Professional Documents
Culture Documents
I owe my profound gratitude to the almighty God who favoured me and for his
grace, mercy and protection throughout my entire period of internship. My
heartfelt gratitude goes to my parents Mr. & Mrs E.I OBANI, my siblings for
their prayers and support especially in my academic pursuit and also during
training.
OBANI MEDLINE C.
TABLE OF CONTENTS
COVER
PAGE I
DEDICATION.. II
ACKNOWLEDGEMENT III
TABLE OF
CONTENT IV
LIST OF TABLES V
LIST OF FIGURES VI
CHAPTER TWO
2.0 Safety
CHAPTER THREE
CHAPTER FOUR
4.1.1Pumping order
6.1 Conclusion
6.2 Recommendation
6.3 References
LIST OF TABLES
1.1 Pipeline systems and their characteristics
1.2 Area offices and their control depots and jetties
LIST OF FIGURES
1.1 INTRODUCTION
The SIWES as one of the instrument of human resource in Nigeria has since its
inception been a welcome development in exposing students to real life working
condition. It employs concept of training as a continuous process for a workers
active life and skill acquisition as an enabling factor in achieving economic
growth and development in the country. Today, I am proud to say that I am one
of the students that has benefited greatly from the programme in 2015 and so, I
can confidently say that SIWES, in its relevance to the completion of my study,
has given me an exposure which is not just an opportunity to learn new practical
ideas but a road map to achieving greater potential in the very near future, a
potential that will be revealed in my service to the community and the nation as
a whole during my training as a microbiologist. I did my industrial training at
PPMC, Eleme Port Harcourt. I was assigned to Quality control laboratory in
OPERATIONS DEPARTMENT.
Furthermore, most of the things written in this report were learnt through
careful observations, asking questions, tour visits, lectures by the staffs,
contributions and detailed documentation in the line of field work.
1.2 OBJECTIVES OF STUDENTS INDUSTRIAL WORK EXPERIENCE
SCHEME (SIWES)
Quality control (laboratory): This unit carries out all the analysis in the
laboratory and record the results obtained. It also determines if a particular
product has attained its required specification before introducing into the
market.
The Quality control unit is in charge of analysing petroleum products and water
(effluent) that are gotten out of crude in the refinery before consumption.
Therefore I was involved in the analysis of effluent water i.e. waste water
Waste water from the refinerys main production units, as well as from
the utility units.
Tank drainage.
Waste water from truck loading terminal and from the port facilities.
This water may possess undesirable constituents such as salts, trace
elements, organic compounds, pathogens e.t.c which may affect soil,
environment, public health and hygiene.
1.4 ORGANIZATIONAL CHART OF PIPELINES AND PRODUCT
MARKETTING COMPANY (PPMC)
CHAPTER TWO
2.0 SAFETY
The composition of waste water depends upon the nature of area sewered, the
amount of industrial waste and the type of industries.
The typical component of waste water is water (99.9%), together with relatively
small concentration of suspended and dissolved organic and inorganic solids
(0.1%).
The properties or characteristics of waste water are derived from the analysis of
the physical, chemical, biological characteristics which enables the pollution of
waste water to be quantified and also treated.
This includes the nature of suspended or dissolved solids in the liquid waste,
temperature, odour, colour and flow variation.
COD level: This is obtained by oxidizing the waste with a boiling mixture of
chromic and sulphuric acid. This test does not give information on the fraction
of waste that can be oxidized by bacteria and the rate at which bio-oxidation
may occur.
In the presence of oxygen, aerobic bacteria convert soluble organic matter into
new cells and simple inorganic elements. The material acts as food for
organisms such as algae which have a main role in waste water treatment as
oxygen producers. Bacteria and algae are the most important organisms in waste
water treatment.
Industrial waste water treatment, covers the processes used to treat waste water
that is produced as a by- product of industrial or commercial activities. After
treatment, the treated effluent water may be reused or released to surface water
in the environment.
In the refinery, the waste water flows through a gutter leading to the community
stream, in this gutter oil beds are fixed as points to absorb oil or grease from the
water. Many oils can be recovered from open water surfaces by skimming
devices. It is a cheap and dependable way of removing oil.
The waste water from the refinery commonly contain large amount of oil and
suspended solids. Therefore, a device known as API oil- water separator which
is designed to separate oil and solids from waste water effluents
The API separator is a gravity separation device. In these the suspended solids
settles to the bottom of these separator as a sediment layer, the oil rises to the
top of the separator and the cleansed wastewater is the middle layer between the
oil layer and the solids.
1. Trash trap
3. flow distributors
4. Oil layer
. an aeration tank where oxygen is ingected and thoroughly mixed with waste
water.
an aeration tank is a place where a liquid is held in order to increase the amount
of air within it. the most common uses of aeration tanks are in WASTEWATER
recovery, the higher the oxygen level the higher the speed at which the water is
cleaned.
There are 2main methods of aerating liquid, forcing air through the liquid or
forcing liquid through air, both methods are common.
There are 2main types of aeration tanks. When a tank has air forced through it,
it becomes shallow and wide, tanks that put water into air are usually tall and
take less ground space than other tanks, in both cases they are promoting
additional natural aeration.
CHAPTER THREE
Waste water, depending on its origin and the nature of the contaminants, can be
treated in intermediate units or treated directly in the refinerys Effluent
Treatment Plant.
Waste water containing acids gases and alkaline are collected from all units of
the refinery via a separate network, recycled and sent to the effluent treatment
plant for further treatment.
On hearing an alarm for an emergency situation, all personnel that are not with
the emergency crew are expected to gather at the assembly point. An assembly
point is a personnel-gatheringpoint at the blast of an emergency alarm. It is
located in front of the administrative section of PPMC area office.
Pigging is done in the oil field to clean the internal of pipelines of accumulated
debris and also to ascertain the condition of the pipelines in the facility. PPMC
has a pig launcher facility in its premises through which a pig can be inserted in
the mainline pipe to clean the inside of the pipe and retrieved at terminal outlet.
The pigging tools are made of several materials to suit the situation of their
planned application. Some of the pig in operation includes:
FOAM PIG: They are cylindrical shaped, made with foam covered with
rubber material. They are used in the initial stage of pigging operations to
check how free the pipeline is and to check the pig fitting that will disturb
the free movement of other solid pigs which is indicated by abrasion and
scratches on the body of the foam pig. Non-abrasion and scratches on the
pig body indicates no obstruction in the pipeline.
SCRAPPER BI-DIRECTIONAL PIG: As the name implies, they are
mainly used to scrap off waxed material from the inner surface of a
pipeline. They are normally launched after a foam pig must have
confirmed a free line.
INTELLIGENT PIG: it is a computerized piece of equipment
consisting of mainly Integrated Circuit (IC) and rays emitting and
receiving gadgets. The pig is capable of detecting the extent of corrosion
and cracks in the pipeline.
PIG LAUNCHER: It is pipeline equipment with different pigging
configurations which allows the insertion of pig into the line and
thereafter aligning the pipe to allow fluid to flow behind the pig driving it
to its destination.
Fig 1.3 Types of pigs
CHAPTER THREE
The Port Harcourt pump station contains two (2) pump houses (one for 2E line
and the other for 2EX line) each of which contains a diesel and electric driven
pumps. Two (2) meter skids (one for line 2E and the other for line 2EX), a pig
launcher facility and a sewage outlet for the disposal of waste product are also
contained in the pump station. The pump station is fully automated with a
system 2E and system 2EX control panels in its control room which are used to
operate the pumps.
Pumps of various designs are used in crude oil and petroleum product pipelines.
Selection of pump design is based on desired efficiency as well as the physical
properties of the materials being moved, especially viscosity and specific
gravity. The pumps head pressure, or the pressure differential it can attain, is
critical for selecting pumps that are capable of moving fluids over elevation
changes. Port Harcourt pump station uses amulti-stage horizontal centrifugal
pump (electric and diesel pumps) in each pump house because less viscous and
lower specific gravity fluids (DPK, AGO, PMS) compared to crude oil are the
pumping products and also large volume of products are needed to be moved at
moderate pressure. Theses pumps consist of two main components; the impeller
and volute. The impeller is the rotating component of a centrifugal pump,
usually made of iron, steel, bronze, brass, aluminium or plastic, which transfers
energy from the motor that drives the pump to the fluid being pumped by
accelerating the fluid outwards from the centre of rotation. The velocity
achieved by the impeller transfers into pressure when the outward movement of
the fluid is confined by the pump casing. Impellers are usually short cylinders
with an open inlet (called an eye) to accept incoming fluid, vanes to push the
fluid radially, and a splined, keyed or threaded bore to accept a drive-shaft. The
volute on the other hand is the casing that receives the fluid being pumped by
the impeller, slowing down the fluid's rate of flow. A volute is a curved funnel
that increases in area as it approaches the discharge port. The volute converts
kinetic energy into pressure by reducing speed while increasing pressure,
helping to balance the hydraulic pressure on the shaft of the pump.
The component that actually provides power to the pump is referred to as the
prime mover. A wide variety of prime movers are in use, including electric
motors, gas turbines, and diesel internal combustion engines. In recent years,
most long-distance transmission pipelines have begun using electric motors or
gas turbines. Virtually any prime-mover pump design combination is possible,
with decisions resting primarily on the physical properties of the fluids being
pumped, the desired throughputs, operating pressures, and transport speeds for
the pipeline and for logistical needs such as meeting operating parameters,
availability of power or fuel for the prime mover, Initial costs, maintenance, and
compatibility with SCADA systems in use and the sensors they rely on.The Port
Harcourt pump station uses both electric driven and diesel internal combustion
engine prime mowers for its two pump houses (2E & 2EX). The electric pump
(which is the cheapest option in terms of initial cost) is the main pump used in
both pump houses because it is more efficient and requires less overhauls over
time as compared to the diesel engine pump. The diesel internal combustion
engine pump on the other hand is constantly offline and in stand-by in case the
electric driven pump develops a fault, is under maintenance or there is public
power outage, where the diesel pump is then used so as not to disrupt pumping
activities and meet operating conditions.
CHAPTER FOUR
4.1.1PUMPING ORDER
4.1.2INTERFACE INFORMATION
Product pipelines are unique, since they are typically used to transport a variety
of petroleum distillate products concurrently in a batch-wise manner. The
petroleum products jointly carried in the same pipeline are always chemically
compatible with each other, but may differ in physical properties such as
density. Some intermixing occurs at the interface of two products sequentially
introduced into the pipeline. Operating methods allow for minimizing the
interface between products. Regardless of how the commodities are separated
while in the pipeline, any mixtures of two commodities are segregated from the
rest of the flow at terminals and handled by downgrading (i.e., marketing them
as product mixtures of lower quality than the original individual products) or by
recovering and refractionating each mixture into the two original petroleum
products. In some instances, a sphere or a specially designed pig can be inserted
between batches to reduce the amount of mixing.
I. Calculate the average flow rate of the product being pumped by summing
each flow rate of the product being pumped excluding the initial flowrate as
the pumping operations hasnt stabled by then and dividing the sum by the
number of flowrates added together.
II. Divide the average flowrate obtained above by the line fill of the mainline
pipe between the pumping and receiving stations to get the time of the
interface arrival at the depot.
III. Fill in a radio telex for stating the interface time, the average flowrate,
volume and type of pumped products and most importantly advising the
receiving station to start sampling for interface two (2) hours before the
interface time calculated as pipeline vandalism repairs has rendered the
pipeline capacity unreliable.
IV. Submit this telex form to the radio station where it would be transferred
through radio to the receiving depot station.
The pumping activity data is logged down by the despatcher in the despatcher
log sheet. It is a large piece of paper with printed headings and columns were
these data can be filled.
I. Collect depot stock report from Calabar, Aba and Port Harcourt depot
through voice (mobile phone). This stock report shows the volume of each
product in its tank, water level, loading information, reception information,
pumping information and also Calabar jetty status.
II. Collect Okrika jetty status from the jetty operator via voice.
III. Collect crude oil and PPU (power plant and utilities) status via voice.
IV. Collect water tank level from pump station operators.
V. Open the am operations excel spreadsheet template file which helps to make
some calculations like ullage, loadable stock and days sufficiency
programmed in the excel spreadsheet.
VI. Insert the data from the stock report collected earlier in the blanks available
in the columns under the required field in sheet 2 of the spreadsheet. Data
needed to input is the gross and net volumes of each products in its available
tanks. After inputting these data, the excel spreadsheet will calculate the
ullage, loadable stock and days sufficiency of each product at a depot.
VII. Move over to sheet 1 the spreadsheet and input the loaded volume and
number of trucks data in the blank space available in the column under the
required field.
VIII. Open the am operations report Microsoft word template and copy all the
tabulated data only in the excel spreadsheet sheet 1 to it under their
respective columns.
IX. Insert the pumping status, reception status, and line fill for each location to
their available required fields in the MS word template. This information can
be gotten from the despatchers log sheet.
X. Insert the jetty status, crude oil and PPU status collected earlier in their
available fields respectively.
XI. Calculate the water volume from the water level collected earlier by using
the formula below;
After preparing the am report, a copy is taken to the DM operations for signing
and afterwards which several copies are made to be distributed to the area
managers office and other offices copied in the report.
A batch of a product which can be DPK, AGO, PMS or water is selected for
pumping from its nominated tank. The product moves under gravity through the
open valve of the tank to the booster pump through its suction valve. The
booster pump (located at the refinery Area five) accelerates the flow of the
product out of its discharge valve and through the meter skid which consists of
two meter banks (primary meter bank 1 or secondary meter bank 2) and then
through the bypass valve (valve 10) to the mainline pumps. The meter bank
calculates the parameters like amperage, pressure and so on of the moving fluid
through it. The valves of the prover loop are opened and the bypass valve closed
when an operator wants to prove the readings of the meter bank in case he/she is
unsatisfied with the readings of the meter bank due to a fault it may have
developed or he/she just wants to be sure of the reading. The product is received
at the suction valve of the mainline pump1 or mainline pump2. If the mainline
pump1 (electric) is to be used, the suction valve of the MLP2 is closed and that
of the MLP1 is opened and vice versa. The product is pumped out of the
discharge valve of the selected mainline pump and through the pressure control
valve (PCV). The PCV is manipulated in order to regulate the discharge
pressure, amperage and flowrate of the moving product to its recommended
values. The fluid then flows through the PCV to Aba. The operator at Aba depot
closes the bypass valve (valve 16) to Enugu pump station so they can receive
the pumped product. The pumped product from Port Harcourt then passes
through the suction valve of the meter skid then through the meter banks which
helps Aba depot to know the volume of product they are receiving. The product
then passes through the bypass valve(valve 17) and then to the nominated
receiving tank.
If more than one product is being pumped simultaneously, as soon as the first
batch of the product to be pumped at PPMC from its tank is exhausted, the
valve of the second nominated product tank is opened. It passes through the
same process till it reaches Aba depot where the interface between the two
immiscible products is collected in a slop tank where the two products settle out
to two distinctive layers and is then separated. This switching from the leading
product tank to the slop tank to collect the interface and then to the trailing
product tank is done calculatedly so as not to contaminate the leading product
with the trailing product. After the pumping of a batch of product(s) is
successful, water is then pumped to push the product from the pipeline so all of
it can be received at the reception depot.
4.5TANK FARM AND STORAGE TANKS
Storage tanks are large containers used for the storage of crude oil and its
products for short or long term before transporting it to the marketers and
finally consumers.
Tank farms are large expanses of land containing cluster of tanks arranged
together in the same area.
Most storage tanks are designed and built to the American Petroleum Institute
API 650 specifications. These tanks can have different sizes, ranging from 2
60m diameter or more. They are generally installed inside containment basin in
order to contain spills in case of rupture of the tank. Industries where storage
tanks can be founded include; petroleum producing and refining industries,
petrochemical and chemical manufacturing industries, bulk storage and transfer
operations, depot etc.
4.5.1CONTAINMENT BASIN
A containment basin is built around tanks and is made of bricks or concrete with
a lining that is impervious to liquid stored to prevent further spills that can cause
fire, property damage or contaminate the environment. The minimum capacity
of the basin volume should be equal to the capacity of the largest tanks plus
10% of the sum of the capacities of others. To prevent spill or other emergency,
the walls of the containment basin must be resistant to the product and must be
able to withstand considerable pressure.
CHAPTER FIVE
5.1PROBLEMS ENCOUNTERED
The challenges facing the pumping of products to depots include the problem of
failure of the system 2E machine and the booster pump due to excess running
and worn out of some parts. In a nut shell, the pumping machine is old and
working below its original capacity; it needs replacement as it has been serving
PPMC since the creation of PPMC. Also vandalization of pipelines by vandals
also causes a huge problem which results in wastage of the product.
Another important observation which calls for great concern is the nature and
rate of gas flaring in the refinery and how it has contributed to greenhouse effect
to the earths atmosphere. This is a result of non-utilization of the gas obtained
from crude separation after processing as fuel. This gas flare is a serious and
unnecessary contributor to climate change considering its composition of toxins
such as benzene which pollutes air and therefore renders the environment
unconducive. It is therefore recommended that various expansion project should
be made by PHRC such as the new gas turbine which will increase the capacity
of the plant to accept oil-associated gas which currently is wasted through
flaring.
Furthermore, the government should strictly enforce a ban of gas flaring. In the
case of pipeline vandalism, security measures should be put in place to prevent
it occurrence. Also, the booster pump and system 2E pumping machine should
be replaced with a new one to prevent further re-occurrence of these problems.
CHAPTER SIX
6.1 CONCLUSION
The industrial training has availed the trainee the opportunity of working with
and learning from skilled and experienced engineers and technologists in
various fields of engineering and technology.
As the company moulds the trainee to be competent, he was also able to make a
good impact while planning; showed competence and compliance to job
accorded to him and rendered excellent and dedicated services throughout the
period of his attachment.
The programme has provided the opportunity to see, initiate and control
practically some of the unit operations which the trainee studied theoretically in
the university, and also the challenges likely to be encountered in his career
practice in future. The training, though strenuous was really worth doing as it
was a source of experimental knowledge to the trainee.
6.2 RECOMMENDATION
It is based on this prime benefits to students that I say that SIWES programme
should be sustained in the national policy on education and if for any reason it is
tampered with, it should be improved upon only and never scrapped or reduced
in value.
REFERENCES
http://ppmc.nnpcgroup.com
http://www.thisdaylive.com/artces/nnpcswiss-and-nigeriantarders/164208