[report about traning at assiut refining oil com
name: ahmed mohamed salah
id:1211046
Department Of Mechatronics
Table Of Contents
Introduction:............................................................................................................1
Petroleum refining processes definition..................................................................1
First: Main Processing Units of Refineries – Treatment............................................2
Second: Crude oil - Distillation Unit.........................................................................2
Third: Measuring Tools.............................................................................................4
Temperature Measurement:....................................................................................4
RTD Sensor:..............................................................................................................5
Pressure Measurement:...........................................................................................6
Level Measurement:................................................................................................8
Third: Control types, control valves and (PLC, DCS And SCADA Systems):................9
Fourth: Types of systems used...............................................................................14
SIS (Safety Instrumented System)..........................................................................14
FGS (Fire and Gas Systems)....................................................................................15
BMS (Burner Management Systems).....................................................................15
Conclusion:.............................................................................................................16
Table Of Figure
Figure 1:Distillation unit flow diagram.....................................................................4
Figure 2:Thermocouple............................................................................................5
Figure 3:RTD Sensor.................................................................................................6
Figure 4:Pressure Gauge..........................................................................................7
Figure 5: pressure transmitter..................................................................................7
Figure 6:Radar sensor..............................................................................................8
Figure 7:Ultrasonic level sensor...............................................................................9
Figure 8: PLC...........................................................................................................12
Figure 9:DCS...........................................................................................................14
Report About (Assiut Refining Oil Company)
Introduction:
The oil originates from Ras Shokeir, situated north of
Hurghada in the Red Sea Governorate, home to a state-of-the-
art oil and gas facility. This oil is efficiently transported
through specially designed petroleum pipelines to the ASROC
facility, utilizing powerful pumps for refining and diverse
applications. Along the transportation route, strategically
placed stations enhance the pressure of the oil and gas,
ensuring a smooth delivery to ASROC. Upon arrival, the oil is
carefully stored in tanks for approximately 72 hours, allowing
sediments to settle at the bottom. This crucial settling period
not only simplifies the filtration process but also optimizes the
subsequent stages, ensuring the highest quality for our
products.
Petroleum refining processes definition
Petroleum refining processes are the chemical engineering
processes and other facilities used in petroleum refineries (also
referred to as oil refineries) to transform crude oil into useful
products such as liquefied petroleum gas (LPG), gasoline or
petrol, kerosene, jet fuel, diesel oil and fuel oils.
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Refineries and petroleum industries are very large industrial
complexes that involve many different processing units and
auxiliary facilities such as utility units and storage tanks. Each
refinery has its own unique arrangement and combination of
refining processes largely determined by the refinery location,
desired products and economic considerations.
Some modern petroleum refineries process as much as 800,000
to 900,000 barrels (127,000 to 143,000 cubic meters) per day of
crude oil.
First: Main Processing Units of Refineries –
Treatment
Crude Oil Distillation unit: Distills the incoming crude oil
into various fractions for further processing in other units.
Vacuum distillation unit: Further distills the residue oil
from the bottom of the crude oil distillation unit. The
vacuum distillation is performed at a pressure well below
atmospheric pressure.
Second: Crude oil - Distillation Unit
The crude oil distillation unit (CDU) is the first processing unit
in virtually all petroleum refineries. The CDU distills the
incoming crude oil into various fractions of different boiling
ranges, each of which are then processed further in the other
refinery processing units. The CDU is often referred to as the
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atmospheric distillation unit because it operates at slightly above
atmospheric pressure.
Below is a schematic flow diagram of a typical crude oil
distillation unit. The incoming crude oil is preheated by
exchanging heat with some of the hot, distilled fractions and
other streams. It is then desalted to remove inorganic salts
(primarily sodium chloride).
Following the desalter, the crude oil is further heated by
exchanging heat with some of the hot, distilled fractions and
other streams. It is then heated in a fuel-fired furnace (fired
heater) to a temperature of about 398 °C and routed into the
bottom of the distillation unit.
The cooling and condensing of the distillation tower overhead is
provided partially by exchanging heat with the incoming crude
oil and partially by either an air-cooled or water-cooled
condenser. Additional heat is removed from the distillation
column by a pump around system as shown in the diagram
below.
As shown in the flow diagram, the overhead distillate fraction
from the distillation column is naphtha. The fractions removed
from the side of the distillation column at various points
between the column top and bottom are called sidecuts. Each of
the sidecuts (i.e., the kerosene, light gas oil and heavy gas oil) is
cooled by exchanging heat with the incoming crude oil. All of
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the fractions (i.e., the overhead naphtha, the sidecuts and the
bottom residue) are sent to intermediate storage tanks before
being processed further
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Figure 1:Distillation unit flow diagram
Third: Measuring Tools
Temperature Measurement:
Thermocouple: A thermocouple is an electrical device that
acts as a temperature sensor, made from two different
metals joined at one end to create a junction. When this
junction's temperature changes, a voltage is produced,
following the Seebeck effect, which is measured to
determine the temperature. Thermocouples are robust, cost-
effective, and can measure a wide range of temperatures,
making them popular in industrial, laboratory, and
appliance applications.
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Figure 2:Thermocouple
RTD Sensor:
An RTD sensor, or Resistance Temperature Detector, is a
temperature sensor that works by detecting the change in
electrical resistance of a material (usually platinum, nickel,
or copper) as its temperature changes. The RTD's resistance
increases with rising temperature, a predictable relationship
that allows external electronics to convert the resistance
measurement into an accurate temperature reading. They
are known for their superior accuracy, stability, and
repeatability, making them ideal for industrial, scientific,
and pharmaceutical applications where precise and reliable
temperature monitoring is essential.
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Figure 3:RTD Sensor
Pressure Measurement:
Bourdon tube (pressure gauge):
A Bourdon tube pressure gauge is a mechanical device that
measures gauge pressure by utilizing a curved, elastic tube
that deforms in response to pressure changes. Pressure
entering the tube causes it to expand and attempt to
straighten, which moves a pointer on a dial to indicate the
pressure reading.
Pressure transmitter:
is a device that measures the expansive force of liquids or
gases and converts it into a standardized electrical signal,
such as 4-20mA current or voltage. This signal can be sent
to a control system or display for monitoring and control of
industrial processes
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Figure 4:Pressure Gauge
Figure 5: pressure transmitter
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Level Measurement:
Radar: Emits radar pulses to measure the distance to the
material surface, providing highly accurate, non-contact
measurement.
Figure 6:Radar sensor
Ultrasonic Level Sensors: Emit sound waves and measure
the time it takes for the echoes to return from the material
surface.
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Figure 7:Ultrasonic level sensor
Third: Control types, control valves and (PLC,
DCS And SCADA Systems):
There are two types of control:
1-open loop.
Definition: A control system where the output does not affect
the control action.
Mechanism:
The controller provides an input signal, but there is no sensor to
measure the system's actual output.
Advantages:
Simplicity: Easy to design, implement, and maintain
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Cost-Effective: Less complex and expensive due to the absence
of sensors and feedback circuitry.
Disadvantages:
Poor Accuracy: Cannot correct for external disturbances or
variations.
Lack of Reliability: Inaccurate results when operating in
uncertain or changing environments.
2-closed loop.
Definition:
A control system where the output is fed back to the input to
influence the control action.
Mechanism:
A feedback loop continuously compares the actual output with
the desired output, allowing the controller to make automatic
adjustments to reduce the difference (error)
Control Valve:
A control valve is a valve used to control fluid flow by varying
the size of the flow passage as directed by a signal from a
controller.
The signal from controller is an analog
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ON/OFF Valve:
On-Off valves control the fluid if it is in the right position or not,
allows or restricts the fluid to mix and stops the flow in
emergency situations.
The signal from controller is a digital.
PLC: A PLC (Programmable Logic Controller) is an
industrial computer for high-speed, discrete control of
individual machines or processes.
PLCs focus on specific tasks with deterministic responses.
Purpose:
Controls individual machines, assembly lines, or specific,
high-speed, discrete tasks.
Architecture:
Typically a single controller or a group of controllers
focused on a specific task or area.
Applications:
Automation of repetitive tasks, controlling motors, pumps,
and other machinery in manufacturing plants, water
treatment, and small-to-medium scale industrial processes.
Programming:
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Uses lower-level languages like ladder logic, function
block diagrams, and structured text.
Key Feature:
Offers fast, high-speed response times and flexibility for
specific machine control.
Figure 8: PLC
DCS: DCS (Distributed Control System) is a complex
system for large-scale, continuous process control, offering
integrated, distributed command and monitoring across an
entire plant.
DCS provides a comprehensive, networked architecture for
managing complex, high-reliability operations like in
chemical or power plants.
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Purpose:
Provides integrated, plant-wide control and monitoring for
large-scale, complex, continuous industrial processes.
Architecture:
Features a distributed, networked hierarchy of controllers
and a single, integrated HMI (Human-Machine Interface)
for comprehensive oversight.
Applications:
Ideal for controlling complex processes in power plants, oil
and gas, and chemical facilities where high reliability and
data acquisition are crucial.
Programming:
Utilizes high-level programming languages for continuous
function charts and provides built-in functions for
managing complex control loops and device operations.
Key Feature:
Offers increased flexibility, scalability, and reliability for
managing large, complex operations.
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Figure 9:DCS
SCADA: A SCADA system (Supervisory Control and Data
Acquisition) is an industrial control system that uses
hardware and software to monitor and control large-scale
industrial processes remotely. It collects real-time data from
remote terminal units (RTUs) or programmable logic
controllers (PLCs), processes it, and displays it to operators
on a Human-Machine Interface (HMI). SCADA systems
are essential for optimizing operations, improving
efficiency, and ensuring safety in critical sectors like
utilities, manufacturing, and water management.
Fourth: Types of systems used
SIS (Safety Instrumented System): is the
overarching framework for industrial safety
Purpose:
To bring process equipment or a plant to a safe state when a
hazardous condition is detected, preventing or mitigating
dangerous events.
Function:
Acts as the last line of defense, detecting abnormal situations
and initiating safety actions such as shutdowns.
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FGS (Fire and Gas Systems): an FGS detects and
mitigates hazardous events like fires and gas leaks
Purpose:
To detect and respond to fires, flammable gas, and toxic gas
releases to protect personnel and plant equipment.
Function:
Monitors process areas for hazards, triggers alarms for
personnel, and can initiate actions to minimize consequences,
such as activating fire suppression systems.
BMS (Burner Management Systems): are specific
types of safety functions that can be implemented within an SIS.
Purpose:
To ensure the safe operation of burners in furnaces, boilers, and
incinerators.
Function:
Employs sequencing and interlocks to manage the burner unit
through its entire operating cycle, including start-up, operation,
and shutdown, preventing explosions.
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Conclusion:
In conclusion, petroleum refineries are an important part of
the oil and gas industry. They play a vital role in the
production of gasoline, diesel, and other petroleum products.
Refinery units are designed to process a particular type of
crude oil and produce the desired set of refinery products.
Petroleum refining is a complex process that involves many
different steps. Refinery operators must carefully monitor the
entire process to ensure that the desired products are produced
safely and efficiently.
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