MECON LIMITED (DELHI)

VOCATIONAL TRAINING REPORT

(From 1st to 31st January, 2020)

Project Report

BASIC INTRODUCTION TO POL TERMINALS

(PROCESS ENGG. GROUP - OIL & GAS SECTION)

MECON LIMITED DELHI

JANUARY, 2020

Prepared By Submitted To
Farmaan Khan
B.tech 2nd year
Enrolment No. 2018BCHE045 Mr. Vinay Kumar
Department of Chemical Engineering (Senior Design Engineer, O&G)
National Institute of technology, Srinagar
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Vocational Training Report

CONTENTS

Sl. No. Description Page No.

1. Acknowledgement 1
2. Preface 2
3. Mecon at a Glance 3
4. Introduction to Oil and Gas Industry 4
5. Cross Country Pipeline 9
6. Pipeline Components 14
7. Block Diagram 24
8. Process Flow Diagram 25
9. Process and Instrumentation Diagram 26
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ACKNOWLEDGEMENT

“EVERY GOOD WORK REQUIRES THE GUIDANCE OF SOME EXPERTS”

I would like to express my deepest gratitude to all the people, who have helped me in the successful
completion of this project.

I am highly obliged to Mr. Kamal Pratap Singh (DGM, O&G and HRD) for giving me an opportunity
to pursue my ‘Industrial Training’ of 1 month with this prestigious organization (MECON Limited,
Delhi).

It is indeed my pleasure and privilege to thank Mr. Vinay Kumar (SDE, O&G) as his guidance, help
and encouragement was a big support and inspiration to me while working under him in the
engineering department.

I owe my heartiest thanks to Mr. Umar Nazir Khan (DE, O&G) , for his guidance and strong support,
without whom I would not have been able to accomplish so much of learning.

Last but not the least; I extend my special thanks to Mr. Mukul Raipur (APE, O&G), Mr. Anand
Kumar (APE ,O&G), Ms. Rashmi (APE, O&G) for assisting and guiding me throughout my training.
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PREFACE
After the completion of academic studies, most of the Chemical Engineering students will serve in
public or private sector industries. The students should have an exposure to the industrial environment to
get a better place in a company. The industrial training develops understanding about tools, plants,
machinery processes and organization. The industrial training serves to bridge the gap between
theoretical and practical knowledge.

Industrial training develops:

 Awareness of industrial environment and work culture.

 Understanding of engineering skills, practices and process involved.

 Understanding of social, economic and administrative consideration and their influence on the
working of organization.

 Understanding about discipline, punctuality, teamwork, value of time and money, dignity of labor
and sense of responsibility.

 Last, but not the least industrial exposure helps creating a professional attitude towards work.

To get acquainted with the industrial environment and to minimize the gap between the theories and
the practical, I completed my industrial training at MECON Limited, Delhi. This office is specifically
responsible for keeping a track of the pipelining contracts taken up by the company. Training at
MECON was an experience in itself that I will relish for the rest of my life. It was here that I learned
about working in the corporate world. The entire scenario was new to me and was a great learning
experience.
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M/S MECON Limited

• MECON LIMITED is a public sector under taking under the Ministry of Steel, Government of
India.

• MECON LIMITED established in 1959 under the aegis of Central Engineering & Design
Bureau (CEDB), is India’s frontline engineering, consultancy and contracting organization,
offering full range of services required for setting up of Project from concept to
commissioning including turnkey execution.

• MECON is a multi- disciplinary firm with 1465 experienced & dedicated engineers, scientists
and technologists, having a network of offices spread all over the country, experienced in
handling consultancy assignments and EPC Projects.

• MECON has played a significant role in the development and expansion of Indian Industries.
MECON is an ISO: 9001:2008 company and is registered with international financial
institutions like WB, ADB, AFDB and has technological tie-ups with world leaders.

Key areas of activities

• Iron Making
• Steel Making
• Rolling Mills
• Non- Ferrous
• Coke Ovens
• By- products & Chemicals
• Raw Materials & Mining
• Beach Sand Mining & Mineral Beneficiation
• Refractories Research & Development

Oil and Gas

• Oil & Gas Pipelines

• Petrochemicals & Refineries
• CNG Stations & City GAS Distribution
• POL Depots
• LPG Bulk Storage, Handling, Bottling & Transportation
• Group Gathering Station.
• Off-Shore Platforms & Marine Pipelines
• Retail Outlets
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INTRODUCTION TO OIL & GAS INDUSTRY

Once crude oil is extracted from the ground, it must be transported and refined into petroleum
products that have any value. Those products must then be transported to end-use consumers or
retailers (like gasoline stations or the company that delivers heating oil to your house, if you have
an oil furnace). The overall well-to-consumer supply chain for petroleum products is often
described as being segmented into three components.

• Upstream activities involve exploring for crude oil deposits and the production of
crude oil. Examples of firms that would belong in the upstream segment of the industry
include companies that own rights to drill for oil (e.g., ExxonMobil) and companies
that provide support services to the drilling segment of the industry (e.g. Halliburton).

• Midstream activities involve the distribution of crude oil to refiners; the refining of
crude oil into saleable products; and the distribution of products to wholesalers and
retailers. Examples of firms that would belong in the midstream segment of the
industry include companies that transport oil by pipeline, truck or barge (e.g.,
Magellan Pipeline); and companies that refine crude oil (e.g., Tesoro).

• Downstream activities involve the retail sale of petroleum products. Gasoline stations
are perhaps the most visible downstream companies, but companies that deliver
heating oil or propane would also fall into this category.

 Oil and gas are amongst the most important resources that we have.
 The Indian oil and gas sector is one of the six core industries in India.
 The Indian oil and gas sector is of strategic importance and plays a predominantly pivotal role
in influencing decisions in all other spheres of the economy.
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Figure 1

PETROLEUM PRODUCTS

Important petroleum products related to POL-Terminal are given below:-

1. High Speed Diesel (HSD)

2. Motor Spirit (MS)
3. Superior Kerosene Oil (SKO)
4. Aviation Turbine Fuel (ATF)
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1. High Speed Diesel (HSD)

HSD is normally used as a fuel in medium and high speed compression ignition engines
(operating above 750 rpm) in commercial vehicles, stationary diesel engines, locomotives
and pumps etc.

2. Motor Spirit (MS)

Motor Spirit also known as Gasoline (American English), or petrol (British

English) is a transparent, petroleum-derived liquid that is used primarily as a fuel in internal
combustion engines. It consists mostly of organic compounds obtained by the fractional
distillation of petroleum. Gasoline is also blended with Methanol.

3. Superior Kerosene Oil (SKO)

Kerosene is distillate fraction of crude oil in the boiling range of 150- 250°C. They are treated
mainly for reducing aromatic content to increase their smoke point (height of a smokeless
flame) and hydrofining to reduce sulfur content and to improve odour, colour & burning
qualities (char value).

4. Aviation Turbine Fuel (ATF)

Jet fuel, aviation turbine fuel (ATF), or avtur, is a type of aviation fuel designed for use in
aircraft powered by gas-turbine engines. It is colorless to straw-colored in appearance. The
most commonly used fuels for commercial aviation are Jet A and Jet A-1, which are produced
to a standardized international specification. The only other jet fuel commonly used in civilian
turbine-engine powered aviation is Jet B, which is used for its enhanced cold-weather
performance.
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STATUTORY & REGULATING BODIES

1. OIL Industry Safety Directorate

The Oil Industry Safety Directorate (OISD) is a regulatory and technical directorate in India.
It was established in 1986 by Ministry of Petroleum and Natural Gas. The OISD formulates
and implements safety standards for the oil industry.

2. Petroleum and Natural Gas Regulatory Board

The Petroleum and Natural Gas Regulatory Board (PNGRB) was constituted under The
Petroleum and Natural Gas Regulatory Board Act, 2006 (NO. 19 OF 2006) notified via
Gazette Notification dated 31st March, 2006. The Act provide for the establishment of
Petroleum and Natural Gas Regulatory Board to protect the interests of consumers and entities
engaged in specified activities relating to petroleum, petroleum products and natural gas and
to promote competitive markets.

3. Bureau of Indian Standards

BIS stands for Bureau of Indian Standards. It is the National Standard Body of India engaged
in the preparation and implementation of the standards, certification schemes for products and
systems, testing and calibration services etc.

4. Petroleum and Explosives Safety Organization

Petroleum and Explosives Safety Organization (PESO) is a department formed by Government

of India under Department for the Promotion of Industry and Internal Trade under Ministry of
Commerce and Industry, to administer Explosives Act 1884, Explosive Substance Act,
Petroleum Act 1934, Inflammable substance Act 1952 and Environment Protection Act 1986 to
control import, export, transport, storage and usage of explosive materials, flammable
materials, pressure vessels, cryogenic vessels, design and installation of all necessary and
relevant infrastructure etc.

5. Bharat Stage Norms

Bharat Stage norms are standards set by the government to regulate emission of air pollutants
from motor vehicles. The norms set the limit for the release of air pollutants such as nitrogen
oxides, carbon monoxide, hydrocarbons, particulate matter (PM) and sulfur oxides from
vehicles using internal combustion engines. The Bharat stage norms are based on Euro norms.
The major difference in every subsequent norm is the release of sulfur particles from exhaust
gases.
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Table 1: Permissible Emission Limit

Emission Norms Sulphur in Gasoline(MS) Sulphur in Diesel

(Values in ppm) (Values in ppm)
BS I 500 2000
BS III 150 350
BSIV 50 50
BSV 10 10
BSV 10 10
BSVI 10 10

6. American Society of Mechanical Engineers

ASME is a not-for-profit membership organization that enables collaboration, knowledge

sharing, career enrichment, and skill development across all engineering disciplines, toward a
goal of helping the global engineering community develop solutions to benefit lives and
livelihoods. Founded in 1880 by a small group of leading industrialists, ASME has grown
through the decades to include more than 100,000 members in 140+ countries. Thirty-two
thousand of these members are students.

7. American Petroleum Institute.

The American Petroleum Institute (API) is the largest U.S. trade association for the oil and natural
gas industry. It claims to represent about 650 corporations involved in production, refinement,
distribution, and many other aspects of the petroleum industry.
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CROSS COUNTRY PIPELINE

Figure 2

Cross country pipeline means all pipeline located beyond the boundary of any facility including
pipelines after separator (exploratory well) and its associated facilities which are required for
transportation of liquid hydrocarbon from one point to another excluding piping within the Refinery/
Separation and / or Processing plant up to plant isolation valves.
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• Originating Station: - Originating station is the first installation in the cross country pipeline
where the liquid hydrocarbon is received for further transportation.

• Originating Pump Station: - An originating pump station is the first installation in the cross
country pipeline having pumps for boosting the pressure of the liquid hydrocarbon to be
transported so that it reaches to next station in the cross country pipeline.

• Spur / Branch Pipeline: - Pipeline originating from cross country pipeline (also called as
trunkline pipeline) for dedicated terminal and/or customer location(s).

• Intermediate pump station: - An intermediate pump station is any installation having facilities
such as pumps etc. between originating pump station and intermediate pigging station and / or
terminal station / receipt station for boosting the pressure of the liquid required to reaches to next
station.

• Sectionalizing Valve (SV):- Valve (MOVs / HOVs) used in the cross country pipeline system for
isolation of a particular pipeline section whenever required. This valve is also referred as main
Line valve (MLV).

• Intermediate pigging stations:- An intermediate pigging station is an installation having facility

for receiving and launching of pigs for pipeline pigging operations and is located between
originating and delivery stations.

• Terminal Station / Receiving Station / Receipt Terminal:- Terminal Station / Receiving station
/ Receipt terminal is the last station on the pipeline used for receipt of liquid hydrocarbon.

 Sump tank: - An underground tank installed at pipeline station to store hazardous liquid
which is released from pressure relief system / filters / scrapper barrels / piping of
stations and subsequently re-injected to either the pipeline system and / or other storage
tanks.

• Intermediate delivery station / Tap off Station (TOP)/ Tap off Points: - An intermediate
delivery station / Tap off station/ Points on the pipeline installation is an installation having
facility to deliver product to any industry / storage tanks through a tapping from the mainline.
Delivery can be through heart cut or full cut.

STATUTORY ACTS & REGULATIONS

Liquid hydrocarbon pipeline and its associated facilities are covered under various regulations and
require specific approval from concerned authorities. Various regulations applicable are as under:

I. The Environment (Protection ) Act -1986

II. Water ( Prevention & Control of Pollution) Act 1974
III. Air ( Prevention & Control of Pollution) Act 1981
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IV. The Petroleum and Mineral Pipelines (Acquisition of Right of Users in Land) Act, 1962.
V. The Petroleum Act’1934.
VI. Petroleum Rule ‘2002 and its subsequent Amendment (if any).
VII. The Explosive Act, 1884.
VIII. Manufacture ,Storage & import of Hazardous chemical Rules-1989
IX. National Highway Act, 1956
X. Railway Act , 1989
XI. The Factories Act 1948
XII. Building & Other Construction Worker’s Act’1996.
XIII. Petroleum and Natural Gas Regulatory Board (PNGRB) Act’2006.
XIV. Indian Electricity Act, 1910 / The Indian Electricity Rule, 1956.
XV. Oil Mines regulation 2017 and its subsequent Amendment (if any).

In addition all other statutory approvals required for laying of the pipelines across rail, road and
water body (canals/rivers etc.) crossings and other utility crossings as notified by local
authorities/State etc. shall be applicable.

DESIGN

The pipelines shall be designed in a manner that ensures adequate public safety under all
conditions likely to be encountered during installation, testing, commissioning and operating
conditions. All materials and equipment shall be selected to ensure safety and suitability for the
condition of use.
Design for pipeline system shall be based on the following evaluation of the properties and
required flow rate of the liquid to be transported, together with the environment in which the
pipeline is to be installed.

a) Sweet or sour liquid, single or multiphase flow conditions.

b) Operating pressures and temperatures.
c) Services i.e. crude / single product / multi product

Design of liquid hydrocarbon pipeline shall be in accordance with ASME B 31.4 unless
specified. In case of discrepancies, this standard shall precede over ASME B 31.4.
Section(s) of cross country pipeline to be installed across estuaries and creeks etc. affected by
tidal fluctuations, waves and currents and cannot be installed using conventional onshore
equipment shall be designed in accordance with OISD-STD-139.

1. Pipeline Design

A design Life of minimum 25 years for pipeline system in general should be considered by the
owner for designing various system and facilities. The life of pipeline can be extended beyond the
design life subject to satisfying the comprehensive pipeline integrity test.

All necessary calculations shall be carried out to verify structural integrity and stability of the
pipeline for the combined effect of pressure, temperature, bending, soil/pipe interaction, external
loads and other environmental parameters as applicable, during all phases of work from
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installation to operation. Such calculations shall include but not limited to the following:

A. Buoyancy control and stability analysis for pipeline section to be installed in areas
subjected to flooding/submergence,
B. Crossing analysis of rivers by trenchless techniques, wherever soil data is favourable for
such operation,
C. Evaluation of potential for earthquake occurrence across fault locations and carrying out
requisite seismic analysis to ensure safety and integrity of the pipeline system.

2. Design Temperature

Appropriate temperature range for design of pipeline / piping system shall be determined based on
temperature of liquid hydrocarbon proposed to be transported through the pipeline, ambient / sub-
soil temperature.

3. Maximum temperature

Maximum temperature for design of above ground section of pipeline / piping shall be the
maximum expected liquid temperature during operation or maximum ambient temperature
whichever is higher. In no case maximum temperature for carbon steel pipelines shall be more
than (+) 120oC.

Maximum temperature for design of buried section of pipeline / piping shall be maximum
expected liquid hydrocarbon temperature during operation or maximum sub-soil temperature
whichever is higher.

4. Minimum temperature

Minimum temperature for design shall be minimum expected liquid hydrocarbon temperature
during operation or minimum ambient / sub-soil temperature whichever is lower. In no case
minimum temperature for carbon steel pipelines shall be less than (-) 29oC.

When maximum liquid hydrocarbon temperature during operation is below 65oC, thermal
expansion and stresses in the above ground section of pipeline / piping shall be evaluated
considering pipe skin temperature of 65oC.

PIPELINE/STATION VALVES

1. Station Valves

Block valves with remote shut off provision from the control room shall be provided at the inlet
(downstream of Tee) and outlet ( up stream of Tee) of the pump / intermediate pigging /
terminal/delivery station piping to isolate the pipeline from station facilities in case of emergency
at station. In addition, Block valves shall be considered at entry and exit of pipeline stations
boundary.
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2. Station bye pass

Station bye pass system shall be provided to facilitate flow of liquid hydrocarbon in the pipeline
bypassing the pumping facilities inside the station premises.

3. Check valves

Check Valves shall be installed to provide automatic blockage of reverse flow in the piping
system, within the station, wherever required. Check valves, when provided to minimize pipeline
backflow at locations appropriate for the terrain features (e.g. hills, steep slopes, etc.), shall be
suitable for passage of all types of pigs including instrumented pigs.

4. Flow/Pressure Control Valve

Design of control valves in stations shall meet the requirement of part I of API 550 / API-RP-553,
ISA (Instrument Society of America) S- 75.01 -75.03, IEC -79 and IEC-529.

5. Insulating Joints

Insulating joints shall be provided to electrically isolate the buried pipeline from the above ground
pipeline. Insulating joints shall be monolithic type and shall allow smooth passage of pigs.
Insulating joints separating buried and above ground pipeline shall be installed in above ground
portion of pipeline, immediately after the buried /above ground transition point. Each insulating
joint shall be provided with surge diverters and shall have provision for checking integrity of the
insulating joint.

6. Branch Connection

• Branch connections of size below NPS 2 are not recommended in buried pipeline section.

• 5 All branch connections from mainline shall be provided with an isolation valve located
at a minimum possible distance from the main pipeline.

• All branch connections or side tap on the piggable section of the pipeline having diameter
equal to or exceeding 40 percent of the main pipe diameter, shall be made using flow tees / bar
tees in order to enable smooth passage of all types of pigs. Such flow tees / bar tees shall
comply with the requirements of ASME B 16.9, MSS-SP-75 or equivalent.

7. Flanged or threaded joints, Bolts, Nuts, Gasket and other fittings

• Threaded joints shall not be used in the underground section of cross country pipelines,
spur lines and branch lines. Threaded joints may be permitted in the above ground stations / above
ground section of SV stations only if a welded isolation valve is provided before it. The number of
flanged or threaded joints for station piping shall be to the extent minimum. The threaded joints,
after tightening, may be seal welded. Flanges shall conform to ANSI B 16.5 or ASME B 16.47 or
MSS-SP 44 or equivalent.
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• The flange joint shall be provided with either spiral wound metallic gaskets or metallic
ring type gaskets, depending upon the piping class. Plain asbestos sheet / reinforced gaskets shall
not be used

• Steel butt welding fittings shall comply with ANSI B 16.9 / MSS-SP-75 or equivalent.
Weld’O’ lets shall comply with MSS SP 97. Steel socket welding fittings shall comply with ANSI
B 16.11.

PIPELINE COMPONENTS

1. Valves
2. Fittings
3. Flanges

1. Valves

A valve is simply a device that directs or regulates flow by opening, closing or partially
obstructing passageways. Valves are instrumental in everything from pumping soap out of a dispenser
to starting a jet.

Types of valves and their applications.

• Gate Valves

Gate valves, the most common type of valve in the industry, are valves that open by lifting a gate
out of the route of the fluid. Gate valves are designed to be fully open or closed; they are
regularly used as a block valve for isolating pipe systems. When a gate valve is open, there is no
obstruction in the flow path resulting in very little friction loss. Gate valves are used when a
straight-line flow of fluid and minimum restriction is desired.

Figure 3:- Gate Valve

These can be controlled by a hand-wheel, air powered diaphragm, electric motor, or a piston
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actuator.

• Globe Valves

Globe valves are used for regulating flow in a pipeline, instead of having the “all or nothing” function
of a gate valve. Globe valves regulate by the position of a movable disk (or plug) in relation with the
stationary ring seat.
A globe valve may have ports that run straight across, or may be pointed at an angle. This type of
angled supply valve is commonly used for corrosive or thick, viscous fluids that tend to solidify.
Having outlets on an angled supply valve that point downward helps the fluid to drain off to prevent
clogging and corrosion.

Figure 4:-Globe Valve

• Needle Valves

The needle valve is essentially a variation of the globe valve used for very fine control of flow.
Needle valves contain a slender, tapered plug, as opposed to the globe valve’s larger and less accurate
disk.

Figure 5:-Needle Valve

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• Butterfly Valves

The butterfly valve is also designed to regulate flow, but with limited control capability. This is a
simpler industrial valve and fitting that is easily operated by rotating a handle 90 degrees. The
butterfly valve has not generally been thought to give a positive shut-off, however modern technology
has facilitated the assembly of a bubble-tight shut-off.

Figure 6:-Butterfly Valve

• Check Valves

Check valves, also known as NRVs (non-return valves), permit fluid to flow in one direction only.
Their purpose is to prevent backflow. There are several types of “stoppers” that prevent backflow in
check valves. Ball check valves and piston check valves operate by requiring a minimum amount of
inbound flow pressure; backflow is not forceful enough to lift the ball or piston back up to travel the
other direction. Flow in a swing check valve pushes through a hinged flap that only opens in one
direction, assuring the fluid cannot travel backwards.

Figure 7:-Check valve

• Relief Valves

The relief valve, also known as the safety valve, is an industrial valve and fitting installed to set a limit
on the amount of pressure in a system. This type of angled supply valve is strictly for preventing over-
pressure that could cause damage to the system.
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Figure 8:- Relief Valve

• Plug Valve

Plug valves are valves with cylindrical or conically tapered "plugs" which can be rotated inside the
valve body to control flow through the valve. The plugs in plug valves have one or more hollow
passageways going sideways through the plug, so that fluid can flow through the plug when the valve
is open. Plug valves are simple and often economical.

Figure 9:-Plug valve

• Ball Valve

A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball to
control flow through it. It is open when the ball's hole is in line with the flow and closed when it is
pivoted 90-degrees by the valve handle.

Figure 10:-Ball Valve

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• Fittings

A fitting is used in pipe systems to connect straight sections of pipe or tube, adapt to different sizes or
shapes, and for other purposes such as regulating (or measuring) fluid flow. These fittings are used
in plumbing to manipulate the conveyance of water, gas, or liquid waste in domestic or commercial
environments, within a system of pipes or tubes.
There are different types of pipe fitting used in piping. Pipe Fittings used in piping work are mainly
Elbow, Tee, Reducer, Union, Coupling, Cross, Cap, Swage Nipple.

Figure 11:-Pipe Fittings

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• Pipe Elbow

The Elbow is used more than any other pipe fittings. It Provides flexibility to change the pipe
direction . Elbow is mainly available in two standard types 90° and 45°. However, it can be
cut to any other degree. They are available in two radius types, Short radius (1D) and Long
radius (1.5D).

Figure 12:- Pipe Elbow

• 90 Degree Elbow Pipe

90 Degree elbow is installed between the pipes to change the direction of the pipe by 90
Degree. Available in both long and short radius form.

Figure 13:- 90 degree Elbow

• 45 Degree Elbow

45 Degree elbow is installed between the pipes to change the direction of the pipe by 45
Degree.

Figure 14:- 45 degree Elbow

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• Long Radius Elbow

In long radius elbow, centerline radius is 1.5 times the nominal size of the pipe or you can say
1.5 times the diameter of the pipe. Normally long radius elbows are used in piping as pressure
loss is less as compared to short radius elbow. It requires more space than short radius elbow.

Figure 15:-Long Radius Elbow

• Short Radius Elbow

In short radius elbow, centerline radius is same as the nominal size of the pipe or you can say
one times the diameter of the pipe. Short radius elbows are used under limited space
application. However, it has a high-pressure drop due to a sudden change in the direction of
flow.

Figure 16:-Short Radius Elbow

• Reducing Elbow

The 90 reducing elbow is designed to change direction as well as reduce the size of pipe
within a piping system. The reducing elbow eliminates one pipe fitting and reduces the
welding by more than one-third. Also, the gradual reduction in diameter throughout the arc of
the reducing elbow provides lower resistance to flow and reduces the effect of stream
turbulence and potential internal erosion. These features prevent sizeable pressure drops in the
line.
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Figure 17:- Reducing Elbow

• Pipe Bend

Long radius pipeline bends are used in fluid transportation line which required pigging. Due to
their long radius and smooth change of direction, pipe bend has very less pressure drop, and
smooth flow of fluid & pig is possible. 3D and 5D Pipe bends are commonly available. Here,
D is the pipe size.

Figure 18:- Pipe Bend

• Miter Bend

Miter bends are not standard pipe fittings they are fabricated from pipes. Usually, they are
preferred for size 10” & above because large size elbow is expensive. Use of miter bend is
restricted to the low-pressure water line. Miter bend can be fabricated in 2, 3, & 5 pieces.

Figure 19:- Milter Bend

• Returns – 180 Degree Elbow

Returning elbows are used to make a 180º change in direction. Available in short & long
pattern. Returns are used in the heating coil, heat exchanger, tank vent etc.
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Figure 20:- 180 Degree Elbow

• Pipe Tee

Pipe tee is used for distributing or collecting the fluid from the run pipe. It is a short piece of
pipe with a 90-degree branch at center. There are two types of Tee used in piping, Equal /
Straight Tee and Reducing / Unequal Tee.

Figure 21:- Pipe Tee

• Straight Tee

In straight tee, the diameter of the branch is same as the diameter of the Run (Header) Pipe.

• Reducing Tee

In reducing tee, diameter of the branch size is smaller than the diameter of the Run (Header)
Pipe.

• Cross

Cross is also known as four-way pipe fitting. A cross has one inlet and three outlets (or vice
versa). Generally, crosses are not used in process piping to transport fluid. But forged crosses
are common in the fire water sprinkler line.
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Figure 22:-Cross

• Concentric Pipe Reducer or Conical Reducer

In Concentric reducer which is also known as a conical reducer, the center of both the ends is
on the same axis. It maintains the centerline elevation of the pipeline. When the center lines of
the larger pipe and smaller pipe are to be maintained same, then concentric reducers are used.

Figure 23:- fig representing different reducers

• Eccentric Reducer

In Eccentric reducer, the center of both the ends is on different axis as shown in the image. It
maintains BOP (Bottom of Pipe) elevation of the pipeline. When one of the outside surfaces of
the pipeline is to be maintained same, eccentric reducers are required.

Offset = (Larger ID – Smaller ID) / 2

• Flanges

A flange is a method of connecting pipes, valves, pumps and other equipment to form a piping
system. It also provides easy access for cleaning, inspection or modification. Flanges are
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MECON LIMITED Oil & Gas Section TERMINALS
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usually welded or screwed. Flanged joints are made by bolting together two flanges with a
gasket between them to provide a seal.

Figure 24: Fig of Flange

Types of flanges

• Weld-Neck
• Slip-on
• Socket weld
• Lap Joint
• Threaded
• Blind

Figure 25: Fig of Types of Flanges

BLOCK DIAGRAM

A block diagram is a diagram of a system in which the principal parts or functions are represented by
blocks connected by lines that show the relationships of the blocks. They are heavily used in engineering
in hardware design, electronic design, software design, and process flow diagrams.
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MECON LIMITED Oil & Gas Section TERMINALS
DELHI Delhi

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Figure 26:- Representing Block diagram of purification of Crude Oil

PROCESS FLOW DIAGRAM

A process flow diagram (PFD) is a diagram commonly used in chemical and process engineering to
indicate the general flow of plant processes and equipment. The PFD displays the relationship between
major equipment of a plant facility and does not show minor details such as piping details and
designations. Another commonly used term for a PFD is a flowsheet.

Typically, process flow diagrams of a single unit process will include the following:

 Process piping
 Major equipment items
 Connections with other systems
 Major bypass and recirculation (recycle) streams
 Operational data (temperature, pressure, mass flow rate, density, etc.), often by stream references
to a mass balance.
 Process stream names
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MECON LIMITED Oil & Gas Section TERMINALS
DELHI Delhi

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Figure 27:-PFD representing refining concepts

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MECON LIMITED Oil & Gas Section TERMINALS
DELHI Delhi

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PROCESS & INSTRUMENTATION DRAWINGS

A P&ID is a complex representation of the various units found in a plant. It is used by people in a variety
of crafts. The primary users of the document after plant startup are process technicians and instrument and
electrical, mechanical, safety, and engineering personnel.
In order to read a P&ID, the technician needs an understanding of the equipment, instrumentation, and
technology. The next step in using a P&ID is to memorize your plant’s process symbol list. This
information can be found on the process legend. Process and instrument drawings have a variety of
elements, including flow diagrams, equipment locations, elevation plans, electrical layouts, loop
diagrams, title blocks and legends, and foundation drawings. The entire P&ID provides a two-
dimensional look at the various operating units in a plant.

Figure 28:- P&ID

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MECON LIMITED Oil & Gas Section TERMINALS
DELHI Delhi

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Process Legend

The process legend provides the information needed to interpret and read the P&ID. Process legends are
found at the front of the P&ID. The legend includes information about piping, instrument and equipment.

Figure 29:-Symbols used in P&ID

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DELHI Delhi

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Figure 30:-Fig representing different transmitters

Figure 31:- Different lines used in P&ID