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
|
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
> 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
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.
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.
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.
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
![space](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image030.jpg)
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
|
![space](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image038.gif)
MIXING SYSTEMS
![space](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image038.gif)
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.
|
![space](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image038.gif)
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
![space](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image038.gif)
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:
- Automotive Lubricating Oil.
- 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.
- Keep moving parts apart.
- Reduce friction.
- Transfer heat.
- Carry away contaminants & debris.
- Transmit power.
- Protect against wear. (anti wear, extreme pressure)
- Reduce corrosion and rust.
- 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.
- Antioxidants. (zinc dithiophosphates)
- Viscosity index improvers. (polymethacrylates)
- Anti-wear. (zinc dialkyldithiophosphate)
- Pour point depressants. (co-polymer of methacrylates)
- Corrosion inhibitors ( alkaline compounds, esters)
- Rust inhibitors (alkaline compounds, organis acids)
- Friction modifiers (graphite, molybdenum disulfide)
- Extreme Pressure (chlorinated paraffins)
- Anti-foaming agents. (dimethyl silicones)
- 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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image056.jpg)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image064.gif)
Supply lines
Set-stop
meter
Batch
blending
tank
Lube oil batch blending
by volume using single set-stop meter
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image065.gif)
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).
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image067.gif)
Supply lines
Lube oil batch blending by weight using load cells
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image068.gif)
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
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image070.gif)
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’.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image072.gif)
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
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image074.gif)
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.
![]() |
||||
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image082.jpg)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image086.jpg)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image088.jpg)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image090.jpg)
Lube oil blender
IN
LINE BLENDING
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image092.gif)
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.
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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 4-2ĆmA
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:
- 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.
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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
|
—
|
—
|
—
|
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![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
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.
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
![](file:///C:%5CDOCUME%7E1%5CSaad%5CLOCALS%7E1%5CTemp%5Cmsohtmlclip1%5C01%5Cclip_image095.gif)
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:
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
Corporate Services
Original signed by:
Louise Saint-Laurent
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
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KEYS to control losses…
The key points where we can apply the CAPA procedures i.e.,
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