Monday, December 31, 2012

Lube Oil Blending Plant (My Industrial training Report)


CONTENTS

INTRODUCTION
MAL PAKISTAN LUBRICANT LTD
Product & Services
Why Synthetics
Army Welfare Trust
PROCEDURE AND CONDITIONS
CONDITIONS GOVERING THE CONSTRUCTION AND OPERATING OF LUBRICATING OIL BLENDING/RECYLING PLANTS
MAL Pakistan Future Plans...
BLENDING (I.L.B)
Equipment
Process control
Types of lubricants:
ADDITIVES USED IN I.L.B
INTRODUCTION TO BASE OILS:
CONSTRUCTION OF STORAGE TANK
Jiskoot Technical Papers
a)      Crude Oil Blending -
b)      Lube Oil Blending –An Overview for Lube Plants
c)      In-line Blending Systems
d)     In-Line Blending (Control Systems)
e)      In-Line Lube Oil Dehydration
Management of Petroleum Storage Tanks

LUBE OIL RECONCILIATION KEYS to control losses…



INTRODUCTION

MAL Pakistan Limited is the exclusive marketer of MOBIL Lubricants in Pakistan.


The MOBIL brand first entered Pakistan in September 1997 with its world-renowned range of lubricants for automotive and industrial use. Business is conducted through our corporate office located in Karachi, regional offices located in Lahore and Islamabad and our state-of-the-art Lube Oil Blending Plant situated in Hub, Baluchistan.

All our locally manufactured products undergo rigorous quality control and testing at our laboratory situated inside the Lube Oil Blending Plant. This has led to a virtually complaint-free reputation in the market, even in the most severe applications. Specialized products not manufactured locally   are   imported from our refinery at Jurong Singapore.

We have  an  extensive sales network throughout  Pakistan  supplying lubricants  to  a  wide  range of automotive  and  industrial users. We have direct and indirect   sales presence throughout   the country including   Karachi,   Hyderabad,   Sukkur,   Rahimyar Khan,   Quetta, Khuzdar, Gwadar, Sahiwal, Sargodha, Multan, Faisalabad, Islamabad and Peshawar, giving us a truly nation-wide coverage.
                       
Our automotive range includes passenger vehicle oils, commercial vehicle oils, transmission oils, brake fluids and greases. Apart from this, we are market leaders in high performance synthetic oils which are being used in a majority of premium class and luxury vehicles across the country.

For industrial applications, we have a broad product range including gas engine oils, heavy duty diesel engine oils, turbine oils, compressor oils, industrial gear oils and hydraulic oils. Our industrial lubricants are being used in almost every industrial application around the world and are endorsed by major equipment manufacturers globally. Segments where our lubricants are market  leaders include;  Power  Generation, Chemicals ,   Oil  &  Gas  exploration ,   Textiles ,   Manufacturing, Construction, Marin



MAL PAKISTAN LUBRICANT LTD
                             

 Insight of LBSP for as a society member.

MAL Pakistan Ltd (formerly Mobil Askari Lubricants Ltd) was registered in Pakistan under the Companies Ordinance in December 29, 1996.

The Company was a joint venture of ExxonMobil Corporation. In September, 2007, under ExxonMobil Corporation’s Global Distribution Framework Model, the stake holders of the Company changed the Company’s name to MAL Pakistan Ltd. and subsequent to that the Army Welfare Trust took over the ownership of the Company.

ExxonMobil Corporation, is the largest Oil Company in the world, operating in over 200 countries. ExxonMobil is a leader in almost every aspect of the worldwide petroleum and petrochemical business. The Army Welfare Trust, established in 1972, has wide ranging investments in banking, leasing, insurance, cement, sugar, pharmaceutical business and real estates.

MAL Pakistan Ltd continues business as usual and is the exclusive marketer of Mobil branded lubricants and coolants developed by Mobil for its global accounts in Pakistan under stewardship of ExxonMobil Asia pacific region.

For over a century Mobil has been an innovator in lubrication technology and has manufactured breakthrough lubricants for automotive, commercial and industrial sectors. These world-renowned Mobil branded products, were launched in the country in September 1997. The Company is the sole authorized importer and distributor of Mobil and Esso branded flagship and synthetic products in Pakistan.

The Company’s Corporate Office is located in Karachi, with a Regional Office in Lahore and Islamabad. The Company’s Lube Oil Blending Plant, situated in Hub Baluchistan, is a-state-of-the-art Plant as per ExxonMobil’s global standard.
In Pakistan, the Company continuously strives to achieve superior financial and operating results, while adhering to the highest standards of business conduct. MAL Pakistan Ltd’s development & employment of local resources / talent, and its extensive operational, technical, marketing guidance and training express the Company’s commitment to Pakistan.


Product & Services

Industrial Grades
Passenger Vehicle Grades
Gas Engine Oils
Petrol Engine Oils
MOBIL Pegasus 1 Synthetic                  
MOBIL Pegasus 1005                            
MOBIL Pegasus 905        
MOBIL Pegasus 805
MOBIL Pegasus 710                                 
MOBIL 1   Synthetic
MOBIL Super XHP Plus 20W50
MOBIL Oil Super 20W50
MOBIL Oil Special 20W50
Turbine Oils & Circulation Oils
Diesel Engine Grades
MOBIL SHC 800 Series Synthetic          
MOBIL DTE 800 Series                           
MOBIL DTE 700 Series                           
MOBIL DTE Named Series                     
Diesel Engine Oils
MOBIL Delvac 1 Synthetic
MOBIL Delvac MX 15W40
MOBIL Delvac Super 15W40 and 20W50
MOBIL Delvac 1330, 1340, 1350
MOBIL Delvac Special 20W50
MOBIL Delvac 1130, 1140, 1150
MOBIL 950
Gear Oils
4 Stroke Motorcycle Oil
MOBIL SHC 600 Series Synthetic          
MOBILgear 600 Series                           
MOBIL Special 4-T 20W50
Compressor Oils
Automatic Transmission Fluid
MOBIL Rarus 800 Series Synthetic
MOBIL Rarus 400 Series          
MOBIL ATF 220
Greases
Brake Oil
MOBIL Askari Grease EP0, EP1, EP2       
MOBIL Askari Grease 2
MOBIL Askari Grease 3                              
MOBILgrease XHP 222
MOBIL Universal Brake Fluid DOT 4
Furnace Engine Oils
Automotive Gear Oils
MOBILgard 412                     
MOBILgard M430                                        
MOBILgard M440                                        
MOBILube GX 80W90
MOBILube GX 140
MOBILube HD 80W90
MOBILube HD 85W140
Hydraulic Oils

MOBIL DTE 20 Series
Hydraulic AW Series

Heat Transfer Oils

MOBILtherm 603 and 605




Why Synthetics
Synthetic motor oils can provide a variety of benefits that help keep your engine running at optimal performance for years to come.

To understand synthetic motor oils, let’s look first at the origins of all motor oils.

Conventional oils come from crude oil that is pumped from the ground. Crude oil is made up of a complex mixture of molecules that form chains and rings of different sizes and shapes. Long chains of carbon atoms produce a thick, viscous fluid that flows slowly. Shorter chains produce fluid that flows more readily.

In an oil refinery, crude oil is separated into various fractions. These become the basis for lubricating oils and fuels. Thick tangled masses of carbon chains become asphaltic materials used in roofing tar and road work. Very short chains and ring compounds of carbon are volatile and can be refined to produce gasoline and other products.

While petroleum refining is an advanced science, small amounts of contaminants, such as sulfur and reactive hydrocarbons, cannot be completely removed from petroleum, and may end up in motor oil base stocks.

All motor oils are made up of base oils and additives. In general, fully synthetic motor oils contain non-conventional, high-performance fluids. Synthetic blends usually use some non-conventional, high-performance fluids in combination with conventional oil.

To meet the demanding requirements of today's specifications (and our customers' expectations), MOBIL 1® uses high-performance fluids, including polyalphaolefins (PAOs), along with a proprietary system of additives. Each MOBIL 1 viscosity grade uses a unique combination of synthetic fluids and selected additives in order to tailor the viscosity grade to its specific application.

Nomenclature
MAL               Mobil Askari Lubricants
API                 American Petroleum Institute
ASTM             American Society for Testing and Materials 
SAE                Society of Automotive Engineers 
NHVI              Number High Viscosity Index
MVI                Medium Viscosity Index
BSHVI            Base Stock High Viscosity Index
Address / Location
D-46, Block 5 KDA Scheme 5, Clifton
Karachi
Ph: 021-111-840-840
Website / E-mail
http://www.mal.com.pk
mobilmarketing@mal.com.pk

 
ISO                 International Standards Organization

An Overview to….
Army Welfare Trust
Askari group of business enterprises
MAL Pakistan Ltd: A joint venture of AWT
               
               

A Culture of Excellence- A Tradition of Trust

AWT started with a modest asset base and high ambitions. Today, after 39 years of investments in various fields, we stand at a dazzling height of success and glory. Ours is a story of perseverance, innovation, business acumen and going beyond the frontiers in Banking, Cement, Insurance, Aviation, CNG, Agriculture, Manufacturing, Sugar, Security Solutions, Real Estate, Lubricants, Defence Procurement and Trading and many other diverse fields. Our investments will go a long way in consolidating the national economy of Pakistan.
                                                              

HISTORY
Milestones in the History of AWT


             
Year of Operation     Company/Business Unit
             
1971                            Army Welfare Trust.
1972                            Stud Farm Probyanabad and Army Farm Rakh Baikunth.   
1984                            Askari Sugar Mills Badin.
1984                            Stud Farm Boyalgunj.
1990                            Askari Real Estate Unit.
1990                            Askari Woolen Mills and Askari Shoe Projects.
1990                            Blue Lagoon & Army Welfare Mess.
1992                            Askari Bank Ltd.
1992                            Fish Farm.
1995                            Askari Aviation Pvt Ltd.
1995                            Askari General Insurance Company Ltd.
1996                            Askari Guards Pvt Ltd.
1996                            Askari Cement Plant Wah (acquired running).
1996                            Mobil Askari Lubricants Pakistan Ltd.
1997                            Askari Cement Nizampur.
2002                            Askari Compressed Natural Gas Project.
2004                            Askari Seeds.
2009                            Askari Enterprises Pvt Ltd.


VISION/MISSION   

Vision            
To be one of the leading business houses employing best business practices.

Mission          
To undertake safe and profitable commercial activities in a manner that portrays AWT's image as a respected market leader while generating maximum funds for meeting the welfare requirements of the Army.

Core Values  
We have an unwavering commitment of being a good partner, focused on building productive, collaborative, trusting and beneficial relationships with governments, other companies, customers, communities and each other.

Business Units

          Public Listed Companies

                     
  >   Askari Bank Ltd 
                       >   Askari General Insurance Co Ltd 

          
Public Unlisted Companies

                      
 >   Askari Cement Ltd Wah 
                      
 >   MAL Pakistan Ltd 
                    
   >   Askari Securities Ltd 
                       >   Askari Investment Management Ltd 

          
Private Limited Companies

                       >   Askari Aviation Pvt Ltd 
                       >   Askari Guards Pvt Ltd 
                       >   Askari Enterprises Pvt Ltd 

          
Other Business Units

                       >   Askari Cement Nizampur 
                       >   Askari Real Estate 
                       >   Askari Projects (Woolen & Shoes) 
                       >   Askari CNG 
                       >   Askari Farms and Seeds 
                       >   Army Welfare Sugar Mills 
                       >   Blue Lagoon & Army Welfare Mess 
                       >   Askari Cement Marketing 
PROCEDURE AND CONDITIONS TO BE FULFILLED BEFORE THE GRANT OF APPROVAL TO CONSTRUCT /MODIFY LUBRICATING OIL BLENDING/RECYCLING PLANT FOR THE MANUFACTURE OF LUBE OIL

1.0  APPLICATION PROCEDURE
                                                                       
Pursuant to the provisions of the Petroleum (Amendment) regulations 1988, all applications for approval to construct/modify lubricating oils blending/recycling plants, oil treatment plants, Petroleum Jelly and Grease/Manufacturing Plants, shall be addressed to the Department of Petroleum Resources Office, situated at 7 Kofo Abayomi Street, Victoria Island, Lagos State, to be accompanied with the following documents as applicable:

Detailed description of the proposal stating clearly:
  • Formulations, Specifications, Classifications, Grades, Trade Names and Identifications of the Products to be manufactured.
  • Detailed description of laboratory facilities and equipment to be used for products quality control and test methods to be used.
  • Proposals on effluent handling and disposal method Codes, Standards and Specifications to be adopted in the design of the plant with specifications of equipment and facilities to be installed.
  • Two copies of the design drawings of the plant specifying the relative distances in meters between the plant and the adjoining properties.
  • Two copies of piping and instrumentation diagram of the Blending/Recycling plant and sectional details of the storage tank.
  • A certificate signed by the Chief Federal/State Fire Officer, or an Officer authorized by him in that behalf, that he is satisfied with the proposed arrangements for the prevention and containment of fire.
  • A letter from the appropriate town Planning Authority, authorizing the sitting of the plant at the proposed site.
  • A copy each of the Certificate of Incorporation, and Memorandum and Articles of Association of the company.
  • A copy of the Company’s Current Tax Clearance Certificate covering the preceding three years.
  • The prescribed application fee as from time to time determined by the Director of Petroleum Resources to be in the form of a bank draft made payable to the Federal Government of Nigeria-DPR Fees Account.
  • A copy each of the Certificate of Registration of Trade Names and under which the company proposes to market the Lubricating oils (if different from that of the Blending Company).
  • Required volume of Base Oils per year for blending the grades and classifications of Lubricating Oils applied for.


CONDITIONS GOVERING THE CONSTRUCTION AND OPERATING OF LUBRICATING OIL BLENDING/RECYLING PLANTS

2.1.0 CONSTRUCTION AND SPACING OF TANKS

For all strong tankers, the minimum distances shall be as follows:
Between the perimeter of the tank and the outer boundary of the installation, it shall be diameter of the tank or 25meters whichever is greater.
Between two adjacent tanks, it shall be the diameter of the smaller tank or 15meters whichever is greater.

STORAGE TANK DESIGN SPECIFICATION AND FITTINGS

All the storage tanks shall conform to the existing approved standards of the Standards Organization of Nigeria, and is constructed from mild steel or any other materials specially approved by the Director of Petroleum Resources for peculiar reasons. They should be externally coated to protect them from rusts and be conspicuously marked with their capacity either in cubic meters or barrels as may be desired.
All the tanks shall be protected against atmospheric static electricity discharges in accordance with the bright colors as approved by the Department.
If they are to be exposed above ground, storage tanks shall be painted in aluminum Grey or other bright colors as approved by the Department.
When sited below the surface of the ground, they shall be covered with a minimum earth thickness of 30.4cm with allowance made at surface level for manhole covers.
If in the event of leakage, there is possibility of contamination of underground water supplies, surface watercourses, or any surface drainage system, the tanks shall be surrounded with puddle clay of not less thank 3.48cm thickness or by fine concrete of a thickness approved by the Director of Petroleum Resources.
When installed wholly or partly above the surface of the ground, they shall be firmly supported with materials of structural integrity to meet the approval of the Director and be surrounded with a retaining bund wall that is large enough to contain 110% of the tank full contents.

In all cases, tanks shall

1.0 Be fitted with manholes of minimum diameter of 60.96cm to facilitate easy access to the insides;
2.0 Be fitted with vents capable of relieving excess pressure or vacuum;
3.0 Have access to their roofs by means of a ladder or staircase constructed and attached to the outer tank shell

Armored cable shall be used for all electrical wiring.
Non-flammable materials shall be used for all constructions within the plant.
All electrical lamp fittings shall be flameproof.


ENVIRONMENTAL PROTECTION

  • All storage tanks shall be surrounded by bund walls constructed with concrete.
  • The enclosure within the bund wall shall be capable of containing the whole contents of the full storage tank plus ten percent of the volume;
  • There shall be adequate piping facilities for evacuating any liquids retained within the bund walls.
  • There shall be installed in the enclosure, an efficient oil interceptor with an isolating valve leading to the drainage system;
  • Water shall not be allowed to accumulate within the enclosure or any part thereof where the storage tanks are on concrete foundations and the bed of the enclosure is also of concrete, drainage of the enclosure shall be effected by means of a pipe fitted with a valve, to be kept close when not in use, and which is capable of being activated from outside the enclosure;
  • The quality of the effluent generated from the drainage system in the plant shall be monitored at such intervals as specified in the existing environmental guidelines issued by the Department and shall be clearly entered in a register specifically kept for that purpose and monthly returns of these effluent analysis shall be rendered to the Department.
  • All other precautions and provision of up-to-date equipment for preventing pollution as specified in the Ministry’s environmental guidelines shall be put in place to the satisfaction of the Director.

FIRE FIGHTING AND PROTECTION MEASURES

  • In every lubricating oil blending or recycling plant, there shall be provided and kept in readiness to the satisfaction and approval of the Chief Federal/State Fire, Officer, adequate equipment for fire fighting and protection.
  • Each item of fire fighting equipment shall be inspected and tested at appropriate intervals by a competent person appointed for the purpose by the licensee. The date of the last inspection shall be entered in a logbook kept for that purpose.
  • All the personnel employed in the installation shall be instructed on the use of fire fighting equipment.
  • Instruction to personnel in case of fire shall be clearly and concisely expressed in writing and prominently displayed at the site.
  • "NO SMOKING" signs shall be conspicuously displayed at strategic locations in the plant and be illuminated for case of identification in dull brightness.
  • Whenever a fire or any accident occurs in the installation a report of the circumstances and probable cause shall be forward to the Federal or relevant State Chief Fire Officer and to the nearest office of the Department by the Licensee within forty-eight hours of occurrence
  • Automatic fail safe emergency alarm devices shall be incorporated in the critical sections of the plant.
  • During operation, no storage tank shall be filled to more than 95% of its capacity.
  • All maintenance requiring hot works on storage tanks shall be carried out under a permit issued by a competent person specifying detailed safety precautions that must be taken in the process.


QUALITY CONTROL

a)      A well equipped laboratory for quality control shall be established to test for the following parameters using international test methods, (ASTM and IP), as applicable to:
  • Specific Gravity
  • Flash Point
  • Kinematics Viscosity
  • Pour Point
  • Viscosity Index
  • Water Content
  • Insoluble Content
  • Acidity Level
  • Total Base Number (TBN)
  • Sulfated Ash Content (Trace metals Pb, Fe, Na, K, V, Ni, Co)
  • Trace of PCB, PNA, depending on oil feedstock source (for lube used oil recycling)

All formulations and specifications of products to be manufactured shall be forwarded to the Standards Organization of Nigeria for consideration and approval.

b) Samples of all blended batches shall be retained for a period of not less thank three months before disposal and be made available to the Department on demand for any desired quality verification test within this mandatory period of storage.

LICENSING PROCEDURE

Upon completion of the construction of blending or recycling plaint, an application for license to operate the plant shall be forwarded to the Department. The application shall be accompanied by the following;

i. Prescribed License Fee in bank draft payable to the "Federal Government of Nigeria, DPR Fees Accounts"
ii. A photocopy of the approval obtained to construct the plant
iii. A copy of the product formulations and specifications approved from Standards Organization of Nigeria (SON).
iv. A copy of the third party blending agreement, (in case of companies without plants), entered into with the blending company. The agreement must have been cleared with the DPR and submitted in a legally executed form.
v. Companies seeking third party blended arrangements shall be required to submit evidence of ownership or management of licensed retailed outlets or supply agreement to licensed end users.
vi. A copy of the product(s) trade name(s) registration with the Federal Ministry’s of Trade.
vii. A final certificate of clearance signed by the Chief Federal/State Fire Officer or any officer designated by him in that behalf, that he is satisfied with the provisions for the prevention and containment of fire.
viii. A set of plant operating manuals

A pre-commissioning inspection of the plant shall be carried out on the satisfaction of the above listed conditions and a license to operate the plant shall be granted on the satisfactory outcome of this confirmatory plant inspection.


DEPARTMENT OF PETROLEUM RESOURCES
APPLICATION FOR LICENCE TO OPERATE LUBRICATING
OIL BLENDING PLANT

1. Name of Applicant/Company ………………………………………………………….
2. Registered Address in Nigeria ………………………………………… ………………
3. LOCATION DDRESS OF PLANT (Town, LGA, State) ………………………………
State Whether Application is for a New Licence or for Renewal (Please Tick as Appropriate) If Renewal, Please Attach a Photocopy of Expiring Licence
5. Storage Capacity of Base Oil…………………………………………………. Litres/kg
6. I/We Hereby certify that all the information Contained in this form and the supporting Documents to the best of my/Our Knowledge are correct.
Fee Paid: =N= …………………………………….…… ………………………………….
(In Figures) (In Words)……………………………………. ………………………………
Authorizing Company Signature Company Stamp and Date
(Bank Draft to be made payable to the Federal Republic of Nigeria DPR Fees A/C)
………………………………………………………………………………..……………


(For DPR Use Only)

7. Bank Draft Reference Number …………………………………………………………
Amount ……………………………………………………………………………………
Receipt Number ………………………………………………………………………….
Name and Signature of Receiving Officer Date and Stamp………………………………
8. Recommendation of Processing Officer ………………………………………………..
……………………………………………………………………………………………..
Name and Signature of Processing Officer Date and Stamp………………………………
9. Licence Number ……..……Date Issued …..……Name and Signature Date……..……


LUBE OIL BLENDING PLANT CHECKLIST

*(print in capital letters only)

Field Office______________________ Identification Code________________________

Name of Company (as per Cert. Of Inc.)_______________________________________

Regd. Address: ___________________________________________________________

Location of Facility: ______________________________________________________

LPG_________________________ State_____________________________

Application type (New/Renewal/Takeover): ___Year of Expiration of Previous Lce.____

FEES PAID…………………………… RECEIPT No……………………………………

RECEIPT ISSUE LOCATION……………… RECEIPT ISSUE DATE…….……..……

BANK DRAFT DETAILS……………………………………………………………......




LIST OF ATTACHED DOCUMENTS
YES
NO
N/A
1
CERTIFICATE OF INCORPORATION OF COMPANY



2
APPROVAL TO CONSTRUCT/LETTER OF RELEASE



3
APPLICATION FOR A LICENCE TO OPERATE



4
APPROPRIATE PLANT PHOTOGRAPHS



5
CERTIFIED TRUE COPY OF MEMORANDUM AND ARTICLE OF ASSOCIATION



6
FIRE REPORT



7
CURRENT THREE YEAR TAX CLEARANCE CERTIFICATE



8
EXPIRED LICENCE



9
HYDROTEST CERTIFICATE



10
APPROVED BUILDING PLAN



11
EIA APPROVED REPORT








PRE-LICENCE PROVISION
YES
NO
N/A
1
ADEQUATE FIRE FIGHTING FACILITIES (FIXED & MOBILE)



2
ADEQUATE SAFETY & OIL/CHEMICALS SPILL CONTAINMENT AND CLEAN UP MATERIALS



3
PERSONNEL PROTECTIVE WEARS FOR OPERATORS



4
SECURITY CHECK POST



5
POWER SOURCE underline type – SUUPLIED/GENERATED OR BOTH



6
LIGHTNING AND EARTHING PROTECTIVE DEVICES



7
EMERGENCY SHUTDOWN SYSTEM



8
BUND WALLS CONSTRUCTED AS PER API, ETC STANDARD



9
CORROSION PROTECTION DEVICES



10
FIRE CLEARANCE ZONE OF MINIMUM 3 METRES AROUND THE PERIMETER FENCE OF THE PLANT



11
COLOUR CODING OF PIPE CONNECTIONS, HOSES, ETC



12
MEDICAL FACILITIES/FIRST AID MEDICAL FACILITIES



13
VEHICLES PARK CONSTRUCTED OUTSIDE THE PLANT



14
LABORATORY FOR QUALITY CONTROL PURPOSES



15
EMERGENCY RESPONSE ACTION PLANS CONSPICUOUSLY DISPLAYED



16
BRICK WALL PERIMETER FENCE, GREATER THAN 1.5 METRES HIGH



17
WATER STORAGE FACILITIES (FIRE FIGHTING & DRINKABLE)





Name of Plant Manager: ___________________No. of Trained Attendants___________



Products
No. of Tank(s)
Capacity of Each Tank (M/Tons)
Vol. Applied for (M/T)


























Approval to Construct by………………………………………... Date…………………..
Name of Inspector_______________________________ Date Inspected_____________
1. Are above inclusions adequate for issuance of Permit/License?        Yes/No
2. Recommendation_______________________________________________________
3. OPSCON’s Signature__________ Name____________________ Date____________
4. DPR HQ validation by___________________________ Date____________________
5. Downstream Remarks____________________________ Date___________________


BLENDING (I.L.B)
One Worker Multiple Machine Layout (OWMM)    
Lubricants and Additives blending units





Grass root plant 3D view (DESIGN LAYOUT)

Equipment
AUTOMATIC BATCH BLENDING (ABB)
DRUM DECANTING SYSTEM (DDS)
INLINE BLENDING (ILB)
In-line blending is the process of mixing together a number of liquids to achieve a finished product of closely defined quality and quantity.
A good blending system should achieve this without the need for blend adjustments (wastage), with sufficient automation to limit the potential for errors and should keep the labour and production costs to a minimum.
Jiskoot and Cellier is an internationally acknowledged leader in the field of in-line blending systems with over 40 years experience of blender design. They can supply solutions ranging from simple ratio control two-stream blenders for fuel and crude oil applications through to large systems with automatic density or viscosity blend optimization. Jiskoot and Cellier is able to provide complete blending solutions from design to start-up and their systems are guaranteed to operate as a totally integrated part of a process plant and reduce the operating costs.
§  Applications
A range of turnkey, integrated in-line blending systems for process liquids including crude oil, LPG, LNG, ethanol and bunker fuel oil.


§  Systems
fully guaranteed turnkey in-line blending systems. The system type depends on the products being blended, the quality of feedstock and the final product specifications.

§  Products
A range of control systems, analyzer loops and mixing systems that offer the optimum performance as part of an in-line blending system.

Process control
SYNOPTIC DISPLAY

CONTROL SYSTEMS

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InSpec Blender Controller
The InSpec blender controller is a true 3-term PID controller, suitable for controlled rate batch blending, wild stream responsive blending and analyzer trim applications.

PNEUMATIC CONTROL ROOM

Safe area blender controller
The InSight is a safe area real-time blender controller with an intuitive user interface. Designed for 2-8 stream in-line blending applications, the InSight can be used for ratio control, viscosity trim, and density trim or analyzer trim blending systems. The InSight can be operated as a stand-alone controller or integrated as part of a distributed control system (DCS).
§  Real-time operating system (not PLC)
§  Self learning algorithms to guarantee accuracy
§  Polynomial meter linearisation for high accuracy blend control
§  Volume or mass blending
§  Volume correction to API 2540 and IP 200
§  Can perform single product bulk loading with metering
§  Flow weighted averages for control parameters
§  User programmable logic
§  Ratio or analyser control modes
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MIXING SYSTEMS

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Mixing at the outlet to a blender header is crucial to ensure that the product delivered is fully homogenous.  Mixing becomes even more important if analyzers are mounted in the blender header to provide quality optimization of the blended products.  Jiskoot and Cellier mixing systems are all designed in accordance with international sampling standards to guarantee product homogeneity.
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Jet Mix mixer
The Jet Mix mixing system uses a pump to withdraw a small portion of the process fluid and re-introduce it into the pipeline, in the form of high velocity jets. 

A Jet Mix has no pressure-drop and is suitable for high-turndown blenders where the pressure drop normally developed across a static mixer is unacceptable. The pumped bypass loop of a Jet Mix system can also be used for the installation of on-line analyzers such as densitometers to avoid the need for mounting insertion devices in the blender header.
Static mixers
In applications where there is a limited flow turn down, a static mixer may have a sufficiently low pressure-drop and provide enough mixing at all flow rates to be suitable for blenders. Static mixers supplied by Jiskoot and Cellier are supported by pressure drop estimates.




ANALYSERS

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Densitometers
Accurate density measurement is crucial to the quality optimization of an in-line blender or custody transfer measurement system. Jiskoot and Cellier has experience of the design and deployment of numerous bypass loop density measurement systems for custody transfer and fiscal applications. Jiskoot and Cellier has alliances with key manufacturers to ensure transmitters are correctly installed and calibrated to optimize performance.



Viscometers
Accurate viscosity measurement is crucial to the success of the quality optimization of an in-line blender. Jiskoot and Cellier has developed alliances with key manufacturers to ensure that transmitters are correctly installed and calibrated to optimize performance in any application.



Types of lubricants:

  1. Automotive Lubricating Oil.
  2. Industrial Lubricating Oil.

INTRODUCTION TO LUBRICANTS:

A lubricant is a substance (usually a liquid) introduced between two moving surfaces to reduce the friction and wear between them. A lubricant provides a protective film, which allows for two touching surfaces to be separated, thus lessening the friction between them. Lubricants are an essential part of modern machinery.

Lubricants are generally composed of a majority of base oil (most often petroleum fractions, called mineral oils) and a minority of additives (chemicals). Typically lubricants contain 90% base oil and less than 10% additives.

PROPERTIES OF LUBRICANTS:

Lubricants perform the following key functions.
  1. Keep moving parts apart.
  2. Reduce friction.
  3. Transfer heat.
  4. Carry away contaminants & debris.
  5. Transmit power.
  6. Protect against wear. (anti wear, extreme pressure)
  7. Reduce corrosion and rust.
  8. Seal for gases.

INTRODUCTION TO ADDITIVES:

Additives (chemicals) are used with base oil to impart desirable characteristics of lubricating oil. Additives are used for reduced friction and wear, increased viscosity, improved viscosity index, resistance to corrosion and oxidation, aging or contamination, etc. A large number of additives are used to impart performance characteristics to the lubricants.

  1. Antioxidants. (zinc dithiophosphates)
  2. Viscosity index improvers. (polymethacrylates)
  3. Anti-wear. (zinc dialkyldithiophosphate)
  4. Pour point depressants. (co-polymer of methacrylates)
  5. Corrosion inhibitors ( alkaline compounds, esters)
  6. Rust inhibitors (alkaline compounds, organis acids)
  7. Friction modifiers (graphite, molybdenum disulfide)
  8. Extreme Pressure (chlorinated paraffins)
  9. Anti-foaming agents. (dimethyl silicones)
  10. Demulsifying / Emulsifying. (polyamines)

ADDITIVES USED IN I.L.B:
ILB of MAL is generally using the following additives.


Viscosity index improver:

 It is prepared by the blending of base oil (100 HVI) and an imported POLYMER. The viscosity of this additive is 850 cst at 100 degree centigrade.
Infenium (calcium long chain alkyl salicylate):
Infenium has some types, which are used for lubricant manufacturing i.e. infenium 1222, C9340, SV210.

INTRODUCTION TO BASE OILS:

The most important component of lubricating oil is base oil. Base oil determines the flow characteristics of lubricant, its oxidation stability (sludge and deposition tendency), its volatility and corrosion potential.

Base oil from petroleum consists of complex mixtures of paraffins, naphthenes and aromatics. If paraffin predominates the base stock is paraffinic, if naphthenes predominates the base stock is naphthenic base stock.

The API has also stabilized five base stock categories, classified according to saturate content, sulfur content and viscosity index.

Base Oil categories

Paraffinic

Paraffinic base oils are made from crude oils that have relatively high alkane contents. The manufacturing process requires aromatics removal.
Paraffinic base oils are characterized by their good viscosity/temperature properties and good stability. They are frequently referred as Solvent neutrals (SN).

Naphthenic

Naphthenic base oils are made from a more limited range of crude oils than paraffinic. Important characteristics are low pour points, because of wax free nature and excellent solvency power. Their viscosity/temperature properties are inferior then paraffinic (low to medium VI).

SYNTHETIC BASE OILS:

Synthetic base oils are chemically derived, most often from ethylene gas, and contain none of the contaminants present in mineral oils. Just as distilled water is pure water derived from gas so synthetic base oils are pure oils derived from gas. e.g,

  • Polyalphaolefins
  • Alkylated aromatics
  • Polybutenes
  • Polyolesters
  • Polyalkyleneglycols



GROUPS
% SATURATES
SULFUR CONTENT
VISCISTY INDEX
GROUP I
      < 90%
        > 0.05 %
       80-120
GROUP II
       >99%
        < 15 PPM
      100-115
GROUP III
       >99%
        < 15 PPM
      120-140
GROUP IV
        100%
                0
      120-140
GROUP V
the base stock excluding group I,II,III and IV base stocks

BASE OIL USED IN I.L.B:

NAME OF BASE OIL
VISCOSITY INDEX
VISCOSITY              (cst)      
POUR POINT (°C)
FLASH POINT (°C)
COLOR
100 HVI
95
18.5-21 @ 40°C
-6
177
1.5
400N HVI
95
9.4-10.4 @ 100°C
-6
227
2.5
BS HVI
95
32-37 @ 100°C
-3
280
5
100N MVI
60
20-24 @ 40°C
-6
177
2
BS MVI
65
35-42 @ 100°C
-3
280
8
650 MVI
60
10.6-11.6 @ 100°C
-3
227
5.5
65N MVI
95
10-12 @ 40 °C
-9
130
1.5
150 HVI
95
28.5-32 @ 40 °C
-6
180
2
500N HVI
95
10.5-11.8 @ 100 °C
-6
227
3.5

CONSTRUCTION OF STORAGE TANK

 
·        Stock in the bottom cone of the tank is called DEAD STOCK.
·         The two holes one at the top and the second at the side wall of the tank are called MANHOLE used for cleaning of tanks.
·         There is a DIP MEASURING HOLE used to measure the height of oil in the tank, this height is used to measure the volume of oil in the tank.
·         DRAIN is used to drain off the oil in the tank at the time of cleaning.
·         INLET AND OUTLET valve are used to fill and empty the tank.

Below is the list of the most commonly found additives in lubricating oil
Additive
Name
Characteristics
Detergency & cleaning action
Phenaltes,Sulphonates, Naphthenates
Interacts with varnish or sludge to neutralize and solubilize.
Dispersant
PBI (Polyisobutylene) Succinimides
Dispersants are soluble in the oil and have a polar end which attracts and binds to contaminants preventing settling and adhesion to metal surfaces.
Antifoaming
Silicone Polymers (very low concentrations)
Not really necessary for diesel engines in properly designed systems, but provides anti-foam in gearbox and also at the refinery during blending.
Pour Point depressant
Polymethylacrylate
Used in SAE 30 grades and below to ensure point criteria are met.
Anti-wear load carrying
ZDTP (Zincdialkyldithiophosphate)ZDDP (Zincdiethlydithiophosphate)
Chemicals react with surfaces forming films which have slower shear strength than parent metal.
VI Improvers
Polymers of: Methacrylate Acrylate Olefin Styrene-Butadiene
Increase in relative viscosity more at high than low temperature.
Rust and corrosion inhibition
Sulphates, Thiourea type chemicals
Chemically absorbed onto bare metal surfaces providing protection and neutralization.



Crude Oil Blending -
The commercial driver for excellence

In-line blending of two or more crude oils provides a major source of competitive advantage by optimizing facility feedstock costs. However, if poorly executed, a sub-standard blender design or configuration has been shown to result in blend errors in excess of 2-5%, which can result in annual losses of over $7 million - $15 million a year (for a 9mmtpa facility).

These losses can be avoided by using companies specializing in complete blending systems (not just control systems) to generate a detailed and achievable specification for a turnkey blender with a performance guarantee early in the design stages. The successful implementation of a crude oil blender hinges on consideration of the whole process from site survey through design to planned blending operations. The relatively small incremental cost of an optimally designed, bespoke blender, compared with one of a sub-standard design shows a significantly improved return on investment (ROI).

Introduction

The increasing availability of lower cost heavy crude oil has driven investment in in-line blending equipment to enhance flexibility and profitability. In-line blending is a cost effective alternative to additional tanks and batch blending and increases a facility's ability to process a wide range of crude oils.
Variation in crude quality, tank layering, and inaccurate (or unknown) blend recipes combined with poor blender design (hardware, software and integration), regularly cause blend ratio errors of 2-5% or more unless blender hardware and control methodology are optimized. For a 9mmtpa throughput facility with a nominal $39 bbl crude price and a 10% discount for heavy crude, the spreadsheet below shows that at least $7-$15 million savings can be made annually by reducing blend uncertainty.

Sources of error:
Error in crude oil blending is derived from two main sources:-

1. Variation in feedstock quality and blend recipes

2. Control system, field equipment and system integration
Feedstock and blend recipes

Crude oil stored in tanks is rarely homogenous even with the use of tank mixers In addition, many crude oils are blends and therefore the composition changes slightly from cargo to cargo.

Blend recipes are often calculated using a "typical" analysis and as a consequence the blend MUST use an excess of the light (i.e. more expensive) crude, thereby exceeding the optimal ratio to, ensure the process specification is met or exceeded. Errors in the blend recipe model result in unnecessary "giveaway", which is directly proportional to the inaccuracy in the recipe.

This variation in quality can be resolved by using on-line analysers (viscosity, sulphur, density etc) to measure the blended crude and provide a dynamic feedback signal; but, to be representative the analyser system must be installed in a location that is homogenous and representative at all process conditions and be correctly compensated to standardised conditions. Representative analysis is one of the most important factors in blender design.

Control system, field equipment and integration

The heart of any in-line blending system is the selection of the correct components, their integration within the package and the performance guarantee of the total blending system. Of vital importance to the success, and hence profitability, of an in-line blender is how well the individual components perform AND how well they operate once integrated in the blender with the control system.
Crude Blender with remote control valves

Selection of appropriate blender components is the vital first stage in ensuring the quality of the final blended product. Below are listed some of the primary design considerations for key components;-

"Flow meters - Turndown, suitability for crude, susceptibility to hydraulic noise

" Control valves - Optimal control, stability and response time without adverse pressure drop

" Mixing system - Pressure drop, degree of mixing and range ability

" Control system - Real-time three-term PID control, proven (i.e. not site-specific)

" Analyser system - Location, noise, response time, flow weighting at standard conditions

Incorrect selection or implementation of any of these components will result in fundamental system errors that are likely to be impossible to resolve. Once selection is made, it is vital to verify that the selected components are proven and can optimally function for the full range of feed and blended crude oils.

One of the most common errors when designing blending systems is a lack of attention to the critical elements; it is risky to select components without understanding how they will interact with each other, the control system and the dynamics of the site environment. This can result in savings during CAPEX but never the optimal OPEX and will therefore fail to deliver the best possible return on investment.

Case Study

Jiskoot has recently supplied a system for blending heavy Mexican crude oil (13API) with lighter (21-35API) crude. The system is a two-stream blender with on-line density measurement designed to accurately produce a range of blend crudes from 16-21 API at up to 800,000 barrels per day.
Crude Oil Blender

Providing user-friendly control, measurement and reporting of the whole blending process, the blend controller uses on-line measurement to continually optimise final product quality. Integration of the real-time blend control system with the facility's Delta-V system enabled the facility to achieve a key objective of implementing a 'maintenance on demand' system.

To guarantee accurate density measurement and ensure that the final product is homogeneous a JetMix, power mixing system, was used in the blend header.The JetMix is unique in that it mixes across a wide range of flow rates and blend ratios with no pressure drop. This, along with ultrasonic flow meters and careful component selection, allowed the blender design to be optimised for a maximum pressure drop of less than 1.5bar.


The control system with flow-weighted averaging and 3-term PID control ensures that the blended crude is on specification at all times during the by batch using unique control algorithms which respond instantly to changes in process conditions. The batch is continuously measured and feedstock adjusted to optimise quality and minimise 'give-away'. The system is designed to ensure consistent blended crude quality even during feedstock quality variations, starvation, loss of power or the unlikely failure of a system component.

The system has been operational for over 12 months with the customer stating:-

"The Jiskoot blender …… is a vital component of our facility enabling us to cost effectively and efficiently produce homogenous blended crude"

"The blender has performed to our satisfaction and over the first four months of operation has blended 37,000,000 barrels of crude oil"

It is clear that significant payback and return on investment can be achieved if the correct technology is selected. The key to success is to select and engage an engineering company specializing in blending systems at an early stage in the project and ensure they are involved in the complete scope of blending operations to maximize the value they bring to the project.

If correctly designed, installed and configured a blender can add significant value to operations. If poorly designed and executed it can result in poor quality blended product, potential revenue losses and plant downtime.



Mixing and Analysis system



Lube Oil Blending –

An Overview for Lube Plants

The blending of liquids and solids is an art which goes back to the early Stone Age and in its simplest form could look something like this.

















From this we can move to a more accurate method using a P.D. meter with ‘set-stop’ as shown here.
     Supply lines


                  Set-stop

                        meter

Batch

blending

tank





Lube oil batch blending by volume using single set-stop meter

Go a stage further and we can produce batches using a weighing method such as shown below in which each ingredient is discharged sequentially and weighed into the mixing tank (kettle).
Supply lines









             Lube oil batch blending by weight using load cells


Another method is to use dedicated meters to measure each component into a recycle-loop. This method is often called ‘stream blending’ and in the diagram below is shown with an additional in-line dehydrator mounted in the loop





Another more sophisticated approach is batch blending which is shown on the right. Batch blending lube-oil in this manner is often called ‘cascade blending’.
























If the blending plant building height allows, cascade blending can produce very accurate batches, very quickly with a minimal risk of contamination. Base components can be metered/weighed into a ‘kettle’ before pre-mixing (cocktailing) which can be flushed clean to avoid contamination.

Contamination is the main concern of the lube-oil blender. Base products and additives are expensive and mis-blending or contamination of the final product may mean down-grading the product or using it to feed the burners. To avoid contamination it is imperative that products are produced in ‘closely-related family groups’, or entirely separately using different mixing tanks. Subsequent flushing and efficient pigging are also essential tools to combat contamination.

In any of the previously mentioned blending methods you take the ingredients to the mixing pot. When this gets scaled-up, in a lube blending plant, it means that almost every one of the base stocks and additives have to be available and measured at the mixing/blending point. This involves a lot of piping, pumps, valves and hose exchanges etc.

An alternative approach is to take ‘the mixing pot to the ingredients’. Such a system can drastically reduce the supply piping since the actual mixing vessels are transported, in turn, to one or two points in the plant where all the base stocks and additives are available through dedicated supply lines. Small volume additive metering would normally be done by volume and large components either metered or weighted (by placing the batch-tank on load cells). The batch tank is then transported to a mixing station and eventually discharged after laboratory checks, using a specialised system of conveyors and/or robots.

Lube oil batch/weigh system


This type of system (shown above) requires a purpose built plant and tends to limit the batch size to about 5 tons, due to transport considerations. If used in conjunction with load cells (with an accuracy/linearity of 0.04% over 10 to 1 range) the small volume additives may have to pre-mixed by cocktailing or dilution before the final process.

As you can see, batch blending is not an instantaneous process. The sequential metering followed by mixing and analysis can take several hours, depending on batch size and the system employed. The picture below shows one of our lube batch blending plants in which some of these mixing problems have been reduced by building the blender around a Jiskoot Lube-Oil Dehydrator. The dehydrators’ recycling feature allows the components and additives to be almost simultaneously metered into the unit which then dehydrates and mixes them prior to discharge.


To summarize batch blending, in its various shapes and guises, I believe that no lube-oil blending plant can do without it, but I also believe that the constraints mentioned early indicate the limitations.

An average/large lube-oil blending plant will use 300 - 400 formulations/finished grades to produce maybe 10,000 batches per annum. The majority of these will be small with individual batch volumes rarely exceeding 2 -3 tons thus creating serious contamination hazards. The special/high quality blend sector can account for 35 - 40% of annual tonnage. In today's high cost atmosphere special care and attention in production planning is essential. This is the reason existing lube blending plants have put greater emphasis on pigging lines, extra flushing and installing dedicated metering lines etc.

A schematic of a typical modern lube blending plant is shown at the top of the next page.

Production starts on the left with the incoming base components and additives in storage tanks. The additives usually require some pre-treatment such as heating, decanting or maybe solids/waxes added. These are often cocktailed before being stored ready for the blending process.

The base components may be wet and require dehydration, which can be done with an in-line lube-oil dehydrator, or heat and an air-sparger blowing in the stock tank (the latter can take some hours).

The batch and in-line blenders take these components and additives and turn them into the final blended products that are discharged to storage,










































Filling machines or dispatched in bulk. The laboratory checks this entire process from start to finish ensuring quality.

In-line blending is a technique that any lube blending plant producing more than 20,000 TPA. Could use to great advantage.

In its very basic schematic form an in-line blender looks like this.












































Each component/base stock stream is accurately controlled and the blend header discharges a final blended product that is correct from start to finish.

The advantages of such a system are:
 Lower production times and labour costs through an almost immediate response to market demand (i.e. ‘you press a few buttons’ and the final product is immediately available). No long mixing delays and hold-ups in large tanks.

"  Better quality control, therefore reduced give-away because even the smallest additive is metered accurately and dispersed evenly from start to finish.

"  Reduced final blended product storage requirements therefore saving on tankage, stock inventory, etc. - reduced capital lock-up.

Reduced labour requirements - reduced floor area.

Whilst in-line blending does offer many advantages, there will always be a place in a lube-oil plant for batch blending facilities; if only because it is such a simple method with excellent operational flexibility when it comes to smaller batch sizes. It provides an almost infinite number of permutations of batch sizes and options of metering/weighing and degree of automation etc.

Let us now look at some of the limitations of in-line blending:

   There is an economical minimum size for an in-line lube blender of approximately 60 - 80 GPM blend rate (16 -21 m3 /Hr). This is primarily caused by the minimum acceptable size of commercially available flow meters for metering additives at percentages as low as 0.1 - 0.2% of blend rate and the general volume/area ratios of piping, strainer, meters etc. An in-line blender, as opposed to a batch blender, relies heavily on meter range ability and this tends to tail off with meters below 1/2".The employment of metering pumps is often used for these low flow applications.

   One normally only has 7 or 8 streams in an in-line blender. This means that some planning is necessary to avoid the same metering stream being used for non-compatible components in successive batches. However the lay-out of a well designed lube blender means that one can adequately clear out piping and strainers, etc.

As a consequence of these limitations, we have adopted the following basic rules when consulted on batch and in-line lube blenders for the ‘average’ plant.

1. An in-line blender can be economically justified for an annual production figure of 18,000 tones and over

2. About 60% (plus) of total tonnage can normally be considered as large batch (fast movers) and ideal for an in-line blender

3. If there is a slight contamination hazard between successive batches the batch size should not be smaller than the equivalent of 4-5 minutes of the maximum blend rate (i.e. for a 100 GPM blender this would be 500 Gallons). This can be reduced for ‘family related’ blends. By inference production planning should be governed by the compatibilities of successive blends.

4. Daily utilization of a typical in-line blender averages at approximately 5 hours with a quality confidence of 99.9%.

The photo (right) show 3 blending systems installed, to segregate feedlines, hydraulics, automation and industrial products.

The photo below shows a typical hose exchange, where the physical selection of base stocks and additives with which this in-line blender is supplied takes place.

The last figure is a schematic illustration of a lube plant I worked on a little while ago. The system was designed to utilize as much of the existing plant as possible.

















IN LINE BLENDING SYSTEM

In-line Blending In-line Blending is the controlled, continuous mixing of a number of components to produce a finished product of closely defined quality.

The quality of the product is controlled as it is made. This is invaluable in continuous process industries because the final product can be blended, analyzed and loaded in a single process.

The alternative

Batch blending is the main alternative. It involves sequentially introducing measured volumes of each component into a tank. The components are then mixed, analysed for quality and any adjustments made to the blend. This is time consuming and makes it necessary to store both pre-blended and finished products. Nevertheless, for small volumes and certain applications, this remains cost effective.

The specialists


Jiskoot is an internationally acknowledged leader in the field of blending systems with over 40 years’ experience in the design, manufacture and supply of customized turnkey measurement systems. Jiskoot has supplied blending systems to many of the world’s major oil companies and has a reputation for excellence and reliability. Our dedicated engineering team is able to select the best measurement and control equipment and design, manufacture, install and commission a turn-key blending system with a performance guarantee.

In-line blending has many advantages over batch blending.

Improved quality

The accuracy of an in-line blending system is governed by the accuracy of the individual component metering devices. Individual component accuracy better than 0.25% over the full Metering range can easily be achieved.

Faster blending

By performing analysis and adjustment of the blend ratio on-line, the time consuming process of batch metering, tank mixing, product analysis and blend adjustment is eliminated. In-line blending greatly reduces process time, and provides a higher throughput potential.

Greater flexibility

Changes in shipping schedules and product specifications can be accommodated simply by selecting a different recipe from the controller. As the blender operates in real-time, configuring a new recipe is quick and easy in comparison with the planning and stock movement necessary with batch blending. This allows you to offer a wide range of products and can provide a valuable competitive edge.

Reduced storage and capital lock-up

In-line blending produces a finished product almost instantaneously. It reduces the need for complicated production planning and there is no need to hold stocks of blended product. An in-line blender can feed products directly into road, rail or ocean tankers for shipment.

Cost optimization

Continuous metering, closed loop control and higher accuracy provides better product dispersion, better quality control and can substantially reduce the give-away of expensive components and additives. Substantial savings can be achieved in plants with a relatively low annual throughput

Reduced operating cost

Centralized control allows a single operator to control several blending operations simultaneously. Once initiated the blender will automatically produce the required final product.

Simplified plant layout

In-line blending enables a simplified plant layout to be achieved. In existing plants this can free tanks, pumps and pipelines for other duties and in new plants can considerably reduce capital costs.


Lube oil blender

IN LINE BLENDING

An in-line blending system comprises field equipment and a control system.

Field equipment

The field equipment (valves, meters, analyzers, etc.) enables the components to be simultaneously metered into the ‘blend header’ to produce the final product. Products
normally exit the blend header through a mixer and can be analyzed to allow quality trim to be performed. In refineries, the components can be taken directly from process units, avoiding or reducing intermediate storage.

Control system



The control system monitors the outputs from the field equipment (flow rates, etc), performs calculations for meter linearization, temperature compensation, etc. and feeds back the appropriate control signals to the field equipment to maintain the blending process within the required parameters (i.e. closed-loop control).Blending control systems use either real-time or PLC (ladder logic) technology. Jiskoot supplies either technology depending on Crude oil blender Application. . However, the cost, response times and control provided by PLC technology has a number of restrictions and Jiskoot also offers a multi-tasking real-time dedicated blending controller, the Jiskoot InSight.

In-Line Blending

(Control Systems)

Introduction

In-line blending is the continuous mixing together of two or more different component streams in order to obtain a final product of closely defined proportions. It is often more economic than batch blending methods, saving money by blending faster, requiring less manpower and storage facilities. An in-line blending system can also be used to deliver the product directly into a pipeline or to road, rail or ocean going tankers.

Jiskoot pioneered process automation techniques and by taking advantage of the advances made in electronic design is able to produce highly accurate blending control systems.

Basic Systems

In-line blending control systems can be divided into two categories:

"   Controlled Rate Systems

"   Flow Responsive Systems

The blend rate of a controlled blending system is governed by the demand flow rate set by the blend controller. This can be manually or automatically controlled and all component flows are maintained in the correct ratio, as a direct percentage of the total blend rate.

The blend rate of a flow responsive system is governed by the ‘Main’ or ‘Wild’ flow rate which is the main component stream to which all components and/or additive flows are ratioed.

Each of these systems has certain advantages. The flow responsive system is usually the cheaper; however, variations and options are available which provide considerable overlap in control features and facilities of both methods.

The basic principle of operation of the Jiskoot ‘controlled rate’ blender is that the flow in each component line is measured by means of a flowmeter, and controlled (regulated) by means of either a control valve, or by varying the output from a positive displacement pump.

The meter may be a positive displacement meter fitted with a pulse transmitter, turbine meter fitted with pick up coils, vortex meter, electromagnetic flowmeter or ‘Coriolis’ mass meter. The signals from these meters would be scaled and totalized by the blender.


Flow responsive blender generates the demand flowrate for each component stream. The demand flowrate is equal to the total blender throughput multiplied by the required stream percentage. It follows, therefore, that by varying the master demand rate the total blend rate is increased or decreased without affecting the individual stream percentages.

The demand signal is fed to each stream controller PID algorithm as a set point and compared to the measured flow from the stream flowmeter. Any deviation between the set point and the measured flowrate is stored in memory and an appropriate adjustment is made automatically to the control valve in that stream. Thus opening or closing the valve to increase or decrease the component flow to bring this back to the required stream flowrate.

If there is starvation of flow in the metering stream, the control valve will open to compensate, but if it reaches a point at which it can no longer properly control, a cut-back (pacing) signal reduces the demand rate to equal the maximum flowrate at which the lagging component can maintain correct ratio and accuracy, and flags an alarm. If, however, when the rate reduces below the minimum blend rate, the blockage in the lagging component is still so great that control cannot be regained, a signal will be automatically produced which shuts down the blender, and flags an alarm. The amount of the lagging component that is missing is stored in the controller memory, and on re-starting the blender after the component flow restriction has been cleared, the component loss will quickly be made up and the blend will continue with no loss of accuracy.

Similarly, if the upstream pressure varies due to line size or tank head, the ability to reach the required or set flow rate is sometimes lacking, in such a case the system will “Cut back” the flow rate to ensure the product ratio is correct and alarm to alert the operator. The systems are so designed to allow “cutback” to continue until one of the streams reaches its low flow limit; at this point the blender will be shut down as accurate flow measurement is not occurring.

In a flow responsive system it is the main or wild component stream which is used as the master and the other components or additives are ratioed to it, and are expressed as a percentage of the main/wild stream.

Control System Accuracy

As the whole system is digital and closed-loop, the accuracy of the electronics should be ±1 pulse for the flow signal, and analogue conversion for temperature is around 1 part in 8000 for the 4-2ƘmA range. The control system accuracy therefore is as good as the accuracy of the field equipment.

Since one pulse represents a very small quantity, the control system is continually calculating the so-called integral error between the required volume and the actual volume. This “error” is transmitted as a change to the control valve signal.

The accuracy of the whole system will depend entirely on the accuracy of the flow meter used. This means, therefore, that we can volumetrically blend components to within ±0.5% of instantaneous flow rate.

It follows that if one knows the quality parameters of the base components and additives, one can produce a very good final product within very close quality parameters. Most blending systems, particularly those in the petrochemical industries, operate this way and produce very good results.

Analyzer Feedback and Trim

There are occasions were the quality of the base components of a blend may vary and yet it is still required to produce a final product to close viscosity tolerances. The solution is really quite simple: we use an analyser in the final blend header and allowed the analyser signal a limited freedom to reset the volumetric ratio setting. Jiskoot has used feedback signals from density analysers, viscosity analysers
RVP analysers & octane analysers.

It is important that consideration is given to the effect of analyser trim, and the possibilities of stream starvation to maintain quality. It is usual to allow only a small drift in quality adjustment before raising an alarm; this prevents the analyser controls from shutting the blender down completely due to a fault in the analyser.

This practice of “analyser feedback” is now a regular occurrence in many multistream applications and it works very well. However the specifications governing the sale of products are becoming much tighter and the product costs are so high that many more quality limits are introduced. For instance, fuel oil at one time was primarily sold on viscosity only. In many cases this involved a simple two component blender that ratioed gas oil to fuel oil. Today viscosity is not the only parameter looked at, some or all of the following may also be controlled, sulphur content, pour point, density, viscosity or the cetane no. for diesel oil.

It follows that the production of fuel oil is no longer a simple two component blend. Indeed it may be a four or five component blend and here we have a slight problem. To adjust an accurate, volumetric flow proportioning device by means of a signal from an analyser does not present a problem. To do likewise with signals from two analysers may still be an acceptable solution, however, one can readily visualise the “pushing-pulling” which could occur if quality parameters were being adjusted which affected each other.

To cope with this problem a system known as a non-interactive blending was designed, non-interactive in the sense that the correction signals from the various analysers are employed in such a way that they do not interact with each other.

However this form of blending requires numerous analysers and a computer with the ability to handle numerous complex calculations (matrix inversion).We are able to offer suitable software packages to provide this facility together with ‘Blend Optimisation’.

Computer Supervised Blending

This consists primarily of a basic multi-stream blending system. However, all information such as component percentages, totaliser, etc are interfaced with a computer, as also is all analyser data. The function of the computer is as follows:

The PC is not used as a blender, but as an interface between our controller which is capable of handling all the field inputs/outputs and specific software for blending, analyser trim, PID control of valves and valve/pump sequencing. In this solution a typical PC is used in addition to our dedicated controller. The PC also provides communication not only to the stream controllers but to other Plant computers or DCS and SCADA systems in the plant or office.

The above configuration allows the system to be totally distributed, the PC is used only for mass data storage and a means for a control room operator interface, the blend control is by stand alone self contained controller. This allows real time control and processing with the added advantage that should the communications link fail between the PC and the blender, the blending process will continue.

Equipment Selection

As can be realised the mechanical components of the system are virtually identical no matter which level of control system is chosen.
The design of the mechanical section requires certain information to be made available. As a minimum this information should be:

  Expected overall system flowrate

  Number of components required to make product.

  Approximate ratios of each component.

  S.G. of each component.

  Viscosity of each component at normal blending temperature.

  Minimum and maximum temperatures and pressures of each component.

  Expected batch sizes.

  Number of recipes.

  Whether an analyser is required and which type.

  Whether those connections are made or the inlets permanently piped.

To this end we can supply blender questionnaires to assist in obtaining the necessary information and to act as a reminder.

Jiskoot has in line blending plants installed over twenty years ago still in operation with the initial equipment, thus good engineering design coupled with correct equipment selection is imperative.

Field Equipment

The basic elements employed in each loop of a good in-line blending system are:

  1. A strainer of suitable mesh to prevent debris from damaging the downstream mechanical components. If air is likely to be present, getting in for example, when a hose exchange is used for product selection, or when the lines are purged after a blend to avoid cross contamination, an air eliminator should be used. A differential pressure switch or gauge should be fitted across the strainer basket to give an indication of blockage.


In-Line Lube Oil Dehydration

A method employed by Mobil

A frequent problem encountered in the process of lube-oil blending is the existence of water in the base stocks. This may be present in dissolved or entrained quantities and must be removed in order to avoid “clouding” of the final blended product.
Generally speaking, lube-oil dehydration is required over a moisture content range from .05 to .001 percent (or better) w/w. A presence of water in excess of .05 percent can usually be reduced to this value by normal stratification methods.

There are various types of analysers to ascertain water in oil contents: however, the most frequently used method is the very simple “crackle” test. This consists of heating a sample of oil over a burner which will cause any entrained or dissolved water to escape in the form of an audible crackle noise. This test is good for a detection of down to 8 parts per million.

This simple heating method is not acceptable as a large scale dehydration method, since many lube oil base stocks can be “damaged” by heating in excess of 170-180° F. It is this reason which caused initial development of lube oil in-line dehydrating equipment to follow the path of “flash evaporation”, under partial vacuum. In this system, heated oil is introduced as a very fine film in to a vacuum chamber. This very successful method is, however, very expensive in initial, as well as running costs.

The Jiskoot in-line lube oil dehydrator is a development of the commonly used batch dehydration methods in which a tank of heated oil is “blown” for several hours. The Jiskoot dehydrator requires heat and air; normal ambient air.

Principles of operation

Oil is supplied to the dehydrator at a constant pre-determined pressure.This passes through the heat exchanger and then is fed to one or more specially designed ejector nozzles.

Ejectors and their nozzles were specially developed for their purpose in which the release of kinetic energy creates a partial vacuum of such value, that large amounts of air are drawn in and finely interspersed with the heated oil. The large contact area so obtained, in the extra long diffuser, provides a rise in air temperature with consequent steep rise in “moisture absorption-ability” of the air.

The air/oil ratio obtained is such that the prevailing humidity has no effect upon the efficiency of the unit.

The resultant air/oil mixture is collected in a fiberglass bath fitted inside the fully enclosed dehydrator receiver. Suitable baffles and primary screening facilities allow the excess air to be exhausted immediately to atmosphere. The heavily aerated oil is subsequently passed through a “de-aerating” section at a low velocity. Various screens of different meshes at different angles will ensure the effective release of entrained air from the oil before the final dehydrated product enters the discharge pump.

Humidity

The question that immediately comes up is the one revolving around “humidity”,e.g., will it work, for instance, on a wet rainy day?

Normal air is only partly saturated with moisture vapour and further raising its temperature increases its capacity for absorbing vapour. This unsaturation of the air may be satisfied by exposing it to water. It is also a fact that air saturated with moisture will deposit liquid water if cooled. Thus in this method, whilst moisture is absorbed from the oil by heated air, the degree of saturation must not rise to such an extent as to produce re-depositation of the water as the air cools on leaving the hot oil.

An extract from psychrometric charts follows, to illustrate the capacity of air to absorb moisture; shown in lbs of water per lb of air.

Table I

Ambient


Relative
Humidity


Air
Temp
10%
20
30
40
50
60
100
40oF
0.001
0.002
0.003
0.0045
0.005
50
0.0015
0.004
0.0075
60
0.003
0.005
0.0065
0.011
70
   0.0055
100
0.017
0.021
0.025
120
0.0075
0.015
0.022
0.030
0.038
0.046
0.087
140
0.012
0.025
0.039
0.053
0.068
0.084
160
0.021
0.094

In Table II the dewpoint is shown for varying degrees of saturation at various temperatures.

Table II





Relative
  Humidity


Temperature
              10%
20
30
40
50
60

40oF

14oF
28
60

----                           36                                   ---                46
100

34
  63
78
83
120

68
  
 
96
140

63
84
   97
106
160

78
  
124
As an example, air on a cool day at 50°F and 50 percent RH containing 0.004 lb water per lb of air, can be heated to 140°F/10 percent RH (Table I) and contain 0.012 lb, lb-a gain of 0.008 lb/lb. This air may then be cooled to 63°F (Table II) before re-depositing moisture.

Carrying the example in (a) a stage further, we may assume an oil with a water content of 0.05 percent which is in contact with the original 50°F/50 percent air, now heated. Each lb of oil contains 0.005 lb water, so that only 1/16 of a lb of air is needed to absorb this moisture and still stay within the dewpoint restriction. This weight of air corresponds to a little less than 1 cu ft at 60°F and the weight of oil to 1/36 of a cu ft, giving an oil/air ratio of 1:50 in volume.
Temperature

Approximate specific heat of oil is 0.42. The Approximate specific heat of air = 0.25. The cool air mixing with the warm oil will lower its temperature. Extending our example a ratio of 1:50 oil/air by volume is 1:1/16 th by weight. By heat balance at equilibrium, the oil will be cooled from 140°F to 133°F, and the air heated from 50°F to 133°F. From this latter temperature the air will cool as it escapes from the oil, the rate of cooling depending on the actual design of the equipment.

Experience

Suitable trials were carried out some years ago at the Mobil Oil Works at Wandsworth and these were very encouraging. As a result of these experiments, Mobil ordered one unit for a throughput of 200 g.p.m (740 m3/hr) for their Birkenhead Works.
This installation (illustrated) has now been in operation successfully for many years.

Very “wet” oils have been dehydrated to pass the “crackle” test by feeding the dehydrator at 50 to 60 percent of its maximum flow rate, thus obtaining a recycle or two-stage dehydrating effect. Initially, problems were encountered with heavy foaming, due to ineffective de-aeration. The enlargement of that section reduced the flow velocity and improved matters considerably. As most base stocks and blended products are initially discharged into buffer or hold tanks, the 20 seconds or so required for the heaviest oils to clear, produces no serious problems. It was also found necessary to install an extraction system for the vapours emanating from the dehydrator. This was particularly desirable in view of the fact that the unit operated within an enclosed building.

Another incidental, but very interesting advantage, is that it is no longer essential to dehydrate slightly wet base stocks before the introduction of additives. If in-line blender is used, followed by a dehydrator, blended products will always come out clear and bright, due to the fact that the “delicate” type of additive had insufficient time to cloud the product.

Management of Petroleum Storage Tanks


PRIMARY GOALS

To avoid the contamination of the environment and negative ecological impacts by preventing leaks, discharges or spills of hydrocarbons (gasoline, diesel, heating oil, waste/used oil).
To ensure adequate containment (during refueling, storage, and transfer) of the hydrocarbons in petroleum storage tanks owned by the Correctional Service of Canada (CSC).
To reduce the releases of volatile organic compounds (VOC) from petroleum storage tanks that contributes to the production of ground-level ozone (smog).

SPECIFIC OBJECTIVES

To demonstrate that CSC registers and manages petroleum storage tanks at its facilities in a way that complies with the applicable acts, federal regulations, guidelines, norms and codes.
To ensure that petroleum storage tanks under CSC's charge are operated, maintained and monitored in accordance with standardized preventive practices.
To reduce the financial and environmental risks (soil, groundwater and surface water contamination) related to the operation of petroleum storage tanks.
To keep monitoring an up-to-date official registry of the petroleum storage tanks owned by CSC.

SECTION 1 - DEFINITIONS, RESPONSIBILITIES AND SCOPE

DEFINITIONS

The following definitions apply to these Environmental Guidelines. For additional definitions, refer to the above-mentioned Regulations and Codes of Practice.
Cathodic protection - A method of preventing or reducing corrosion of a metal surface by making the metal a cathode, using an impressed direct current or attaching sacrificial anodes.
Dispenser sump (dikes) - A container, located underneath or near a dispenser or self-contained suction pump, that collects or contains leaks (raised part of dike floor).
Internal lining - A coating of a non-corrodible material bonded firmly to the interior surface of the tank and resistant to the petroleum products or allied petroleum products stored.
Leak detection - A device or a method that is capable of detecting leaks in storage tanks and piping with a probability of detection of 0.95 and a probability of false alarm of 0.05.
a.   Level 1 detection: Device or method that is capable of detecting a leak of 0.38L/h.
b.   Level 2 detection: Device or method that is capable of detecting a leak of 0.76L/h.
c.   Level 3 detection: Device or method used in pressure piping that operates whenever the submersible pump starts up, and that is capable of detecting a leak of 12L/h.
d.   Level 4 detection: Device or method that is capable of detecting a leak:
                     i.        before the monitoring sump or interstitial space fills up to 50% of its capacity by volume; or
                   ii.        Before 600 litres has leaked, whichever comes first.
Motive fuels - Any fuel that powers a vehicle (gasoline, diesel, ethanol, etc.).
Overfill-protection device - An electrical or mechanical device that is installed in an underground storage tank, fill tube, or vent and helps prevent a storage tank from being overfilled.
Petroleum product - A single product or mixture of at least 70% hydrocarbons, refined from crude oil, with or without additives, that is used, or could be used, as a fuel, lubricant, or power transmitter. Without restricting the foregoing, it includes such products as gasoline, diesel fuel, aviation fuel, kerosene, naphtha, lubricating oil, fuel oil, and engine oil (new or used), and excludes propane, paints and solvents.
Registered tank - Any underground storage tank for petroleum or allied products that have a capacity of more than 230 litres, as well as any outside aboveground storage tank system for petroleum products having a single or total capacity of more than 2,500 litres.
Secondary containment - Containment that prevents leaks from the primary storage tank system from reaching outside the containment area. It includes double wall underground storage tanks and piping, and liners.
Spill containment device - A container fitted to the inlet of a storage tank or to the suction coupling of a used oil storage tank that helps prevent spills from entering the environment.
VOC recovery system (phase I) - Equipment used to recover motive fuel vapours that escape between the fuel delivery trucks and the storage tanks.
VOC recovery system (phase II) - Equipment used to recover motive fuel vapours that escape when refueling motor vehicles.
Volatile organic compounds (VOC) - Gases that contribute to the production of ground-level ozone.

RESPONSIBILITIES

The Institutional Head, his or her Assistants and the Corcan Operations Managers are accountable to ensure compliance with these Environmental Guidelines.
The Chief, Plant Maintenance (CPM) will normally be the person responsible for managing and monitoring the implementation of these Environmental Guidelines.

SCOPE

All CSC facilities that manage petroleum storage tanks are subject to these Environmental Guidelines.

SECTION 2 - GENERAL REQUIREMENTS

1. An institutional inventory of all on-site storage tanks containing petroleum products will be kept up to date at all times and placed in the appropriate file of the institution's Environmental Management System (EMS).
2. Copies of documents that are essential to the management of the institution's petroleum storage tanks (e.g. registrations, reports of leaks/spills, etc.) must be sent to the CSC's Regional Environmental Officer (REO) for information and future use.

SECTION 3 - SPECIFIC REQUIREMENTS

STORAGE TANK REGISTRATION

1. All underground storage tanks for petroleum products with a capacity of more than 230 litres, as well as aboveground storage tanks with a capacity of more than 2,500 litres are regulated and therefore must be registered with CSC National Headquarters (NHQ), which serves as the "appropriate federal department" (AFD). To this effect, an official CSC form [refer to Annex A] must be completed, signed, and dated for each registered tank.
2. The custodian of a petroleum storage tank must register it within 60 days after the installation is completed, or within 60 days of the tank being filled for the first time, whichever comes first. For compliance purposes, NHQ must be advised of all changes that pertain to the information requested in the registration form, and be notified within 60 days of a tank replacement, modification, or withdrawal from service.

DESIGN AND INSTALLATION

3. All work carried out on storage tank systems containing petroleum products (installation, tests, upgrades, dismantling) must be carried out by contractors who are qualified and accredited for petroleum equipment installation.
4. The design, operation, and maintenance of tanks must meet the following Technical Guidelines and Codes of Practice:
a.   Technical Guidelines for Underground Storage Tank Systems Containing Petroleum Products and Allied Petroleum Products, Environment Canada, 1995;
b.   Technical Guidelines for Aboveground Storage Tank Systems Containing Petroleum Products, Environment Canada, 1996;
c.   Environmental Code of Practice for Underground Storage Tank Systems Containing Petroleum Products and Allied Petroleum Products, CCME, March 1993;
d.   Environmental Code of Practice for Aboveground Storage Tank Systems Containing Petroleum Products, CCME, August 1994.
Note: The principle requirements for the design and installation of petroleum storage tanks are summarized in Annexes B and C.
5. All new under and aboveground motive fuel storage tanks as well as all existing under and aboveground motive fuel storage tanks with a capacity of 2,500 litres or more located in the Lower Fraser Valley, the Windsor-Quebec City corridor and the Saint John N.B. region, should have (where available) a phase I and phase II volatile organic compound recovery system.

MAINTENANCE PLAN - EQUIPMENT INSPECTION AND INVENTORY CONTROL

6. Within institutions, every tank covered under the Regulations will be assigned a custodian, i.e. the person who operates the tank.
7. The tank custodian must prepare a formal operation, maintenance, inspection, and testing plan for each tank. The CPM can provide the necessary planning services.
8. A leak detection system must be installed and maintained on all regulated tanks.
9. A card/key lock pumping station must have signs posted that provide details of operating and spill procedures and emergency telephone numbers.
10. The planned frequency and protocol for most pressure, vacuum and other tests on tanks can be based on manufacturers and installers instructions, except that once every two years a professional engineer should be retained to inspect and recertify the integrity of protection systems (e.g. cathodic) of every tank with underground components.
11. It is suggested that the Maintenance Management System (MMS) operated by the Chief of Plant Maintenance (CPM) be used to schedule tests of all tanks and record test results.
12. Any leaks and any abnormal or unexplained variances that result from the inventory reconciliation must be acted upon immediately and reported to CSC's Regional Environmental Officer (REO).
13. For underground tanks, and for aboveground tanks that are connected to underground fuel distribution pipes, the institutional custodian must:
a.   once weekly take a dipstick measurement of the quantity of water and fuel, respectively, in the tank (this requires special pastes for the dipstick);
b.   once weekly, simultaneously with the dipstick measurement, take a reading of the amount of fuel pumped from the tank;
c.   once weekly calculate the amount of fuel that should be in the tank based on a perpetual inventory of fluid transfers in and out (compare the dipstick measurement result with the calculated inventory and average the discrepancy between calculated and measured inventory during the last four weeks); and
Note: The custodian must immediately investigate suspected leakage if:
                     i.        the water level at any time exceeds 5 cm (2 inches);
                   ii.        The 4-week moving average difference between calculated and measured fuel levels exceeds 0.5% of tank capacity.
d.   Once monthly inspect monitoring wells and take action if leaked fuel is detected. The CPM can normally provide this service.
14. For aboveground tanks, the institutional custodian conducts a weekly visual inspection and records this as having been done in the appropriate EMS registry.
Note: If combined with acceptable statistical inventory reconciliation, inventory control of underground motive fuel storage tanks with a capacity of less than 5000 litres is an acceptable form of leak detection (level 2). Inventory control of underground motive fuel storage tanks with a capacity of greater than 5000 liters is an acceptable form of inventory monitoring, but is not an acceptable form of leak detection.

SECTION 4 - DATA MANAGEMENT AND REPORTING

RECORDS

1. Upon request from regional or central authorities, the CPM will submit the following information:
a.   up-to-date registration information of the petroleum storage tanks;
b.   where applicable, the inventory control data (records) for the requested period; and
c.   where applicable, the petroleum product leak or spill reports.
2. The documents required by these Environmental Guidelines (registrations, maintenance files, upgrade project briefs, inspection reports, inventory control registry, and leak and spill incident reports) need to be kept on site at least five years after the petroleum storage tank has been removed or its operational life has expired.
3. Inventory control and reconciliation records must be kept on site in an acceptable manner and format, and maintained for a period of at least two years for examination by the authority having jurisdiction.

REPORTING

4. Any episode involving a major petroleum product leak or spill (that is to say one that had or could have significant environmental impact or that requires the intervention of external expertise and equipment to confine and recover the contaminants) must be written up in an environmental incident report within 24 hours of the event. This report must be given to CSC's Regional Environmental Officer (REO). Where applicable, depending on the nature and severity of the incident, the appropriate CSC authorities will provide a written report to Environment Canada. In cases of major spill, institutional authorities must advise directly by telephone Environment Canada (Environmental Emergencies Division) in their region.
Note: The contact numbers for Environment Canada - Regional Environmental Emergency Divisions are indicated in Annex D of CSC's Environmental Guidelines on Environmental Emergency Plan.

SECTION 5 - REFERENCES

1. For more information on managing petroleum storage tanks, please see the Technical Assistance Bulletins (TABs) developed by the Federal Programs Division of Environment Canada. They are available on the info net at: www.on.ec.gc.ca/pollution/fpd/tabs/intro-e.html. The bulletins are an excellent source of information on managing, operating and maintaining petroleum storage tanks.
2. The federal government's tank registration and other requirements are summarized in the compliance promotion bulletins at: http://www.on.ec.gc.ca/pollution/fpd/cpb/3017-e.html.
3. Justice Canada info net site on the Registration of Storage Tank Systems for Petroleum Products and Allied Petroleum Products on Federal Lands or Aboriginal Lands Regulations at: http://laws.justice.gc.ca/en/C-15.31/SOR-97-10/text.html.
4. Canadian Council of Ministers of the Environment (CCME) internet site at: http://www.ccme.ca/ccme.
Assistant Commissioner,
Corporate Services
Original signed by:
Louise Saint-Laurent





ANNEX A - Petroleum Storage Tank Registration Form *

* Note: This official CSC form is available on the infonet at: http://infonet/forms/forms/1265-02.doc.
ANNEX B - Underground Storage Tank Systems Containing Petroleum Products and Allied Petroleum Products: Principle Requirements of the Technical Guidelines
The following table summarizes the requirements set out in the Technical Guidelines for Underground Storage Tank Systems Containing Petroleum Products and Allied Petroleum Products.


(1) The appropriate federal department may require additional equipment if justified.
(2) May not be required for the suction tubes in certain cases.
* For more information on the classification of CSC sites, consult Annex D.
Note: For more information, consult the Environmental Code of Practice for Underground Storage Tank Systems Containing Petroleum Products and Allied Petroleum Products, CCME, March 1993.
ANNEX C - Aboveground Storage Tank Systems Containing Petroleum Products: Principle Requirements of the Technical Guidelines
The following table summarizes the requirements set out in the Technical Guidelines for Aboveground Storage Tank Systems Containing Petroleum Products.

Note: For more information, please consult the Environmental Code of Practice for Aboveground Storage Tank Systems Containing Petroleum Products, CCME, August 1994.
ANNEX D -Classification of CSC Sites with Underground* Motive Fuel Storage Tank Systems



LUBE OIL RECONCILIATION KEYS to control losses…
The key points where we can apply the CAPA procedures i.e., Corrective Action Preventive Action after going through the risk analysis and possible hazards detection for loss prevention are given below...
Here is some pictures based study...




























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