CHAPTER 1

1.1 BACKGROUND OF SIWES

As a result of student’s inability to contribute to the growth and development of Nigeria SIWES was
Introduced into the industrial and educational sector.

SIWES which is an acronym for Student Industrial Work Experience Scheme started in the year 1973
with over 743 students from 11 institution of learning. In 1978 the scope of participation had
increased to about 5000 students from 32 institutions.

Economist being able to evaluate the role technology plays in a country’s economy concluded that
for an economy to grow and develop there be advancement in the technology sector of the country.

SIWES was solely funded by ITF (Industrial Training Funds) during it’s early stage however due to
some financial constraint the fund withdrew from the scheme in1978. The Federal government
noting the significance of the skill training handed the management of the scheme to both the
National Universities Commission (N.U.C) and the National Board for Technical Education (N.B.T.E) in
1979.

The management and implementation of the scheme was however reverted to the ITF by the federal
Government in November 1984 and the administration was effectively taken over by ITF in July
1985, with the funding solely borne by the federal government.

The scheme was borne to enable students with the opportunity of familiarizing and exposing
themselves to the needed equipment and machinery that are usually not available in their
situations.

The ITF was also designed to supposed such mid carrier attachment by contributing to the
allowances payable for students.

1.2 OBJECTIVES OF SIWES

1. It provides the avenue for students in higher institutions to acquire industrial skills and
experience in their course of study.
2. To enhance students contacts with potential employers while on training.
3. To boost the interest of students in their different disciplines thereby creating an avenue for
improvement of their performance.
4. It makes transition from school to the labour market.
5. Allows students to work with real technology and gears that are not present in their
institution.
6. Enlist and strengthens employer’s involvement in the entire educational process and
prepare students for employment after graduation.

1.3 THE COMPANY

1
Fig 1. The Entrance of WRPC

1.3.1 HISTORY OF WRPC

Nigerian National Petroleum Corporation (NNPC) was formed in 1977 through the merger of some of
the departments of the ministry of petroleum resources and the old Nigerian National Oil
Corporation (NNOC) in order to create a virile oil agency as well as optimize the scarce human and
infrastructural resources available to the government. This lead to the establishment which led to a
rapid expansion so many oil and gas industries such as Shell Petroleum Development Company,
MOBIL, Texaco and GULF.

In 1978, the corporation was commercialised into strategic business unit. These include:

 Pipelines and Product Marketing Company (PPMC)

 National Petroleum Investment Management Services (NAPIMS)
 Nigerian Petroleum Development Company (NPDC)
 The Nigerian Gas Company (NGC)
 Integrated Data Services Limited (IDSL)
 National Engineering and Technical Company Limited(NETCO)
 Warri Refining and Petrochemical Company Limited (WRPC)
2
  Kaduna Refining and Petrochemical Company Limited (KRPC)
 Port Harcourt Refining Company Limited (PHRC)
 Department of Petroleum Resources (DPR)

The WRPC is one of the strategic business unit. It was commissioned in 1978 by LT.COL.OLUSEGUN
OBANSAJO. It was built and designed by snamprogetti, an Italian company with an initial capacity of
100,000 barrels per stream day of crude oil. It was de-bottle necked in 1987 to 125,000 barrels per
stream day (17000 metric tonnes per day)

The fuel plants were designed to process the CHEVRON’S ESCRAVOS crude oil (sweet crude) and
SHELL’S UGHELLI QUALITY CENTRE (UQCC) crude oil (sour crude).

The petrochemical plant (polypropylene and carbon black) which were built to optimize the refinery
were commissioned in March 1988. An HYDRO-FLOURIC alkylation unit was also added to the
refinery the same year.

1.4 DESCRIPTION OF WRPC

MISSION STATEMENT

To efficiently and profitably process crude oil into petroleum products, manufacture and market
petrochemical products through effective resource utilization, while exploiting new business
opportunities.

VISION STATEMENT

To be a leader in the petroleum processing business in Africa.

QUALITY POLICY

Quality excellence is the foundation of our business and the cornerstone of our goal of customer
satisfaction. It is therefore our policy to:

i. Produce and supply Petroleum and Petrochemical products in conformity with

customer’s requirement.
ii. Continually improve our Quality Management System, Process, Products and
Services to ensure customer satisfaction.
iii. Continually upgrade technology, knowledge and skill for improved business
performance.
iv. Vigorously promote a safe and environmentally healthy workplace.
v. Promote a team work in the organisation and harmonious relationship worth our
host communities.

CORE VALUES

i. Respect for individuals.

ii. Staff department growth
iii. Integrity, transparency and accountability
iv. Professional excellence.

3
1.5 FUNCTIONS OF WRPC

WRPC is primarily involved in the processing of crude oil into finished and semi-finished

products. Its products are sold in the Nigerian local market as well as overseas. The high quality

of its products favours her significantly in both local and foreign markets.

The marketable products from the facilities are:

• Liquefied Petroleum Gas (cooking gas/refrigerants)

• Premium Motor Spirit(Petrol)

• Kerosene(Domestic/Aviation)

• Automotive Gas Oil(Diesel)

• Fuel Oil

• Polypropylene Pellets (Nipolene)

• Carbon Black Pellets. Etc.

WRPC also creates opportunities for students and young school leavers to gain industrial

knowledge by giving them placement for S.I.W.E.S and NYSC programs respectively. Research,

human resource development and capacity building are performed by the company. These

functions are achieved through equipped library, sponsoring its staff to local and foreign

training and seminars and installation of modem laboratory facilities

4
1.6 ORGANIZATIONAL CHART

MANAGING
DIRECTOR

COMPANY
SECRETARY

EXECUTIVE EXECUTIVE EXECUTIVE

DIRECTOR DIRECTOR DIRECTOR
OPERATIONS FINANCE SERVICE

PRODUCTION FINANCE
COMMERCIA
DEPARTMEN AND
L
T ACCOUNTS

ENGINEERING SUPPLY
AND TECNICAL MANAGEMEN CHAIN
SERVICES T ACCOUNT MANAGEMEN
DEPARTMENT T

PROGRAMMING GERNERAL
AND QUALITY TREASURY
CONTROL ADMIN

FIRE SAFETY
AND
ENVIRONMENT SECURITY
DEPARTMENT

MAINTENANC HUMAN
E
DEPARTMENT RESOURCES

POWER
PUBLIC
PLANT AND
AFFAIRS
UTILITIES

PLANNING
AND BUDGET
MONITORING

TOTAL
QUALITY
MANAGEMEN
T

5
1.7 INTRODUCTION TO POWER PLANT AND UTILITIES DEPARTMENT
The power plant and utilities(PPU) department of WRPC (a subsidiary of NNPC) is committed to
conducting its activities in a manner that promotes the Health and Safety of its Employees, Assets
and the Public as well as the protection of the environment.

The department is primarily responsible for the following key functions:

 Generating electricity required to meet the entire electric power needs of the company, as
well as satisfy the power requirements of the Nigeria Gas Company and the Pipelines and
Products Marketing Company both subsidiaries of NNPC.
 Producing utilities required in the operations of the production plants as well as for internal
consumption within the departments. These utilities include low pressure, medium pressure
and high pressure stem, demineralised water, compressed air, portable water, cooling water
and nitrogen (for inerting purpose).
 Treatment of industrial and sanitary wastes thus minimizing environmental pollution from
effluents.
 Steam requirements within the company are met using 2 direct-fired steam boilers; two are
rated 110tons/hr, 8.2kg/cm2 . Other auxiliary boilers within the production process plants
also augments primary steam production in the department.
 WRPC rated electric power generation; gas turbine [3] generator rated 20MW, 11.0KV and
operating on the simple Bryton cycle was installed 1987; two other Gas Turbines rated
30MW, 11.0KV each, were also installed and commissioned in 1990. The 30MW heat
recovery steam generator (HRSGs) incorporated in them to improve their thermal efficiency.
The HRSGs are each sized to produce 55tons/hr, 8.2kg/cm2of steam
 The Manager who reports to the Executive Director Operations department. Deputy
Manager Oversees running of the Power and Utilities Sections. The plants/units within these
two sections are headed by Superintendents, who reports to the Deputy Manager.

NB: As an Industrial Trainee I was in charge of taking area loggings and process data readings from

compressors, opening and closing of different valves, ensured that the different bearing oil levels are

normal refilling chemical dosing tanks and monitoring dosing time. I also gave out product samples

for lab analysis, defrosting the outer walls of the cold box, monitoring of sanitary waste as well as

evacuation of wastes to the waste water treatment plant and monitoring of the cooling water and

raw water level.

1.8 DEPARTMENTAL ORGANOGRAM

6
 MANAGER POWER
PLANT AND UTILITIES
DEPARTMENT

SECRETARY

UTILITY MANAGER
DEPUTY MANAGER
POWER GENERAL
UTILITIES SECTION
SECTION

SUPERITENDENT
SUPERITENDENT SUPERITENDENT
STEAM GENERATION SUPERITENDENT WWT
GAS TURBINE UTILITIES

CHEIF OPERATOR 4- CHEIF OPERATOR CHEIF OPERATOR 4- CHEIF OPERATOR 4-

SHIFT 4-SHIFT SHIFT SHIFT

PANEL OPERATOR PANEL OPERATOR 4- PANEL OPERATOR PANEL OPERATOR

4-SHIFT SHIFT 4-SHIFT 4-SHIFT

AREA OPERATOR
AREA OPERATOR 4- AREA OPERATOR 4- AREA OPERATOR
SHIFT SHIFT 4-SHIFT
4-SHIFT

EXTERNAL OPERATOR EXTERNAL OPERATOR EXTERNAL OPERATOR EXTERNAL OPERATOR

4-SHIFT 4- SHIFT 4-SHIFT 4-SHIFT

7
CHAPTER 2
2.1 UNITS IN NITROGEN PLANT
1. UNIT 600 (RAW WATER PLANT)
2. UNIT 650 (PORTABLE WATER PLANT)
3. UNIT 680 (COOLING WATER PLANT)
4. UNIT 750 (AIR SEPERATION PLANT)
5. AIR COMPRESSION UNIT
6. HIGH PRESSURE NITROGEN PLANT
7. WASTE WATER TREATMENT PLANT
8. DEMINIERALIZED WATER PLANT
9. STEAM PLANT

2.1.1 RAW WATER PLANT

8
The raw water plant in nitrogen plant WRPC comprises of three wells which are each about 150m
deep. Each of these wells has a submersible pump G601 A, B, C

 Submersible pump: it is about 100m deep and has a capacity of 150m2/hr. the submersible
pump is a mechanical device that enables us to extract any fluid that is submersed by
increasing its pressure. The submersible pump at WRPC consists of the switch, pressure
gauge, two valves that enables us to direct the flow of the water.

Pump G601Aand G601B are always in service serving the fire and safety department and nitrogen
plant respectively while G601C is a standby pump in case of any failure.

 De gasifier: The submersible pump extracts water from the well and sends it to the
degasifier with the use of fibre coated pipes. The fibre coated pipes are made use of here
because the water is acidic and can lead to rusting.
The degasifier has an air blower attached to it. The air blower mainly comprises of an
impeller and motor. The motor converts electrical energy to mechanical energy which
powers the impeller thereby introducing artificial air to the degasifier which works counter
currently with the water. This helps to remove the carbon dioxide in the water by increasing
the surface area of the water molecule before sending it to the serviced water tank or pre-
treated water tank D601 at a flow rate of 180m2/hr.

Pump G602A, G602B and G601R sends the water to four places;

i. To Network as serviced water

ii. To Cooling water basin as makeup water
iii. To the sand filter DY651/1A and DY651/1B
iv. To the fire water tank D951

NOTE; I was in charge of monitoring the tank level, giving out water samples to the laboratory
technicians, starting and stopping the well pump to meet the required water level as need be.

2.1.2 PORTABLE WATER PLANT

9
Water leaves D601 to the sand filters. We have two sand filter DY651/1A and DY651/1B which work
sequentially.

 Sand filters: this is a filter that is made up of two beds;

a. Activated charcoal(carbon) which has a high affinity for colour and also helps to
make the water tasteless.
b. Silica which removes the sand in the water into sand beds and also aluminates for
colour eradication.

After filtration there is need for mineralization where the water goes into the chemical dosing unit.

 Chemical dosing unit: the chemical dosing unit consist of three dosing tank DY651/2,
DY651/3 and DY651/4. These tanks contain sodium hypochlorite(NaOcl), Magnesium
sulphite (MgSO4) and Calcium chlorites (Cacl2
 sodium hypochlorite(NaOcl); for treating of micro-organisms in the water and improves the
PH of the water. It can be viewed as the sodium salt of hypochlorous acid. When there is
high concentration it can lead to skin burn and can cause eye damage.
 Magnesium sulphite (MgSO4): it is obtained from the mineral epsomite. It is a white solid
that aids digestion.
 Calcium chlorites (Cacl2 : it is deliquescent salt used in de-icing the water. It also aids strong
teeth and bones and kills bacteria’s.

The water leaves the chemical dosing unit and is sent to the portable storage tank D602 which has
three water pump G602A, G602B and G602R.

 Surge drum: the surge drum DY651/5 with the aid of an air blower PY651/5 that is attached
to it allows air to enter the drum at a high pressure which thereby extracts force on the
water and pushes it further. The main function of the surge drum is to enable water reach a
long distance.
 Polisher/cartridge filter: the polisher DY651/6 is the last filter the water goes through for
further purification before going to network. It contains carbon which helps to make the
water colourless.

10
fig 2 SCHEMATIC FLOW DIAGRAM OF PORTABLE WATER UNIT

11
2.1.3 COOLING WATER PLANT
3
It’s made up of a cooling tower with two basins with a capacity of 2700m /hr. Water is being pumped into the basin by

two pumps FG681 (electric pump) and FC681R (diesel pump). Water falls into the basin in a down pour motion through

the baffles which increase surface area of water molecules and cause the force drought fan FD681A/B to introduce air

into the water molecule to cool water. The window like structure called the loop also helps in allowing air to cool water

molecules as it pours down. And can also reduce water volume thereby makeup is needed via cooling water makeup

line.

The cooling water under goes purification whereby it being treated with chemicals to avoid corrosion at high

temperature. They include;

 Corrosion inhibitor: Bio treat 1000 contains amide group that forms a sliming layer preventing direct contact

with pipe. thereby preventing the wearing of metals of the equipment.

 Dispersant: Tower Treat 3000 reduces the effect of trapped substances in the water by spreading the trapped

particles and dead organisms so that the wont combine together to cause corrosion.

 Biocide: Bio treat 3500 takes care of the microorganisms. It kills the bacteria’s in the water e.g. algae and

fungi. It reduces their effect of fouling which can lead to rust in water pipes.

 Sodium Carbonate (Soda Ash): It controls the Ph. of the water and water ph. level must not drop below 7.5

but should be between 7.5 &9.

 Calcium hypochlorite: it is a bleaching powder that is used as a disinfectant and oxidizing agent. It also helps

to improve the ph. of the water.

12
2.1.4 AIR COMPRESSION UNIT

It is made up of a compressor, dryer and surge drum. Compressors P701 is a electric compressor with a capacity 3500
2
cubic meters. it is a screw driven compressors that compresses air to a pressure of 8kg/cm as operational pressure and
2
has a design pressure of 10kg/cm .

Air is sucked into the compressor from the atmosphere where it is compressed in the compressor chamber that is made

up of two stages i.e. the low pressure and high pressure element with an intercooler in between to keep the

temperature of the compressed air in ambient condition with increase in pressure. Air passes through an outer cooler

to about 30ᶿc in temperature before it enters the dryer DF701A/B with a 12hrs cycle. Molecular sips in dryer sucks

moisture from air. The dryer absorbing is always in service for 12hrs then it becomes regenerated to activate molecular

sips and the other dryer in regeneration comes into service. Dryer uses electrical heat to regenerate molecular sips.

Heating lasts for three hours to free pores of trapped water molecule in sips and then cool off for 9hrs before going into

service again.

The absorbed air from dryer enters the surge drum D701 to boost up pressure. A part of the air goes to network as

Service Air while some goes to cartridge filter DF702A/B for further purification before being sent to network as
2
instrument air. Both service air and Instrument air are sent to network at 7kg/cm .

N.B: Instrument air is used for pneumatic processes while Service air is used for the purging and flushing of vessels. The

dew point of air is always monitored. It’s meant to be between 75 to 76 degrees Celsius.

13
2.1.5 AIR SEPERATION UNIT
Theatrical principles: most import constituent of air are-

Chemical symbol %age(V) %(W) boiling point

Nitrogen N2 78.09 75.47 - 195.8oC

Oxygen O2 20.95 23.20 - 182.9

Argon Ar 0.93 1.28 - 185.7

Carbondioxed CO2 0.03 0.04 - 78.5

Water vapor H20 vary vary 100OC

About 99.13% of air consists of O2 and N2. It is constant all over the world; same with air of 0.93%
Concentration of other gases such as H2, CO2 and Hydrocarbon also vary.

The water vapors (H20) content differs considerably, depends on temperature (degree of saturation),
relative humidity (subject to local conditions).

Nitrogen gas is an invisible, tasteless, odourless gas. Air from the atmosphere goes through the air filter(DP751/R)

which sucks in the air and sends it to the Centrifugal 4 stage compressor(P751/R) with a capacity of 5600kg/hr. it

compresses the gas by impacting energy to the as at a pressure of 8-8.5Bar for each stage. A high speed rotating

impeller increases the velocity of air which is sent to the diffuser that converts the velocity of air into pressure.

1st stage; 0kg/cm2 to 1.33kg/cm2

2nd stage; 2.5kg/cm2 to 3kg/cm2

3rd stage; 4kg/cm2 to 4.5kg/cm2

4th stage; 8kg/cm2 to 9kg/cm2

14
REFIGERATION OR CHILLER UNIT(E752)

Here we use Freon 22 (chlorodifloromethane CHCLF2). It is a colourless gas at room temperature it is non-toxic, non-

flammable and transparent liquid under the pressure created by itself. It has excellent thermal and chemical stabilities
0
and no corrosively to metals. It cools the air from 27 c to 100c and the air becomes heavier. The chiller unit is
lagged in order to prevent heat loss.

DRIER UNIT(DF751A/B)

We make use of two driers which removes moisture and CO2 from the air. It further cools the
temperature down to 50c. the absorbers used are molecular sieve (absorbs water) and silica alumina
(absorbs carbon). In this unit inversion and regeneration takes place. Inversion occurs when one
dryer changes over which takes up to 30 minutes to complete. While regeneration is he process of
preparation of the dryer to go into service.

COLD BOX(D753)

This is a cryogenic system which operates under a very low temperature of -172 0c. The processed air
entering the cold box consists of nitrogen, oxygen and rare gases.

In the cold box we have;

 Main heat exchanger E755

 Liquefier exchanger E756
 Distillation /tray column C751
 evaporator exchanger E757
 Expansion turbine FT751

Because this system requires the processed air to be at low temperature in order to separate the
cold box is insulated (cold insulation).

E755 is a heat exchanger that is indirect, it drops the temperature to 135 0c.

E756 the air becomes a saturated vapour at a temperature of 1630c. It releases the processed air
into C751

C751 is a vessel with 18 trays. Here we have the up risers and down comer column in order to
maintain purity. As the liquid is flashed into the tray the heavier molecule goes down and the lighter
molecule goes up. This system operates at a temperature of -1650c to -1670c. The point of entry of
the product is called the flash zone. The upper tray is called the electrifying zone while the bottom
tray is the stripping zone. The oxygen which goes to the bottom comer is released into the
atmosphere.

After this process the nitrogen is purified and contains about > 0.5ppm of oxygen. Part of the
nitrogen is sent into the storage tank D751.

FT751 the air is cooled here by following the principle of Joel Thompson effect which states that the
change of temperature of a gas when it is allowed to expand without doing any external work. the
gas becomes cooler if it was initially below a certain temperature. The cooled air is sent to the main
heat exchanger.

15
Evaporator exchanger E751A/B/R it changes the liquid nitrogen to gaseous where by it is sent to
network.

Fig 3 SCHEMATIC FLOW DIAGRAM OF NITROGEN PLANT

16
2.1.6 HIGH PRESSURE NITROGEN UNIT
Nitrogen from cold box leaves to compressor P753R for further compression and then it is sent to
the network at about 200kg/cm2 as high pressure nitrogen. Compressor is on auto start when
pressure is at 100kg/cm2and auto shut down when pressure is at 200kg/cm2. High pressure Nitrogen
produced at this unit is stored in two tank bottles to be used.

2.1.7 WASTE WATER TREATMENT UNIT

A sanitary pump G410AM/BM is used to send water to the waste water basin where it is meant to
be further treated before being expelled out to the river. The sanitary pump is switched on every
morning to enable this operation.

2.1.8 DEMINERALIZED WATER UNIT

It is demineralized water i.e. water without no ionic charge. It is used mainly for palletization
because it does react with palletized material since no ionic charge. It is also used to wash silos. The
tank is situated in the Nitrogen plant perimeter and is controlled mainly by the refinery part of the
company.

2.1.9 STEAM
It is also gotten from the Boiler part of the refinery and its transported to different part of the
Company in pipes that a lagged to prevent heat loss. It is used in reactors by a conduction process. It
is also used to heat up vessels and other manual operations where necessary

17
2.2 USES OF NITROGEN
 it is use for blanketing of vessels.

 it is use for purging.

 it is use for preservation.

 it is use for pressurization of reactor seal (as a support to reactor seal R 201).

 it is use for removing contaminations from process streams.

 it is use for catalyst organization; in Fluid Catalyst Cracking unit (FCC) and Reforming unit

2.3 HAZARDS OF NITROGEN

Discovered in 1772, Nitrogen is a nontoxic, odourless, colourless, tasteless non-flammable gas. It
contains 78%(by volume) of the air we breathe. Oxygen constitutes approximately 21%. When
nitrogen concentration increases and oxygen level decreases below 19.5%, rapid suffocation occurs.

Nitrogen gas is classified as a ‘’simple asphyxiant’’. This means nitrogen will displace oxygen and
create oxygen deficient (>19.5%) atmospheres without significant physiologic effect.

Inhalation of a nitrogen enriched atmosphere may cause dizziness, drowsiness, nausea, vomiting,
excess salivation, diminished mental alertness, loss of consciousness, and ultimately death.

In addition to being an inhalation hazard, liquid, nitrogen is a colourless, odourless and extremely
cold liquid (-2000c). contact with this liquid or cold vapours can cause severe frostbite.

2.4 PRECAUTIONS
1. Atmosphere in a confined space should always be tested safe before workers enter the
space.

2. Workers should always wear an air breathing apparatus while entering a confined space.

3. Nitrogen sample should not be carried in a plastic container because it can lead to explosion.

2.5 BRIEF ENVIRONMENTAL AND ATMOSPHERIC PHYSICS OF NITROGEN

18
2.5.1 NITROGEN DEPOSITION;
Nitrogen deposition describes the input of reactive nitrogen from the atmosphere to the biosphere
both as gases, dry deposition and in precipitation as wet deposition.

NITROGEN DEPOSITION EFFECT ON HABITATS AND SPECIES

Nitrogen is a major growth nutrient. It is a major constituent of assimilatory and structural tissue,
facilitating conversion of carbon dioxide to carbohydrate and combining with carbon to form amino
acids.

Vascular plants take up their nitrogen mostly through the roots but it can also absorbed above the
ground through the stomata gases or the cuticle.

Non vascular plants absorb nitrogen through their entire surface.

Most plants us reactive nitrogen, but some can use organic nitrogen.

If the carbon assimilation is restricted e.g. by insufficient phosphorous(P), light or water, then
nitrogen can potentially be accumulated to excess and become toxic i.e. nitrogen will no longer act
as a nutrient rather it becomes a pollutant.

Nitrogen deposition can increase the risk of damage from abiotic factors e.g. drought (summer and
winter) and frost. Where nitrogen deposition leads to enhanced foliar nitrogen concentration there
is increased risk of damage from pest and pathogens both above and below ground.

Detrimental impacts of nitrogen below ground include loss of species diversity with respect to
ectomycorrhizal and reductions in decomposer populations e.g. enchytraeid worms.

Nitrogen deposition can also cause acidification of the soils.

WEATHERING

Ecosystem needs nitrogen and other nutrient to absorb carbon dioxide in the pollution. It’s the
weathering of the rocks that breaks the nitrogen.

We know that the presence of carbon dioxide in the air help boost the growth of some plants (a
negative feedback loop that works in our favor) which can remove carbon dioxide from the
atmosphere, storing it in their leaves, stems, bark etc. as they grow. But the amount they can grow
can be limited by the amount of available nitrogen.

RECENT DISCOVERY

Ben Houlton the director of the John Muir institute of the Environment at the University of
California, Davis. He discovered using techniques like isotopic finger printing to trace nitrogen
molecules as they make their way through the environment was that the amount of nitrogen
contained in the bedrocks is much higher than we previously thought. We now know that as much
as 26% of all thee nitrogen on the planets resides in the ground.

Over geologic time scales (millions of years), rocks weathering is what controls the earths climate.
The rate of rock weathering increasing with temperature. As the rock weather, they store carbon
dioxide. When its cooler, they store less. So this feedback effect acts to regulate the plants
temperature.

GREENHOUSE EFFECTS
19
 The size of N2 reservoir in the solid earth directly affects the evolution of the earth’s atmosphere.
Nitrogen now in the solid earth was once in the atmosphere which have resulted in a higher
atmospheric pressure and therefore strengthened the greenhouse effect by pressure broadening
the absorption of greenhouses gases.

2.5.2 NITROGEN CYCLE

Nitrogen cycle is the biogeochemical cycle by which nitrogen is converted into multiple chemical
forms as it circulates among atmosphere, terrestrial and marine ecosystem.

 Nitrogen fixation
 Nitrification
 Assimilation
 Ammonification
 Denitrification

Nitrogen fixation- the conversion of nitrogen gas (N2) into nitrates and nitrites through atmospheric,
industrial and biological processes. Atmospheric nitrogen must be processed or fixed into a usable
form to be taken up by plants. Mostly this is done by free living or symbiotic bacteria known as
diazotrophs but 5 to 10 billion kg per year are fixed by lightning strikes.

Assimilation – if nitrate is absorbed, it is first reduced to nitrite ions and then ammonium ions for
incorporation into amino acids, nucleic acids, and chlorophyll. In plants that have symbiotic
relationship with rhizobia, some nitrogen is assimilated in the form of ammonium gas directly from
the nodules.

Ammonification – when a plant or animal dies or an animal expels waste the initial form of nitrogen
is organic. Bacteria or fungi convert the organic nitrogen within the remains back into
ammonium(NH4+).

Nitrification- it is important for ammonia(NH3) to be converted to nitrates or nitrites because

ammonia gas is toxic to plants. Due to their very high solubility and because soils are highly unable
to remain anions, nitrates can enter ground water.

Denitrification – it is the reduction of nitrates back into nitrogen gas (N2) completing the nitrogen
cycle. This process is performed by bacterial species such as Pseudomonas and Paracoccus under
anaerobic conditions. The denitrifying bacteria use nitrates in the soil to carry out respiration and
consequently produce nitrogen gas, which is inert and unavailable to plants.

20
Fig 4 illustration of nitrogen cycle

21
2.6 INSTRUMENTATION
The plant is designed to operate automatically. The maintenance and repair works are
allocated to various departments such as mechanical maintenance department,
instrumentation department, electrical department etc. the following tools are used for day
to day activities.
Valve key;
It comes in various sizes. In my plant it was used to open or close valves for different
purposes like the depressurization valve, drain valve, serviced water valve, portable water
valve etc.
Distributed control system (DCS);
It is the core of an automated process control system. It ensures fulfilment of all main
functions of control, visualization, registration and reporting of process including;

 Automated regulation
 Program (logic) control
 Alarms and notification management
 Collection and processing of process and equipment data
 Graphic presentation of process and equipment condition data
 Detection and alarms of emergencies and deviation of process from pre-set limits
 Keeping of event log
 Report generation
 Data exchange with external system

22
2.7 EQUIPMENTS AND THEIR FUNCTIONS
Valves
It is a device that regulates, directs or controls the flow of fluids by opening, closing or
partially obstructing various passage ways.

Fig 5 dual plate check valve

Fig 6 Gate valve

23
Fig 7 Pneumatic Check valve
Gauge;
This is a device used to display certain dimensional information
Submersible pump;
It is a device which has a hermetically sealed motor close-coupled to the pump body. It is
used to pump water out of the wells.
Vaporisers;
It is used to change used to change liquid nitrogen into gaseous form before being sent to
the storage.

24
Heater;
It is used to regenerate dryers when they are not in service by heating them up. Waste air
from the cold-box called nitrogen rich in oxygen passes through the heater at a volume>
1200m3/hr and heats the aluminium balls in the dryers for 3hours.

Fig8 B751 heater

Polisher;
Is an advanced water treatment system. It is used to remove small (usually microscopic)
particulate material, or removes very low concentration of dissolved materials from the
water.

25
Fig 9 polisher and surge drum

Screw compressor;
It is a type of gas compressor that uses a rotary-type positive displacement mechanism. The
main advantage of this compressor is that it can supply compressed continuously with high
pressure delivery.

Fig 10 P701 screw compressor

Centrifugal four stage compressor;
They achieve a pressure rise by adding kinetic energy/velocity to continuous flow of fluid
through the rotor or impeller. The kinetic energy is then converted to an increase in
potential energy static pressure by slowing the flow through a diffuser. The pressure rise in
the impeller is in most cases almost equal to the rise in the diffuser.

26
Fig 11 P751 Centrifugal compressor

Chiller;
A chiller is a machine that removes heat from a liquid via a vapour compression or
absorption refrigeration cycle. This liquid can then be circulated through heat exchanger to
cool equipment, or another process stream (such as air or process water).

Fig 12 Refrigerant or Freon chiller

Dryer;
Compressed air dryers are special types of filter system that are specifically designed to
remove the water that is inherent in compressed air.

Fig 13 Compressed air driers

27
Cold box;
It is where separation process takes place in nitrogen production. Liquid and gaseous
nitrogen are separated and a reflux reaction takes place from the fractionating column.

Fig 14 cold box

Tanks;
It is a large receptacle or storage chamber especially for liquid or gas.

Cartridge filter;
They are simple modular filter that are inserted into a housing and can be used to remove
particles, or sometimes chemicals, from the water.

28
Fig 15 Cartridge air filter

Surge drum;
It is used to boost pressure and flowrate of water sent out to users.
Sand filter;
They are used in the water treatment process of water purification. It is made up of two
beds; activated charcoal(carbon) which has high affinity for colour and also helps to make
the water tasteless. And silica which removes the sand into sand bed and also aluminates
for colour eradication.
Dosing pump;
It is a small, positive displacement pump. It is designed to pump a very precise flow rate of
chemical into water.

Fig 16 The three dosing pumps

Force drought fan;
It is a type of fan supplying pressurized are to cool water molecules in the cooling tower.

29
Baffles;
It is designed to support table bundles and direct the flow of fluids for maximum efficency
PC DCS panel;
It is used to monitor process data during production and to control automated equipment.

Degasifier;
It is used to remove dissolved carbon dioxide from water with the help of an air blower.
Water from the well contains CO2 which is harmful to the body so the surface area of water
is increased due to down pour motion and blower blows out CO2 into the atmosphere. The
reversible chemical reactions
H2CO3(L) H2O(L) + CO2(g)

Fig 17 Air blower attached to the degassing tank

30
2.8 SAFETY TRAINING FOR STUDENTS ON SIWES IN WRPC
Venue: Old Auditorium Admin Conference Room
Time: 10am
Objective of this induction
At the end of this induction you should know
 Meaning of safety, Hazard identification and Control
 Hazards in operational areas
 PPEs required for different jobs
 PTW system
 Categories and Features of Safety signs
 Types of Emergencies and response
 Safe Lifting Position

Some rules in the process plant

1. Carrying of Spark/Ignition Source into WRPC is prohibited
2. Smoking is prohibited in the process plant
3. Hard drugs are prohibited
4. The use of GSM phones are not allowed in the plant area
5. Display of Identity Card is a must

31
 6. Horse play is not allowed especially in the process plant
7. Fire arms are not allowed in the plant area
8. PPEs must be worn in the process plant
9. Wear your seat belt when in a vehicle
10. Speed limit of 25km/hr.
Safety
What is safety
 Absence of danger from physical harm
 Freedom from unacceptable risk of harm
What is hazard
 Something that has the potential to cause harm (loss)
Hazard control
Hazard control is the elimination or reduction of hazards from either the source of the
hazard or the transfer path
Identifying workplace hazard
A job hazard analysis is an exercise in hazard detective work. Your goal is to discover the
following:
 What can go wrong?
 What are the consequences?
 How could it arise?
 What are contributing factors?
 How likely is it that the hazard will occur
Some methods of hazard control
1. Elimination method
This method involves removing the hazard
2. Substitution method
Reducing the hazard to an acceptable level by substituting something less
hazardous
3. Isolation method
This method is by installing physical barriers between people and the hazards.

Hazards
Some hazards encountered while working in the plant
32
  Heat
 Noise
 Dusty environment
 Working in confine space
 Working at height
 Hydrocarbon leakage
 Hot work
 Handling chemicals
 Working with Electricity
 Radiation

Heat
Heating is a major activity in the refinery. For personnel, It is termed as a raised
temperature above the normal body temperature.
Problems:
1. Heat stroke
2. Heat Exhaustion
3. Heat Cramps
4. Heat Rashes
5. Heat Fatigue
Noise
Irregular and or irritating sound. It could be continuous, intermittent or impulsive/impact.

Risks:
1. Temporary Threshold Shift (TTS)
2. Permanent Threshold Shift (PTS)
3. Tinnitus
4. Non-Auditory effects
5. Pain

Dust
33
Fine particles of matter found in the air

Risks:
1. Respiratory problems
2. Silicosis
3. Asbestosis
4. Lung infection
5. Asthma
Confine space
It is a place where there is limited entry or exit and is not meant for permanent occupation. e.g.
Tanks, Columns, Heaters, Converters, Heat exchangers, pipes and pipelines etc.

Risks:
1. Oxygen Deficient
2. Toxic Environment
3. Flammable Environment
4. Entrapment
5. Extreme Temperature

Hot surfaces
These are surfaces that have the potential to cause burns. e.g. Heaters, Boilers, Pipes
surfaces, burners, heat exchangers etc.
Risks:
1. Burns
2. Pains
3. Heat Stresses

Working at heights
Working in an elevated area of more than 1.5 meters is considered as working at height.
Risks:
1. Fall
2. Dizziness

34
 3. Phobia
4. Loss of concentration
5. Increased Heart beats
Leakages
Leakages are bound due to the aging equipment in the refinery. Causes of leakages are:
over pressure, nature of joints and welds, corrosion, pressure spikes, chemical reaction,
temperature abrasion, external pressure, etc.
Risks:
1. Exposure to toxic materials
2. Possible Fire Outbreak
3. Slip and Fall
Inclined and slippery surfaces
These can reduce the friction between the floor and the sole of one’s shoes. Example oil
spill on floor.
Risks:
1. Slip and Fall
Radiations and xray
It is the emission of radio active particles. Radiations and x-rays are used in order to know
the integrity of pipes, weld melt, etc. It can also be emitted from radio antennas.
Risks:
1. Carcinogen
2. Brain Damage
3. Sterility
4. Genetic Diseases
5. Kidney Disorders
Toxic environment
The emission of CO, CO2, H2S, Ammonia, VOCs, hydrocarbon phthalates ethers, ethyl glycol
ethers, Benzene, Heavy metals (Lead, mercury, chromium, manganese etc)
Risks:
1. Lungs and Heart disorders
2. Kidney problems
35
 3. Skin diseases
Electric shock
The unpleasant feeling when exposed to electric current.
Risks:
1. Electrocution
2. Brain damage or paralysis
3. Fire outbreak
4. Burns, Etc
Work stress
This is a physical and psychological disorder that arises from over-work or perceived over-
work.
Risks:
1. Illness
2. Mental disorder
3. Lack of organization and coordination
4. Anger
5. Violence
Ergonomical factors
This considers proper man and machine interface. It takes into consideration the comfort in
doing a job as regards the design and usage of the equipment. E.g. positioning, lightings,
ventilation, methods etc.
Risks:
1. Musculoskeletal disorders e.g. back injuries, neck pains, cramps, etc.
2. Accidents
3. Inefficiencies
4. Eye diseases, etc.

Personal protective equipment

 Specialized clothing or equipment worn for the protection against health and safety
hazards
 This strategy is applied as the last resort, when other
36
 controls are not practicable or have failed.
 ‘PPE’ only protects or reduces the severity of injury
on a victim when accident occurs. It does not prevent accident
ppes are categorized into the following
 Hearing and head protective devices
 Respiratory protective devices
 Eye and face protective equipment
 Hand and foot protective devices
 Protective clothing and protective creams and lotions
EYES AND EARS PROTECTION TO PREVENT INJURY TO THE EYES AND EARS WHILE AT WORK

HEAD AND HANDS PROTECTION TO PREVENT INJURY TO THE HEAD AND HANDS WHILE AT
WORK.

37
FOOT AND BODY PROTECTION TO PREVENT INJURY TO THE FOOT AND BODY WHILE AT
WORK

Permit to work system

The Permit To Work System Is One Of Safety Management Tools For Accident Prevention.
Types of permit to work
 Ordinary Work Permit
 Hot work permit
 Excavation Work Permit
 Electrical Isolation Work Permit
 Confine Space Permit System (For Both Cold & Hot Works)
 X-ray permit
Signs and signage
Types of sign signage
 Ordinary Work Permit
 Hot work permit
 Excavation Work Permit
 Electrical Isolation Work Permit
 Confine Space Permit System (For Both Cold & Hot Works)
 X-ray permit
Prohibition
A red circular band with diagonal crossbar on a white background, the symbol within the
circle indicates that a certain behavior or thing is prohibited
38
Warning signs
A yellow triangle with black border. The symbol within the yellow area warns of a specific
hazard

Mandatory signs
This has a blue circle with white symbol denoting a sign that indicates that specific course of
action must be taken

Safe condition signs

A green oblong or square with a symbol of text in white denoting a safety sign providing
information about safe conditions

39
Fire equipment sign
A red oblong or square with symbol in white denoting a safety sign that indicates the
location of fire-fighting equipment

40
CHAPTER 3
FIELD WORK AND SIGNIFICANCE
The major work that was carried out by me was the process supervision and manual
operation of the plant during production
PRODUCTION OF NITROGEN
Cryogenic Fractional Distillation of Liquefied Air: This is the process by which gaseous fluids
are kept in liquid state by cooling them below their critical temperature.
The cryogenic fractional distillation of 22liquefied air has various equipment:
A– Compressor
B– Freon unit
C– Air driers D– Cold-box
E– Storage tank
F– Vaporizers
START-UP OF THE AIR PURIFICATION SECTION
1. Make sure that the purification section is completely at atmospheric pressure.
2. Check that all the drains and exhausts valves of the purification section are closed,
except those interceptions of the water automatic dischargers, which must be opened.
3. Open the air instrument valves V51 and V7. The valve V6 must be closed.
4. Check that the valves XV-5101/5103/5104/5105/5106/ 5107 are in correct position
in order to have the adsorber DF-751A or DF-751B in operation.
5. Check that the valves V8, V10, V12, V15, V16, V17, V27, and V55 are closed, Open
the V17,
Close V51, then Open V6.
6. Start the air compressor according to the procedure (SOP).
7. Open gradually the V8 until the required flow rate is reached. (Minimum of
1200m3/hr.)

41
 8. Start the refrigeration unit according to the instructions of the manufacturer.
9. Put in service the dryer-CO2adsorbers according to the instruction.
Remark: it is necessary that the air does not pass through the dryer–CO 2 adsorbers until the
pressure in the purification system reaches 8kg/cm2; otherwise, the same would be
overloaded.
PREPARATORY PROCEDURE OF THE P751/R COMPRESSOR
1. Ensure the discharge compressor valve is open.
2. Ensure the cooling water valves are open.
3. Ensure that the air fitter is clean (if not clean them before start)
4. Carry out visual inspection around the unit
5. Check oil, air and water leaks
6. Ensure that all moisture traps on compressor are closed.
7. Ensure “READY” indication is present.
8. If “NOT READY” is displayed assess and repair faults.
9. Ensure that the inlet valve is completely close and the discharge valve completely
open. If not, contact the instruction crew to rectify the fault.
START PROCEDURE OF THE P751/R COMPRESSORS

1. Press the “START BUTTON”

2. Inlet valve move to the inlet unload position
3. By-pass valve must remain 100% Open
4. The prelude oil pump (POP) will stop automatically after starting time timeout.
5. Keep running in ‘‘unload’’ at least 3 minutes before loading.
6. Make sure the drains are open to remove moisture after the compressor is started.

RUNNING UNLOADED
1. The inlet valve will be at the inlet unload position and the bypass valve at 100%
open.
2. Unit is ready to be loaded.
3. Record any alarms or trips in the “INFO” folder.

42
RUNNING LOADED ON THE COMPRESSOR
1. Press the load button
2. The inlet valve will move to reach the minimum load current (usually around 50A).
3. The bypass valve will then start to close.
NB: Do not be alarmed if the bypass valve does not respond from 100% opening, it will
automatically decide by the CMC controller. The Bypass or Blow off valve will eventually
regulate to maintain the system set point if there is no problem.
STOPPPING PROCEDURE FOR P751/R COMPRESSOR

1. If the running compressor is in “UNLOAD” mode, by pressing the STOP button, it will
stop the unit immediately.
2. However, if the compressor is in service, the “UNLOAD” button must first be pressed
and 3 minutes afterwards before the “STOP” button is pressed.
3. Always allow the cooling water and prelube pump to run for at least 30 minutes
after compressor is stopped before all water is isolated or power is switched off.
4. The emergency Stop button is used in the case of emergency shut down by pushing
it in and the compressor will stop immediately.
NB: A case of a prolonged stoppage of the machine, it is essential to open the manual
bypass valve of the moisture traps.

REMEMBER
1. The compressor will only start if the “READY” indication is present on the display.
2. The system folder will display all necessary information about the compressor.
3. The “INFO” folder will display all alarms and trips that occurred. The hour’s meter is
display on page 2/3.
4. The “SETTINGS” folder is only for INGERSOLL RAND staff.

DRYER DF751A/B
The preliminary check of the Air Separation Dryer DF751A/B is done before the compressor
is started.
 Identify the dryer that would be in service.
 Know how long has this dryer been in used. If the dryer has been in service
6hrs or more before the shutdown, it is advised to fast forward close to inversion
43
 time.(i.e. use the dryer to stabilize, then change over to the new dryer before
pressurizing the cold-box).
 This on one hand, if the plants just came down and to be started in next
hours, continue from where the dryer has stopped.
 Check all the valves on the valves on the dryer whether they are properly
aligned.
 Before start-up of the compressor make sure that valve 9, 10, 11, & 12 (inlet
to the cold box) and valve 15 are all closed.
 Pressurize the dryer that is in service, then open v8 to use for regeneration of
the spent dryer DF751. (Maximum flow is 140Nm3/hr. ).

FREON START- UP
 At start-up, check the oil level to meet the manual level.

 Open the Hot by-pass valve 100%

 Make sure that the compressor oil sump is hot enough.

 Close the manual cooling water by-pass valve.

 Check all the alarms and get cancelled.

 Then press the start-up button.

 About two seconds crack open the manual cooling water by-pass valve.

 Watch the high pressure discharge Freon (should not be more than 20kg/cm 2). As

it is increasing you continue to open the cooling water by-pass valve.

 Then continue to close the Hot-Pass valve until it is 100% closed.

 Lastly, monitor the parameters.

. START-UP OF THE COLD - BOX

O The purification units are all running.

O The cold box and expansion turbine FT751 are completely isolated that is to say

V9,10,11,12,15,20,55,63,100,101,102 are closed.

The following operation must be effected.

O Put Pressure valve controller PIC 5113 on manually to about 50-60%.

O HV 5101 & HV 5102 should remain closed.

44
 O Open the drain V201.

O Open V55 to give pressure to the bearing gas system (7-8kg/cm2). At this point the

expansion turbine FT-751 is ready to run. i.e. Bearing gas pressure from the vaporizer is

cut-off and v55 is open.

O Crack open V9 or V10 to pressurize the cold-box until the pressure at the purification unit

is equal to the pressure in the cold-box, then open fully. Read the pressure on the

pressure indicator PT5107.

COOLING OF THE PLANT

The cooling of the plant can follow on the temperature indications TE-5108, TE-5109 (at the
inlet and out let of the expansion turbine. Very important during this period) after 10 hours
approximately from the beginning of the start–up, the temperature of the indicator TE-5109
will fall down to -179oc approximately. A liquid signal will begin to appear on the level
indicator LIC-5101.
PUTTING N2 PLANT INTO PRODUCTION
When the level in the column has reached 70% or above of the full range, call out the face
plate at HV5101 and then begin to close the valve HV5102 slightly and open slightly HV-
5101 while monitoring the inlet turbine pressure which should not exceed 4.5kg/cm 2 . This
operation must be effected very slowly, otherwise the column level will disappear and a
long time will be necessary before it reappears.
The above operation will continue until the valve HV5102 is completely closed. From this
time onwards HV5101 must not be absolutely opened further on or the column level will
continue to rise.

CONTROL OF THE PC NITROGEN PLANT

The control system is designed to maintain a low content of oxygen in the nitrogen
produced avoiding excessive gaseous flow rate drawn from the top of column, and assure
the constant pressure of 7kg/cm2 in the nitrogen supply line and a constant pressure inside
the plant of 8kg/cm2.
The automatic flow controller FIC-5106 maintains a flow rate that cannot be higher than
normal 1460Nm3/h. When the request of pure nitrogen is higher than set point of the
controller FIC-5106, the pressure in the nitrogen network tends to go down and a certain
quantity of liquid nitrogen drawn from the tank D751 Is automatically vaporized in the
vaporization unit E751A/B/R to satisfy the above request.

45
When the request of gaseous nitrogen is lower than set point of the controller FIC-5106, the
pressure inside the plant tends to increase and then the pressure controller of the air
compressor opens the control valve discharging the air excess to the atmosphere.

On gaseous nitrogen run: The expansion turbine cold production would be excessive if all
the waste gas passed through it at maximum pressure. Consequently, it would result to a
continuous increase of the liquid air level at the bottom of the column and then flooding of
the same. To prevent this, the level controller LIC-5101 operates by sending signal to the by-
pass valve LV5101B of the expansive turbine. if the level at the bottom of the column tends
to increase, the bypass to the turbine reduces the pressure at the inlet of the same.
The reduction of the cold production prevents the liquid level from increasing in the
column, while on the contrary, if this level decreases, the by-pass valve LV-5101B is lightly
closed and a greater quantity of waste gas passes through the turbine at a higher pressure
and the cold production increase re-establishing the correct level.

On gaseous + liquid Run:

The cold production must be maximum and consequently the formal control does not
operate on this mode.
The gaseous + liquid run transfers the level control from the LV-5101B valve to the LV-
5101A valve.
The by-pass valve of the turbine remains permanently closed and every increase of the level
on the bottom of the column causes a greater opening of the liquid nitrogen valve LV-5101A
and increases the liquid production seat to the storage tank D751.
On the contrary, if the level of the liquid decrease this means that too much liquid is drawn
and the valve LV-5101A, is partially closed and the liquid nitrogen with drawn is reduced.

CONTROL OF THE REFLUX RATIO

To obtain the nitrogen in the required quantity and purity, it is necessary to have a certain
reflux ratio in the separation column.
That is the gaseous nitrogen amount drawn from the top of the column must not exceed a
fixed fraction of the liquid transferred from the bottom of the column to the condenser–
evaporator E757 where it is vaporized.
The liquid flow drawn from the bottom of the column is set up manually by the controller
HIC5101 which signals the expansion valve HV-5101; this flow is constant at all the running
conditions of the plant.

46
It is suggested that the set regulation of HIC-5101 is made during the Gas + liquid run,
regulating the opening of HV-5101 so that the pressure at the turbine inlet reaches the
height fixed valve, which is 4kg/cm2 read on PT-5108.
CONTROL OF THE PRODUCT PURITY
The oxygen content in the gaseous nitrogen is continuously controlled by the analyzer AT-
5103 if the oxygen content rises above the previously fixed limit (5 V.P.M.) the value FV-
5106 closes, while the solenoid value XV-5110 opens, discharging a part of impure nitrogen
to the atmosphere. On the control panel the light and alarm, signalizing the impure product
are switched. The light remains switched while the alarm can be silenced.
If the plant is on GAS + LIQUID run it will switch automatically to GAS run, to prevent impure
liquid nitrogen into the storage tank.
The plant will not return automatically to liquid production when the purity is re-
established. In the previous conditions, with valve FV-5106 closed, the gaseous nitrogen
supply is maintained by the liquid nitrogen storage tank until the purity re-established.
When the oxygen content returns to the fixed valve of the purity, the solenoid valve XV-
5110 closed and the valve FV-5106 opens, so that the pure gas is drawn from the plant
again.
However, the return from the GAS production to the GAS + LIQUID production must be
operated manually.
The humidity of the process air content can be checked at start up and occasionally by the
analyzer AT-5101 (maximum dew point to read -72OC)
Normally the analyzer AT-5101 and the recorder AR-5101 have the function to check the
humidity of the air leaving the dryer-CO2 absorbers.
If the humidity content in the air exceeds the fixed limit -72OC it is signalized by a light and
an alarm on the control panel.
CONTROL OF THE NITROGEN CAPACITY OUTPUT AND PRESSURE
The flow controller FIC-5106 limits the quantity of gaseous nitrogen which can be drawn
from the column. If the nitrogen request is lower than the capacity of the plant, the
pressure on the downstream line will increase until it equalizes that in the column. At this
point the by-pass valve is open discharging air to the atmosphere. In this way the plant
capacity is reduced in accordance with the nitrogen request. When the pressure in the
nitrogen supply line falls below the request value, the pressure controller PIC-5122 opens
the value tanks D751 to the vaporizer E751A/B/R by which it is vaporized to make up the
deficient pressure in the network.

UNIT 850 (EMERGENCY DIESEL GENERATOR)

47
An emergency power system is an independent source of electrical power that supports
important electrical systems on loss of normal power supply. Emergency power systems are
installed to protect life and property from the consequences of loss of primary electric
power supply.
With regular generators, an automatic transfer switch is used to connect emergency power.
One side is connected to both the normal power feed and the emergency power feed; and
the other side is connected to the load designated as emergency. If no electricity comes in
on the normal side, the transfer switch uses a solenoid to throw a triple pole, single throw
switch. This switches the feed from normal to emergency power.
Y851 emergency generator run on auto and comes up immediately there is a cut-off of
power supply and it uses two air compressors that builds up air pressure of the Y851 to
10kg/cm2. the electrical driven compressor is always running when its pressure drops below
the set point of 25kg/cm2 in order to keep the Y851 prepared for emergency while the fuel
driven air compressor is on standby in case of failure from the electrical driven air
compressor.

COMMISSIONING OF MEDIUM & LOW PRESSURE STEAM

A boiler or steam generator is a device used to produce steam by applying heat energy to
water. The LP steam mini. Average pressure is 4-5 kg/cm 2 while the MP steam pressure
mini. Average pressure is 15-16 kg/cm 2.

COMMISSIONING OF STEAM
1) Crack open all vent/drain along the LP or MP steam line to be commissioned.
2) Then open the by-pass valve at the battery limit header.
3) Allow all the condensate on the line to go out the drain for at least 1-2hr until
it is noticed that it is only steam coming out from the vent/drains.
4) Close the drains to 100% (on conditions were the steam traps are working).
5) Then open the Main valve 100% to commission steam proper.
6) Close the by-pass at the battery limit 100%.
NB: If this procedure is not followed properly there will be a mixture of steam and
condensate leading to a hammering effect that can cause explosion.
USES OF STEAM
1) Regenerating of our air compressor dryers.
2) To drive our gas turbine.
To heat up cold bottom plate of Freon 22 at start up
48
PRODUCTION OF PORTABLE WATER
Service water from D601 is distributed by G602A/B/R. This water has been degasified as
mentioned before.
By opening the necessary valve; service water is admitted to the sand filters DY 651 A/B
with a capacity of 50m3/h each, 1500mm high, and 2000 mm diameter. It has the primary
responsibility to reducing the turbidity to a value lower than 1ppm (as SiO 2).
Each sand filter consists of a bed of carbon and sand as the filtering medium. The following
characteristics are available:
Filter bed/medium: 400mm carbon, 600mm sand i.e. 1000mm Carbon/sand.

WATER (TO BE FILTERED) CHARACTERISTICS:

HCO-3 100ppm as CaCO3 Fe3+ 0.2ppm as Fe
CL- 100ppm as CaCO3 Silica 16ppm as SiO2
SO-4 0ppm as CaCO3 Turbidity 5ppm as SiO2
NO-3 2ppm as CaCO3 CO2 5ppm
Ca2+ 15ppm as CaCO3 pH 5.6
Mg2+ 3ppm as CaCO3 Filtering Vel. 16m/h
49
Na+ 4ppm as CaCO3 Max. Pressure drop before regeneration 0.7kg/cm2

STERILIZATION/MINERALIZATION
SODIUM HYPOCHLORITE: For Portability of water, minerization by addition of sodium
hypochlorite (NaOCl 1%) is required. This chemical sterilizes water which entails the
elimination of microbes by adding NaOCl to it. Micro-organism make water deleterious,
odorous, colorful etc. but dosing NaOCl entails that a residual of 0.1-0.3ppm of free chlorine
is left in the water as recommended by World Health Organisation (WHO).
CALCIUM CHLORIDE: Pour 400kg of commercial CaCL2 (about 77% as pure CaCl2) into the
tank DY651/3 to give us a desirable pH of 6.5-7.5 This mineralizes water to a calcium and
magnesium total quantity of 80-100ppm (as CaCO3) and chloride quantity of 25-50ppm (as
CaCO3).
MAGNISUM SULPHATE: Pour 200kg of commercial MgSO4 (about 25% as pure MgSO4 ) into
the tank DY651/4 assist in maintaining Calcium plus magnesium total quantity of 80-
100ppm (as CaCO3) and chloride quantity of 25-50ppm (as CaCO3) .
THE CHEMICAL DOSING SYSTEM
For chemical treatment (sterilization and mineralization) to be effective, the said chemicals
must be dosed into the filtered water at the desired rates.
Three (3) chemical tanks exist: DY651/2 for NaOCL (1%), DY651/3 for CaCL 2 (1%); DY651/4
for MgSO4 (1%) ; each with two accompanying dosing pumps (which operates thus: while
one is in service the other is on standby).
The tanks and pumps have the following characteristics: exist: DY651/2 : NaOCL
NB: Normal flow rate (2.8L/h) each of these pumps operate at 50% stroke to give. Half their
maximum discharge (Flow rate of 5.6L/h). At peak demands however, Each of these pumps
work at 100% stroke to deliver 5.6L/hr.
PRODUCTION OF COOLING WATER
In many industrial processes, heat is produced. The removal of this heat is vital to the
successful operation of any equipment. The simplest examples in internal combustion
engines, water is passed to the cylinder walls; in machine tools, oil or water is used to cool
cutting tools and air compressors are cooled with water. Heat generation is often an end
result of a chemical process and this necessitates the need for the removal of the generated
heat using water.
OPEN RECIRCULATING SYSTEM: This is the most commonly used and it consists of
pumps, heat exchangers and a cooling tower. The pumps keep the water Circulating
through heat exchangers (where it picks up heat) and onto the cooling tower where heat
is released from the water through evaporation. Because of evaporation, water in open
recirculating systems undergoes changes in basic chemistry.
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COMMON PROBLEMS: corrosion, fouling, Scale, Wood decay, Microbiological
contamination.
Average Temperature change: 10-17 0C
Amount of water used: Moderate

Blow
Down
Make –
Up
Water Heat
Exchanger

Cooling
Tower

Pump
Fig 10. Open Recirculating system.

PC COOLING WATER TECHNICAL DESCRIPTION

PC open recirculating cooling system has been designed to satisfy all the requirements of
the cooling water system. It operates with two pumps G681 -Electrically driven pump and
FG681RDiesel driven, both with a capacity of 2700m3/hr. The diesel pump FG681R is on
standby in case of emergencies.
The systems include:
1. Cooling tower
2. Cooling water circulating pumps
3. Retention basin
4. Side stream sand filter
5. Equipment for dosing chemicals for corrosion protection and for biological
fouling prevention.
Start-up procedure of the cooling water System: Just before cooling water system
pretreatment, the same shall be filled and cleaned. These consist of cleaning, filling, and
pretreatment.

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START-UP PROCEDURE OF THE COOLING WATER SYSTEM
CLEANING PROCEDURE: The cooling water system is cleaned by passing water through the
basin and opening the blow down valve to flush out debris. It is also suggested to carry out
cleaning of the piping only a few days before the operation pretreatment with chemicals,
unless it is possible to dry up the cooling system to avoid the piping and equipment getting
rusted.
FILLING PROCEDURE: The cooling water system is filled only with the water from the

raw water treatment plant (pre-treated water). Ensure that the cooling tower and

relevant pumping station are completed; the basin must be cleaned to remove any

woods or other foreign bodies.

Pre-treated water will be pumped into the basin A681 through the proper pipe by
means of pumps
G602A/B/R provided for the make-up into the basin of the cooling tower.
The filling will be made up to the maximum level (1900mm from bottom of basin A
681).

COOLING TOWER FAN HOUSING CLEANING AND MAINTENANCE

The fan housing should be carefully scrubbed and disinfected. This is a common

problem area; chemical treatment cannot always prevent bacteria from getting a

strong hold in these areas. Vapors from the air cause condensation to form biological

growth which can be difficult to remove with traditional on-line treatment programs.

Your Tower Hygiene Team will clean and disinfect this area in an effort to prevent the

spread of airborne pathogens and minimize the risk of corrosion.

COOLING TOWER BASIN CLEANING AND MAINTENANCE

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Tower basins should be cleaned and disinfected as well. These large volume areas are

extremely critical as they contain a large amount of the cooling water. This area pools

and allows bacteria to grow. This water is also temperate, oxygen rich and provides a

great breeding ground for biological activity. Cleaning, disinfecting and adding the

proper chemicals to the end or startup of your cooling season can only enhance your

overall water treatment program.

COOLING TOWER DISTRIBUTION FAN CLEANING AND MAINTENANCE

These areas can sometimes become clogged with debris that is not removed from the

system through normal filtration. All distribution fans should be opened and cleaned

providing increasedwater flow. Reduction in flow from clogged distributors can

reduce the tower ability to cool water tremendously. Left untreated, this can cause

major increase in energy usage.

PRETREATMENT PROCEDURE: After the cleaning and filling operations, the system
will be pre-treated in order to prepare the inside surfaces to accept a corrosion inhibitor
film. The performances of the directions above are under the control of the company to
whom the treatment of the cooling system is ordered.

Preliminary Start-up procedure

 Put all manual valves in an open or closed position as necessary for normal
operation, but close the valve size 28’’ on the line 28’’ –A43-557c5 (cooling water
to network).
 Put diesel engine FC681R on manual control from local panel.

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  Close manual control valves H4601, H4602.
 Open the butterfly valve size 14’’ on line 28’’ –A21-531C2 (water recycle to
Basin A682).
 All the valves on the cooling water network and on the users must be open.

Start-up procedure
 Start G681 electric motor powered pump
 Open the side stream filter sand filter cooling water inlet valve  Used the
recirculation valve to control the pressure to net work
 Start the cooling water fan.
 Start the dosing pumps of corrosion inhibitor, biocide and dispersant tank.
 Then request PP Lab to take sample and analyses.
OPERATING PROCEDURE OF THE COOLING WATER SYSTEM
After the pre-cleaning performed during start-up, a chemical treatment, as noted in the
description is necessary for the system to have high availability and high heat Exchange
capacity.
• Operating parameters: The following below are the operating Parameters for the cooling
water system

Cooling water supply conditions at B.L.

 Temperature: ≤ 31 0C (min. 15 0C)
 Pressure: 3.5 kg/cm2 – 4 kg/cm2
 Flow-rate (FR 4603): 2500m3/h max

Cooling water return conditions at B.L

 Temperature : ≤ 41 0C
 Residual Chlorine : 0.5ppm by weight (shock chlorination)
 Flow rate to sand filter DF 681: 200m3/hr.

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  Blow down flow rate: to be defined according to manufacturer’s Instructions.
 Level in basins A681 - A682: 300 – 600mm under top of basins
 Level in tank DFC681 R/2: Normally the tank should be full.

SHUT DOWN PROCEDURE OF THE COOLING WATER SYSTEM

If the whole cooling water section has to be shut-down for maintenance purposes, the
following operations have to be carried out:
1. Shut-down cooling water pumps G681 or FG681R according to supplier’s
instructions.
2. Shut-down cooling tower air fans P681 A/B according to supplier’s
instructions.
3. Close the manual valve on the make-up water feeding line (6’’ –AG1).
4. Close the manual valve on the blow-down line (4’’-AR39)
If maintenance operations do not have to be carried out inside the cooling tower basin and
on the cooling water network, the plant can be left full of water (for a short time)The shut-
down for maintenance should be carried out when P.P and C.B plant are in shut-down
condition and do not require instrument and service air. When one pump G681 or FG681R is
shut-down for maintenance the other must be previously started and running in parallel and
done on supplier’s instruction.

PROBLEMS OF COOLING WATER

COMMON PROBLEMS: corrosion, fouling, Scale, Wood decay, Microbiological
contamination.
Corrosion is a natural process, which converts refined metal to their more stable oxide. It is
the gradual destruction of materials (usually metals) by chemical reaction with their
environment. In the most common use of the word, this means electrochemical oxidation of
metal in reaction with an oxidant such as oxygen.

FOULING: This is the accumulation of solid materials other than scale such that the
operation of plant equipment is hampered and thus contributing to its deterioration. E.g.
dirt and silt, sand, corrosion (products), natural organics, microbial deposits, aluminum
phosphates, iron phosphate.

55
Fouling materials can consist of either living organisms (bio fouling) or a non-living
substance (inorganic or organic).
SCALE: Common feed water contaminants that can form cooling water deposits include
calcium, magnesium, iron, aluminum, and silica. Scale is formed by salts that have limited
solubility but are not totally insoluble in cooling water. These salts reach the deposit site in a
soluble form and precipitate. There are certain temperatures that are not advisable to
operate the cooling water to avoid scale formation. Temperature above 60 OC scale
formation is evident.

MICROBIAL GROWTH: Cooling water systems, particularly open recirculating systems,

provide a favorable environment for the growth of microorganisms. Microbial growth on
wet surfaces leads to the formation of biofilms. If uncontrolled, such films cause fouling,
which can adversely affect equipment performance, promote metal corrosion, and
accelerate wood deterioration. These problems can be controlled through proper bio-
monitoring and application of appropriate cooling water antimicrobials.

TREATMENT OF COOLING WATER

BIOCIDE TREATMENT: we treat our cooling water with basically Stabrex ST40 which takes
care of microorganism that are aerobic in nature and NALCO 7330 which takes care of
anaerobic microorganism in the cooling water.
Dosage: 42L/Day of Stabrex ST40 and 52L/Day of NALCO 7330 @ PC DISPERSANT
TREATMENT: NALCO Trasar 3DT-190 is used applied to cooling water to
disperse coagulant of debris that can cause corrosion or fouling or scale in the cooling
water. Dosage: 20L/Day @ PC

CORROSION INHIBITOR TREATMENT: NALCO Trasar 3DT-129 is used to inhibit corrosion

reaction (wear and tear) in the cooling water equipment.
Dosage: 20L/Day @ PC

PH TREATMENT: Na2CO3 (soda ash) is used to keep the PH in check. The dosage quantity is
subject to the laboratory analysis from Quality control lab.
Dosage: 10kg/Day @ PC
PRODUCTION OF INSTRUMENT AND SERVICED AIR
(DDF701A/B) with Adsorbent type of alumina balls and it is sized to achieve a dew point of
150C at 7kg/cm2 .The drying unit consist of two adsorbent mass (alumina) beds, one in
service and the other is in regenerating phase.
56
PROCESSES: The two phases are inverted automatically at pre-established Intervals, by
means of a valve system operated by suitable timed apparatus. The adsorbent mass is
regenerated by means of hot air in a closed loop.
Air is then filtered in the final dust filter and sent to the surge drum D701.
SURGE DRUM (D701): It feeds directly the service air network and through the instrument
air filters DF702A/B the instrument air network.
Service Air Header is automatically cut off by means of the pressure switch when the air
flow rate is insufficient. The pressure switch is put on the instrument air that close a valve
on the service air to network. The Surge drum can serve the feed instrument air to network
5-10 minutes in emergency conditions (both compressors not running)

CHAPTER 4
My industrial training at Warri Refinery and Petrochemical Company limited, Ekpan Warri
was knowledgeable and Productive. It prepared my mind for challenges ahead of the labor
market, as my knowledge about the labor market grew wider. Finally, I am grateful to the
S.I.W.E.S managers for the opportunity to have an on-the-job experience applied to the
57
utilities Department such as the water treatment, Nitrogen production etc., and the
importance of safety in the working environment among others.

4.1 CONCLUSION
In the course of the program, I came to terms with the different behavioral attitude of the
working class. The program got me a new view on how to handle operational issues with
limited time. In all these, I became confident of my ability to think independently.
The SIWES training programme has been an intriguing, encompassing, knowledge building,
experience gathering and exposure acquisition process for me as an architect in training. I
have come to realize that “academics” and “practice” are very different but are both vital as
they complement each other to make a better professional in one’s field; this realization has
definitely improved and broadened my perspective of the industrial sector of oil and gas
exploration.
It was brought to my understanding that no matter the pressure mounted by time and
serviceability, one should not compromise safety for either speed or monetary gain or even
favor as the case may be. My initiative and intelligence was also tested by my Industry
based Supervisor by giving me some jobs to carry out during my stay with the company.
Personally speaking, it has improved my mental and practical capabilities in the
Thermodynamics of a system where those theories learnt in class were shown first-hand in
the field. With these and other values gained during this few weeks, I can say with great
confidence that the purpose of SIWES has been accomplished and the knowledge gained
cannot have been passed across during normal lectures.
The overall benefits have been immeasurable and invaluable. Therefore it should be
encouraged and empowered immensely.

4.2 RELEVANCE OF THE S.I.W.E.S PROGRAM TO STUDENTS

Generally, the importance of the S.I.W.E.S program cannot be over emphasized as it
contributes immensely in the following ways:

58
  It exposes the students to work methods and techniques in handling equipment and
machinery that may not be available in the university. It provides students with the
opportunity to apply theoretical knowledge to real work situation.
 It prepares students for the work situation they are likely to meet in the real world.
 It provides an avenue for students in Nigerian universities to acquire industrial skills
and experience in their course of study.
 It creates a platform for students to apply their theoretical knowledge in a practical
form, thereby bridging the gap between the academia and the industrial world.
 It makes the transition from the university to real world easier and thus increases
the students contact for future job employment.
 The program exposes students on how to co-operate with colleagues and staffs in
their various places of attachment and to be able to face real life problems.
 The program helped develop a more safety conscious attitude in the student.
 It gives the students the opportunity to improve their social skills and
communication

4.3. SUGGESTIONS FOR IMPROVEMENT OF THE SCHEME

I strongly suggest that the program be introduced right from the second year of study in all
science disciplines and third year in all Engineering disciplines. This will enable students to
be exposed to more than one industry and also increase the duration/frequency of the
program. Students will be equipped with the skills required for working in more than one
firm, thereby, increasing the level of employment opportunities for the students in the near
future.
It is necessary to sensitize staff of the various companies on how to relate to students by
helping them to get the needed knowledge.
It would be very important if the organizers of the S.I.W.E.S program could sit with the
various companies and discuss the relevance of the program and to create more IT spaces.
Financial aids should be given to students in order to help them with feeding, transportation
etc.
The scheme should improve on their visit to check on students frequently because some
students don’t come regularly. Though the benefits of the student industrial work
experience scheme cannot be over emphasized, however there is a need for improvement.
Also government should endeavor to widen the industrial sector by providing places for
student attachment.

59
The place of attachment should try as much as possible in making a proper plan for
industrial training students.

4.4. ADVICE TO FUTURE PARTICIPANTS

 Adhere to all safety instructions strictly especially in the field, workshop, or any
hazardous area.
 They should be careful not to bring disrepute to the program by involving in indecent
act.
 The program itself should be taken seriously, even to the submission of IT
application as well as self-comportment within the organization as supervisors
within the firm scrutinize the students from these little things.
 They should take their studies seriously now as such theoretical knowledge gotten in
school serve as a foundation for them understanding the basis in real life
performances
 Never be too shy to ask questions, make researches, go online, read company
manuals and go to your supervisors with questions, there will be definitely be at
least one person who will appreciate the effort and be willing to assist you.
 Lastly, always be punctual, as punctuality is the sole of a business

4.5. RECOMMENDATIONS
It is necessary to sensitize staff of the various companies on better ways to relate to
students.
It would yield great improvement if the organizers of the S.I.W.E.S program could sit with
the various companies and discuss the benefit of the program and need to create more IT
spaces.

4.6 REFERENCE

 Krupa, S.V. 2003 Effects of atmospheric ammonia (NH3) on terrestrial vegetation: a

review Environmental Pollution 124 179-221
60
 Marschner, H. 2005 Mineral Nutrition of Higher Plants Mineral Nutrition of Higher
Plants 2 672
 WHO, 1997 Effects of atmospheric nitrogen compounds (particularly nitrogen
oxides) on plants. Environmental Health Criteria Series 188 115–191
 WRPC profile manual.
 Instruction manual (PC Utility Plant)
 Meyer, E. (1998). Chemistry of hazardous Materials, (3rd Ed.), Prentice hall, page 458
 Cryogenic nitrogen plant - Wikipedia

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