DANGOTE PETROLEUM

REFINERY AND
PETROCHEMICALS

Technical Services
Presentation

BY

OLABIYI BISOLA SHUKURAT

NZEKWE ANITA CHIDIOGO
TABLE OF CONTENTS
• Overview of Technical Services
• Role of Technical Service Engineers in the Refinery
• Plant monitoring and Inspection
• Penex Catalyst and Loading (Technical Services Scope)
• Process Safety
• Process Safety Management
• Process Safety vs Occupational Health & Safety
• Importance of PSM at DORC
• Process Safety Tools at DORC

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Overview of • Like the saying goes, ‘Operators are
Technical the owner of the refinery’……..but
Technical Service Engineers are the
Services heartbeat of the refinery.

• Technical Service Engineers provide

Who is a technical support for plant
operations.
Technical Service
Engineer? • They monitor, troubleshoot, design,
develop and optimize refinery
processes.

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 • Plant monitoring and inspection
• Scheduled plant shutdown and startup

Role of • Identify Design Gaps

• Process modification and simulation

Technical • Process troubleshooting

• Yield calculation and efficiency prediction

Service • Supervise Pre commissioning and commissioning

activities

Engineers in the
• Steam, Power, Catalyst and chemical consumption,
selection and estimation.
• Preparing Standard Operating Procedures

Refinery (SOPs) such as Catalyst loading procedures

TS is seen as the hope of any process industries

and oversee any technical issues; hence, they are
called the doctor of the refinery.
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Pre-commissioning and
commissioning activities Some
phases of
the
preparation
for
commission
ing by TS
engineers
Here, there is a large amount are but not
limited to:
of detailed preparatory work king
Chec gainst
which should be done by TS Safe
ty
a
Unit ng and
Pipi ument
Engineers in cooperation with Instr rams
Diag
others at the job site. The
primary purpose of this is to
inspect the equipment to make
certain the construction was PD on
c ti e ls
done exactly as per wi B c
th he
P& last ck
e
p s
Ins Ves ther t.
of d o en
specification of the licensor ID est
an ipm
u
eq
and as shown on the piping
and instrument diagrams

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 Plant Monitoring and Inspection
Monitoring, inspecting, operating & maintaining a process plant safely & efficiently
depends upon having adequate information on which to base critical decisions
• Monitoring is carried out during operation. Here,
TS check process parameters e.g. pressure,
temperature, flow rate, input and output, yield
specifications, battery limit conditions etc. to
ensure that the plant is operating within design
scope.
• Inspection is done before startup, after shutdown
and sometimes during normal operations.
Equipment are inspected to ensure they are
according to design, if its after shutdown, it is to
ensure the equipment is very okay to provide the
needed service. This is to ensure nothing affects
the process operations, causes delay due to
disruption while in service, prevents total
breakdown due to oversights and many other
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reasons.
Plant Monitoring and Inspection
• This information includes Engg.
drawings defining the plant, known as
Process Flow Diagram (PFD), Piping &
Instrumentation Diagram (P&IDs),
Equipment General Arrangement
Drawings (GA), Isometric Drawing
(ISO) etc.
• Every process plant starts with design
Basis i.e capacity, feedstock, products
configuration, market specification etc,
the role of Technical Service during
inspection is to ensure that before startup,
all process equipment are meeting up
with design specifications.
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Plant Monitoring and Inspection

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Plant Monitoring and Inspection
• The occurrence of a vortex in a
fluid system leads to a reduction
of pressure. So, the requirement
of pumping force increases
• It creates erosion of pipes and
fitting.
• Increase or reduction in vortex
breaker height from the design
values reduces it effectiveness

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PENEX Catalyst Loading • Safety: Proper Personal Protective Equipment (PPE)
should be worn during all loading activities
• Before, during, and after catalyst loading, the catalyst
Another major role of TS in the must be protected from moisture at all times
refinery is catalyst loading. • All punch list items of the vessel will be loaded should
Catalyst plays a very important be resolved. Verify all internal measurements inside
the vessels (internal diameter of the vessel, dimensions
role in refining and must be of outlet collector etc.).

handled with care because they • Prior to the loading of the Reactors with catalyst,
the following major materials will be required:
are very expensive. • Crane, Forklift, Catalyst loading assembly and
Also, prior to catalyst loading, Dense Loading Device, Special quick release drum
with lid retainer rings (two required), Bailing wire,
some procedures and Plastic sheeting and tarps, Dry nitrogen (less than 5
precautions must have been ppm of H2O), Dry hoses for nitrogen purging,
Grounding wire, Measuring tape to determine
followed which include: outages on reactor, Equipment for hoisting catalyst
drums, New gaskets for flanges and manways
which were opened etc

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 PENEX Catalyst loading (Contd)
• Reactors loading will carry out in • After Shut Down procedures and
two different steps: preparation of Reactor section for
loading (cooling, pressure relief,
• first step is installation of the evacuate hydrocarbons, nitrogen
catalyst support materials before blowing etc.) unbolt top manway head
drydown, acidization. (900 elbow) and immediately wrap it
• second step is the catalyst loading and the inlet distributor in plastic
after the unit has been finally dried • The catalyst loading assembly must
out. be immediately installed
• The main idea of acidizing
activities is to decrease moisture
content to less less than 1 ppm.
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 PENEX Catalyst loading (Contd)
• The catalyst will be transferred from • Ensure that a positive nitrogen
the loading assembly to the dense pressure is maintained in the reactor
loader using a canvas sock. The sock during the loading. Static electricity
should be secured to the bottom of the may build up during the catalyst
loading assembly and extend of a loading. It will be necessary to use a
length of 12 inches below the top of grounding wire to connect the loading
the dense loading hopper. hopper to the reactor in order to
• The dense loading device will be discharge any static electricity. The
mounted on the top manway of the loading assembly and adaptor should
liquid/vapor mixing tray. be grounded to the reactor; the loading
sock grounding wire should be
• Connect nitrogen with reactor inlet connected to the reactor.
and loading assembly
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PENEX Catalyst loading (Contd)
• UOP strongly recommends that the
opening, loading, and closing of the
reactor should be a continuous
operation with no breaks, except
during inclement weather. As less time
the reactor is opened, the lower chance
that water and foreign materials will
contact catalyst. If at any time it starts
raining, no matter how much, the
loading must be stopped immediately,
and the reactor manway must be
completely covered to prevent water
from contacting with catalyst.
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PENEX Catalyst loading (Contd)
• Start rotating the Dense Loading • As quickly as possible after the
Machine, adjust nitrogen flow to loading is completed, install the
the dense loader motor and inlet distributor, ceramic fiber
achieve the correct RPM’s and set rope, reactor head and inlet
the RPMs accordingly based on the elbow. If necessary, clean the
falling height as per dense loading
mating surfaces of the top flange
curve (falling height is the outage
from the rotor to the catalyst bed, faces. Continue the dry nitrogen
not from the manway to the purge to the top of the reactor
catalyst bed). As each catalyst drum and purge out the bottom to
is loaded, record the lot and drum flare
number and weight of each drum
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Process Safety Management
(PSM)
What is Process
Safety?
• A blend of engineering and
management skills focused on
preventing catastrophic accidents and
near-misses.
• It deals with the prevention and control
of events that have the potential to
release hazardous materials or energy.
• Such events can be toxic release, fire,
explosion or structural collapse and
could ultimately result in serious
injuries, property damage, lost
production, and environmental impact.

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 Goal of Process
Safety
Management
The goal of process safety
management is to develop plant
systems and procedures to prevent
unwanted releases that may ignite
and cause toxic impacts, local fires or
explosions.

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 Pillars of Process Safety
Management

COMMIT TO UNDERSTAND MANAGE RISK LEARN FROM

PROCESS SAFETY HAZARDS AND RISK EXPERIENCE

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Elements of Process Safety
Management

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 Anatomy of a Process Safety
Incident
HAZARD

• Mechanical Failure • No Flow • Fire

• Loss of Utilities • Low Temperature • Explosion • Injury/Fatality
• Procedural Error • High Pressure • Toxic Release • Property Damage
• Raw Material Variation • Mis-operation • Shutdowns • Business Interruption
• Environment Conditions • Loss of Containment • Equipment Damage

Initiating Process Loss

Cause Deviation Event Impact
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 Process Safety Vs. Occupational
Health & Safety
The key differences between occupational health and safety and process safety are:
• The mechanism of action: Process safety and OHS both refer to the potential loss of
control of hazardous energy, but process safety is about managing higher levels of
energy.
• Potential severity of consequences: Process safety incidents are less common but more
severe while OHS incidents are more common but less severe.
• OHS is primarily about the safety of those who interact with systems while process safety
is about the safety of the system.

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Occupational Health & Safety
Incidents

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Importance of the PSM System
at DORC
By implementing process safety management systems, major disasters involving
catastrophic releases of flammable and toxic chemicals can be avoided.
Qualitative Benefits
• Corporate Responsibility: Process safety protects a company’s image, reputation, and
brand.
• Business Flexibility: Process safety preserves a company’s license to operate.
Quantitative Benefits
• Risk Reduction: Process safety prevents human injury and avoids significant losses and
environmental damage.
• Sustained Value: Process safety helps to boost productivity and produce high quality
products on time and at lower cost.

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A Process Safety
Incident

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 The following are few of the tools used
in DORC to ensure process safety:
Process • Hazard & Operability Study (HAZOP)
Safety • Pre-Start Up Safety Review (PSSR)
• Process Knowledge Management
Tools at (PKM)
DORC • Management of Change (MOC)

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Hazard & • HAZOP is a structured and systematic
examination of a complex planned or
Operabilit existing process or operation in order to
identify and evaluate problems that may
y Study represent risks to personnel or
equipment.
(HAZOP) • The intention of performing a HAZOP is
to review the design to pick up design &
engineering issues that may otherwise
not have been found.

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 Hazard & • The technique is based on breaking the overall
complex design of the process into simpler
Operability sections called nodes which are then
individually reviewed.
Study • It is carried out by a suitably experienced
multi-disciplinary team during series of
(HAZOP) meetings.
• The team consists of:
o HAZOP Chairman
o Scribe
o Process Engineer
o Operator
o Discipline Specialist
o Maintainer.

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 Hazard & Operability Study
(HAZOP)

Guide Word Meaning

• In order to identify deviations, the NO or NOT Complete negation of the design intent

team applies a set of Guide Words to MORE Quantitative increase

each node in the process. LESS Quantitative decrease

AS WELL AS Qualitative modification/increase

• To prompt discussion, or to ensure
PART OF Qualitative modification/decrease
completeness of the HAZOP,
REVERSE Logical opposite of the design intent
appropriate parameters which apply to
the design intent are also applied. Such OTHER THAN / INSTEAD Complete substitution

parameters include flow, temperature, EARLY Relative to the clock time

pressure, level, composition, etc. LATE Relative to the clock time

BEFORE Relating to order or sequence

AFTER Relating to order or sequence

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A Typical HAZOP Sheet

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Management of Change
(MOC)

Management of Change (MOC) system defines a comprehensive structure for identifying,

communicating, reviewing, planning and documenting all changes to plant, process,
organization, and procedures.

Any modification to process chemicals, processing steps/sequences, dosages, sequence

of actions, equipment, procedures, utility systems, control & monitoring system, safety
systems, procedures, staffing, organisational structure/responsibilities.

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Types of MOC

Permanent changes

Temporary changes

Emergency changes (including temporary bypassing of safety

critical equipment)
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 • An MOC addresses:
- Technical basis for requested change
- Identification and risk analysis of impacts on safety
Managem and health

ent of - Necessary modifications to operating procedures

- Identify time period for the change to occur
Change - Authorisation requirements

(MOC) - Completion of follow-up activities

• Hazard Identification and Risk Assessment is the

most important part of any MOC system.

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 Physical, chemical, and toxicological information
related to the chemicals, process, and equipment are
verified.
Process Information such as:
Knowledg • Written technical documents and specifications
• Engineering drawings and calculations
e • Specifications for design, fabrication, and
Managem installation of process equipment.
• Relevant codes and standards
ent (PKM) • Properties of hazardous materials
• Information, data and tools related to process
safety management processes

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Pre-Startup Safety Review
(PSSR)

A PSSR consists of a checklist of items to be

thoroughly verified before a process begins or restarts
in order to ensure that potential hazards have been
properly addressed.

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Why is PSSR important?

Experience has shown that the frequency of incidents is higher

during process transitions such as startups. These incidents have
often resulted from the physical process conditions not being
exactly as they were intended for safe operation. Thus, it is
important that the process status be verified as safe to start.

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 PSSR for complex startups, such as
those for new units or entire plants
Who may involve many people, from all
partakes the disciplines that are part of the
project.
in PSSR?

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Pre- • Actions in a PSSR are classified as “Category
Startup A”(critical for safe startup) and “Category
B”(non-critical).
Safety • The Category A items must be “signed off”
before introduction of hazardous materials
Review and Category B items must be tracked to
completion based on an agreed timeline.
(PSSR)

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Stages of PSSR

• Stage A PSSR: This shall be organised when systems are mechanically completed and FORMAT-III
of P&ID systems in a process unit is issued by PMC and FORMAT-III of non-P&ID systems is issued
by Construction and accepted. On successful completion of Stage A PSSR and approval by Head of
Operations, pre-commissioning activities can commence.

• Stage B PSSR: This shall be triggered when FORMAT-IV document is issued by EIL SCT for a
process unit. Stage B PSSR shall be conducted process unit wise when pre-commissioning
activities are completed, leak test of systems is done and process unit is ready for hazardous
material introduction. On successful completion of Stage B PSSR and approval of Operations
Director, startup cam commence by introduction of hydrocarbon feed/ hazardous materials.

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PSSR Workflow
PSSR Initiation Kick-off Meeting PSSR Walkdown

PSSR Team is selected Presentation of PSSR Scope. Assemble team/s

Required technical disciplines are named Review PSSR documents Assign Team/s Scribe
and contacts are provided. Review the relevant PSSR checklist Trace the whole scope
Agree on the PSSR walkdown plan. Utilize the PSSR checklist
Consolidate PSSR observations in the Team/s scribe form

PSSR Observation Closure PSSR Observation Categorization Meeting

Approve Startup Notification Verify closure using evidences Review the scribe/s consolidated observations
Sign off PSSR Report Assign category
Sign off PSSR Certificate Assign Action Party and Target Dates

Start Up

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