 1501-FT-113 Naphtha 3" 26.75 43.65
90 - 140 SR
2 1501-FT-114 Naphtha 4" 29.39 43.74
Heavy
3 1501-FT-115 Reformate 6" 39.15 67.00
LT,HT FCC
4 1501-FT-116 Gasoline 6" 91.00 96.40
5 1501-FT-117 MTBE 2" 4.75 11.70
HSD Blending [Automatic] :
This document explains the functional design details of the Blend Ratio Control
software for inline blending of HSD at IOCL Gujarat.
Rundown streams from various units are routed through the respective lines to
one common header(DHDS HSD rundown header), the Blend Header. The
blended HSD stream is routed to the HSD product tanks. A static mixer in the
blend header ensures proper mixing of all the rundown streams. Two analyzers,
one for Sulfur content measurement and the other for Recovery measurement
are positioned, in-line, at the down stream of the static mixture on the blend
header.
The continuous blending operation is implemented by the sequence logic in the
DCS with relevant software modules for Property Trim Control and Tank Quality
Estimate executed in the field control station (FCS) and operator station (ICS)
of Centum CS system. Tank Quality Estimate module calculates the quality of
the product in the tank at regular intervals. The Property Trim control module
101
carries out corrections for the tank product quality by continuously monitoring
the analyzers’ inputs for Sulfur content and Recovery measurements and
manipulating the SKO and DHDS feed flow rates on a continuous basisi to keep
the HSD product within the recovery and Sulfur specifications.
The Blend Ratio Control module residing in the OM&S DCS receives inputs from
various sources. The tank information such as level, volume and level related
alarms are obtained from the Enraf / Entis system through ABB-IMS station.
Analyzer inputs i.e. Sulfur and recovery measurements are communicated to
OM&S DCS by serial communication. All flow PV and SP data from the process
units are hard wired to the OM&S DCS.
The SKO/DHDS feed stream PID controller status as well as its high/low limit
status values will be fetched from the GR-NET and the same will be displayed
in the OM&S DCS.
Annexure-I of this document gives the details of the DCS configuration.
Nomenclature
This section includes all abbreviations used throughout this document.
BRC – Blend Ratio Control
PTC - Property Trim Control
TQE - Tank Quality Estimate
IQC - Instantaneous Quality Control
TQC - Tank Quality Control
FCS - Field Control Station
ICS - Information Command Station (Operator Station)
EWS - Engineering Work Station
GHC - Gujarat Hydro cracker Unit
GRSPF- Gujarat Refinery Secondary Processing Facility
Overview
Process Overview
AU-1 HSD and Kerosene streams
AU-II combined HSD and Kerosene streams
AU-III combined HSD and Kerosene streams
AU-IV combined HSD and Kerosene streams
AU-V combined HSD and Kerosene streams
GHC combined HSD and Kerosene streams
DHDS HSD and DHDS feed HSD streams
GRSPF H N stream
The Blending scheme for HSD product is shown in the Annexure-II.
Annexure-III provides the DCS tag details.
The following properties are to be controlled for HSD.
Recovery in Vol.%
Sulfur content in wt%
Property Specifications :
102
recovery : 95% by volume @ 3700C
Sulfur content : 0.25% by weight
Following HSD final (certified) product properties from the LAB are entered by
Operator into the system to enable BRC pick these values as the Tank Heel
property data during any Blend change operation.
Recovery in vol%
Sulfur content in wt%
Density
Control Scheme for various streams are as follows :
HSD and SKO from AU-I join together and this stream joins the HSD blend
header with one flow direction. SKO stream is under flow control and HSD
stream flow is monitored. If operator selects AU-I SKO stream for recovery
correction, then SKO flow SP is set by BRC.
Combined HSD and SKO from AU-II join together and this stream joins the HSD
blend header with one flow direction. SKO stream is under flow control and
HSD stream flow is monitored. If operator selects AU-II SKO stream for
recovery correction, then SKO flow SP is set by BRC.
Combined HSD and SKO streams from AU-III join the HSD blend header with
one flow direction. These flows are monitored.
Combined HSD and SKO from AU-IV join together and this stream joins the
HSD blend header with one flow direction. SKO stream is under flow control
and HSD stream flow is monitored. If operator selects AU-IV SKO stream for
recovery correction, then SKO flow SP is set by BRC.
Combined HSD and SKO from AU-V join together and this stream joins the HSD
blend header with one flow direction. SKO stream is under flow control and
HSD stream flow is monitored. If operator selects AU-V SKO stream for recovery
correction, then SKO flow SP is set by BRC.
DHDS HSD and DHDS feed HSD join together and this stream joins the blend
header in one flow direction. DHDS feed HSD stream is under flow control and
HSD stream flow is monitored. DHDS feed HSD flow SP is set by BRC, as this
stream is adjusted for Sulfur correction.
H N stream from GRSPF joins the HSD blend header with one flow direction.
This flow is monitored.
Control System Overview

The main functions of the control module are sequence and ration control,
Property Trim Control and Tank Quality Estimate. MMI screens are developed
in DCS for the blending scheme : Blend Instruction screen, Blend Operation
Screen and Blend Tank Information Screen. (Refer Annexure V,VI,VIII).
Blend Instruction Screen : Blend change sequence is done from this screen.
Operator can select the product tank from this screen.
Blend Operation Screen : Flow Set Point change is triggered from this screen.
103
Blend Tank Information screen : Product tank information such as level, volume
and alarms are displayed in this screen.
A typical blend operation involves the following steps.
Blend definition through the Blend instruction screen by the BRC module
whenver a new blend operation has to be started.
Blend change operation through the Blend instruction screen.
Component flow set point change to meet the tank quality specifications during
the blend operation is done through Blend operation screen either by the BRC
module or by the operator manually. Normally BRC module will update the flow
set point values, operator entry is a back-up function.
Blend Instruction Entry Function
Blend instruction for a new blend can be given in two ways. Either the new
blend instructions are downloaded from standard recipes in the library or
entered by the operator manually. Offline library is provided in the DCS for
selecting the recipe manually. The following are the details of instruction for a
new blend.
Blend ID
Product Tank
Target Dip and Volume
Component Source
Product Specification Range Limits
Blend change function

After defining a new blend recipe operator has to confirm the line up operations.
On clicking the BLNDCHG soft key in the Blend instruction screen blend change
sequence is executed. The blend change sequence performs the following
checks.
• checks whether the product tank is in level HIHI alarm state
• checks whether the target mass is more than the ullage mass
available in product tank
• checks whether the component flow controller of the selected
component is in RCAS mode and not in the alarm state
• a dialogue message is issued for getting the operator confirmation
for tank line-up in the field
• checks whether the targeted component flow is within the flow limits
of that particular stream, when the component flow set point
calculated by the BRC is outside the HI/LOW limits
If any of the above condition exist, then appropriate operator guide messages
are issued and blend change sequence is not started.
When the blend change sequence starts, following process takes place :
BRC Status
BRC status change switch is set. BRC status change sequence is executed. BRC
status is changed to ACTIVE.
Summation Data Reset
104
The summation data of each flow meter, which indicates the actual transferred
volume, is reset to zero values to re-accumulate the transferred volume for the
new blend.
Actual Transferred Volume Operator selection switch is provided for selection

for considering actual transferred volume as tank volume change or flow
summation. If the operator selects the tank volume then change in product
tank volume for a particular time interval is considered as the actual transferred
volume fduring that time. In case the operator selects the flow summation, the
actual transferred volume is considered from the flow summations.
Blend Instruction Data Transfer

The blend instruction data entered through the Blend instruction screen is
transferred to the blend operation data, which are used in the Blend operation
screen so that the component control is carried out using the new blend
instruction data.
Component Change
While a Blend is in progress, the operator can change the available control
component. BRC has the feature of updating its available component database
to accordingly manipulate the SP of the corresponding flow controllers.
Component flow set point change
Blend operation screen is provided to monitor the current blending operation
during blend execution and to alter the component flow SP values.
BRC checks the following before downloading the flow SP’s to the respective
DCS controller.
checks whether the component flow controller of the selected component is in
RCAS mode and not in the alarm state. In absence of the required condition for
control, BRC will generate an appropriate message for the operator.
Checks whether the targeted component flow is within the flow limits of that
particular stream. When the component flow SP calculated by the BRC is outside
the HI/LOW limits, BRC generates an operator message for appropriate action
by the operator.
If | SP-PV | > TOL, where TOL is the tolerance limit for each of the component
flow controller, then alarm is raised and BRC shall not download the set point
further.
A switch is provided to enable the operator to select a particular SKO

component to be used as the control stream for BRC. OM&S DCS operator shall
ensure the respective component flow controllers are on RCAS mode on the
respective unit DCS. A flow SP change switch is provided to enable the operator
to confirm the download of flow SP’s to the respective component loops by the
BRC.
The component flow rate is set to each flow controller by the flow rate set-up
function. This function implements the flow rate ramping-up and
105
When the total blended quantity is 90% of the final value, a message is issued
to prompt the operator. When this reaches 95%, BRC is turned OFF with an
alarm message. On the total quantity reaching 100% HIHI alarm will be
generated.
Special Functions Implemented in DCS

Appropriate operator guide messages are displayed in case of communication
failure between OM&S DCS & GR-NET and OM&S DCS & IMS network.
BRC Operating Philosophy
Product quality in the tank is calculated periodically and displayed on the

operator screen. Tank heel volume and its properties t the start of the blend
operation are taken into account while calculating TQE. At an interval of time
equilvalent to Recovery Analyzer cycle time the product tank quality is
compared with the specifications. Any deviation from the specification is taken
care by manipulating SKO flow or DHDS feed HSD flow for Recovery and Sulfur
correction respectively. Operator has also the option to choose the control
based on Instantaneous Quality. In such a case, the BRC will control based on
Analyzer output for the batch of HSD passed through the header for one cycle
time of Recovery Analyzer.
BRC Operation in different scenarios

The main objective of BRC module is to maintain recovery and Sulfur content
in the HSD product stream within product specification. SKO stream is used for
recovery correction and DHDS feed HSD is used for Sulfur correction.
106
MOVs in Receipt Section
There are 31 MOVs in receipt section. All MOVs are operated from locally.
SN LOCATION DESCRIPTION SIZE- Rating - # MOV-No.

inch
1 701 Rreceiving line 18 13
5 770 Receiving line 19
6 771 Rreceiving line 17
7 772 Receiving line 18
9 901 Outlet line 30 150
16 ATF KRPL manifold 18 150 401
17 FO IOTL manifold 18 300 5
18 HSD KVSPL manifold 20 150
19 HSD KRPL manifold 18 150 404
20 HSD KDPL manifold 2
21 HSD IOTL manifold 18 300 4
22 LABFS IOTL manifold 14 300 3
23 MS KVSPL manifold 20 150
24 MS KRPL manifold 18 150 403
25 MS IOTL manifold 10 300 1
26 Naptha KDPL manifold 1
27 SK IOTL manifold 14 300 2
28 SKO KVSPL manifold 20 150
29 SKO KRPL manifold 18 150 402
30 SKO KDPL manifold 3
31 South Road crossing of 19
Gujarat 5 &8
crude
107
O M & S MANUAL
Chapter – 7
DESPATCH OF PRODUCTS
108
Chapter-7
DESPATCH OF PRODUCTS
For efficient functioning of the refinery one of the major factors is to regulate
off take movement of products.
Since large volumes of high priced products are involved, utmost care is called
for in handling of products during despatch. Despatch of products by the
different modes depending upon a number of factors like market requirement,
product availability etc. is an important exercise for the Oil Movement and
Storage Section. To achieve the smooth functioning of despatch systems a close
co-ordination between Marketing, Railways and other agencies involved in the
process is called for.
A product becomes ready for despatch only after getting the quality certificate
from laboratory and after complying with the necessary excise formalities.
There are three modes of transport operating in this refinery for the despatch
of products.
They are:
Pipeline
Road
Rail
OM&S receipt is responsible for pipeline dispatch. The road dispatch is looked
by TTL and rail dispatch is taken care by tank wagon loading.
7.1 DESPATCHES BY PIPELINE

Product by pipeline is despatched to destinations namely:
KAPL near Ahmadabad MS,SK,ATF,HSD
KSPL
KDPL
KRPL
NIRMA - LABFS
IOTL- MS/SKO/HSD
ASOJ - FO/LDO
OMC - BPC & HPC
General Procedure
For transfer of product to Koyali Ahmadabad Pipeline (KAPL), the tanks are
jointly dipped before and after pumping by the representative of refinery and
“pipelines”. The dip memos are jointly signed by witnessing parties and a copy
109
is handed over to pipeline representative. The same procedure is followed for
other pipelines.
Preparation of Transfer Tank
Ensure that the product is certified by the refinery quality control laboratory.
Drain all the possible water from the tank. The tank and the entire system
should be properly isolated. In the event of abnormal transit losses a detailed
investigation should be conducted.
In case of KAPL transfer normally there are no shutdown between switchover

of tanks. Hence, long before the switchover the tank, next product tank must
be kept ready in all respects. Flying switches should be carried out without
starving the pipeline pump(s).
After all pipeline transfers when closing dips are taken, the quantity despatched
alongwith all relevant data i.e. dips, temps, density etc. should be informed to
Marketing Division for preparation of invoice.
7.1.1 Pipeline Despatches to Sabarmati

(KAPL)
The products despatched to Sabarmati Installation by Pipeline are:
• Euro-III MS
• Kerosene
• A.T.F
• Euro-III HSD
• Army HSD
The product, size of parcel and the cycle for pipeline transfer to Sabarmati is
decided jointly by IOC Marketing Division and Refinery (DMPN-Receipt). IOC
Marketing on their part are planning in consultation with Sabarmati installation.
The parcels of different products that follow each other without any interruption
in them, movement of oil through the pipeline are planned very carefully to
follow certain definite norms that the quality control demands. For example:
A parcel of ATF is sandwiched between SK parcels. Normally 1500-KL SK is

planned before ATF and 1500 KLs after ATF parcel. Minimum 1200 KLs SK
should be planned before and after ATF.
If the ullage position at the receiving end and product availability at refinery
demands then the size of the SK parcels can be reduced to minimum
permissible size and used as plug, normally 800 KLs.
However, after pumping motor spirit it is necessary to send full consignment of
SK and HSD before sending ATF.
Product pipeline should not be shutdown, keeping ATF in the line.
110
Piping Lay-out of KAPL
Across road no.7 opposite to MFA chemical plant a common manifold known as
“Pipeline Manifold”, is provided. Independent headers for each product, which
serve a group of tanks are tied up in this manifold through double block valves
and hammer blinds. A single line from this manifold proceeds to the pumping
station of “pipeline”. This line serves as suction for the pumps.
Motor Spirit
A single line, which can bring product from any of the eight tanks mentioned
above, is tied up in “pipeline” manifold.
A.T.F
A single header which joins the “Pipeline” manifolds is connected to GR, ATF
tanks.
S.K.O
A separate header to bring Kerosene from GREP tanks to the “Pipeline” manifold
is provided.
H.S.D
There are two independent headers for HSD, one serves a group of tanks on
GR side and another to GREP tanks. The GR header is not in use. HSD to KAPL
is supplied through GREP tanks only.
7.1.2 Pipeline Despatches to OMC (BPC &

HPC)
MS, SK & HSD are despatched to HPCL Installation at Nandesari and BPCL
installation near gate no.10 of Refinery.
All the products are transferred through inline MASS FLOW METERS except
SKO.
Pipeline Parcel to OMC

Other Marketing Companies such as BPCL/HPCL can be feed with products viz.
MS, SK, HSD from the individual tanks the headers are laid upto a common
manifold and from there a common header goes as suction to OMC pump house
situated near GRE product control room. Discharge of these pumps goes to
respective marketing company.
Before resuming the pumping operation joint dips are taken alongwith Refinery
and Marketing Division representative and after pumping required quantity
again closing dips are jointly taken. Both the times dip memos are prepared
and jointly signed by both the parties.
7.2 DESPATCHES BY TANK WAGON
111
Products are dispatched through tank wagons. The finished prodcts are
lined up for tank wagon loading as per advice of shift in charge of tank
wagon gantry. All product tanks have manifold in which suction line is
given for tank wagon loading pumps as well as pipeline transfer. Tank
wagon section do not have any tankage.
7.3 DESPATCHES BY ROAD
Products are dispatched through road. The tank truck loading (TTL) section
have small capacity tanks for Naptha, FO, LSHS, PFRCB. Product is
transferred to these tanks for TTL loading. In case of emergency provision
has been made for loading from mother tank
112
O M & S MANUAL
CHAPTER – 8
Measurement of
Petroleum Products
GUJARAT REFINERY
113
MEASUREMENT OF PETROLEUM PRODUCTS
All tanks for storing Petroleum Products are calibrated to permit measurement
of volume in terms of the height of liquid in the tanks. This height is measured
along the vertical distance between a reference mark on dip hatch and the
datum plate on which the bob of measuring dip tape strikes. A calibration table
is prepared for liquid volumes inside the tank at various heights after making
allowances for the volume displaced by roof supports, heating coils and other
fittings inside the tank. In case of floating roof tanks, allowance is made for the
volume of liquid displaced by the floating roof.
Material below the datum plate is also calibrated and liquid volume of it is
decided and it is incorporated in calibration chart. This volume is called dead
volume or dead stock.
In order to determine the quantity in a calibrated vessel, the following data is

required.
a). Dip of the tank (i.e. height of the liquid column) in CMS.
b). Average temperatures of the whole mass in degree centigrade
c). Average density of the contents.
1.0 DIP TAPE:

The instrument used for gauging the tank is dip tape. It consists of a fine 10
mm wide 2,15 or 20 meter long steel tape, calibrated in meters, centimeters
and millimeters, would round a circular disc with a handle. One end of the tape
is secured on the disc while other end is fitted through a hook, with a removable
tapering brass bob. The bob is calibrated in CMS and MMS.
1.1 METHODS OF DIPPING :

There are two methods for dipping a tank:
1) The innage method and

2) Outage method
1.1.1 INNAGE METHOD:

The most commonly used method is innage method. Here, the distance
between the datum plate and the surface of the liquid is measured with the
help of dip tape. The gauging method is described below -
Know the approximate height of liquid in the tank from the auto-gauge (local
indicator) fitted on outside of the tank, before going to the top of the tank. The
approximate height of liquid level can be seen from the records also.
114
Lower the bob and tape through the dip hatch slowly touching the hatch or
brass strip provided on the inner side of dip hatch where reference height is
markers, till the bob touches the datum plate lightly taking care to see that the
tape reading equals reference height, marked on the dip hatch. If it does not
then ullage method adopted for measuring.
1.1.1.1 GROSS DIP:

Pull the tape out and read the oil cut. If the tape is clean then heavy oil will
leave a clear mark on the tape and it can be read. In case of light products a
thin film of oil finding paste is spread over the tape in the region where oil cut
is expected. A number of readings should be taken till last two readings are
constant. On a windy day on floating roof tank where it is very difficult to keep
the tape straight, take at least 6 readings and then find the mean and report is
as the gross dip of the tank. While pulling the tape out of the tank do not stand
against the wind and drop all the oil inside the tank with the help of cotton
waste. Do not throw cotton waste inside the tank as it may cover the datum
plate or it may travel to the pump and land in the strainer, if there is one, or in
the pump itself. Do not throw the cotton waste on the tank or in the tank farm.
An oil soaked cotton is a serious fire hazard. Moreover, good housekeeping is
the responsibility of the operating personnel.
1.1.1.2 CARE OF DIP TAPES:

After using the dip tape for MS, Naphtha, Toluene and Benzene wipe it with
Kerosene.
A dip tape should always be carried with its bob detached. The bob should be
attached only at the time of lowering the dip tape into the tank for gauging.
Once the dipping is over, the bob should be removed. Only for this purpose, a
provision of hook is made at the end of the tape. The weakest point in the
whole dip tape is the point where the hook is riveted to the tape and it breaks
when the tape is carried with bob attached to it.
1.1.1.3 WATER CUT:

For determining the water content at the bottom of the tank, apply a thin layer
of water finding paste at the lower part of the bob. Lower the dip tape in the
tank till the bob touches the datum plate. Hold the tape straight and touch for
at least two minutes then pull it. Either paste will get discoloured or washed
away on that portion of the tape, which is immersed in water.
Sometimes no water cut is indicated on the bob although there is indication of

water inside the tank. In such cases, the dip of water is taken from dip hatch
situated towards the center of the roof of the tank. All tanks do not have
additional dip hatch.
115
In case of heavy oil, the water cut is not clearly visible on the bob or tape. In
such cases, pour petroleum product such as Kerosene over the area where
water finding paste is applied. This will wash out the heavy oil leaving water
finding paste clear and unaffected.
1.1.1.4 OIL FINDING AND WATER FINDING

PASTES:
Oil finding paste and water finding pastes are supplied either in small plastic
containers or in collapsible metallic tubes. The containers must be kept tightly
closed. The water finding paste is rendered useless if exposed to atmosphere
for long time or if it comes in contact with water. Likewise oil finding paste
becomes ineffective if contaminated with petroleum products.
After the dipping of the tank is over, close the cover of the dip hatch.
Do not drop any oil on the roof of tank or on gauging platform. It will make the
area slippery and hazardous for operating personnel.
1.1.2 OUTAGE METHOD (ULLAGE METHOD) :

Lower the bob through the dip hatch slowly till it touches the liquid surface.
Lower it a couple of centimeters more. The difference between the readings
taken at the reference height mark and of the oil mark on bob or tape give the
height of empty space in the tank. By subtracting this from the reference height,
the height of liquid column in the tank is obtained.
2.0 PRECAUTIONS:
Never use a kinked tape. Never use a bob, which is worn out at the bottom.
Before a new dip tape is accepted from manufacturer/supplier, check the first
100 CMS (i.e. from the bottom of the bob) against a standard scale for accuracy.
Quality control demands that separate gauging equipment must be kept for
ATF. Similarly, there should be one set for White oil and a separate set for black
oil. The three sets should be accurate upto one millimeter. In storage tanks
with bigger diameters, one CM equals around 49 KL and that is lot of oil and in
terms of money which is staggering. Dipping errors contribute to paper losses
and gains, which create oil accounting and excise problems and give misleading
figures of losses. Now, we come to the next important aspect of measurement
of oil namely the measurement of temperature.
3.0 CUP AND CASE THERMOMETERS:
116
The equipment used consists of a wooden block slightly longer than the length
of the immersible type of thermometer. At one end of the wooden block, a hook
made of brass is fitted, while at the other end a brass cup is fitted. The
thermometer is fitted in groove in the block in such a way that the thermometer
bulb is fully covered by the brass cup taking care to see that the thermometer
bulb does not touch the cup. A cotton rope of a length slightly longer than the
height of the tank is tied to the hook (never use a nylon rope). The thermometer
is held by small brass clips screwed in the block.
The thermometers are graduated in degrees centigrade. They come in different

ranges. The one which commonly used in Gujarat Refinery is of the range (-)
100C-1100C. Before the thermometers are put in service, they are checked in
the laboratory for accuracy. Normally, two sets of thermometers are kept. While
one set is in use, the other set is being tested in laboratory for accuracy. Every
fortnight, the inspected and certified set is put in service while the other set is
taken out from service for inspection.
Every time before using a thermometer, check that the mercury thread is not
broken and thermometer is not showing any abnormal reading. The cup should
also be checked every time for leaks.
Presently, new type of cup and case thermometer is in the use. The cup is made
of insulated material and thermometer is secured in brass case.
3.1 TEMPERATURE MEASUREMENT:

Lower the cup and case thermometer slowly into the liquid in the through the
gauging hatch till it reaches approximately to the middle of the liquid column.
Hold is for about 2 minutes then take it out. Empty the contents of the cup back
into the tank and lower the hermometer into the tank again to the required
depth. Keep it immersed for two minutes in case of light oil and for 5 minutes
for heavy oils. Pull out thermometer slowly without spilling the contents of the
cup. Before reading the temperature, see that the cup is full of oil and the bulb
of thermometer is fully immersed. In case of heavy oils, wipe the thermometer
stem with cotton waste and read the temperature, in case of light oils like
Naphtha, Ms, Benzene, Toluene and like Products the rate of evaporation is fast
and this causes quick drop in temperature on thermometer. To overdone above
problem of quick drop in temperature, new type of insulated cup thermometer
should be used which does not allow temperature of the product in the cup to
drop quickly.
In this manner, take several readings till the last two readings are constant.
Temperature readings play very vital in oil accounting. An error of one degree
can lead to a difference of several tonnes. Recording of temperature of oil in
tank. Wagons and tank trucks are also of great importance. Minor discrepancy
in temperature reading of the containers (tank wagon/tank trucks) can lead to
a big difference in material balance where the quantity cleared from the
117
despatched. On a windy day, shelter the thermometer inside the gauge hatch
so that wind does not affect the temperature.
Use different thermometers for black oils and white oils. Keep a separate
thermometer for ATF only.
3.2 CARE OF THERMOMETERS:

Thermometer is a precision instrument, which must be handled with extreme
care. Never jolt or set it down roughly. Heavy oil form an insulating film on
thermometer if not cleaned properly the subsequent reading taken by it may
be inaccurate. After se in heavy oils, clean with Kerosene, dry it and store it.
4.0 SAMPLING:
Samples are collected from tanks to check the quality of the stock and density
for oil accounting. The importance of proper sampling cannot be over
emphasized.
4.1 SAMPLING EQUIPMENT:

The sampling equipment consists of a cage with a heavy bottom, in which a
sample bottle fits. There is arrangement to jerk open the loosely fitted cork
from the sample bottle. There are variations of this equipment. In order to take
bottom samples from tank wagon and tank trucks, the equipment consists of a
brass (bottle shaped) container with an opening at the bottom which operates
with the help of a lever. It opens when it touches the bottom and liquid from
the floor of the container rushes in. When lifted, it automatically closes
preventing any liquid either going in or coming out. It is called sample thief.
A new type of all liquid level sampler is introduced. It is made of brass in bottle
shaped having about 800 c.c. Vol. Lower the sampler by cotton rope in the tank
at desired level. Watch for a while and pull up. The sampler is full of product,
transfer the product in the lean bottle and take second sample at different level.
There are different types of samples collected from storage tanks. They are
meant for different purposes. The types of samples are described in detail in
the following paragraphs.
4.2 TYPE OF SAMPLES:

Before taking any sample ensure that the bottle/container is clean. It should be
rinsed with the product from the tank, which is going to be sampled.
4.2.1 AVERAGE RUNNING SAMPLE:

118
Average sample is one that consists of proportionate parts from all sections of
the containers (i.e. tanks, wagons, etc.).
Lower the sampling cage with bottle fitted with cork to the bottom of the tank.
After it touches the bottom, raise it by about 50 CMS. Pull out the stopper with
a jerk of the cork. Immediately after the cork is opened, pull out rapidly with a
uniform speed, so that it is not completely full when it emerges from oil. If it is
full, drop the contents back into the tank and draw the sample again.
4.2.3 T M B SAMPLE:
TMB Sample (T=Top, M=Middle, B=Bottom)
Here top, middle and bottom indicate the top, middle, & bottom of liquid column
in the tank. Bottom sample is taken from 500 mm above the datum plate and
middle sample is from mid point of the top and bottom.
Top sample is collected from the 500 mm below the surface of liquid. Bottom
sample is taken from 500 mm above the datum plate and middle sample is from
mid point of the top and bottom.
The simplest and most practical way of taking TMB sample is described below
Lower the sample cage with closed sample bottle in the tank slowly till it hits
the liquid. Lower it further by about 500 mm. Tie a knot in the rope where it
touches the collar of dip hatch and give jerk to the rope to open the cork. Let
the bottle fill. Pull it out. This is top sample. Lower the sample cage with closed
sample bottle in the tank slowly till it touches the datum plate. Pull it around
500 mm and tie a knot in the rope where it touches the collar of dip hatch and
give jerk to the rope to open the cork. Let the bottle fill. Pull it out. This is
bottom sample. Now tie a knot in the rope at the mid point from the two knots
already there. For middle sample, lower the sample cage with closed sample
bottle till the mid point knot reaches upto the mouth of gauging hatch. Give the
jerk to open bottle. Let the bottle fill. Pull it out. This is middle sample. Normally
the TMB sample is collected when the depth of liquid in the tanks is more than
250 CMS., then only middle sample is taken.
4.2.4 DEAD BOTTOM

Lower the sample cage with closed sample bottle into the tank till it touches
bottom. Raise it slowly by about 500 mm. Give it a jerk to open the cork in the
sample bottle and as soon as the bottle opens, release the rope to allow the
sample bottle to lie down on the tank floor. Let the bottle get filled before it is
pulled out.
Most of the tanks are provided with additional gauge hatches towards the
center of the tank. Normally, the dead bottom samples are taken from these
119
additional dip hatches from where it is possible to reach right upto the tank
floor.
4.2.5 SPECIAL SAMPLES:

At times, on critical stocks feed stock for CRU or Udex some special samples
are requested. These are required to be taken from an interval of every one
meter of the liquid column.
Start with bottom sample and work upward at the interval of every meter. The
knot tied in the rope for bottom sample should be used as guide for measuring
every meter interval.
5.0 SAFETY PRECAUTIONS:

1. Never use a nylon rope as it can produce static electricity, which can be
a source of fire and/or explosion.
2. Use hand gloves, while lowering the dip tape into the tank do not slide
the tape over naked hand. The edges of steel tape can cause injury.
Cotton waste can be used as padding. If cotton waste is used, do not
throw it either inside the tank or on the roof of the tank or in the tank
farm. Bring the used cotton waste back and throw it in the waste
collecting bins/drums.
3. Do not allow the rope, while sampling or taking temperature, to slide

freely and fast over naked hands. It can cause injury.
4. Do not throw broken sample bottles inside the tank or on the roof of the
tank or on staircases or in the tank farm. They may cause serious injuries
to your colleagues or even to you when you visit next time during dark
hours. A little trouble taken to deposit them at the waste collection point
will go long way to save you and your colleagues from avoidable injuries,
pain and lost time
5. During night, make use of safety torches.
6. When entering tank farm and going on tanks, use walkways and access
platforms. Short cuts can lead to accidents.
7. Make use of handrails while climbing or descending from the tank.
8. Before opening the dip hatch, note the direction of the wind and keeping
your face away from dip hatch, position yourself in such a way that the
vapors, if any, from the gauging hatch do not blow on your face.
120
9. Do not go on the floating roof of the tank, when the tank is moving i.e.
when the petroleum liquid is coming into the tank or is going out from
the tank.
When the tank is dead meaning there is no movement of liquid entering or

leaving the tank, if you are required to go on the floating roof, make sure that
one person is standing on the gauging platform as a standby for getting help in
case of any trouble.
10. After dipping, sampling is over make sure to clean the area around the
dipping hatch, with cotton waste as this may constitute a slipping hazard.
11. To avoid the generation of static electricity ground the tape of dip tape
to the rim of gauging hatch or the guide fitted therein.
12. Do not go on a tank wearing shoes with protruding nails or other spark
producing metal on the sole.
13. To protect against static electricity always touch/hold the railing with
naked hand while climbing or descending the staircase and while
opening the dip hatch.
14. Do not go on the floating roof of the tank when the roof is resting on its
legs.
15. Do not gauge or sample a tank when it is under circulation.
16. The following precaution must be taken while collecting the samples:
a) The sample bottle or can must be clean.

b) The container in which sample is to be collected should be
properly rinsed with the product to be sampled.
6.0 LABLELLING OF SAMPLES

Sample tags (labels) which should be prepared in advance, should be
immediately put on the bottle before drawing next sample. This is to avoid mix
up. The sample tag should contain the following information: -
1. Sources of the sample i.e. tank no./tank wagon no./tank lorry no. etc.
2. Product
3. Date
4. Time
5. Type of sample i.e. Average, Top or Middle etc.
121
6. Test required e.g. density, distillation, RVP, or full test, etc.
7. Name to the sample.
7. AUTO TANK GAUGING :

Around 148 tanks in crude and product services are installed with Servo and
Radar gauges. Highly accurate tank oil level, temperature, density, oil and
water interface will be available continuously through’ DCS in OM&S Control
Room.
122
O M & S MANUAL
Chapter – 9
Quality control
Chapter-9
9.1 Product specifications

123
Product specifications are essential to create mutual trust between Refinery and
consumer. Product specifications provide.
• Performance standard
• Confidence for the consumer
With proper quality control refinery can achieve higher efficiency and maximize
production for economic growth.
Quality control is a set of procedure to maintain the quality of petroleum

products according to the specifications laid down by various institutes (ISI, IP,
ASTM, BIS) so that product is acceptable to the consumers.
Keeping in view the useful ness of each product for the specific purpose,
standard organizations have drafted methods of tests and specifications.
How the specifications are maintained:
On the unit side it is adjustment of the operating variables of the process. On

the other hand blending plays an important role in maximizing the production
of a product without upsetting its specification.
Offsite receives products in the semi-finished and finished conditions, few

routine tests of semi-finished products are desired for making proper blends.
Finished products need detailed testing for getting the quality certificate, as no
product can be despatched from the refinery otherwise. Besides, some tests
are required for excise purpose for levying duty.
Quality control of rundown products is primarily a responsibility of process units.

Offsite plays an important role in controlling the quality of finished products by
blending and carrying out a speedy disposal of products in co-ordination with
the laboratory and process units. Offsite personnel should be familiar with the
product specifications, which must be met as per standards laid down by BIS.
The products which are produced are required to meet BIS standered. In order
to further strengthen the quality, refinery has further strengthened the spec by
making manufacturing spec.
The specification of various products as per BIS standered as as follows:
8.1.1 LPG DOMESTIC BULK

SN CHARACTERISTIC SPECIFICATION
LIMIT & UNIT
1 Copper corrosion @40 C 1 hr. not worse than 1
124
2 Free water content Not present
3 Hydrogen sulphide Passes the test
4 Odour Min. 2.0
5 Total volatile sulphur Max. 150.0 ppm
6 Volatility(evapor. Temp 95% V @ 760 mm Hg) Max. 2.00 CEL
7 Vapour pressure @ 38 C 520.0 .. 1050.0 kPa
8.1.2 NAPTHA:
LIMIT & UNIT
1 Apperance Clear bright & free
from solid matter
2 Density @ 15 degC 660.0..740.0 kg/m3
3 Distillation – IBP Min.35.0 CEL
4 Distillation – 50% volume recovered CEL
5 Distillation – FBP Max. 180.0 CEL
6 Residue on evaporation – air jet Max. 5.00 mg/dcl
7 Reid vapour pressure @ 38 C Max. 0.700 kg/cm2
8 Aromatic content Max. 12.00% (V)
9 Carbon hydrogen ratio Max. 5.80
10 0lefin content Max, 1.00% (V)
11 Chloride as Cl Max, 1.00 ppm
12 Calorific value gross Min. 11000 Cal/gm
13 Calorific value net Min. 10200 kcl/kg
14 Sulphur (total) Max. 500.0 ppm (m)
8.1.3 MS – EURO III

SN CHARACTERISTIC SPECIFICATION LIMIT & UNIT
1 Colour 0range
2 Desnsity @ 15 C 720.0 .. 775.0 kg/m3
3 Recovery upto 70 C (E70) 10.0 .. 45.0 % (V)
4 Recovery upto 100 C (E 100) 40.0 .. 70. % (V)
5 Recovery upto 150 C (E 150) Min. 75.0 % (V)
6 Final boiling point (FBP) Max. 210 CEL
7 Residue Max. 2.00 % (V)
8 Research 0ctane number (RON) Min. 91.0
9 Motor 0ctane number (RON) Min. 81.0
10 Existent Gum Max. 40 g/m3
11 Sulphur, Total Max. 5.0 mg/dcl
12 0xydation stability Min. 360.0 min
13 Sulphur, Total Max. 150.0 mg/kg
125
14 Lead content as Pb Max. 0.005 g/l
15 Reid vapour pressure @ 38 C Max. 60 kPa
16 Vapour lock index-other months Max. 950.0
17 Benzene content Max. 1.0% (V)
18 Copper strip corrosion -3h/50 C Class 1
19 0lefin content Max. 21.0 % (V)
20 Aromatic content Max. 42.0 % (V)
21 0xgen content Max. 2.70 % (m)
22 Engine intake system cleanliness MFA used
126
MS – EURO IV
1 Colour, Visual Red

2. Density @ 15 deg C 720-775 kg/m3
3 Distillation
a) Recovery upto 70 deg C (E 70) 10-45% volume
b) Recovery upto 100 deg C (E 100) 40-70% volume
c) Recovery upto 150 deg C (E 150) 75 min% volume
d) final boiling point (FBP), max 210 deg C
e) Residue, max 2% volume
4 a) Research 0ctane number (RON), min 95
b) Motor octane number (MON), min 85
5 Gum content (solvent washed), max 5 mg/100ml
6 0xidation stability, min 360 minutes
7 Sulphur total, max. 50 mg/kg
8 Lead content (as Pb), max 0.005 g/l
9 Reid vapor pressure (RVP), max 60 kpa
10 Vapor lock index (VLI)
a) summer, max 750
b) 0ther months, max 950
11 Benzene content, max 1
12 Corrosion stripper for 3 hrs @ 50 deg C, Class-1
max
13 0lefin content, max 18% volume
14 Aromatic content, max 35% volume
15 0xyten content, max 2.7 %mass
0xygenates content:
a) Methanol, max 3% volume
b) Ethanol, max 5% volume
c) Iso-propyl alcohol, max 10% volume
d) Iso-butyl alcohol, max 10% volume
e) tertiary-butyl alcohol, max 7% volume
f) Ethers containing 5 or more carbon 15% volume
molecule, max
g) 0ther oxygenates, max 8% volume
127
8.1.4 BS-II MS
SN CHARACTERISTIC SPECIFICATION LIMIT

& UNIT
1 Colour 0range
2 Density @ 15 C 710.0 .. 770.0 kg/m3
3 Dist – recovery upto 70 C (E-70) 10.0 .. 45.0 % (V)
4 Dist – recovery upto 100 C (E-100) 40.0 .. 70.0 % (V)
5 Dist – final boiling point Max. 215.0 CEL
6 Residue Max. 2.00 % (V)
7 0ctane No. research Min. 88.0
8 Anti knock index (AKI) Min. 84.0
9 Existent gum Max. 40 g/m3
10 Potential gum (4 hr) Max. 50 g/m3
11 Sulphur, Total Max. 500.0 mg/kg
12 Reid vapour pressure @ 38 C 35 .. 60 kPa
13 Vapour lock index – Summer Max. 750
14 Benzene content Max. 3.0 % (V)
15 Copper strip corrosion – 3h / 50 c Class 1
16 Engine intake system cleanliness MFA USED
17 Lead content as Pb Max. 0.013 g/l
8.1.5 SUPERIOR KEROSENE

LIMIT & UNIT
1 Acidity inorganic in mg. KOH /gm Max. 0.00
2 Bloom on glass chimney Not darker than grey
3 Copper cor @ 50 C for 3 hrs Not worse than 1
4 Burn test char value Max. 20.0 mg/kg
5 Colour saybolt Min. 10.0
6 Density at 15 C Kg/m3
7 Recovery @ 200 C (T) 20.00 vol%
8 Dist – FBP Max. 300.0 CEL
9 Flash point Min. 35.0 CEL
10 Smoke point Min. 18.00 mm
11 Sulphur content total Max. 0.2500 mass %
128
8.1.6 HSD-EURO III
LIMIT & UNIT
1 Acidity – onorganix in mg. KOH/gm Max. 0.00
2 Acidity – total in mg. KOH/gm ---
3 Ash content Max. 0.010% (m)
4 Carbon residue (ramsbottom) on 10% residue Max. 0.30 % (m)
5 Cetane number (CN) Min. 51.00
6 Cetane index (CI) Min. 46.0
7 Dist. - %(v/v) recovered st 360 C Min. 95.0 vol%
8 Flash point (abel) Min. 35.0 CEL
9 Kinematic viscosity @ 40 C 2.000 .. 4.500 cSt
10 Desnsity @ 15 C 820.0 .. 845.0 kg/m3
11 Total sulphur Max. 350.0 mg/kg
12 Water content Max. 200.0 mg/kg
13 Pour point (winter) Max. 3 CEL
14 Cold filter plugging point (winter) Max. 6 CEL
15 Total contaminations Max. 24.0 mg/kg
16 Oxidation stability Max. 25.0 g/m3
17 Polycyclic aromatic hydrocarbon (PAH) Max. 11.0 % (m)
18 Lubricity, corr scar wear dia (wsd) – 60 C Max. 460.0 um
19 Copper strip corrosion – 3 hr 100 C Class 1
129
HSD-EURO IV
LIMIT & UNIT
1 Ash, max 0.01% mass
2 Carbon residue (Rams bottom) 0.3 % mass
on 10% residue, max Without additives
3 Cetane number (CN), min 51
4 Cetane index (CI), min 46
5 Distillation:
95% vol. recovery at deg C, max 360 deg C
6 Flash point
a) abel. Min 35 deg C
7 Kinematic viscocity@ 40 deg C 2.0-4.5 cst
8 Density @ 15 deg C 820-845 kg/m3
9 Total sulphur, max 50 mg/kg
10 Water content, max 200 mg/kg
11 Cold filter plugging point (CFPP)
a) winter, max 18 deg C
b) summer, max 6 deg C
12 Total contaminations, max 24 mg/kg
13 0xidation stability, max 25 g/m3
14 Polycyclic aromatic
Hydrocarbon (PAH), max 11 % mass
15 Lubricity, corrected wear scar
Diameter (wsd 1,4) @60deg C, max 460 um (microns)
16 Copper strip corrosion
For 3 hrs @ 50 deg C, max Class-1 rating
8.1.7 BS II HSD
LIMIT & UNIT
1 Acidity – igorganic in mg. KOH/gm Max. 0.00
2 Acidity – total in mg.KOH / gm ---
3 Ash content Max. 0.0100 % wt
4 Cu corrosion – 3 hr. 100 C Class 1
5 Cetane index Min. 46.0
6 Cold filter plugging point (summer) Max. 18 CEL
7 Density at 15 C 820.0..860.0 kg/m3
8 Dist - % (v/v) recovery at 350 C Min. 85.0 vol%
10 Flash point (abel) Min. 35.0 CEL
11 KV at 40 C 2.000 .. 5.000 CSt
12 Particulate matter Max. 24.0 mg/kg
130
13 Pour point (summer) Max. 15 CEL
14 Carbon residue (Ramsbottom) on 10% residue Max. 0.30 % (m)
15 Sediment by extraction Max. 0.0500 % (m)
16 Total sulphur Max. 500.0 mg.kg
17 Water content Max. 0.0500 % (V)
19 Total sediment Max. 1.50 mg/dcl
8.1.8 DHPP (A)

LIMIT & UNIT
1 ACIDITY – IGORGANIX IN MG. koh/g Max. 0.00
2 Acidity – total in mg. KOH/g Max. 0.500
3 Aromatics Max. 20.00 vol%
4 Ash Max. 0.010 wt%
5 ASTM colour Max. 3.5
6 Copper corrosion @ 100 c 3 hrs. Not worse than 1
7 Carnon residue ramsbottom on 10% residue Max. 0.20 wt %
8 Density at 15 C 800.0 .. 860.0 kg/m3
9 Diesel index Min. 50.0
10 Dist – FBP Max. 385.0 CEL
11 Dist – residue Max. 2.00 vol%
12 Flash point (PMCC) Min. 45.0 CEL
13 Kinematic viscocity @ 38 C 2.00 .. 7.50 cSt
14 Olefins content Max. 5.00 vol%
16 Dist – recovery upto 350 C Min. 90.0 vol%
17 Sediment Max. 0.050 wt%
18 Sulphur total Max. 0.25 wt%
19 Water content Max. 0.050 vol%
20 Particulate matter Mg/kg
8.1.9 LSHF DIESEL

LIMIT & UNIT
1 Acidity – inorganix in mg. KOH/gm Max. 0.00
2 Acidity – total in mg.KOH/gm ---
3 Ash content Max. 0.0100%wt
4 Cu corrosion – 3 hr 100 C Class 1
131
5 Cetane index Min. 46.0
6 Cold filter plugging point (winter) Max. 6 CEL
7 Density at 15 C 820.0..860.0 kg/m3
10 KV at 40 C 2.000 .. 5.000 cSt
11 Particulate matter Max. 24.0 mg/kg
13 Carbon residue (ramsbottom) on 10% residue Max. 0.30 % (m)
14 Sediment by extraction Max. 0.0500% (m)
15 Water content Max. 0.0500% (V)
17 Total sediment Max. 1.50 mg/dcl
18 Flash point (Penskey Marten). Min. 66.0 CEL
19 Total sulphur for LSHF HSD (0.2% wt) Max. 200 mg/kg
8.1.10 LDO
LIMIT & UNIT
1 Acidity – inorganic in mg. KOH/g Max. 0.00
3 Carbon residue remsbottom Max. 1.20 wt%
5 Flash point Min 66.0 CEL
7 Kinematic viscocity @ 38 C 2.50 .. 15.70 CSt
8 Pour point winter Max. 12 CEL
10 Copper corrosion @ 100 C 3 hrs Not worse than 1
8.1.11 FO
LIMIT & UNIT
1 Acidity – igorganic in mg.KOH/g Max. 0.00

5 Calorific valve net in kcal/kg ---
132
6 Gross calorific value Kcl/kg
7 Water content Max.1.00 vol%
8 Kinemetic viscosity @ 50 C Max. 125.0 180 CSt
9 Pour point winter max. 15.0 CEL
8.1.12 LSHS
LIMIT & UNIT

2 Carbon residue (conradson method) Wt%
5 Calorific value net in kcal / kg ---
6 Gross calorific value Min. 10500 cal/gm
8 Kinemetic viscosity @ 100 C Max. 100.0 CSt
9 Pour point Max. 72 CEL
10 Sediment Wt%
Sulfur content and viscisity of LSHS with different parties are as follows
PART NAME KV- MAX cst Sulfur % max.
IOC Trombay (TEC) 50 0.20

IOC BASSEIN 70 1.2
GNFC 100 1.3
YEHLANKA 100 1.3
NFL 100 2.0
IFFCO KALOL 100 2.2
GEB 100 2.0
8.1.13 FOOD GRADE HEXANE

LIMIT & UNIT
1 Density at 20 C 660.0 .. 687.0 kg/m3
2 Refractive index at 20 C 1.375 .. 1.384
3 Dist. IBP Min. 63.0 CEL
133
4 Disttiled between 64 – 70 C Min. 95.0 vol%
5 Non volatile residue Max. 0.0005 g/dcl
6 Reaction of non volatile reside Passes the test
7 Sulphur content Max. 5.000 mg/kg
8 Lead as Pb Max. 1.000 mg/kg
9 Benzene content Max. 0.050 vol%
10 Polycyclic Aromatic Hydrocarbons Passes the test
8.1.14 LABFS
LIMIT & UNIT
1 Acidity – inorganix in mg. KOH/g Max. 0.00
2 Aromatic content Max. 25.00 vol%
3 Bromine number Max. 1.0
4 Copper corrosion @ 50 C 3 hrs. Not worse than 1
5 Colour say bolt Min. 18.0
6 Density at 15 C 790.0 .. 820.0 kg/m3
7 Dist. – IBP Min. 140.0 CEL
8 Dist. – FBP Max. 270.0 CEL
9 Flash point Min. 35.0 CEL
10 Saturates Vol%
11 Smoke point Min. 18.0 mm
12 Sulphur content Max. 3000 ppm
8.1.15 LINEAR ALKYL BENZENE (LMW)

LIMIT & UNIT
1 Specific gravity @ 15.5 C 0.856 – 0.865
2 Bromine number Max. 0.010
3 Saybolt color Min. 29
4 Water Wt% max. 0.02
5 Sulfonation Wt% min. 98.0
6 2 phenyl alkanes Wt% min. 25.0
7 Alkyltetralines Wt% max. 0.50
8 Appearance Clear
9 N-alkylbenzene Wt. % min. 92
10 Paraffins Wt % max. 0.4
11 Molecular weight 235 – 239
8.1.16 TOLUENE
134
1 Acid wash colour Max. 2.0

2 Dist – 1% V CEL
3 Dist – 96% V CEL
4 Benzene Max. 0.050 vol%
5 C8 Vol%
6 Saturate Vol%
7 Tolune Vol%
8 Sp. Gravity @ 155 C 870.0 .. 874.0 kg/m3
8.1.16 TOLUENE
1 Acid wash colour Max. 2.0

2 Dist – 1% V CEL
3 Dist – 96% V CEL
4 Benzene Max. 0.050 vol%
5 C8 Vol%
6 Saturate Vol%
7 Tolune Vol%
8 Sp. Gravity @ 155 C 870.0 .. 874.0 kg/m3
8.1.17 EXPORT NAPTHA - DAHEJ
1 Density at 15 deg C 0.69-0.74

2 RVP at 100 deg F 10 psi max
3 C/H ratio 6.0 max
4 Total Sulfur 300 ppm max
5 FBP 180 deg C max
6 Gross Calorific Value 11000 K Cal/ Kg min
7 Total Pafaffins 62 PCT vol min
8 Colour (saybolt) +20 min
Cholride content 1 ppm max
Olefins 1 PCT vol max
135
8.2 CRITICAL TESTS AND THEIR
SIGNIFICANCE:
8.2.1 Cetane Number:

ASTM Cetane number of Diesel Fuel is the whole number nearest to the
percentage by volume of normal Cetane in a blend with Hepta Methyl Nonane
that matches with the ignition quality of the fuel. The Cetane nos. of Cetane
and Hepta Methyl Nonane are 100 and 15 respectively.
The Cetane number of a diesel fuel is determined by comparing its ignition

quality with those for blends of reference fuel of known Cetane Number under
standard operating conditions.
This is done by varying the compression ratio for the sample to obtain a fixed
delay period, that is time interval between the start of injection and ignition.
When the compression ratio for the sample is bracketed between those for two
reference fuel blends differing by not more than five Cetane Numbers, the
rating of the sample is calculated by interpolation.
8.2.2 Colour:
Colour of oil products is estimated by three methods.
ASTM Colour :
This method describes a procedure for the visual determination of the colour
of a wide variety of petroleum products such a lubricating oils, heating oils,
diesel fuel oils and petroleum waxes.
A sample container is filled upto an indicated level and placed in a housing. This
housing has a cover, viewing device, light source and glass colour standards,
note down the glass that matches with the colour of the sample or the next
higher one if exact colour matching is not possible and report the colour as less
than it.
Saybolt Colour :
This method is used for refined oils like Kerosene, Naphtha, solvents etc. The
sample is taken in a tube and compared with standards under a day light blue
lamp illuminating source. By matching the colour of the oil with the standard
colour the Saybolt can be determined from the appropriate chart.
136
8.2.3 Copper Strip :
A polished copper-strip is immersed in a given quantity of sample and heated
at a temperature, for a given time depending upon the characteristic of the
material being tested. At the end of this period, the copper strip is removed,
washed and compared with ASTM copper strips corrosion standards. The test
is done at 50oC for 3 hours or at 100oC for 2 hours, according to the requirement
of the fuel.
Significance:
This test indicates the presence of sulphides, which are highly corrosive. In the
case of Motor Spirit, Aviation fuels and gas-oil, it is necessary to protect the
fuel lines, etc. from corrosion especially when there are brass or copper parts.
8.2.4 Distillation :
Exactly 100mls. of the samples is distilled in a standard distillation under
prescribed conditions. Systematic observation of the thermometer readings and
the volumes of condensate are made and from the data, the results of the test
are calculated and reported.
Flash point :
A sample of oil in a cup, as specified for the different methods, is taken and
heated at slow and uniform rate, as stipulated in the test method. A small test
flame is directed into the cup at regular intervals and flash point is taken as the
lowest temperature at which the application of the test flame (specified size)
caused the vapour above the sample to ignite a distinct inside the cup.
Freezing Point :
The freezing point is the temperature at which crystals of hydrocarbons formed
on cooling disappear when temperature of fuel is allowed to rise.
Octane Number :
This is an important test for rating the antiknock of the motor fuels. The
knocking of the motor fuels is compared using blends of isooctane and Normal
Heptane in a single cylinder CFR engine. The rating can be done either by
Research method or motor method.
Penetration Test :
Several standard grades of Bitumen are commercially available, which are

normally classified into different grades on the basis of penetration test.
The other important tests are softening point and ductility.
137
The sample is placed in a suitable container and brought to a temperature of
25oC in a water bath. The weighed needle is brought to the surface and at the
end of 5 seconds interval, the penetration of the needle into the Bitumen, in
units of 1/0 mm, is recorded as “Penetration” of the Bitumen.
Pour Point :
Pour point is the lowest temperature expressed as a multiple of 3 oC at which

the oil ceases to flow when cooled and examined under prescribed conditions.
Silver Corrosion Test :
Silver-strips of 99.9% purity of specified dimensions, thoroughly polished and

having no deformity or blemishes on the surface, are kept in one litter of the
sample at 45oC for 16 hours and examined for surface colouration to assess the
corrosion on the basis of ratings prescribed by the method.
Smoke point :
This method describes a procedure for evaluating Kerosene in respect of its

ability to burn without producing smoke.
The smoke point is defined as the maximum flame height in millimeters at which
Kerosene will burn without smoking when determined in the apparatus and
conditions specified for the purpose.
Softening Point :
Bituminous material does not change from the solid state to the liquid state at
any definite temperature, but gradually becomes softer and less viscous as the
temperature rises. For this reason, the determination of the softening point
must be made by a fixed, arbitrary and closely defined method.
Softening point is the temperature at which a substance attains a particular

degree of softness under specified conditions of test.
Sulphur :
Sulphur by Bomb Method :
This method describes the procedures for determining Sulphur in petroleum

products like lubricating oil, residual fuel oils and such other heavy oils that can
not be burned completely in wicklamp. There are restrictions in this method
when the materials under test yields precipitate other than barium sulphate
during the course of the analysis.
Method:
138
A known quantity of weighed sample is oxidized in a specific bomb containing
oxygen under pressure. Sulphur is oxidized during combustion and is estimated
by gravimetric methods after converting to Barium sulfate.
R.V.P (REID VAPOUR PRESSURE)
The Reid Vapour Pressure Test method covers the determination of the
(absolute) vapour pressure of volatile nonviscous petroleum materials, volatile
crude oil and natural gas, liquids having nominal vapour pressure at 37.8 oC.
The sample is placed in the liquid chamber of the apparatus, which is connected
to air chamber fitted with a pressure gauge or a manometer of mercury. The
apparatus is heated to 38.8oC in a bath and shaken periodically, until a constant
pressure reading is obtained. Results are reported after making due corrections
for Barometer reading etc.
Viscosity :
Viscosity of a liquid is measure of the flow characteristics of the liquid.
The three methods commonly in use are:
Redwood I and II
Saybolt and
Kinematic Viscosities
In the case of Redwood I and II and Saybolt method, the sample is taken in a
container and heated under specified conditions and brought to the described
temperature at which the determination is required.
Allowing sufficient time for stabilization of temperature the oil is allowed to flow
through an orifice into a graduated container placed at the bottom. The
temperature is maintained constant through and time of efflux for a fixed
volume collected is noted by starting a stop watch when orifice is opened, and
stopping the same when oil has filled upto the mark in the receptacle. The
results are reported as Redwood seconds or Saybolt seconds for the given
temperature. In the case of Kinematic Viscosity, time in seconds is measured
for a fixed volume of liquid to pass through an orifice under an accurate
reproducible head and closely controlled temperature. The Kinematic Viscosity
is calculated from the flow time and the calibration constant of the viscometer.
Water and Sediment :
Centrifuge Method:
A known quantity of the oil mixed with a specified quantity of solvent is

centrifuged under specified conditions. The volume of water and sediment is
observed at the bottom of the centrifuge, correct to 0.05 ml to 0.1 ml.
139
Significance:
In the case of crude oil and also of other products the test helps to deduct the
quantity of water and sediment from the total observed volume for calculating
the quantities of oil actually delivered. Large differences are noticed at times
and correct deductions save a lot of money for the purchaser. The test also
helps on estimating the contamination of the product and predicts
sedimentation in the storage tanks. In the case of fuel oil, the water and
sediment affect the performance of the oil and large quantity of sediment would
choke the burner tips.
O M & S MANUAL
Chapter – 10
140
Chemical, Additives
&
MSDS
CHAPTER – 10
A number of chemicals and additives are used in a petroleum refinery. In OM&S,
following Chemicals and Additives are handled:
1. Orange Dye
2. Multi Functional Additive (MFA)
3. Metal deactivator (MDA)
4. Caustic
5. Mercaptan
6. Methanol
7. Lime
Orange dye, MFA and MDA is used in OM&S receipt section. ASA is used in units
for dozing in ATF. In case conductivity of ATF is less, ASA is dosed in tank from
top.
Caustic, Methanol and mercaptan is handeled by LPG section. Caustic &

Methanol is send to units for their use. Mercaptan is used in LPG mounded
bullets for giving smell in LPG.
141
Lime is used by Bitumen.
10.1 ORANGE DYE :

Orange Dye is added in MS. Dye injection in the product is done at chemical
plant. 3 ppm of dye is added im MS. The dye also comes in liquid form but in
refinery powder dye is used.
DOSE : 3 ppm.
APPEARANCE:
It is in powder form and having redish colour. It is odour less.
HEALTH HAZARD:
• It may cause sensation to skin or eye on contact.
TREATMENT:
• Use large amount of water.
SAFE USAGE & HANDLING:
• Use respiratory propective equipment.

• use eye / face protection
• wear gloves & protective clothings.
10.2 MFA:
MFA comes in the drums. A shade on the platform is provided to store these
drums. Drums are stored in vertical position.
Two vessels are provided to store MFA. For decanting the contents from drum
to storage vessels; two pumps 13P02A and B are provided.
Ten drums can be unloaded at a time through a manifold. Drums are placed
horizontal and a flexible hose is connected with the nipple to the drums. Other
end of the flexible hose is connected to manifold which is inturn connected to
the suction of pump 13P02A/B.
Discharge of these pumps is connected to vessels. Vessels can be bypassed

and MFA can be pump through the line connected to suction header and
discharge header of 13P02A/B. Vessel’s level can be checked with the help of
level indicator. Vessel is connected through a line to the suction of two pump
viz. 13 P01A and B. Discharge of these pumps is backed to vessel as return
header.
142
It is dosed in MS at the rate of 102 ppm or as per advice of Process.
PROPERTIES:
Sp. Gr. @ 60 F 0.857

Flush pt. C 43
KV 10.28
Pour pt. C -21
MATERIAL SFETY DATA SHEET (MSDS) of MFA:
APPEARANCE:
It is dark brown liquid and has punjent smell.
HEALTH HAZARD:
• SKIN: contact with skin creats irritation.

• EYE : it is eye irritant.
• EXPOSURE : if over exposed with vapours causes drowsiness,
weakness, headache and dizziness.
TREATMENT:
• In case of contact : immediately flush eyes or skin with plentry of

water.
• Call physician.
• In case of inhalation remove to fresh air. If not breathing, give
artificical respiration preferab ly mouth to mouth.
SAFE USAGE & HANDLING:
• Use respiratory propective equipment.

• use eye / face protection
• wear rubber hand gloves & gum boots. Wear full protective apron.
• Never using cutting torch (gas cutting) for cutting the empty drums.
10.3 MDA ( METAL DE ACTIVATOR)

Metal deactivator (MDA) is used as fuel additive and lubricant additive and
added in petrol. It is added 5 cc / kl of MS and not more than 1.35 cc /kl of
petrol. It comes in 180 liters of drums.
PHYSICAL AND CHEMICAL PROPERTIES:
Physical state: Viscous liquid
143
Appreance: Black
Odour : Odourless
Solubility: Soluble in MS
FIRE AND EXPLOSIVE HAZARDS DATA:
Explosivity: Moderte
Flammability:Dangerous
Extinguishing media: Foam, DCP, water spray may be in effectie
Special procedures:
Water may be used to cool fire exposed container. If leak or spill has not ignited,
use water spray.
HEALTH HAZARD:
INHALATION: It may cause headache, fatigue, vomiting.

CONTACT: Irritation on contact with skin. Use water & soap to reduce
the effect.
EYES: Irritation.
10.4 CAUSTIC SODA

Caustic is received, stored and supplied by OM&S but consumed by
processing unit and TPS.
In Gujarat Refinery caustic is mostly received in the form of liquid. It

may come in tank wagons and / or in tank trucks. When the suppliers
are not very far from here, it always comes in tank trucks. Most of
these trucks are fitted with their own pump and carry their own hoses.
FACILITIES:
The caustic handling facility in OM&S consists of :
• Truck unloading point (one)

• Two pumps (one Russian make and one Kirloskar pump) H-1 and H-
2
• Two storage (cone-proof) tanks of 100 M3 capacity each (tank nos.
124, 125)
• Delivery lines to processing units and TPS.
RECEIPT:
144
a. Weigh the truck on the weigh brodgeG and record it.
b. Wear protective clothing including hand gloves, face shield.
c. Draw samples from the truck and send it is laboratory for quality.
d. Sample to be taken from each compartment from top.
e. Connect the discharge hose from the pump mounted on the truck to
the discharge / return line of h-1/h-2 going to tanks 124/125. 0pen
the tank valve of the tank which is to receive.
f. In case truck is not fitted with a pump, then connect the hose from
the delivery line of truck to the suction side of pumps h-1/h-2.
g. Ensure that the valve on the discharge line of h-1/h-2 going to
TPS/Process units is shut tight.
h. Take the opening dip of the receiving tanks.
i. After starting the cooling system start the pump.
j. Keep track of the contents of the tanker by using the dip rods of the
truck.
k. Stop the pump when truck is empty.
l. Disconect the hose.
m. Keep water hose running during the entire operation. Keep water
shower also on.
n. Wash out any spillages with water.
o. Close the system
p. Remove the protective clothing
q. Take the closing dip of the receiving tank after half an hour.
r. Weight the empty truck. The difference in quantities is the net
quantity delivered.
s. Make necessary entries in the register provided for keeping account
of caustic.
SUPPLY
There are two caustic storage tanks. One tank is earmarked for the
preparation of solution of 30% strength by addition of water into the
tank and circulating it. Caustic solution is supplied from this tank.
a. use all the protective equipments.

b. Circulate the tank for 30-60 minutes depending upon the volume
in the tanks.
c. Collect sample from the tank to ascertain the strength of solution.
See that it meets the requirement of the consuming parties.
d. Take the opening dip of the tanks.
e. Ensure that only receiving party is open to receive caustic. Others
on the receiving line are closed.
f. Line up the tank and start pumping.
g. Stop when receiving party requests to stop.
h. Take closing dip of the tanks.
i. Ascertain the quantity cleared from the tank and check with
receiving party that they received the same quantity.
j. Make necessary entries in the register.
145
k. Close the system.
PRECAUTIONS:
Precautions to be taken while handling caustic:
1. Use:
i. Goggles
ii. Face shield
iii. Rubber apron
iv. Jacket
v. Rubber hand gloves
vi. Rubber boots
2. Avoid inhalation of caustic vapours and splasing of caustic soda.

3. Whenever caustic solution is spilled, wash it with wate
immediatelty.
4. Always keep a running water hose standby.
5. Use protective equipment while dipping, sampling or attending
any leak.
EMERGENCY TREATMENT
1. If any part of the body is contaminated by caustic sods, wash it

off quickly with water.
2. If clothing is contaminated, remove it while under the shower and
wash the body thoroughly.
3. If eyes are involved, wash them with copious quantity of water.
4. report for medical attention.
MATERIAL SFETY DATA SHEET (MSDS) of CAUSTIC
Trade Name: Caustic Soda

Formula: NaOH
Physical state: Liquid

Appreance: white to colour
Odour : odourless
Specific gravity: 1.53 (50% solution)
Strength: 47 TO 49%
146
Explosivity: Non combustible

Flammability:Non flammability
Special procedures:
Use water spray to cool fire. Take care not to splash this material.
HEALTH HAZARD:
INHALATION: It may cause damage to upper respiratory tract.

CONTACT: Skin severe burns often resulting in deep ulceration and
ultimate scarring.
EYES: Very rapidly causes severe damage.
EMERGENCY TREATMENT:
Remove victim to fresh air.

INGESTION: Give large quantities of milk or water to conscious victim only.
Vomiting may occur spontaneously but should not be induced.
Get proppt medical attention.
CONTACT: Flush immediately with plently of water, while removing
contaminated clothing.
EYES: Wash eyes immediately with large amount of water.
SAFE USAGE DATA:
a. Use safety googles.

b. Use dust masks.
c. Use PVC gloves, plastic face shield, gum boots, PVC
apron.
10.5 ETHYL MERCAPTAN

GENERAL:
The supply of ethyl mercaptan comes in metal urms of 190-200 litres each.
The contents of drums are transfereed to an underground tank by gravity. The
under ground tank is a pressure vessel.
Before receiving LPG from units into the LPG bullets, a calculated quantity of
ethyl mercaptan is added to the empty bullet before it is lined up for receipt of
LPG.
PROPERTIES:
147
It is colourless liquid with pentrating garlic like odour. This liquid is added in
PLG for detection of leakage from the LPG cylinder.
It is dangerous when it decomposes due to heating or by coming in contact

with acid or acid fumes. It emits highly toxic fumes of oxides of sulphur. It
will react with water or steam to produce toxic and flammable vapours. It can
react vigorously with oxidizing materials.
It is flammable and dangerous when exposed to heat flame / atmosphere.
DOSEAGE
Maximum – 55 ppm
Minimum – 35 ppm
ADDITION SYSTEM AND PROCEDURE
A reciprocating pump is provided for pumping required dosage of mercaptan to

the particular bullet. Dosage can be increased / decreased by adjusting strokes
of the pump.
CHARACTERISTICS OF ETHYL MERCAPTAN
1. Colour water white to pale yellow

2. distillation 1% not below 34.4 C
3. Ethyl Mercaptan 98.5% content, % by wt.
4. Sp. Gravity 0.840 – 0.846
5. solubility in water 1.8 %
6. Flash point – F below zero
7. Average mol wt. 62
8. Sulphur content, % wt. 50.9
MATERIAL SFETY DATA SHEET OF ETHYL MERCAPTAN
Trade name: Mercaptan

Product name: EHANETHAOL
Formula: C2H5SH
Physical state: liquid

Appreance: colourless
Odour: garlic / penetrating
Salability in water: slightly
Specific gravity , 20 C 0.8390
148
Flamability: dangerous
Special procedure: In case of fire keep drums cool by spraying with water
avoiding direct contact. Emits highly toxic, Sox, fumes in high temperature.
Flash back may occur.
HEALTH HAZARD:
Headace, nausea fatigue, slight irritation to eyes. In case of inhalation remove

victim to fresh air give artificial respiration (not mouth to mouth). Wash eyes
immediately with large amount of water.
SAFE USAGE DATA:
Use goggles, rubber hand gloves
10.6 MATERIAL SFETY DATA SHEET (MSDS) of METHANOL
Trade Name: Methanol

Formula: CH3OH
Physical state: Liquid

Appreance: Colourless
Odour : Alcohol
Solubility: Soluble
Specific gravity: 0.79
Explosivity: Moderte
Flammability:Dangerous
Extinguishing media: Foam, DCP, water spray may be in effectie
Special procedures:
Water may be used to cool fire exposed container. If leak or spill has not ignited,
use water spray.
HEALTH HAZARD:
INHALATION: It may cause headache, fatigue, vomiting.

CONTACT: Skin readily absorbed producing symptoms similar t in
halation.
EYES: Irritation.
149
10.7 LIME
MATERIAL SFETY DATA SHEET (MSDS) of LIME
Trade Name: Lime Calcium Hydrate

Formula: Ca(OH)2
Physical state: Solid

Appreance: white
Odour : odourless
Specific gravity: 2.08 – 2.34
Solubility: 0.185 gm/ 100 CC
Explosivity: Non combustible

Flammability:Non flammability
Special procedures:
Reacts violently with phosphorus, cheats heat on mixing with water.
HEALTH HAZARD:
CONTACT: Skin burning sensation and inflammation.
EYES: Eyes – pain and watering.
150
O M & S MANUAL
CHAPTER-11
CLOSED CIRCUIT TV
(CCTV)
GUJARAT REFINERY
151
CLOSED CIRCUIT TELE VISIONS - CCTV
11.0 INTRODUCTION
CCTV’s are provided in different sections of OM&S like Receipt, Despatch, TTL
and LPG to have proper and fine observation of the entire work place.
At various locations different cameras have been provided. The movement of

the cameras can be carried out from the respective control rooms.
A control box for movement as well as selection of the camera is provided in

each of the control room.
In receipt sections, there are 3 nos. of cameras provided at following 3 locations

:
1. Near Bitumen plant
2. Near FCC Plant
3. Near Laboratory cross roads
All the 3 cameras can be used for viewing the field area in OM&S Receipt control
room. In other areas i.e Despatch, LPG and TTL sections separate cameras
have been installed.
11.1 CAMERA LOCATION

(Dispatch, LPG, TTL) :
SR NO CAMERA NO. LOCATION NEAR
1 CAM 1 Tower No. 47 South Gate
2 CAM 2 High Mask Tower Nr Mounded
bullet no.-9
3 CAM 3 Tower no. 39 Between LPG C/R
& LPG gantry
4 CAM 4 Tower No. 83 TTL weigh bridge
5 CAM 5 Tower No. 43 TTL White Oil
pump house
6 CAM 6 Tower No. 48 North Gate
7 CAM 7 Entrance south Gantry no. 5
11.2 CAMERA LOCATION

(RECEIPT TANFARM ) :
SR NO CAMERA NO. LOCATION NEAR
152
1 CAM 1 Mask Light East of tk 100 on
ML-11 road no. 7
Tanks –
99,100,102,103
2 CAM 2 Mask Light East of tk-78 on rd -
ML-28 7
Tk-78,76,91,92
3 CAM 3 Mask Light South of tk 777 (rd
ML-03 crossing 5&8) road
no. 7
Tanks – 777,521,60
4 CAM 4 Mask Light East of tk 208 on
ML-10 road crossing 5 & 6
Tanks –
207,208,905,906,907
5 CAM 5 Mask Light Rd crossing 3 &4
ML-19 Tanks – 908,
909,910
11.3 MONITOR LOCATION :

SR NO MONITOR NO. LOCATION
1 MON 1 DWSPATCH CONTROL ROOM
2 MON 2 CPNM ROOM
3 MON 3 LPG CONTROL ROOM
4 MON 4 TTL CONTROL ROOM
5 MON 5 RECEIPT CONTROL ROOM
6 MON 6 RECEIPT CONTROL ROOM
11.4 KEY-BOARD LOCATION :

SR NO. KEYBOARD NO. LOCATION
1 KB 1 DESPATCH CONTROL ROOM
2 KB 2 LPG CONTROL ROOM
3 KB 3 TTL CONTROL ROOM
4 KB-4 RECEIPT CONTROL ROOM
153
O M & S MANUAL
CHAPTER-12
SAFETY & EMERGENCY HANDLING

IN OM&S
GUJARAT REFINERY
154
SAFETY SYSTEM & EMERGENCY
HANDLING IN OM&S
12.1 GENERAL SAFETY REGULATIONS:
(1) Smoking is not allowed in any part of the Refinery area except in smoking
booths specifically constructed for this purpose. Smoking outside
specified area is forbidden.
(2) When any dangerous/unsafe condition is observed, it should be

immediately reported to your supervisor and/or Fire and Safety Division.
(3) Employees should be careful to clean the job area as soon as the job is
completed. Good house keeping will eliminate many unnecessary
hazards causing accidents.
(4) Where walkways are provided, use them instead of short cuts. If you are
to use the roadway keep to right side so that you can see the
approaching vehicle.
(5) All stairways, platforms and walkways must be kept clean at all times.
(6) Exercise care in walking and in moving about your work. Avoid slipping,
tripping or falling. Do not attempt major work while standing on line or
fitting. Avoid running during normal operations.
(7) Walking on pipeline is prohibited.
(8) Compressed air must not be used for blowing dust out of clothing.
(9) Never look directly into the arc produced while welding without proper
eye protection.
(10) Horseplay is strictly forbidden. Apply your thoughts to safety and

thorough workmanship.
(11) Do not use defective equipment of any kind.
(12) Keep the fire fighting equipment free of obstructions, as these are
required to be used in emergencies.
(13) Any injury, no matter however slight, must be reported to your

supervisor immediately and treatment obtained. Even a small accident
can become a potential source of permanent disability.
155
(14) Should your clothes get saturated with oil, change them immediately and
wash the affected parts of your body with water.
(15) In case of an acid/caustic splash, wash yourself with copious quantity of

water and report immediately to medical center for further
treatment/advice.
(16) No clothing or other inflammable material should be dried out on steam

lines of any other hot equipment.
(17) If any gas leak occurs, inform your supervisor and the Fire Station and
ensure that automotive equipments are kept away from the
contaminated area.
(18) Operators must always stand on the windward side when taking samples
or draining lines or equipment.
(19) When a person is working in any vessel, one person must be stationed
at the opening of the vessel as a watcher. Persons working in the
confined places should use safety belt with a lifeline. The free end of a
lifeline should be held by the man kept outside the vessel. Breathing
apparatus should be worn, if necessary.
(20) Walking on or over any mechanical or rollers conveyor is strictly

prohibited.
(21) When working around moving machinery the wearing of loose clothing
as Dhotis, Lungies, etc. is strictly prohibited.
(22) Employees should not walk on the rail tracks.
(23) Passing under railway wagons as a short cut is very dangerous and is
strictly prohibited.
(24) Loose shunting of railway wagons is prohibited.
(25) Sample bottles should not be used for any purpose other than taking
samples.
(26) Motorcycling through/into any operating area is prohibited.
(27) Protective valve caps must always be placed on all gas cylinders
(Oxygen, Acetylene, Ammonia, Carbon Dioxide, LPG, Chlorine etc.)
except when in use. Gas cylinders should never be dropped especially
from trucks or plat forms.
(28) Never remove or adjust the guard while the machinery is in motion. The
machine must be rendered inoperative by the removal of fuses or such
156
other methods before the guard is removed or some repairs/
adjustments are carried out. Guards must, however, be put back in
position before the machinery is operated.
(29) It is strictly prohibited to sue gasoline or any other highly inflammable

liquid or corrosive chemicals such as caustic soda or acid for cleaning
purposes.
(30) When electrically driven pumps, compressors, etc. are shut down for
repairs the electrical circuit must be isolated before repairs commence.
(31) For maintenance work inside vessels or tanks which re gas free, a low
voltage transformer must be used on the electric light extension cord.
The voltage must not exceed 24 volt.
(32) Do not tamper with or attempt to repair instruments. Only instrument

section is permitted to work on instruments.
(33) Do not lee tools or materials where they may accidentally drop on
persons below.
WORKING SAFETY:
House Keeping:
a) Maintain the working area clean and orderly.
b) Place all cleaning rags in proper containers.
Installation of Blinds:
Before opening any flanged joint for the installation of a blind, the following
should be observed:
a) Ascertain from the designated operating personnel that the equipment

or piping is properly prepared and released for blinding.
b) Determine what product or material has been contained in the

equipment or pipeline. If this material is hazardous, obtain and wear the
appropriate protective clothing or equipment.
c) Check to be certain that lines and equipment have been depressursied

and drained. Be certain that drain valve are open and clear by inserting
wire through the valve and into the pipe or equipment.
FACE SHIELDS:
157
Certain operations present a hazard to the face as well as to the eyes. In such
cases, face shields provide suitable protection. The head bond is the only
adjustable feature on the face shield. It should be adjusted so as to hold the
shield in place. Since the shield is of plastic, it is easily scratched. It should be
replaced when these scratches cause interference with a vision.
HAND PROTECTION:
a) Protective gloves are required to be used for protection of the hands

against the injuries effect of chemicals, heat, heavy material, oil,
electricity, etc.
b) Rubber gloves give protection to the hands against the injurious effect
of chemicals.
c) PVC gloves give protection against chemicals and solvents. Chemicals or

oil should be washed from the gloves after use.
d) Canvas gloves should be used while handling material or working on

equipment where there is possibility of getting cuts and abrasion on
hand.
FOOT PROTECTION:
Rubber boots are used to protect against chemical splashes. Safety shoes are
used to protect against chemical splashes. Safety shoes are used to protect
against heavy weight.
BODY PROTECTION:
a) Rubber and PVC Aprons:
These provide protection for the body when working with chemicals,
aromatics or solvents.
b) Leather Aprons:
These are used to prevent burns from flying sparks.
SAFETY BELTS:
All employees must use safety belts to give protection in performing jobs at
elevated locations where adequate protection against falling is not available.
Safety belt and body harness with a life fastened at the back should always be
used wherever one works on an elevated location or enters into tanks or bins
so that he can be easily lifted and brought out. Belt and harness for this purpose
may be chrome tanned leather or cotton webbing. Webbing is much reasonably
158
well in the vicinity of chemicals’ tanks. Well-tanned leather is not easily attacked
by most chemicals but it should not be left in contact with chemicals for long.
Bulk truck loading persons to be instructed to use safety belt and use hand
railing system. Movement of persons on tankers is not permitted.
HEAD PROTECTION:
Safety helmets are rigid and designed to protect the workman’s head not only
from impact but also from flying particles and electric shock or any combination
of the three.
12.2 ACCIDENTS - ADMINISTRATIVE PROCEDURE:
Reporting of the Accidents:
With a view to timely transmission of the information or submission of the notice

of the accident to the Inspector of Factories within the stipulated time
prescribed under the rule 103 of Gujarat Factories Rule, 1963 the following the
procedure has been followed by Gujarat Refinery.
Any accident, however, small to an employee is reported to his supervisor/shift

in charge.
When the injured person is not in a position to report himself, such reports are
made by anybody present at the site of the accident. As soon as the supervisor
gets the information, he arranges for the ambulance from the hospital and also
informs the following:
1. Fire Station
2. Hospital
3. Sectional/Department head
4. Refinery Shift Manager
ELECTRICAL SHOCKS:
a) General Guidelines:
(1) ACT AT ONCE - DELAY IS FATAL

(2) DEATH FROM ELECTRIC SHOCK IS RARELY INSTANTANEOUS
(3) PATIENT MAY BECOME UNCONSCIOUS ONLY DUE TO SEVERE SHOCK.
THEREFORE, LIFE CAN BE SAVED BY IMMEDIATE ARTIFICIAL
RESPIRATION.
(4) SEND FOR, BUT NEVER WAIT FOR, A DOCTOR
159
(5) CONTINUE ARTIFICIAL RESPIRATION UNTIL A DOCTOR PRONOUNCES
DEATH.
b) Removal from Electrical Contact:
(1) If the person who has received the shock is still in contact with the
apparatus/circuit, immediate action should be taken to remove him.
(2) Switch off the current immediately or send someone to do so.
(3) If it is not possible to switch off the current immediately and render the
apparatus/circuit dead, steps must be taken to remove the injured
person keeping in mind THAT THE CIRCUIT IS ALIVE.
(4) Care should be taken to ensure that the rescuers do not themselves
become casualties. Contact through bare skin of the person to be
rescued and the rescuer with a passage to earth must be avoided.
(5) Do not attempt to remove a person from contact with high voltage
without using articles suitably insulated for the system voltage. When
attempting to free a person from contact low or medium voltage use
rubber gloves, boots, mats, or insulated sticks, but it these are not
available, use a loop of rope or a coat to drag the person free. Whatever
is used should be dry and non-conduction.
c) Action after removal from electrical contact:
(1) If the person’s clothes have caught fire, extinguish the fire by
smothering.
(2) Get the patient into fresh air.
(3) In cold weather, avoid exposure of the casualty to cold; if possible use
blankets.
(4) If the patient is unconscious, immediately check and remove, all foreign
matters like tobacco, false teeth, etc. if any, in his mouth and throat.
Now start ARTIFICIAL
RESPIRATION AT ONCE according to the instructions given in the Resuscitation

chart. Continue it until the doctor arrives or breathing has been restored to
normal.
(5) If the patient recovers before medical assistance arrives, regulate your
artificial respiration to the rate of patient’s breathing, and when he has
sufficiently recovered make him conformable and give him hot tea. Do
160
not allow patient to exert himself even by waling until he has been seen
by a doctor as the shock may have affected his heart.
(6) On the arrival of the Medical Officer, he will take charge and issue further
instructions, as may be necessary. If the patient requires to be sent to the
hospital for treatment or to be kept under observation. The Medical Officer will
make necessary arrangements.
12.3 B U R N S:
(1) In case of burns from corrosive fluids, get the patient under a shower or
if a shower is not available in the vicinity, wash the area of burn with
copious quantity of clean water.
(2) In case of burns from fire, hot metal or from contact with electrical
apparatus, do not wash with water.
(3) On the burn, keep several layers of sterilized gauge soaked in 5%

solution of Tannic acid or burn-ointment which ever is available in the
first aid box, and do the bandage lightly. Application of dressing, which
is surgically unclean, is more dangerous than no dressing. Strong
antiseptic like Bichloride or Mercury or Carbolic acid should not be used.
Send the patient to First Aid Post/Hospital.
(4) In cold weather keep the patient warm with blankets or coats.
(5) If the patient has become unconscious:
(a) Carry him to fresh air,

(b) Lay him with head lower than rest of the body.
(c) Loosen clothing around his body.
(d) Rub his limbs towards the body.
(6) Further treatment will be decided by the Medical Officer.
(7) If the patient’s breathing is interrupted, start artificial respiration at once

according to the instructions given in the Resuscitation charge and
continue breathing has been restored to doctor arrives and tacked
charge of the patient.
(8) Administer oxygen from an oxygen inhaler in conjunction with manual

artificial respiration. If the breathing is normal, there is no need to apply
artificial reparation.
(9) On the arrival of the Medical Officer he will charge if the patient is
required to be sent to the hospital for treatment or to be kept under
observation, the Medical Officer will make the necessary arrangements.
161
(10) If the patient has sufficiently recovered before medical assistance arrives
make him conformable and give him hot tea or coffee. Do not allow the
patient to exert himself even by walking until he has been examined b a
doctor.
Safety in refinery is for human being and property. Both are most
important during normal running operation of refinery. This requires
use of safety appliances in proper way as per the requirement of the
job and the knowledge of the job. The oisd standards should be
followed to achive full safety. Further the fire in refinery to be avoided
for achieving no loss to property.
In common language, fire is burning of matter. In technical terms,

fire is a chemical reaction where matter reacts with oxygen under
certain conditions to release heat and light energy. From the above,
it is clear that three conditions are essential component of any fire :
- Fuel (i.e. combustible matter)

- Oxygen
- Heat
Definition
12.4 FIRST AID FOR BITUMEN BURNS
1. Do not attempt to remove any Bitumen.
2. DO NOT use ice.
3. DO NOT remove clothing that is stuck to the bitumen – this may

cause more injury.
4. DO remove belts, rings and any other constrictions, provided doing

so does not cause further damage to the affected area.
5. DO NOT attempt to clean the affected area.
6. DO NOT apply lotions or ointments.
7. Pour cold water for a minimum of 20 minutes. (If a burns kit is

available, use the gel pads to cool.
162
8. Cover any exposed burns (i.e those not covered with bitumen) with
clean non-stick dressings to exclude the air.
9. The patient may be in shock – keep him/her warm, but DO NOT let
blankets touch burns or bitumen.
10. Eye burns – flush with water (for 20 minutes). DO NOT REMOVE
THE BITUMEN.
11. Unless patient has only superficial burns (minor splashes), he or she
should be taken to the nearest Medical Centre or Hospital. Dial
6444/7444 for an Ambulance as promptly as possible. Wherever
possible, get somebody to telephone ahead to let medical staff know
that a bitumen burn case is on the way.
12. An experienced person should accompany the injured partly through

the system until they reach the hospital to prevent incorrect or
uneducated removal of bitumen.
13. DO NOT give anything by mouth until cleared to do so by medical

personnel.
12.5 DEFINITIONS :
A. FLASH POINT :
The minimum temperature at which the liquid gives sufficient

vapour that this vapour, when mixed with air, forms an ignitable
mixture and gives a momentary flash on application of a small
pilot flame under specified conditions of test.
B. CLASSIFICATION OF PETROLEUM PRODUCTS :
As per petroleum Act. Following classification of petroleum

products is adopted :
Class A Products : Flammable liquids having flash point

below 23º Centigrade.
Class B Products : Flammable liquids having flash point of 23º
Centigrade and above but below 65º
Centigrade.
Class C Products : Flammable liquids having flash point 65º C
and but below 93º Centigrade.
163
Excluded Petroleum: Flammable liquids having flash point of 93
degrees C and above.
Liquefied petroleum gases are guided by Gas Cylinder Rules

1981. Table 2.2 gives the class of various hydrocarbon streams
in a refinery.
C. AUTO-IGNITION:
The lowest temperature to which a solid, liquid or gas requires to

be raised to cause self-sustained combustion without initiation by
a spark or flame.
D. EXPLOSIVE LIMITS:
Explosive limits are those concentrations of inflammable vapour

or gas in air below or above which propagation of a flame does
not occur on contact with a source of ignition.
E. LOWER EXPLOSIVE LIMIT:
The Lower Explosive Limit (LEL) is the minimum concentration of

inflammable vapour/ gas in air below which the vapour air mixture
is too “lean” to burn or explode.
F. UPPER EXPLOSIVE LIMIT :
The Upper Explosive Limit (UEL) is the maximum concentration

of inflammable vapour/ gas in air above which the vapour air
mixture is too “rich” to burn or explode.
A vapour or gas in air mixture above its UEL should always be potential hazard
since it may acquire vapour concentration below UEL at any time due to
constant dilution in atmosphere.
Auto ignition temp., Flash point and Explosive Limits of some of the petroleum
products are given in Table 2.2.
164
12.5.1 AUTO IGNITION, FLASH POINT AND
EXPLOSIVE LIMITS OF SOME OF THE
PETROLEUM PRODUCTS & THEIR CLASS;
Sr. No. Material Auto Flash Explosive range Class
ignition point c volume % in air
temperatur Lower Upper
ec limit limit
1. Crude 0il Depends 19 Depends A
upon upon
nature of nature of
crude crude
2. Hydrogen 585 Gas 4.1 74
3. Ethane 514 Gas 3 12.5
4. Propane 466 Gas 2.4 9.5
5. Butane 430 Gas 1.5 9
6. Benzene 563 -11 1.3 7.1 A
7. Toluene 536 4.5 1.2 7.2 A
8. Naphtha 288 -18 1.1 5.9 A
9. Gasoline 246 -7 1.4 7.6 A
10. ATF 254.4 38 0.7 5 B
11. SK 254 35 0.7 5 B
12. HSD 256.6 32 0.7 5.0 B
13. LDO 66 C
14. LSHS 316 66-160 C
15. FO 262-407 65 and C
above
16. Bitumen 485 205
17. Raw Coke 315.6
18. MTO 32.2 B
12.6 FIRE PROTECTION FACILITIES ON STORAGE TANKS
Following types of tanks are used for storing petroleum products and LPG.
FIXED ROOF TANKS
FLOATING ROOF TANKS
FIXED CUM FLOATING ROOF TANKS
LPG MOUNDED BULLETS
165
HIGH VOLUME LONG RANGE MONITORS (HVLR) are provided in large
capacity tanks. The details of HVLR for tanks are given in the tabl.
SL. Location of unit /FW Capacity of Flow No. Of

NO. network loop where The HVLR requirement HVLR
high volume long range monitor for each monitors
monitors are installed monitor in installed
m3/hr.
12 ARROUND TANK FARM 2000 GPM 454.24 12
(TK NO. 905 TO 910)
13 ARROUND TK. NO. 901 2000 GPM 454.24 4
TO 904
14 ARROUND TANK 2000 GPM 454.24 4
NO,.770,771
15 ARROUND TANK 2000 GPM 454.24 4
NO,.701 TO 704
16 LPG MOUNDED 1000 GPM 227.12 2
BULLETS (OLD)
FIXED ROOF TANKS:
Fixed roof storage tanks are provided with foam chamber connections. Theses
connections are connected to fire appliance by means of fire hose. The fire
appliances draw water from hydrants and after inducting 3% foam compound
discharge foam to the tank. The foam chamber connections are brought to the
road side. The water monitors are provided on the bund wall around the storage
tank for cooling action during emergency.
FLOATING ROOF TANKS.
Floating roof tanks properly designed and kept in good mechanical condition
have a limited fire hazard. Experience has shown that the fires take place at the
seal of the rim. Fire water ring around the tanks and foam poures are provided
in floating roof tanks. The water monitors are provided on the bund wall around
the storage tank for cooling action during emergency.
12.7 LPG MOUNDED BULLETS:
The LPG bullets are provided with water spray system. These can be operated
through a deluge valve (locally as well as from new control room). Further
monitors are provided near the bullets. The bullets are provided with gas
tetecotr system. Incase of any leak, gas detector system sence the leak & give
alarm in control room DCS.
166
LPG TANK WAGON LOADING:
Tank Wagon platforms are provided with water sprinklers. These sprinklers are
operable through 3 deluge valve locally located.
12.8 FOAM FLOODING SYSTEM FOR TANK WAGON RAILWAY GANTRY
Foam Flooding Systems have been provided for 6 th gantry to handle any Fire
emergencies. The system is associated with foam nozzles ,covering total 19
Zones. It has got 8 nos inlet connections at the each side of road to get the
system activated through Foam solution pushed by help of Foam Tenders.
12.9 ACTION TO BE TAKEN ON NOTICING FIRE:
1. Shout “Fire Fire”

2. Try to extinguish the fire with the fire fighting equipment available.
3. Inform the fire station from the nearest telephone / fire alarm / hotline. In
case the telephone is out order or not available nearby, send the fire call
message through somebody or come running to the fire station.
4. Inform nearest control room.
5. While giving a fire call massage on Telephone.
• Give your name and section.
• Give exact location of fire and if possible inform nature of fire.
• Confirm that your fire call massage is repeated by the control
room attendant, Fire Station.
6. If the fire call massage is given by fire alarm, stand near the fire alarm to
guide the fire fighting team to the arrival of the brigade.
7. Report to the Fire Station and your supervisor even if the fire is
extinguished by you before the arrival of the brigade.
12.10.1 STORAGE TANK FIRE
1. RAISE ALARM AND BREAK FIRE GLASS NEAREST AVAILABLE.

2. START FIRE WATER SPRAY SYSTEM
3. INFORM FIRE STATION AND OM&S CONTROL ROOM.
4. CHANGE THE TANK
- IF RECEIVING TO ANOTHER LOW DIP TANK
- IF FEEDING TO ANOTHER FEED TANK INFORMING UNITS
5. ISOLATE THE AFFECTED TANK COMPLETELY.
167
6. START FIRE WATER SPRINKLER.
12.10.2 UNIT FIRE OR POWER FAILURE
1. STOP FEED PUMPS OF AFFECTED UNIT ONLY AFTER CLEARANCE

FROM UNIT SHIFT IN – CHARGE.
2. CHANGE PRODUCT RUNS DOWN TANKS TO LOW DIP TANKS.
* LPG RUNS DOWN TO LOW LEVEL MOUNDED BULLET.
* NAPHTHA RUNDOWN TO LOWEST LEVEL NAP. TANK
* SKO TO LOWEST LEVEL SKO TANK
* ATF TO LOWEST LEVEL ATF TANK
* SKO TO LOWEST LEVEL SKO TANK
* HSD TO LOWEST LEVEL HSD TANK
* FO TO LOWEST LEVEL FO TANK
* LSHS TO LOWEST LEVEL LSHS TANK
* SLOP TO LOWEST SLOP TANK DIP
4. FLUSH LSHS LINE LINE WITH FLO AFTER CONSULTING PNM.
12.10.3 OVER FLOW OF TANK
1. Area corden off by closing the road.

2. Stop vehicle movement. Take help of CISF.
3. Run down to be changed to other tank and take action to
gravitate or transfer to other tank.
4. Inform concerned unit.
5. Stop all hot jobs in the surrounding area.
6. Inform F&S, RSM and area incharge.
7. Water sprinkler of tank to be started.
8. Dyke valve to open drain to be closed.
12.10.4 SIPHON DRAIN VALVE STUCK UP IN OPEN

CONDITION

3. Take action to gravitate or transfer to other tank.
4. Call Mech. Maintenece for attending the valve.
5. Make arrangement to fill water inside tank through siphon drain.
12.10.5 GASKET REPTURE IN TANK

4. Call Mech. Maintenece for attending the gasket.
168
12.10.6 CLOUD FORMATION DUE TO OVER FLOW OF TANK

12.10.7 RIM SEAL FIRE IN FLOATING ROOF TANK

3. Isolate the tank by closing the run down valve.
7. Put foam in side tank through foam pourer line.
8. All efforts to be made to add foam in side tank.
10. Water sprinkler of adjacenyt tank to be started.
12.10.8 HANDLING OF EMERGENCY DUE TO LPG FIRE
i. Person noticing LPG Leakage/ vapour cloud must immediately

inform to PNE (LPG).
ii. Suspend operation in bulk loading gantry.
iii. Switch off power supply to the smoking booth in the south-east
corner of LPG area.
iv. Start water sprinkler.
v. Depending on the gravity of leakage press the push button signal
to TPS for cutting off Power supply to the LPG area and for getting
the fire-water pumps at job-250 started.
vi. Contact the fire station through Hot lines and inform the shift-in-
charge about the LPG leakage.
vii. Start the hand siren to warn every one in the area.
viii. Activate all the ROVs on the LPG supply/vapour return
lines/circulation lines for bulk loading (TW) from Control Room.
ix. Activate the deluge valves/auto water spray system.
x. Inform the RSM of the situation in the area.
xi. Do not allow any vehicle to start in the affected area.
xii. Isolate affected bullet completely.
xiii. In case of LPG, do not extinguish the flame except by fuel
elimination.
169
12.10.9 RAIL TANK WAGONS GANTRY FIRE:
a) Operator at gantry notifing fire to inform shift in charge. Inform Fire

& safety, RSM & sectional in charge. Take action to extinguish
fire.
b) Stop loading operations at all gantries. Stop all loading pumps.
c) Close the ROVs from control room or loacally.
d) Remove the spouts and close the domes of all unaffected
wagons.
e) Start water spray from hydrant & foam pourer system. Keep
cooling in nar by tanks.
f) Pump out any liquid in the wagon, if possible.
g) Remove the rake from the adjacent gantry if possible.
h) Barricade the area.
i) Railway & Marketing staff to be informed for not doing any activity
in gantry.
j) Apply cooling water spray foam delivery hose lines to the burning
wagon and adjacent wagons.
k) Keep water cooling.
l) Remove unaffected tank wagons from the fire areas, if possible.
RECOMMENDATIONS FOR TANK WAGON:
a) All the wagons should have proper filling pipes and no splash filling must
be done.
b) Earthing of the railway track and the filling hoses should be properly done
and must be checked regularly. It should be the responsibility of the
loading personnel to ensure that the proper earthing to the gantry and
filling points exist before the loading operation are stared.
c) The loading hoses should be tied properly so that there is no possibility

of its getting dislodged during loading operation.
d) One track should always be left free so that in case of emergency other
wagons can be pulled out to safer places without loss of time.
12.10.10 TANK TRUCK LOADING (TTL) FIRE:
170
1. Inform shift in charge, F&S , RSM, Sectional head & take action
to extinguish fire.
2. Stop all pumping / loading operations.
3. Close block valves on lines at TTL manifold.
4. Apply cooling water spray to blanket the truck completely. Protect
adjacent equipments and other tank trucks with cooling water
streams.
5. Remove other trucks to safe area if possible.
6. All drivers & khalasi to be removed from site & assemble at
assembly point.
7. Inform fire & safety, RSM and SPNM/CPNM.
8. Barricade the area.
9. Inform CISF at gate no. 10 for not taking any truck inside.
12.10.11 HEAVY RAIN FALL
There are around 150 tanks and each tank is surrounded by

dyke pit. When monsoon starts, all the rainwater gets
accumulated inside dyke. This water can be routed to OWS or
open channel depending upon the requirement and site
condition from dyke pit. Following routing facilities are
available:
1. The dyke pit valve connected to open channel is kept closed

and that OWS is kept open. The dyke pit valve to open
channel is kept closed under normal condition. When first rain
of season occurs, all the dykes are personally checked for
presence of oil if any. If no oil is there, the rainwater is drained
to open channel. In case oil is observed, the oily water is
routed to OWS under controlled condition.
2. All the tanks roof is checked and cleaned under pre-monsoon
activity. Thoroughness of roof drains, open channel inside
dyke and outside dyke is checked & cleaned.
3. In case there is continuous heavy rain and open channel level
is high, it is advisable to close dyke pit valves connected to
open channel and OWS. This is being done to avoid ingress
of rainy water in OWS. The water draining is done during
subsequent days under control condition.
12.10.12 Pyrophoric Iron

Spontaneous ignition of iron sulfide either on the ground or inside
equipment due to coming in contact with air leads to fire in Pyrophoric
171
iron. Most commonly, pyrophoric iron fires occur during shutdowns. The
sludge which comes out of the LPG storage vessel, pump have tendancy
of such fire. The strainer material of LPG pump, MS pump and naptha
pump have property.
Precautions to Avoid Pyrophoric Iron Fires
The scraps and debris collected from cleaning of filters in naphtha,

crude, MS and LPG service must be kept wet and disposed of
underground.
O M & S MANUAL
CHAPTER-13
APPENDIX
172
GUJARAT REFINERY
173
13.0 TANK CLEANING PROCEDURE
Procedure for gas freeing and cleaning of tanks which have

contained petroleum products free of lead:
Pump out the tank to the lowest possible level first through main outlet and
then through water draw. Blind all the inlet/outlet connections for petroleum
product, gas, vapour, steam, etc.
In case of Bitumen tanks, empty out the tank by filling bitumen drums through
clean out door & making a pit around clean out door.
Before opening the manhole covers of the tank, the area around tank should
be cordoned off for safety reasons and no such work, which may constitute fire
hazard, to be permitted till the tank and area is gas-free.
After the entry into the tank before starting the regular job of cleaning, gas
tests should be conducted at various points throughout the tank.
Whenever men will be working inside the tank, someone must stand by outside
the tank near the manhole to take appropriate action in case of emergency.
Men entering into the tank shall wear safety helmet, boiler-suit, gum-boots and
hand gloves.
If fresh air apparatus is used, the air intake must be from a place where there
is no chance of contamination.
While removing sludge, scales, deposits from tanks, breathing apparatus and
life line should be worn, because through the atmosphere in the tank may be
initially gas-free, toxic concentrations may quickly develop during disturbance
of the sludge/scales.
Tanks that may contain self-igniting deposits/scales must be kept wet the water
until such materials have been removed. Until all sludge is removed non-
sparking tools should be used for cleaning purpose. When de-scaling and
removing rust the interior of tank should be kept wet and the cleaning crew
must wear dust respirators.
174
PRE MONSOON JOB CHECK LIST FOR TANKS
S.No Description Yes No
CIVIL
1 Cleaning of roof drain sump including roof deck of all floating
roof tanks. Also, sampling platform to be cleaned for fixed roof
tanks
2 Soil removal and grass cutting to be done under the foam lines
and inlet outlet lines of all tanks
3 Tank pad to be repaired if found damaged at any tank
4 Tank dyke to be repaired if found damaged at any tank
5 Cutting and removal of wild vegetation inside dyke
6 Cleaning of dyke pit and open channel
7 Insulation to be repaired if found damaged.
8 Line passing through dyke to eb sealed if found unsealed.
9 Hole in dyke, cracking in dyke if found in any dyke, same to be
repaired
10 All open drain / all open channels, outside duke to be cleaned
11 All OWS lines, thoroughness to be checked. If found chocked,
dechkoing to be done
12 OWS chamber wall to be repaired if found damaged
MECHANICAL
13 Goose neck and its wire mesh cleaning to be done on all fixed
roof tanks
14 Cleaning of all flame arrestor on fixed / fixed cum floating roof
tanks to be done
15 Water make up to be done it all ERD seal pot of all floating
roof tanks
16 Revisioning and testing of all PVRV of fixed roof tanks
17 Tightening of weather shroud sheets to be done in all floating
roof tanks, if found damaged
18 Freeing and greasing of guide roller, staircase roller to eb done.
19 Thoroughness of roof drains system to be checked and NRV
revisioning to be done for all floating roof tanks.
20 All tanks OWS dyke pit, open channel valve and OWS valve
revisioning to be done and to eb kept in closed position.
21 Roof to ladder, ladder to shell earthing wire to be checked. If
found damaged or corroded, to be changed
22 Rim vent to be flushed of all floating roof tanks
ELECTRICAL
23 Checking and rectification of earthing connections of all tanks
24
MECHANICAL ELECTRIAL CIVIL PRODUCTION
175
13.0 CHECK LIST HANDING OVER FLOATING ROOF
TANK FOR M&I

1 Inlet / outlet line to the tank to be blinded
2 Circulation line to be blinded
3 All types of utility line provided on the tank to be blinded.
4 Receiving line to be blinded.
5 If side entry mixer is provided in the tank, LOTO for the same
to be done.
6 All manhole / skylight available in the tank to be opened.
7 Water flushing to be started and water to be overflown from
manhole to OWS.
8 Continue water flushing till the traces of hydro carbon is
removed.
9 Emergency Roof Drain (ERD) seal pot to be flushed with water.
10 Roof drain pipe also to be flushed.
11 The entire pontoon box to be checked and to be kept in full open
position. If HC found inside pontoon box, same to be removed
and flushed with water.
12 Water to be drained from the siphon drain.
13 Clean out door to be opened if provided in the tank.
14 Exhaust fan to be provided and light (24V) arrangement to be
done for facilitating manual civil cleaning of tank.
15 Hydrocarbon to be checked from all the manholes and skylight
locations. If found ok, then man entry to be allowed only for 2
meter from manhole with Gas detector. Again at this location,
gas testing to be done and if found ok and no suffocation is
observed by the entrant, step by step clearance shall be given for
going inside tank.
Above activity to continue till the Gas detector reading at all

places inside the tank reads zero and oxygen % is more than 19.5
vol%.
16 Circulation line jet mixer to be checked. If hydro carbon smell
comes then same to be water flushed.
17 Civil cleaning job cannot be started till all above mentioned
points are found ok.
18 Once cleaning is over, inspection of the tank is carried out by
Inspection department. If hot job is required in the tank, then
foam seal to be removed irrespective of whether it is oil soaked
or not.
19 After this, all support legs & breather legs with sleeve to be
checked for any smell of hydrocarbon with gas detector. If
smell of HC is found then same to be water flushed. In 90% of
cases, suppot legs / breather legs are found to be free from HC.
20 All equipments related to instrumentation are to be removed.
176
21 Instrument cable related to DCP flooding system also to be
removed, if exists.
22 All OWS chambers related to this tank are sealed along with
siphon drain pit. Also, asbestos cloth is put over the sealed
chambers.
23 Foam line blinding to be done.
24 All grass inside the dyke to be cut and removed from the dyke.
Also any other flammable material is found within the dyke
like paint drums etc to be removed.
25 Dyke OWS valve to be kept closed.
26 All body flange, valve flange to be covered with asbestos cloth.
27 If patching job is observed over tank bottom plate and roof
deck plate, then drilling of the plates to be done to remove any
trapped hydrocarbon. Ensure removal of trapped hydrocarbon
between two plates.
28 For carrying out hot job on any tank where bottom plates are to
be removed, big man way to be provided by cutting the shell.
This ensures easy exit of the person working inside the tank.
177
CHECK LIST HANDING OVER FIXED CUM
FLOATING ROOF TANK FOR M&I

to be done.
manhole to OWS.
removed.
9 The entire pontoon box to be checked and to be kept in full
open position. If HC found inside pontoon box, same to be
removed and flushed with water.
10 Water to be drained from the siphon drain.
11 Clean out door to be opened if provided in the tank.
observed by the entrant, step by step clearance shall be given
for going inside tank.

places inside the tank reads zero and oxygen % is more than
19.5 vol%.
Inspection department. If hot job is required in the tank, then
foam seal to be removed irrespective of whether it is oil
soaked or not.
17 After this, all support legs & breather legs with sleeve to be
checked for any smell of hydrocarbon with gas detector. If
smell of HC is found then same to be water flushed. In 90% of
cases, suppot legs / breather legs are found to be free from
HC.
178
19 Instrument cable related to DCP flooding system also to be
removed, if exists.
chambers.
21 Foam line blinding to be done.
22 All grass inside the dyke to be cut and removed from the
dyke. Also any other flammable material is found within the
dyke like paint drums etc to be removed.
23 Dyke OWS valve to be kept closed.
24 All body flange, valve flange to be covered with asbestos
cloth.
25 If patching job is observed over tank bottom plate and roof
deck plate, then drilling of the plates to be done to remove any
trapped hydrocarbon. Ensure removal of trapped hydrocarbon
between two plates.
26 For carrying out hot job on any tank where bottom plates are
to be removed, big man way to be provided by cutting the
shell. This ensures easy exit of the person working inside the
tank.
179
CHECK LIST HANDING OVER FIX ROOF TANK FOR
M&I

to be done.
manhole to OWS.
removed.
9 Oil to be removed from oil seal breather valve system ,it to be
flush with water for trapped hydrocarbon
10 Water to be drain from siphon drain
11 Clean out door to be open if provided in tank.
observed by the entrant, step by step clearance shall be given for
going inside tank.

places inside the tank reads zero and oxygen % is more than
19.5vol%
Inspection department.
chambers.
19 Foam line blinding to be done
20 All grass inside the dyke to be cut and removed from the dyke.
Also any other flammable material is found within the dyke
like paint drums etc to be removed.
21 Dyke OWS valve to be kept closed
22 All body flange, valve flange to be covered with asbestos cloth
180
23 If patching job is observed over tank bottom plate then
drilling of the plates is to be done to ensure the trapped
hydrocarbon
24 In case of hot job, stick hydrocarbon(in case of black oil) with
inside shell is to be also removed by scraping or shot blasting
25 Oil soaked insulation is to be removed & is to be kept outside
of dyke.
26 All equipment provided on fix roof (breather valve /goose
neck) to be removed from tank flange for natural illumination
& ventilation
27 For carrying out hot job on any tank where bottom plates are to
be removed, big man way to be provided by cutting the shell.
This ensures easy exit of the person working inside the tank.
181
13.1 CHECK LIST FOR FIXED ROOF TANK AFTER
MAINT.

1 Whether tank inside cleaned and debris taken out.
2 Whether siphon drain line has been cleaned and is through.
3 Whether datum plate is properly fixed and the top surface is
cleaned.
4 Whether dip tape bob is touching datum plate when dip tape
lowered.
5 Whether dip hatch and actual reference height is matching with
calibration Chart.
6 Whether goose neck checked for proper thoroughness and
fitted properly.
7 All siphon drain valves operating smoothly & in closed
position.
8 All bolts of siphon drain checked for tightness & no short
bolting.
9 Bolts of all flanges manhole, inlet outlet etc are tight & no
short bolting.
10 Whether 0.5 inch wire mesh provided at goose necks to stop
entry of bird.
11 Whether PVRV fitted in position.
12 Whether level gauge float movements along guide checked and
found OK.
13 All earthing strips checked & nothing found broken.
14 Whether dial thermometer has been provided.
15 Whether steam coil pressure testing done & no leakage
observed.
16 Side entry mixer shaft propeller fitted inside the tank & shaft is
rotating.
17 Whether jet nozzle is fitted with its tip facing 45 degrees
upward.
18 There is no blind on jet nozzle.
19 Whether the slope of the tank bottom is towards the water
draw-off line.
20 Whether the steam coils are supported to prevent hanging of
the coil.
21 Whether staircase condition is O.K.
22 Whether tank insulation is in good condition.
23 Whether roof skylight covers boxed up with fresh gaskets.
24 Tank side flanges manhole, clean out door, valves etc. boxed
with new gasket.
25 Checked that there is no body inside tank.
26 Whether drain funnel to underground OWS is clear and de-
choked.
27 Whether tank shell earthing is properly provided.
182
28 Whether the fire fighting facilities like foam lines etc. are
properly fitted.
29 Whether operating platform for tank valve operation is as per
requirement.
30 Whether tank pad is in good condition.
31 Whether approach path from road to tank dyke, manifold &
stair cleaned.
32 Whether all oil spillage removed from tank dyke ground
dressed up.
33 Whether reference height, safe filling height and product name
painted.
34 Whether steam trap assembly of stem coil is OK.
35 Whether opening inside the tank dyke has been repaired
properly.
183
13.2 CHECK LIST FOR FLOATING ROOF TANK
AFTER MAINT.
cleaned.
4 Whether sufficient space exist for sample bottle at datum plate
lowered.
calibration Chart.
7 Whether brass rollers provided at dip hetch.
position.
bolting.
short bolting.
11 Whether water is filled in emergency drain.
12 Whether level gauge float movements along guide checked
and found OK.
15 Whether stopper is provided at roof roller so that wheel do not
fall on roof.
16 Side entry mixer shaft propeller fitted inside the tank & shaft is
rotating.
upward.
19 Whether the slope of the tank bottom is towards the water
draw-off line.
20 Whether the steam coils are supported to prevent hanging of
the coil.
22 Whether tank insulation is in good condition.
23 Whether all roof skylight covers boxed up with fresh gaskets.
with new gasket.
choked.
27 Whether tank shell earthing is properly provided.
28 Whether earthing from roof to ladder & ladder to shell, shell to
pit exist.
184
properly fitted.
requirement.
Whether tank pad is in good condition.
stair cleaned.
dressed up.
painted.
properly.
painted.
38 Whether pontoon boxes have been checked and found to be free of leaks.
39 Whether pontoon box lids have been properly fixed.
40 Whether floating roof top has been cleaned and all debris taken out.
43. Whether roof drain sump cleaned and the perforated cover fixed on sump.
44. Whether NRV direction checked at roof drain serviced and fitted back.
45. Whether floating roof foam seal is in good condition.
46. Whether foam seal weather protector is in good condition.
47. Whether foam seal vents checked for thoroughness & flame arrestor
fitted.
48. Whether roof is on higher legs.
49. Whether roof is on lower legs.
50. Whether the brass roller provided between dip hatch & roof.
51. Whether the sliding ladder on the floating roof is in proper working
condition.
52. Whether two earthing wire fitted from deck to ladder & from ladder to
shell.
53. Whether tank is painted from inside.
54. Whether the brass roller provided between dip hatch & roof are free.
185
13.3 CHECK LIST FOR FIXED CUM FLOATING ROOF
TANK AFTER MAINT.
cleaned.
lowered.
calibration Chart.
6 Whether goose neck checked for proper thoroughness and
fitted properly.
position.
bolting.
short bolting.
10 Whether 0.5 inch wire mesh provided at goose necks to stop
entry of bird.
11 Whether level gauge float movements along guide checked
and found OK.
upward.
16 Whether the slope of the tank bottom is towards the centre.
18 Whether roof skylight covers boxed up with fresh gaskets at
floating roof.
19 Whether roof skylight covers boxed up with fresh gaskets at
fixed roof.
with new gasket.
choked.
23 Whether tank shell earthing is properly provided. All earthing
strip fixed to shell.
properly fitted.
requirement.
26 Whether tank pad is in good condition.
186
stair cleaned.
dressed up.
painted.
properly.
painted.
32 Whether pontoon boxes have been checked and found to be free of leaks.
33 Whether pontoon box lids have been properly fixed.
34 Whether floating roof top has been cleaned and all debris taken out.
35 Whether floating roof foam seal is in good condition.
36 Whether foam seal weather protector is in good condition.
37 Whether foam seal vents checked for thoroughness & flame arrestor
fitted.
38 Whether roof is on higher legs.
39 Whether roof is on lower legs.
40 Whether the brass roller provided between dip hatch & roof.
41 Whether two earthing wire fitted from deck to ladder & from ladder to
shell.
42 Whether tank is painted from inside.
187
13.4 CHECKLIST FORMAT FOR HANDING OVER OF PUMPS TO
MAINTENANCE
Tag no. & Service of pump _________________________Date :_________
Name of Operator / Shift In Charge
YES NO
REMARKS
1. Denergisation status of
motor (kick start to
confirm)
Precautionary
tags/boards (“Do not
operate, Men at
work”)provided
2. Isolation of the pump
including
➢ Warm up block
valve
➢ Process piping
(suction / disch)
➢ Cooling water
➢ Sealing fluid
➢ Quench steam
2. Pump Drained/ Vented to

OWS/Flare and
CBD/Flare isolated
3. Pump depressurized
4. Blinding/wedge
opening as per scheme
5. Steaming
6. Final checking of
blinding/wedge
7. Checking of LEL,H2S
8. Area cordoning done

9. Pyrophoric Iron
suspected
Note : 1) The said format will aide the operator in ensuring safe handover of the pump
to Maintenance.
2) Suction Discharge Nozzles to be end blinded if pump is removed.
3) PPEs to be used : Safety Helmet, Hand Gloves, Safety Shoes & Canister Gas
Mask/B.A.Set as per requirement.
4) Ensure availability of permit and clearance at site
5) Pyrophoric iron material to be kept in water. Don’t expose to atmosphere.
188
13.5 CHECKLIST FORMAT FOR TAKING OVER OF PUMPS FROM
MAINTENANCE
Name/Tag no. of the equipment _____________ Date: __________

Name of Operator / Shift In Charge
YES NO/Not Reqd.
REMARKS
1. De-pressurization
ensured before giving
clearance for boxing-up
2. Ensure boxing-up of the
pump including
➢ Process piping
(suction / disch)
➢ Suction Strainer
& direction
➢ Cooling water
connections
➢ Quench steam
➢ Drain / Vent/
sample point
3. Coupling Guard in
position
4. Shaft checked for
freeness (ensure motor
de-enegisation)
5. Bearing housing / oil cup
level checked
6. Line up of utilities & leak
checking
7. Pump suction valve
crack open for leak
checking of suction,
discharge, strainer,
sealing lines, casing vent/
drain flanges/ ferrules
8. Suction Valve line-up
9. Surrounding area
checked for oil, rags,
mechanical debris etc.
Note : 1) The said format will aide the operator in ensuring safe takeover of the pump
from Maintenance.
2) PPEs to be used : Safety Helmet, Hand Gloves, Safety Shoes & Canister Gas
Mask/B.A.Set as per requirement.
3) Ensure availability of permit and clearance at site
189
Indian Oil Corporation Limited
Gujarat Refinery
ANNEXURE – I
STARTUP CLEARANCE PROCEDURE
Format No.: IOCL / GR / SC / 01
STARTUP CLEARANCE CERTIFICATE [SCC]

(To be filled after completion of Format No-IOCL / GR / SC / 02
Unit:→
Department;→
Duration of Shut down: From: ---------------- To ------------------
Type of shutdown [Please √]: M&I / Decoking / Regeneration / Catalyst

Replacement / Idle for more than 30 days / Minor modification / Major modification
/ Idle shutdown where some maintenance jobs done / Tank M&I /
Any other shutdown [Please specify]: ____________________________
(A) Clearance From Maintenance / ES / Projects
All planned and additionally approved/agreed jobs are completed, all work permits
are closed, all blinding/ de-blinding required for unit start-up done (as requested by
the operation section), all safety guards and interlocks are in place /line, earthing
/bonding of equipment/instruments/ fittings is maintained, majority insulation jobs
done and area house keeping carried out as per the satisfaction of the operation
department.
Signatories Name Signature Date Time

HOD(Mech. Maint.)
HOD (Electrical)
HOD (
Instrumentation)
HOD ( Civil)
HOD (Engg.
Services)
HOD (TS-Process)
HOD ( Project)
(B) Clearance from Inspection / Fire & Safety

All the inspection Recommendations have been carried out, area housekeeping is
satisfactory, all safety, first aid and fire fighting equipment are in place and the plant
is apparently safe for start up.

HOD (Inspection)
190
HOD ( F&S)
191
ANNEXURE – I (contd.)
(C) Acceptance by Operation
All jobs as described in points (A) and (B) have been completed to the
satisfaction.

HOD(Operation)
(D) Final Clearance by DGMs
Certified that all the jobs related to maintenance activities have been completed
as per requirement for safe start-up of the unit.

DGM(Maintenance )
DGM (Project)
DGM(ES/TS)
DGM(P&U)
Approved that all the jobs as required for safe start-up of the unit / equipment (for
power plant) have been done to the satisfaction of operation department.

DGM (Operation )
Copy To: GM (T)

: Office File
Note:
Format No.: IOCL / GR / SC / 02, compliance report of Format No.: IOCL /GR / SC /
03 and compiled report of Format No.: IOCL /Gujarat Refinery / SC / 04 to be attached
with Format No.: IOCL / GR / SC / 01 before putting up for signature by respective
HODs / DGMs.
192
Gujarat Refinery
ANNEXURE-II
OPERATIONAL READINESS REVIEW
[To be filled jointly by Production, Process, Maintenance (Mechanical, Electrical, Instrument and Civil),
Engineering Services, Projects and Inspection]
SN Action Attributes YES/ Comments Initial

by NO/NA if any
Insp Have all planned static
1. equipment been inspected,
tested or otherwise verified as
ready for operation
Insp Are all planned safety valves
2. tested and properly tagged?
Mech Are all safety valves installed
3. back in place?
Maint
Mech Are plugs and blind flanges
4. installed?
Maint
Mech Have all blinding / de blinding
5. done as per operational
Maint
requirement?
Mech Have lube oil/seal levels in
6. pumps, compressors, turbines
Maint
etc been checked?
Mech Are all flanges that were opened
7. during the shutdown properly
Maint
mated?
Mech Is area clean up satisfactory?
8.
Maint
Mech Have all temporary hoses, piping
9. connections, scaffold, etc been
Maint
removed?
Civil Have all temporary hoses, piping
Maint
removed?
Civil Have all identified oil socked
11. insulations removed / replaced?
Maint
Civil Have all OWS cleaned?
12.
Maint
Civil Is area clean up satisfactory?
13.
Maint
193
Elect Are all explosion proof devices
14. properly installed, gasket
Maint
provided and completely bolted
Elect Are all motors in place ,cables
15. terminated and properly sealed?
Maint
Elect Have all conduit gasket and
16. covers been installed?
Maint
Elect Is Emergency light system OK?
17.
Maint
Elect Is area clean up satisfactory?
18.
Maint
Instr Flange taped and pressure tested
19. (required where flanges are
Maint
tested with gas e.g. air)?
Instr Are all explosion proof devices
20. properly installed, gasket
Maint
provided and completely bolted
Instr Are all flow meters orifices
21. restriction orifices, NRVs installed
Maint
directionally correct?
Instr Have all control valves been
22. installed, checked for correct fail
Maint
safe position, correct flow
direction, stroked and verified as
operating correctly?
Instr Have all the process interlocks
23. been checked and generated
Maint
checklist liquidated?
Instr Have all instruments been
24. properly sealed, traced insulated,
Maint
etc?
Instr Have all conduit gasket and
25. covers been installed?
Maint
Instr Is area clean up satisfactory?
26.
Maint
Instr Have all temporary hoses, piping
Maint
removed?
Process Are all new and / or modified
28. equipment system properly
identified?
Process Have all P&ID’s been updated &
29. new operating instruction written?
194
Oper Are all safety valves isolation
30. valves locked open?
ation
Oper Are all non essential vents & drain
31. valves closed? Are plugs and
ation
blinds flanges installed?
Oper Have the blinding /de-blinding
32. checked physically and register
ation
updated?
Oper Have lube oil/seal levels in
33. pumps, compressors, turbines etc
ation
been checked?
Oper Have all control valves been
34. installed, & Stroke checked?
ation
Oper Have all the process interlocks
35. been checked and generated
ation
checklist liquidated?
Oper Are all necessary operating
36. procedures. including start up
ation
procedure in place and current?
Oper Are plans in place to pressure test
37. facilities and air free before
ation
introduction of feed?
Oper Have utility system been reviewed
38. and all utility connections
ation
completed?
Oper Are operations personnel properly
39. trained to start up and operate the
ation
equipment?
Oper Is a start up staffing plan in place
40. with contingencies and call out
ation
persons list?
Oper Is area clean up satisfactory?
41.
ation
Inspection done by: - (Departmental S/D coordinator)
195
Deptt Name Design Signature Date Time
Operation
Inspection
Process
Electrical
Mechanical
Instrument
Civil
Project
196
Gujarat Refinery
ANNEXURE-III
FIRE & SAFETY CHECKLIST FOR STARTUP CLEARANCE

Name of Process Unit: _______________________________
Date & Time of Inspection: ___________________________
Inspection by: (Name & Designation): _______________________________
S.N Attributes Remarks by F&S Officer Compliance

status by Area
Manager
1. FREE ACCESS TO UNIT:
2. FREE ACCCESS TO PROCESS
EQUIPMENT & EMERGENCY EQUIPMENT:
• Unwanted scaffoldings have been
removed from the approach paths
and ensure free access to
equipment.
• All Manholes are covered.
• Area free from unwanted
mechanical scraps and leftovers
• Floor and platforms of equipment
and surfaces are free from oils,
grease and other chemicals
• Area identified as not safe for
accesses have been properly
barricaded.
• Free access maintained for all fire
hydrants/monitors, fire alarm
extinguishers, emergency showers
Catalyst drums and other drums/jerry
canes removed from the unit.
3. FIRE PREVENTION
Any oil soaked insulation observed
during random inspection
4. MACHINE GUARD:
Guards or protective covers found
missing on any moving part of
machines such as on coupling
shaft belt etc.
197
5. Earthling / Bonding:
The earthling of any electric motor /
switches / process equipment e.g.
columns, vessels etc. found physically
broken or detached
6. Gas Detectors / Water Spray
System:
Gas Detectors /smoke detectors
showing o.k. in annunciation panel.
Water sprayers are Ok?
7. Emergency Shower and Eye Wash
fountains are operative.
8. BA Sets and Gas Masks are OK
9. Fire Extinguishers tested, marked,
and
Placed in Painted locations.
10. Fire Alarm points painted, identified,
glass o.k., hammer o.k.
11. Fire Hydrants /Monitors& Water
Sprayers in good working condition,
isolation valves lubricated and
identified, no leakage from
Nozzles ,aqua foam monitors OK
foam compound drum in full.
12. Any other observations.
Signature of Officer of F&S

Copies to:
Area Manger/RSM/HOD (F&S)/Unit Maintenance –In charges/ (MM, EM, IM,
CM)
Note: Area manager will attach a copy of Format No.: IOCL / GR / SC / 03 with Format No.:
IOCL / GR / SC / 01 after necessary compliance of all points rose by F&S officers. If any point
can be attended later considering safe start up of the unit / equipment, it shall appear in thee
exceptional list of Format No IOCL/GR/SC/04.
198
Gujarat Refinery
ANNEXURE-IV
EXCEPTION LIST
(Number of items in this list shall be as minimum as possible)
Following job/s is/are not completed and is/are excluded from the start up
clearance certificate. This will not affect the safety of the plant and start up
activities.
Manager (Operation, Civil, Mechanical, Instrument, Electrical, Project,

Engineering Services, Process, Fire &Safety) of Concerned Section shall note
the exceptions and submit the same to the area manager.
Based on the above, a compiled exception list shall be prepared by him and
submit it for approval along with the individual department’s exception list.
List of exceptions (if any):
S Deptt Description of Target Signature of Date / Complet Signature Date /

N incomplete Date HOD Time ion date of HOD Time
jobs with
reasons
1
2
3
4
5
6
7
8
APPROVED BY: DGM (Operations, or respective departments)

Signature: ____________________________________________
Name: ______________________________Date & Time:

_______________________
Note:
• Copy to be given to the area manager for compilation and further
necessary action in the. Format No.: IOCL / GR / SC / 04 to be attached
with Format No.: IOCL / GR / SC / 01.
• Copy to be given after compilation to DGM (Operations, or respective

departments)
BREATHER VALVE CUM BREATHER OIL SEAL

FLAME ARRESTOR VALVE CUM WITH FLAME GOOSE
TANK PRODUCT TYPE FLAME ARRESTOR NECK
199
SAFETY DEVICES ON TANK
ARRESTOR
VERTICAL HORIZONTAL
WITHOUT
CANOPY CANOPY
CANOPY
64 BENZ FIX+FLO YES - -
66 TOL FIX+FLO YES - -
85 ATF FIX YES YES -
205 LABFS FIX+FLO - YES - -
514 N-PARA FIX YES - -
727 LSHF FIX - - YES - YES
101 LSHS FIX YES - -
93 LSHS FIX YES - YES
94 LSHS FIX YES - YES
95 FO FIX YES - -
96 FO FIX YES - -
219 FO FIX YES - -
220 FO FIX YES - -
733 FO FIX YES - -
97 LDO FIX YES YES -
108 MTO FIX+FLO YES - -
109 MTO FIX+FLO YES - -
87 LMW FIX YES YES -
98 HMW FIX YES YES -
1101 MTBE FIX+FLO YES - -
1102 MTBE FIX+FLO YES - -
200
OM&S TTL TANKS STATUS
BREATHER VALVE CUM BREATHER VALVE

FLAME ARRESTOR CUM FLAME OIL SEAL
PRODUCT TYPE ARRESTOR WITH REMARKS
VERTICAL HORIZONTAL WITHOUT FLAME GOOSE
TANK CANOPY CANOPY CANOPY ARRESTOR NECK
NOT IN
104 FIX+FLO YES YES SERVICE
NOT IN
NOT IN
NOT IN
107 FIX+FLO YES SERVICE
124 CAUSTIC FIX YES
125 CAUSTIC FIX YES
126 CAUSTIC FIX YES
301 LSHS FIX YES YES YES
302 FO FIX YES YES YES
303 FO FIX YES
304 FO FIX YES
401 PFRCB FIX+FLO YES
402 PFRCB FIX+FLO YES
403 FGH FIX+FLO YES
404 FGH FIX+FLO YES
405 MTBE FLO
406 PFRCB FLO
751 NAPHTHA FIX+FLO YES Side window
752 NAPHTHA FIX+FLO YES Side window
753 NAPHTHA FLO
755 N-PARAFFIN FLO
1105 METHANOL FIX YES
1106 METHANOL FIX YES
201
Water Auto-drain facility in tanks.
Auto water drain facility has been provided in 12 tanks. This is to ensure no water
carry over to pump suction, and also less hydrocarbon loss compared to manual water
draining.
The tanks provided with auto drain valve are
MS Tanks: 59,60,61,76,78,82,83,84
Naphtha Tanks: 75,77,905,908
A rough sketch of the same is given below.
Operation:
a) First Open valve-1
b) Then open valve-2 for venting of any hydrocarbon vapour
c) Then open valve-3 for equalization
d) Finally open valve-4 for water draining
e) Never operate valve-5. It is to be operated in case of failure of auto drian valve.
202
O M & S MANUAL
Chapter – 14
GUJARAT REFINERY
203
CHAPTER-14
TANK CLEANING PROCEDURE
HAZARDS OF TANK CLEANING
The cleaning of petroleum storage tanks can be performed safely if the adequate
procedure and precautions are followed. Without such safe guards, injury or
property damage may occur from :
(a) Explosion of fire

(b) The presence of toxic liquid, vapours of dusts
(c) Physical hazards such as slipping, falling or falling objects.
Explosion of Fire
It may occur when fuel (in Vapour) from air (oxygen) and a source of ignition
combines. Mixture of petroleum vapour and air can be ignited only if with in certain
limits. The lower and upper flammable limit for this mixtures are approximately 1
and 7 percent by volume respectively.
SN Vapour Concentration Hazards
1. Above 7% petroleum As mixture escapes to

vapour in air,-Indicates outside air, it may ignite
100% on Explosimeter
indicator.
2. 1 to 7% petroleum Flammable, dangerous to vapour in air –

Indicates breath, burns if ignited
100% on indicator
3. Below 1% petroleum Not flammable, too lean

vapour in air – Indicates to burn. May still be
0-100% on indicator dangerous to breath
4. Below 500 ppm on Safe to breath unless toxic

Approximately 4% on vapours to gives are
indicator present. Use caution and
continue perific gas sam
-pling follow area :
Safe for hot work.
Important Points
(a) Ignition does not occur in petroleum vapour and air mixture which are richs
than the upper flammable limits.
204
(b) Rich mixture may be ignited and burn when diluted with outside air at points
of escape from tanks, such as Hatches, manholes and oaths openings.
(c) A rich mixture may rename in a tank after product has been removed.
(d) Vapours which escapes from openings in a tank are heavier than air and if
released year ground level may travel a considerable distance from the tank.
(e) Even after a tank has been free of vapour flammable mixture may be from
usidual liquids or sludge’s.
(f) Vapours of liquid petroleum may enter a tank through in blinded lives or leaks
in the bellow of the tank.
(g) Vapour too may evolve within the tank from sludge, metal scale, or liquid
residue, or all trapped in hollow of supports, unsealed sections of foam
chambers, pontoons or heating coils.
(h) Flammable mixture may be ignited by open flames, welding sparks, spark from
electried lamps, tools, fixtures, switches or appliances which are not explosion
proof.
(i) Another source of ignition may be present in tanks which have been used for
the storage of sour stock. From polysulfide deposits which one pyropheric on
exposure to air, may form when sulphur compounds in sour strocks reacts with
the iron of storage tanks.
These pyroferric deposits, when come in Contact with the oxygen in the air a
chemical reaction takes place which generates heat. If the heat is not dissipated,
spot temperatures high enough to ignite a flammable mixture can be reached.
Note: Checklist format for Tank Handover & Take over to/from Maintenance is
provided in the Annexures-1/2/3 at the end of this Manual
Prevention of Toxic Substances
Hydrogen Sulphide :
H2S is colorless and highly toxic odourless gas, which is encountered in the production
and processing of high sulphur content crude oil.
- All tanks which have contained sour stocks should be considered toxic.
- In low concentration, H2S is detectable by its characteristic rothen egg odour.
- A concentration as small as 10 ppm by vol. Of H 2S is the limit for safe

exposure for an 8 hrs working day.
- Accurate tests for concentration of H2S in an atmosphere can be made with

H2S indicators.
205
- Excess exposure to H2S causes death by paralysis of the respiratory system.
In milder doses it attacks the eyes.
- H2S is a flammable gas and burns in air the flammable limits are 4.3 to 46%
by vol. In air.
Excess petroleum vapours and deficiency of Oxygen.

The exposure of vapours to the person entering the tank without respecting
equipments will vary depending upon the product involved and the duration of
exposure.
If petroleum vapour in strong concentration is breathed, a reaction results which

produces a stage excitement leading to unconcionsness.
If a tank has been cleared and is empty for sometime, then also the air within
the tank will become deficient in oxygen due to rusting (oxidation) of the metal
of the tank. Before entering in the tank either the person wear protective
respiratory equipments or the tank has been ventilated.
Physical Hazards
In addition to injury or property damage which may result from fires, explosions, toxic
conditions or asphysiation, trouble may result from other causes such as
i. Discharge of steam, high pressure air, water or oil into the tank or against
personnel working outside.
ii. Structural failure of the tank shell, no. of support members, seving line cables,
or other tank member
iii. Tools or other objects dropping from everhead
iv. Falls through or from the roof or from scaffoldings, stairs, or ladders
v. Slipping over hose, pipes, tools or equipments
vi. Slipping on wet, oily surfaces or colliding with objects in inadequately lighted
interiors
vii. Inadequate training of workmen or lack of competent supervision
viii. Insufficient of faulty personnel protective equipment
ix. Use of wrong or poorly maintained tools, especially electrical tools or
equipments
x. Failure to disconnect or make inoperative electrical or mechanical equipment
when not in use or to blind pipes connected to the tank.
CLEANING METHODS AND PROCEDURES
These are three types of products which are stored in tanks :

i) White oil – such as Naphtha, superior Kerosene, ATF and HSD.
ii) Black Oil – such as Crude oil, Furnace oil, VB Feed, and RFO/HPS
CLEANING PROCEDURE OF WHITE OIL TANKS
- Preparation of the Tank before handing over for cleaning
206
- Pump out the tank material to the lowest possible level, thru main outlet and
then thru water draw (syphon drain)
- Blind all the inlet/outlet connections for petroleum product.
- Open the sky light and manhole covers.
iii) Pump out the residual oil thru suction hose/pipe introduced thru manhole using
a portable pump.
iv) When it is no longer possible to take the suction by the pump of the little
quantity that may be left inside, use syphoning method and drain into IS
system.
v) Introduction water into the tank thru manhole. Let water overflow through the
other manhole into the IS system/or tank dyke keep storm water channel open
to SS system.
Important Point to note
(a) Before opening the manhole covers of the tank the area around the tank should
be cordoned off for safety reasons and no such work, which may constitute
fire hazard, to be permitted till the tank and the area is gas free.
(b) The traped traces of oil sludges which are heavier than water will start floating
on the surface of water come out through manhole. Disturb the tank bottom
with a jet of water from outside the tank, from time to time. The flushing with
water to continue round the clock, till there is no smell of hydrocarbon and no
sign of traces of oil or sludge.
vi) Drain the water completely
vii) Take gas tests from manholes and skylights
- If it shows high concentration, repeat water flushing for another 48 hrs., or

more.
- When water flushing is going on the veritilation is also taking place by natural
draft of air.
- In case of still higher concentration of gases, use forced draft of air
- In the forced draft vertilation, air under pressure is introduced from one
manhole and is allowed to come out from the opposite manhole.
- The process of ventilation should be continued round the clock for few days
- The tank air sample is to be tested perivelically with explosimeter to find out
the % volume of petroleum vapour in air. If it is 1% of the lower explosive
limit, it corresponds to a reading of 0.1 on the explosimeter
207
viii) After ensuring vapour free, the tank can be handed over for man entry for
cleaning etc.
Preparation for Cleaning of the Tank
i) A competent supervisor should be placed incharge of the tank cleaning

operation.
ii) To determine the approx amt. of sludge with in the tank and physical condition
of the tank.
iii) To survey the surrounding area to determine whether it is safe to perform the
cleaning operations.
iv) Equipment used for tank cleaning operations should be inspected to ensure
that it is free of defects and it is adequate for the purpose intended.
v) Personnel protective equipment should be inspected to assure that it is of first

quality, in perfect condition and suitable for the use intended.
Cleaning of the Tank
After completion of all the above operations and gas Texman entry permit for
cleaning the tank may be issued on “Vessel – Entry – Permit”.
i) People entering the tank should use breathing apparatus of approved type
regardless of test results for flammable vapours until sludge has been removed.
ii) Tools used should be non – sparking type.
iii) If the vapour concentration is between 0.05 to 0.1 people can enter the tank
without breathing apparatus but the duration stay inside should be 15 minutes
after which try should spared 15 minutes outside in the fresh air before entering
again.
iv) If the vapour concentration is less than 0.05% by volume it is safe for men to stay
inside without breathing apparatus
v) After the entry into the tank, and before starting the regular job of cleaning, gas
tests shmed by conducted at various points throughout the tank
vi) Whenever, men will be working inside the Tank, some one must stand by outside
the tank near the manhole to take appropriate action in case of emergency
vii) The following personal protective clothing to be used by the men entering into
the tank :
(a) Safety helmet

(b) Suit
(c) Gum boots/safety shoes
208
(d) Leather hand gloves
viii) While remaining sludge, scales, deposits from the tanks, breathing apparatus and
life line should be warm, because, though the atmosphere in the tank may be
initially gas free, toxic concentrations may quickly develop during disturbances
of sludge’s/scales.
ix) Tanks that may contain self igniting deposits/Scales must be kept wet with water
until such materials have been removed.
x) Until all sludge’s is removed non-spearling tools should be used for cleaning
purpose.
xi) When de-sealing and removing rust the interior of tank should be kept net and
the cleaning crew must wear dust respirators.
xii) Sludges, scales, rust, deposits etc. Removed from the tank should be kept must
and eventually buried.
xiii) If pyropheric iron is suspected in the tank, free steam should be used in
conjunction with air during the process of degassing.
CLEANING OF BLACK OIL TANKS.
Cleaning of Crude Oil Tanks
- Preparation of the Tank for handing over to Cleaning.
- Continue to feed the unit with this TK to the Lowest possible dip without
any disturbance in the unit.
ii) Close both the feeding valves of the TK and insert blind.
iii) Get installed portable transfer pump. Connect its suction with one of the
209iphon drain of the tank and pump discharge to be connected with the
transfer line bleeder of the keep close both the receiving line moves.
iv) Keep close both the receiving line move.
v) In order to sludge melting receive 2500 kl of LGO from AVV.
- While receiving hot LGO wild hammering in the line near crude booster
pump will be experienced. It should be overcome by regulating the LGO
Valve.
- Incase, LGO is not available or due to some other operational constrains,

receive HSD from 81 Pump House.
vi) Open steam to the tank and maintain temp. around 600C
vii) Run side mixers intermittently in day time.
209
viii) After 24 hrs. Mixing, transfer material from the tank to other crude TKS by
running portable pump.
- Keep both the transfer line moves at the TK closed, while pumping out
material from the TK.
ix) When TK’s float rests on its leg stop transfer from the TK to other crude TK.
x) Introduce water in the TK thru one of the 210iphon drain and float the
- Keep steam to heating Coil opened and maintain temp. around 60 0C
xi) After 24 hrs. Heating, again start transfer of material from the TK to other
crude TK by pertable pump. Continue transfer till the pump looses suction.
xii) Get floating roofs sky light manholes, and bottom manholes opened and
isolate steam to heating crls.
xiii) Insert blinds at the following places

a) TK inlet line flange at the TK.
b) TK outlet line flange at the Tk.
c) Steam inlet line valves D/s flange at the Tk.
d) Steam outlet line valves U/s flange.
e) All the 210iphon drain valves D/s flange.
xiv) For degasification introduce water with fine hose from manhole and alone
to overflow from the other manhole the overflow of water and oil to be
channelised to C5 manhole.
xv) After effective overflowing for 24 hrs. Gas tests from top manholes and
bottom manholes to be done and after satisfactory reading – Man Entry
Permit to Civil Department to be issued for sludge removed and cleaning.
Cleaning of other Black Oil TK’s.
Preparation of the Tk before handing over for cleaning.
a) Pump out the tank bottom material to the lowest possible level first through
main outlet and then through water drain.
b) Blind all the inlet/outlet connections and slain locating coils inlet and outlet
connections.
All the steps mentioned earlier for “White Oil Tanks” cleaning procedure
will be applicable here also..
c) Selection, Training and Supervision of Personnel
d) All the persons to be engaged for the tank cleaning should be medically
examined before taking up the job. The name and address of all such
personnel to be recorded.
210
ii) During the course of work all men concerned should be examined after every
week.
iii) The tank cleaning contractor must appoint a supervisor who must have and
previous tank cleaning experience. He must be conscientious and
painstaking, have a good knowledge of the safety procedures required.
iv) Everyone involved in tank cleaning must first be adequately trained in the
following.
(a) The hazards involved.

(b) The safety procedures to be followed.
© The use of protective clothing and equipments.
Facilities Required for Tank Cleaning.
Make sure that the following facilities are available on site before work
is begun. :
i) A wash room with bath or shower. This room must not be used for storing or
cleaning contaminated equipments.
ii) A cleaning room or separate temporary shelter is required where

equipment can be cleaned.
The following materials for tank cleaning to be kept.
S.No. Description Remarks

1. Bins or drums with lids For contaminated
clothings.
2. Sinks or Bins For washing dirty
clothings.
3. Clean rags, For cleaning
Scrubbing, brushes, clothing and
Kerosene detergent equipment.
Soap.
iii) A clearly defined area for clean equipment and tools, a container or area
approximately marked for equipment to be di-contaminatd, and another
area for items to be destroyed by burning.
iv) Steel or polythene trays about 1.3 Metre squares, 100 mm deep, in which
men can stand while their suits are being washed down water soap
solution.
v) Steel sheets with non-slip surface on the ground at entry and exit
manholes.
211
vi) The area in which it is necessary to wear respiratory equipment should
be surrounded by ropes and pickets and “MASK AREA” board be
displayed.
i) Clothing to be worn for work inside tanks.
Protective clothing worn with appropriate respiratory protection will

protect the wearer from direct contact with gasoline vapours and lead
alkyl bearing vapours, liquids and solids.
The following protective clothing and respiratory equipments to be

provided by the refinery.
a) White Vest
b) White Underwear
c) White Cap
d) White Socks
e) White Cotton – over – all
f) PVC Gloves
g) PVC Boots
h) Positive air pressure repirator.
ii) Respiratory Protection for work inside tanks
Men should wear air supplied helmets or air supplied respirators fed from
air compressor with air reservoir. If air supplied respirator is worn, the
head and hair should be further protected by neoprene or PVC – proofed
fabric cap.
Safety Harness
a) Any man entering a tank should wear a safety harness with attached lines
leading outside the tank.
b) While men are inside a tank, one man should remain outside at the
entrance to summon help in case of emergency.
c) The harness should be of non-absorbent material (cotton or leather

should not be used).
d) The harness should not interfere with breathing equipment.
e) An attendance register should be maintained for the persons involved in

cleaning operation and their presence should be checked daily once in
the morning and then after days’ work. Reasons for absence must be
noted down clearly.
f) At a time only two cleaners should enter the tank, and they should be
allowed to remain inside the tank for ½ hr duration.
212
g) Cleaner should not enter the tank with empty stomach. Once showing
any abnormal physical symptoms like pain, headache, vomitting, fatique
should immediately be sent to hospital for medical check up.
Ventilation
Before a tank can be entered for cleaning it must be ventilated to reduce the
concentration of flammable vapour to a safe working level.
Two methods can be used to ventilate a tank :

a) An air extractor
b) An air blower
Before starting ventilation, as much gasoline as possible should be removed, so that

least time is taken to reach safe working conditions. As the toxic and flammable
vapours are heavier than air, fresh air should be drawn or blown into the tank at high
level and the effluent vapour should be extracted at low-level about two meter from the
tank floor – by means of flexible trucking from a top manhole. If possible the air
should be expelled at a high level so that flammable and toxic vapour does not
accumulate in the bound. The bund and downwind area should be kept clear of men
as far as practicable. No possible source of ignition should be allowed in the area any
time.
Before men start working in the tank, the air inlet should be removed to a low level
(say 2 M above floor level) to give maximum diluting of the toxic atmosphere in the
working area. Throughout the tank cleaning operation, continuous ventilation is
necessary to prevent any build-up of flammable vapour when sludge is disturbed. The
explosimeter should be used to check that the concentration of vapour does not rise
above 1% of the lower explosive limit.
CLEANING OPERATIONS
Always observe safety precautions, men may be tempted to take short cuts, resulting
in accident : 100 percent supervision is recommended to ensure that all safety
precautions are adhered to.
Clothing and respiratory equipment
Suitable protective clothing must be worn at all times.

One man should be detailed as dresser. He should wear a canister respirator, PVC
gloves, cotton over all and an apron and PVC boots. His duties are:
a) To help the men into their equipment

b) To wipe down overalls or suits while they are still being worn, as the
men are leaving the tank.
c) To help the men out of their clothing, preventing contamination of
respirators, gloves, overalls and boots.
The dresser should not be too near the entrance of the tank and upwind
of the job.
Case of Hoses and Pipelines
213
Hoses supplying air to respirators should be chose with care, they should be cleaned
after use by wiping with rags damped with detergent and water or kerosene and
checked every day to see that they are in sound condition oil free from cracks or pin
holes.
Cleaning Routine at the end of each day.
i) Tank cleaning is to be done during the day time. The cleaning time should be
counted from the time of wearing the protective clothing till the man comes out
of the fenced area after washing their normal dresses.
ii) At the end of each day’s work sufficient time should be allowed for all
equipment to be cleaned. Shovels, buckets etc. Should be cleaned with
kerosene. All mechanical equipments should be cleaned with kerosene to
remove sludge and wash with water containing detergent and then dried. Even
after cleaning tools should not be stored in changing room.
iii) Oily sludge on suits, boots and gloves is first best removed with kerosene; they
should then be washed with warm soapy water.
iv) Gloves and boots should be cleaned on the outside with warm soapy water.
v) From time to time inside cuffs, collars, trouser legs, boots and gloves should be
examined and cleaned to prevent accumulation of dirt. If they are cracked or
perished they should be discarded and burnt.
vi) Respirator face pieces should be washed in clean, warm, Soapy water
containing a very small amount disinfectant (i.e. dettol).
vii) Canister respirators may be cleaned in the same manner as other respirators
taking care not to allow water into the canister. The number of hours usage’s
must then be entered on the record card/register. The canister should be
discarded when its life has been used up.
viii) All used clothing should be set aside for laundering. Any heavily contaminated
(cotton) clothing should be burnt. Before leaving the site each day every one
should have had a shower and changed out of all the clothes worn during the
day.
Inspection, Repair, Demolition and Disposal of Tanks
i) Inspection of Tanks.
After removal of sludge and scale, there are still sufficient Organo-lead derivatives
absorbed on the sides of the tank to produce toxic atmosphere. Therefore the person
making the inspection of the tank should wear air supplied respiratory equipment,
cotton overall, PVC gloves and safety boots.
ii) Tank Repairs
214
Tank repairs normally require a longer period in the tank, with the resultant higher risk
of coming into contact with lead compounds. Any person who enters a leaded gasoline
tank to carry out repair work should wear air supplied respiratory equipment, works
clothing and protective clothing appropriate to the operation being undertaken.
iii) Disposal of Tank Plates
The scale on plates from tanks taken out of service must be regarded as toxic to touch
and plates should be handled with gloves. When dust is present dust masks must be
worn; if the plates are heated, canister respirators should be worn. If the plates are to
be disposed of for scrap, they can be regarded as safe only after heating.
Table – 1
Equipment for tank cleaning
SN Description Remarks
1. Air extracter, powered by For draining vapours from tanks-
compressed air should be used with flexible trun-
king to draw from low level in
tank and discharge at higher level
2. Air lower, driven by flame To introduce air into tank if

proof electric motor. possible at high level.
3. Water pump (medium For use with hoses to remove

pressure). Sludge and scale. Water jets not
allowed until tank is free from
flammable vapour. Nozzles must
be carefully earthed with the tank.
4. Sludge pump driven by Plastic hoses are prefered.

Flame proof motor.
5. Air Compressor, diesel The compressor should be sited

driven with air reservoir. Upwind of the job.
6. Lighting. Should be flameproof.
7. Cleaning Tools-brooms Wood can be used, but can not

squeegees, scrapers, be decontaminated and should
shovels and wire brushes. be burnt after use.
8. Buckets, bins or drums For handling sludges where

with lids. pumping is not possible.
9. Bin or drums with lids. For contaminated clothing.
10. Sinks or bins. For washing dirty clothing.
11. Clean rags, scrubbing For cleaning clothing and

brushes, kerosene, equipment.
Detergent, soap.
215
12. Clean towels, nail For wash room, where showers
brushes, soap. and hot water should be available
13. Explosimeter. To be used with nylon sampling

tube.
14. Wind indicator. To assist with site preparation.
Table – 2
Clothing for tank cleaning operations :
(a) White – vest, underparts, socks.
(b) White cotton over all, and white cap.
(c) Air supplied respirator.
Table – 3
Cleaning Procedre and protection required :
SN Operation Protection Remarks

Required
1. Empty gasoline - This stage includes floating

from tank off residual product with
water.
2. Assemble and - -
check all equipment
3. Disconnect and PVC gloves -

blank off delivery
and suction lines
4. Open manholes Air supplied No respiratory equipment

respirators is required until the joint is
or canister broken.
respirator
PVC gloves
5. Fit ventilation
Equipment
6. Test ventilated Air supplied Continue ventilation

tank with respirator,canister at all times.
Explosimeter respirator suitable
if the tank is not
entered
7. Fit sludge pump Full protection -

suction in tank at
low point.
8. Open clean out PVC gloves air

doors(if fitted) supplied or air
216
supplied or
canister respirator
in the last stages
9. Hose sludge Air supplied Hosing may be

towards sludge respirator,canister omitted especially
pump suction respirator may be where water supply
but do not enter used if the doors is limited, or
tank are on the wind- disposal difficult.
Ward sides of the
Tank
10. Enter tank if Full protection Continue ventilation

necessary and
at all times.
continue cleaning
with hoses,
shovels etc.
11. Inspect Air supplied Although the tank

respirators, PVC may look clean,
gloves toxic vapours is
presents for some-
times, even with
good ventilation.
Table – 4
Summary of precautions – work inside tank
Condition Location Type of Protection Remarks

Of Tank Work
Roof in Below roof All work Air supplied To protect against

Position respirator residual lead vapour
Roof in Above roof of All work Air supplied Ensure sufficient

Position floating roof respirator or oxygen present if using
tank canister canister respirator
respirator
Roof Inside tank All work Air supplied or
removed canister
respirator
Summary of precautions – work outside the tank
Condition Location Type of Protection Remarks

Of Tank Work
217
All stages Outside the Cold work, Dust mast or To protect against dust
of job tank dusty canister mask.
Cold work, X -
& non-
dusty
All hot Air supplied or Protection against
work canister fumes
respirator
218
14.2 Do’s and don’t’s of TANK M&I
PROCEDURE FOR HANDING OVER A TANK FOR M&I
SL.NO. CHECK POINTS DESCRIPTION PURPOSE

1 PUTTING THE TANK ROOF ON KEEP THE ROOF AT
MAINTENANCE HEIGHT MAINTENANACE HEIGHT
DURING LAST FILLING FOR EASE IN MAINT
UP/OPERATION ACTIVITIES
2 EMPTYING OUT THE CONTENT MINIMISING THE
BY MAIN PUMP TO THE MAX HYDROCARBON CONTENT
AFTER ISOLATING INLET OF OF THE TANK
TANK .IN CASE OF STEAM
COILED TANK, NO STEAM TO
COIL TO AVOID OVER HEATING
OF BARE COIL.
3 ELEVATION OF LIQUID MINIMISING THE
HYDROCARBON LEVEL BY HYDROCARBON CONTENT
TAKING WATER THROUGH OF THE TANK
BOTTOM DRAIN &
SUBSEQUENT PUMPING OF
HYDROCARBON
4 RUNNING OF PORTABLE PUMP MINIMISING THE
,IN CASE OF DIFFICULTIES IN HYDROCARBON CONTENT
CARRYING OUT ACTIVITY OF THE TANK
MENTIONED IN SERIAL NO-3
5 POSITIVE ISOLATION OF TANK NO INGRESS OF
BY PUTTING BLINDS ON INLET HYDROCARBON IN THE
LINES TANK
6 OPENING OF MANHOLE COVER WEATHERING/VENTILATION
INCLUDING THOSE AT ROOF
7 OPENING OF CLEAN OUT DOOR FACILITATE DESLUDGING
,IF EXISTS
8 WASHING /DESLUDGING OF FACILITATE DESLUDGING
TANKS BY POURING WATER
FROM OUTSIDE
9 MAKING PONTOON BOX FACILITATE HOT JOB
HYDROCARBON FREE ,IF
REQUIRED
10 REMOVAL OF DAMAGED FOAM FACILITATE HOT JOB
SEAL & PROPER WASHING OF
ABSORBED HYDROCARBON IN
THE FOAM,IF NECESSARY
11 RUNNING OF BLOWER SUFFICIENT WEATHERING
/EXHAUSTER
12 PROPER GAS TEST& THEN PROPER WEATHERING &
REMOVAL OF SAFETY
BLOWER/EXHAUST
13 PROVISION OF SUFFICIENT NOS LIGHTING
OF SAFETY LAMPS (24V supply)
219
WITH LONG CABLE without any
cut or joint.
14 ISSUING OF MAN ENTRY CARRING OUT JOBS INSIDE
PERMIT THE TANK
15 PROPER CLEANING OF TANK FACILITATE HOT JOB
FROM INSIDE
16 ISSUE OF HOT JOB PERMIT HOT JOB INSIDE & OUTSIDE
AFTER ENSURING SUITABLE THE TANK
CONDITION INSIDE & OUTSIDE
THE TANK
17 Check for presence of pyrophoric
iron sulphide
i) Entry of air into the tank
is prevented as far as
possible until all interior
surfaces have been
wetted, and
ii) The interior surfaces of the tank
are kept-wet until the tank is gasfree.
Hazards of static electricity IS :

9964 ( Part 1 ) – 1981
Use of high speed water jets for
washing down the sludge or
introducing water at high speed into
the cone roof tanks for floating of
remaining oil may generate static
electricity and result in creation of
high charge densities leading to
possible discharges. These incendiary
practices may not, therefore be
considered safe, especially in case of
cone roof tanks containing crude oil,
gas oil or lighter fractions. Water may,
however be introduced in cone roof
tanks safely at a velocity of less than
1 metre/sec.
The hazard of static electricity is also
present where steam is used
for gas-freeing of tanks. Though the
charges left on the steam nozzle may
be controlled by proper bonding, the
charges left in the steam after it left
the nozzle may collect on metallic
objects inside the tank which are
insulated from the ground. S-parks
may then occur between a charged
object and a grounded object. (The
220
somewhat prevalent idea of spark
discharges within the steam clouds
themselves has not yet been
substantiated.)
221
PROCEDURE FOR TAKING OVER A TANK AFTER M&I
SL.NO. CHECK POINTS DESCRIPTION

1 TAKE CLEARANCE FROM INSPECTION ON COMPLETION OF
ALL M & I JOBS
2 TAKE NEW CALIBRATION DATA FROM TECHNICAL SERVICES
DEPTT
3 CHECKS THE TANK INTERNALLY AND EXTERNALLY. NO
FOREIGN MATERIALS ARE TO BE PRESENT INSIDE OR ON THE
ROOF OF THE TANK.
4 CHECKS THAT ALL INSIDE AND OUTSIDE FITTINGS ARE
FIRMLY SECURED.
5 ENSURE THAT CIRCULATION NOZZLE IS FITTED BACK AT 45
DEG INCLINATIONS TOWARDS THE TANK ROOF
6 CHECK THE TANK SURROUNDING IS FREE FROM DEBRIS OR
ANY OIL ACCUMULATION.
7 CHECK THAT ALL APPROACH PATHS TO AND FROM THE
TANK ARE IN GOOD CONDITION
8 THE TANK IS HAVING INSULATED LINES, CHECK THAT ALL
INSULATIONS ARE PROPER
9 CHECK WHEATHER ALL THE EARTHING CONNECTIVITIES
ARE IN HEALTHY CONDITION
10 BOX-UP THE TANK & FILL UP THE EMERGENCY DRAIN WITH
WATER
11 DEBLIND ALL THE INLETS AND OUTLETS
12. COMMISSION THE TANK BY GRAVITATINGFROM ANOTHER
FILLED TANK OF THE SAME MATERIALS
13 CHECK THE LEVEL IN THE TANK AND ALLOW THE OIL
.ENSURE THAT THE ROOF IS FLOATING NORMALLY.
14 CHECK THE FLANGE AND MANHOLE COVER FOR ANY LEAK,
GET LEAK RECTIFIED IMMEDIATELY.
15 INFORM PLANNING SECTION WHEN THE TANK IS
COMMISSIONED
Indian Standard: 9964 ( Part 1 ) - 1981

RECOMMENDATIONS FOR MAINTENANCE AND OPERATION OF
PETROLEUM STORAGE TANKS PART 1 PREPARATION OF TANK FOR SAFE
ENTRY AND WORK
222
CHECK LIST FOR TANK CLEANING AND ENTRY
A-I. Has process supervisor and maintenance engineer reviewed all the probable
hazards connected with tank cleaning ?
A-2. Is work permit system followed?
A-3. Are special precautions taken for cleaning tanks that has contained leaded
products?
A-4. Is respiratory protective equipment in good condition? Are men trained in their
pro-per use and know their limitations?
A-5. Are gas testing equipments in good operating conditions?
A-6. Endeavour to completely empty out all liquid hydrocarbons from the tank
through (i) feeding to unit, (ii) suction lines, (iii) water draw off, and (iv) repeated
floatation of water.
A-7. Do not introduce water into tanks until temperature of oil is well below 100°C.
iii) Preferably use tested standard steel piping instead of hoses.
A-9. Have you ensured that vapour will not come in contact with ignition source,
while vapour-freeing ?
A-10. Do not allow entry inside the tank until all lines are blinded.
A-11. Make effort to clean the tank from outside as far as practicable.
A-12. Do not allow entry inside the tank even with respiratory equipment, above 20
percent of lower explosive limit ( lower flammability limit ).
A-13. Have you kept astand-by while men are working inside the tank ?
A-14. Have you ensured complete removal of all liquid hydrocarbons, deposits,
sludge combustibles, etc. and also examined pontoons, linings, and bottoms prior to
starting hot work? Have you taken combustible gas indicator readings and seen that it
reads zero?
A-15. Have you ensured that no one is left inside the tank and no material is kept
inside, prior to buttoning up tbe tank?
223
DO’S & DON’T DURING TANK M&I
DO’S
1. Do gas test to check H2S and hydrocarbon, before entering any tank. It should
be nil. Gas testing is mandatory for all blinding/ de-blinding jobs in process line
in services of toxic gases/ Hydrocarbon. In case there is presence of toxic gas,
suitable respiratory protection devices shall be used.
2. All lifting tools, tackles and equipment used shall be tested and certified by
competent authority. Ensure pre-use check of heavy equipments/ Tools &
Tackles.
3. Full Body Safety harness with double lanyard shall be used for carrying out
maintenance job at a height of 2.0 meters and above.
4. Supplied Airline mask shall be used to enter and work inside OWS/ Sewer
manhole/confined space.
5. Check history of tank like tank cleaned on date, due date of cleaning/M&I.
6. Before going to tank roof, check near tank entry for any caution.
7. Check visually the health of staircase.
8. Inform the other person if going on tank top.
9. Carry Walkie-talkie
10. Walk on pathway provided on tank roof.
11. Walk slowly on roof. Use lifeline while walking on Roof.
12. Check earthling of the tank.
13. Keep one supervisor to stand at manhole all time if entry permit is given.
14. If going on roof taken canister mask/breathing apparatus. There should be one
man as standby.
15. Take safety belt.
DON’T
2. Do not enter the tank if gas test is not done.
3. Do not walk here and there on tank roof.
4. If hydrocarbon is there in side tank, don’t enter.
5. Do not use 240 volt supply for illumination and any other purpose.
6. Do not use any bamboo material.
7. Do not allow any person inside tank more than 20 minutes for the first time.
8. Do not allow female to work inside tanks.
9. Do not go to roof during abnormal weather.
10. Do not use nylon rope.
FIXED AND FLOATING ROOF CHECKING

1. In case any tank roof is defective or doubtful, put caution board at stair case
entrance.
2. Don’t go alone on tank roof.
3. Use safety belt while going on tank roof.
224
4. One person should stand at stair case top.
5. Don’t walk freely on tank roof.
6. Always move on platform (Pathway) provided at tank top.
7. There should be pathway for movement to approach manhole, goose neck,
breather valve.
8. In case, old tanks don’t have the same, then platform to be provided during tank
M&I.
9. No employee should be allowed to work on roof alone.
10. Anybody going to tank roof should take permission from shift-in-charge.
11. Gas test to be done for hydrocarbon, oxygen and hydrogen sulphide in case entry
permission is needed.
12. Hydrocarbon and hydrogen sulphide should be zero and oxygen should by more
than 19%. Then only entry permission is to be given.
Over & above following safety points are to be looked into by safety supervisors of
concerned contractors
• CONFINED SPACE
➢ Take clearance from Production at field..

➢ Maintain a book for accounting people entry/exit
➢ Keep a man outside for helping during problem.
➢ Ensure proper illumination and ventilation before entry.
• WORKING AT HEIGHT
➢ Not to undervalue Safety Precautions irrespective of Size & Nature of Work

or Measure of Height if it is above 2 M. make standard scaffolding for height
job and to be certified before use.
➢ Over Precaution is always better than Over Confidence.
➢ Ensure Use of right PPE & Safe Work environment.
➢ Insist upon Adequate Training & Tool Box Talk prior to starting the job.
➢ Design and Standardize Work Procedures.
➢ Use safety net wherever feasible.
➢ Cordon of the Work area.
• FIRE PROTECTION
➢ Keep Fire hose charged condition

➢ Check the fire hydrant readiness
➢ Take Hot job clearance
➢ Maintain Good House Keeping.
➢ Keep fire bottle near hot job
➢ Cordon off the area.
• ELECTROCUTION
225
➢ Power supply inside the tank through ELCB
➢ No supply beyond 24 volts allowed inside the tank for illumination.
➢ Ensure the cable must not damage while shifting materials inside the tank.
➢ Ensure proper earthling
➢ No joint cable allowed for welding.
• MATERIALS HANDLING & LIFTING AT HEIGHTS
➢ Tools are to be tested before use.

➢ Cordon off the area while lifting heavy plates at height
➢ Ensure at top people must use proper PPE
➢ Use roller for shifting materials at ground
• NO TWO AGENCIES I.E. CIVIL & MAITENENCE TO BE ALLOWED TO
WORK SIMULTENOUSLY.
• NO PAINTING JOB TO BE ALOWED DURING ANY HOT JOB IN THE
TANK
CHAPTER-15
List of TSVs (total 61 numbers) installed in hydrocarbon / water line and their
testing date is reproduced below:
No Date of Notificati Handing over

List of TSVs released for testing and of release on date from
inspection TSV from PN Number MM
29th 1207852
2 6th June'14
Tk-205: Inlet & Outlet line May'14 15
29th 1207852
2 6th June'14
29th 1207852
2 6th June'14
29th 1207852
2 6th June'14
29th 1207852
1 6th June'14
Tk-203: Inlet line May'14 15
TK-204: TSV missing. TSV was provided
miss
but missing. Same to be provided during
ing
M&I.
8th 1207878
2 18th june'14
TK-738: Inlet & Outlet line June'14 87
8th 1207878
3 18th june'14
TK-739: One in Inlet & two in Outlet line June'14 87
6" line no-44 near tk-908 manifold 22th 1207909
1 01thjuly'14
along road no-04 june'14 49
226
6" line no-45 near tk-908 manifold along 22th 1207909
1 01thjuly'14
road no-04 june'14 49
4" line near tk-908 manifold along road 22th 1207909
1 01thjuly'14
no-04 june'14 49
18" HSD line near tk-909/910 manifold 22th 1207909
1 01thjuly'14
along road no-04 june'14 49
02th'july20 1207934
1 22th july'14
18" fo line near TK-734(2115-trv-1805) 14 45
6" HSD line near tk-733/734 02th'july20 1207934
1 22th july'14
manifold(2115-trv-1802) 14 45
8" outlet line from tk-1509(2115-trv- 02th'july20 1207934
1 22th july'14
1501) 14 45
02th'july20 1207934
1 22th july'14
6" inlet line from tk-1509(2115-trv-1503) 14 45
10" inlet line from tk-1508(2115-trv- 02th'july20 1207934
1 22th july'14
1504) 14 45
18"Discharge line from 2200-pm- 26thjuly 1207990
1 5th aug 14
3A/B/2B 2014 12
26thjuly 1207990
1 5th aug 14
14"Discharge line from 2200-pm-1A/B 2014 12
26thjuly 1207990
1 5th aug 14
14"Discharge line from 2200-pm-3C 2014 12
26thjuly 1207990
1 5th aug 14
10"Discharge line from 2200-pm-02A 2014 12
not possible due to no valve in both
1
TK-771 Inlet line (18") side
1
TK-771 outlet line (18") side
1
TK-772 Inlet line (18") side
1
TK-772 Outlet line (18") side
4thaugust 1208013
1 20th2014
TK-701 Inlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-703 Inlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-770 Inlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-770 outlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-781 Inlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-781 Outlet line (24") 2014 51
4thaugust 1208013
1 20th2014
TK-782 Inlet line (18") 2014 51
4thaugust 1208013
1 20th2014
TK-782 outlet line (24") 2014 51
4thaugust 1208013
1 20th2014
TK-783 Inlet line (18") 2014 51
227
4thaugust 1208013
1 20th2014
TK-783 Outlet line (24") 2014 51
24th
1208064 18th
1 august
21 sept2014
TK-777 HSD(10"-P-IT) 2014
24th
1208064 18th
1 august
21 sept2014
TK-777 HSD(8"-P-IT)) 2014
24th
1208064 18th
1 august
21 sept2014
TK-731 HSD(12"-P-IT) 2014
24th
1208064 18th
1 august
21 sept2014
TK-731 HSD(8"-P-IT) 2014
24th
1208064 18th
1 august
21 sept2014
TK-731 HSD(18"-P-IT) 2014
24th
1208064 18th
10"HEADER(TK-95,96,97,98,99)TSV- 1 august
21 sept2014
SR.NO-603687 2014
24th
1208064 18th
20"HEADER(TK-78,81,84)TSV-SR.NO-93- 1 august
21 sept2014
1986 2014
24th
1208064 18th
EURO FOUR STATIC MIXER LINE(8"-PTP- 1 august
21 sept2014
328,1501-TSV-0102) 2014
24th
1208064 18th
EURO THREE STATIC MIXER LINE(8"-PTP- 1 august
21 sept2014
327,1501-TSV-0101) 2014
24th
1208064 18th
STATIC MIXER BY PASS LINE(8"-PTP- 1 august
21 sept2014
329,1501-TSV-0103) 2014
24th
1208064
1 august
21
TK-97 (12") NOT FOUND BY INSPECTION 2014
24th
1208064 18th
1 august
21 sept2014
PUMP-P-751-P-10G(10"P,TSV-20.6) 2014
24th
1208064 18th
1 august
21 sept2014
PUMP-P-751-P-10G(14"P,TSV-20.6) 2014
24th
1208064 18th
1 august
21 sept2014
2115-P-108A(10"IFO,PRV-1718) 2014
24th
1208064 18th
1 august
21 sept2014
2115-P-108B(10"IFO,PRV-1720)) 2014
24th
1208064 18th
1 august
21 sept2014
2115-P-108C(10"IFO,PRV-NO TAG)) 2014
228
24th
1208064
2115-P-105A(PUMP SEAL POT,2115- 1 august
21
TRV-5207) 2014
24th
1208064
2115-P-105B(PUMP SEAL POT,2115- 1 august
21
TRV-5202) 2014
24th
1208064
21
TRV-5210) 2014
24th
1208064
21
TRV-5214) 2014
24th
1208064
2115-P-110B(PUMP SEAL POT,2115- 1 august
21
TRV-5209) 2014
24th
1208064 18th
1 august
21 sept2014
14" PUMP DISCHARGE(2115-P-106A) 2014
24th
1208064 18th
1 august
21 sept2014
14" PUMP DISCHARGE(2115-P-106B) 2014
24th
1208064 18th
1 august
21 sept2014
TK-63 INLET/OUTLET LINE(6") 2014
24th
1208064
2115-P-108A/B/C SUCTION LINE(10"- 1 august
21
2115-1926,2115-TRV-1903) 2014
24th
1208064
2115-P-108A/B/C SUCTION LINE(10"- 1 august
21
2115-1927,2115-TRV-1904) 2014
229

OM&S-R - Updated

Uploaded by

Copyright:

Available Formats

OM&S-R - Updated

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OM&S-R - Updated

Uploaded by

Copyright:

Available Formats

What are the main facilities discussed in the document?

What are the main facilities discussed in the document?

What is the purpose of the operating manual?

What is the purpose of the operating manual?

OM&S

INDIAN OIL CORPORATION LTD.

SK VERMA,PNM S.SRIDHAR-SPNM SATYAWARTI KUMAR

It is expected that personnel involved in various activities in OM&S will study

Some of the information contained in the manual is of a confidential nature and

OM&S-1’s Receipt &Blending operation

CHAPTER - 2 SUB SECTION OF RECEIPT

CHAPTER – 3 CRUDE OIL HANDLING

CHAPTER 4 STORAGE TANKS

CHAPTER 5 Pumps, Valves, Blinds

5.19 FEW IMPORTANT POINTS ON OPERATING OF HAMER

CHAPTER 6 RECEIPT, BLENDING & SUPPLY

CHAPTER7 DESPATCH OF PRODUCTS

CHAPTER 9 Quality control

CHAPTER 10 Chemical, Aditives & MSDS

CHAPTER-11 CLOSED CIRCUIT TV (CCTV)

CHAPTER-12 SAFETY & EMERGENCY HANDLING IN OM&S

CHAPTER-15 List Of TSV’s

REV DATE DOC Prepared Checked by Approved

UPDATED, ISSUED SL NIRANTAR RS PATEL

Sr. No. ISSUED TO CONTROLED COPY NO.

The Objectives and functions of OM&S are as follows: -

3. Receipt, storage, accounting of finished products and intermediates ex.

4. Supply of intermediates (feed) to processing units.

5. Preparation of finished products tanks for dispatch. Sampling for Quality

6. Product dispatch by pipeline, T/W & TTL.

8. Unloading the rail wagons declared either sick by railway or contaminated

9. Unloading of Truck of different chemicals. e.g Benzene.

11. Preparation of Tank for cleaning, inspection, repair & maintenance.

14. Co-ordination with service departments (Maintenance /inspection/ Technical

a) Receipt and Blending

a) Atmospheric Distillation Unit-I (AU-I)

Catalytic Reforming Unit (CRU)

a) Light Charge Stock - 700 C - 900 C cut

Crude Oil to AU-I, AU-II, AU-III , AU-IV and AU-V

South Gujarat crude

The modes of dispatches of finished products are as follows

In Tank Wagon, packed LPG and Bitumen in Railway wagons.

To Sabarmati IOC installation near Ahmadabad, to GSFC, to IPCL, to HPCL and

SLOP 6" 6"

10" DRY LIGHT 6" 6"

4" 3) PROPER APPROACH PLATFORM NEEDS TO BE PROVIDED FOR THE

OPERATING CONDITIONS : LEGEND

They also maintain upto-date records, pertaining to above activities, as required

GR- crude control room

2.1 GR- crude control room

2.2 GRE- crude control room

2.3 GR- product control room

2.4 GRE- product control room

2.5 BOD sump or GR/GRE Sump

There is a sump provided to gather the slop a provision of level indication is

1. Slop tanks 201 and 202 directly.

SCHEME FOR PROVISION OF FACILITY FOR CARRYING OUT MAINTENANCE OF

Scheme reproduced below:

Crude Oil Handling

CRUDE OIL HANDLING