Kiseka Ivan Project Report
Kiseka Ivan Project Report
PROJECT REPORT
BY
KISEKA IVAN
20/UPIK/DUPO/016G
YEAR TWO
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DECLARATION
I Kiseka Ivan declare that this project “Design and installation of an automatic blending control
system during product blending processes” was carried out by the undersigned individuals of the
department of the Upstream/Downstream Petroleum Operation.
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DEDICATION
This project is dedicated to “the one in whom we live, move and have our beings, the source
of our very existence”, JESUS CHRIST. He is the source of all things we depend on every
second of our lives, blessing us immensely with excellent health, sound mind, and love
without limit, extraordinary grace and unlimited supply of all our needs throughout our
“sweet-bitter” undergraduate experience.
I would like to also dedicate this project to my project supervisors, beloved parents, my
fellow classmates of Uganda Petroleum Institute Kigumba whose inputs at one point or the
other has been of an immense blessing to me.
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APPROVAL
This is to certify that KISEKA IVAN with the registration number 20/UPIK/DUPO/016G
did and completed his student project report and this document has been doing with our
guidance and has been revised by us the fellow student, thus ready to be submitted to the
examination body.
Project supervisors.
Signature: ……………………
Date: ……………………….
Signature: ……………………
Date: ……………………….
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ACKNOWLEDGEMENT
First, I would like to thank GOD almighty for the gift of life and the ability to carry out this
project, GLORY TO HIM FOREVER MORE!
In a special I thank (Mr) Semutumba Enock, (Mr)Nkyanungi John Mary and MrMuhumuza
Oscar for the constructive criticism, patience, encouragement, patience and their belief in me
even in times when I didn’t portray capabilities.
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ABSTRACT
The main objective of this proposal document is to design and install an automatic
homogeneous blending control system that will automatically blend the base material and the
additives to obtain a homogeneous product.
During this process, the quantity of base material and additives pumped to the mixing tank
will be monitored automatically using a timer. The duration of the mixing will also be
monitored automatically for quality enhancement.
For increased production purposes, two pumps are connected in parallel to ensure continuous
production. Both pumps will be used to pump the different fluids for a given time after which
a tank line to the tank is automatically isolated using a valve and another tank line is
automatically opened.
The design also puts in place a reliability control method where two pumps are connected in
parallel. Each pump can be isolated using a valve, therefore in case one of them fails, its
(failed pump) is isolated while production continues in the other line.
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TABLE OF CONTENT
CONTENT
DECLARATION........................................................................................................................i
DEDICATION...........................................................................................................................ii
APPROVAL.............................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................iv
ABSTRACT...............................................................................................................................v
Introduction................................................................................................................................1
1.1 background of study.............................................................................................................1
1.2 Problem statement................................................................................................................2
1.3 Objective of the project........................................................................................................2
1.4 Significance..........................................................................................................................3
1.5 Justification..........................................................................................................................3
1.6 Scope of the project..............................................................................................................3
CHAPTER TWO.......................................................................................................................5
2.0 Literature review..................................................................................................................5
2.1 Introduction..........................................................................................................................5
2.2 Components and equipment of a blending system...............................................................5
CHAPTER THREE....................................................................................................................8
3.0 PROJECT METHODOLOGY.............................................................................................8
3.1 Introduction..........................................................................................................................8
materials and equipment............................................................................................................8
Design and installation of the tanks.........................................................................................10
ASSEMBLY OF THE PROCESS COMPONENTS...............................................................12
3.2 Data collection methods.....................................................................................................12
3.3 Design of the proposed project..........................................................................................13
3.4 Geographical area of the existence of the proposed project..............................................14
Challenges................................................................................................................................15
Conclusion...............................................................................................................................15
REFERENCES.........................................................................................................................16
APPENDICES.........................................................................................................................17
4.1 The budget of the proposal.................................................................................................17
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4.2 Time framework/ work plan..............................................................................................18
4.3 Instruments/tools................................................................................................................19
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CHAPTER ONE
Introduction
This chapter contains the background of study, problem statement, significance, objectives
and scope of the project and justification.
Many companies (oil companies) aim at achieving a continuous and quality-based products
(oil products). In this regard therefore an automatic homogeneous blending system is very
imperative to these companies.
Automatic means a device works by itself with little or no direct human control.
Control system is a device or set of devices that manage, command, direct or regulate the
behavior of other devices or system.
Blending refers the process of mixing the optimal combination of components (among
various petroleum streams) to produce the final finished products. It’s the last step in the
refining process and it’s much more complicated than simple mixing of components.
Therefore, an automatic homogeneous blending system refers to a set of devices that manage,
command, direct or regulate the behavior of other devices/system so as to achieve a
homogeneous product.
All refineries need to meet tight product specifications in the form of temperature, viscosities,
octane number, flush points, pour point etc. To achieve the desired minimum specifications
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of these important parameters, blending is carried out. A typical refinery has four product
blending pools which include; Liquefied Petroleum Gas (LPG) pool (allows blending of
saturated C3s and C4s to generate C3 LPG and C4 LPG), Gasoline pool, Gas oil/diesel pool
(produces automotive diesel and heating oil from kerosene, Low Gas Oil (LGO), Low
Vacuum Gas Oil (LVGO) s and slurry) and fuel oil/bunker oil pool (haring diesel, heavy fuel
oil and bunker oil are produced from LVGO, slurry and cracked residue)
In line through a manifold. Appropriate amount of each component is injected into the
mains where turbulence promotes a thorough mixing.
Batch blending in tanks. All components are fed into a mixing tank and stirred until
homogeneous blend is achieved.
On board blending into marine vessels.
This proposed project is therefore a step for companies to achieve continuous and quality-
based products since the system will be automated hence having negligible errors in the
quantity of feedstock pumped in the mixing and quality of the homogeneous blend.
Uganda’s Oil and Gas sector is promising. However, during the refining operations (Product
blending) based on various case studies by Emerson Process Management that outlined how
Inaccurate blending of Gasoline results to products that don’t meet specifications and
doctoring of the blend in the final tank which costs time and money. Challenges of
inaccuracy in values, inconsistent quality products and low production rate due to time lag
may arise. As students, we found need to design and install an automatic homogeneous mixer
system to achieve a homogeneous mixture in the oil refinery during product blending
processes to achieve product specification and save time and money.
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To design and install a system that will automatically blend the base materials and additives
in a process tank.
a. To design the P&ID model for blending the additives and base material in a process
industry.
b. To design the PLC program for the model developed
c. To install and test the operation of the system
1.4 Significance
This project will be beneficial to the oil and gas industry of Uganda if implemented as this
will help the industry to produce quality products which can out compete the world market.
Reduce the emission of CO, HC, and CO2 better than when using pure Gasoline.
It would also improve engine brake torque and power for a low blending fraction.
Other industries like the juice producing industries can also benefit from the same project by
producing homogeneous mixtures which are of quality and able to meet the market demands.
1.5 Justification
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1.6.1 Geographical scope.
The project activities will take place in the instrumentation and welding workshop depending
on the specific task to be accomplished at a given period, at UPIK campus.
1.6.2Content scope
The project will be applicable in the midstream and downstream sectors in the oil and gas as
well as other process industries that involve blending. This will enable UPIK students
appreciate the significance of PLC program as well as the significance of product blending in
the refinery.
The project will be achieved in five months from July to December, 2022.
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CHAPTER TWO
2.1 Introduction
The main objective of this project is to design and install an automatic mixer system that
helps achieve a homogeneous mixer with a major aim of producing quality products. The
project solves the problems of inaccuracy, inconsistence in the values of the inputs resulting
into fluctuating quality of the products, high costs due to huge number of workforces needed
and increased time of production. This system (project) being automatic, is capable of solving
the above-mentioned challenges since the pumps will be programmed to pump a required
amount of fluid in the mixing tank in a given time interval and then the fluids are mixed for a
given time to achieve a homogeneous mixer.
Proven that in the refinery additives such as corrosion inhibitors, metal deactivators, etc.
which are added to the oil during blending to obtain finished products. Additives improve on
the quality of the products i.e.; they give the product the required characteristic that meets the
customers demand.
As Uganda boosts its oil and gas sector, it’s therefore necessary for her to prepare for the
competition in the sector so as to increase profits from the industry. One of the ways of
increasing the profit margin is producing quality products.
It is therefore reasonably practical to design and install an automatic mixer system to achieve
a homogeneous mixture for quality-based purposes.
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A mixing tank is a machine container that is used to blend various components together. The
tank is made up of different materials such as plastic, strong rubber, glass, but the most
common type of mixing tank is made up of stainless steel. The different types of mixers
include; tumbler blender (for dry mixing), Ribbon Blender (for bulk solid and powder
blending), Paddle Mixer (For solids, wet-dry mixing, viscous/slurry liquid mixing) and
Agitator (Liquid-liquid mixing or liquid-gas mixing).
A centrifugal pump operates through the transfer of rotational energy from one or more
driven rotors, called impellers. The action of the impeller increases the fluid velocity &
pressure and directs it towards the pump outlet. With its simple design the centrifugal pump
is well understood and easy to operate and maintain.
Centrifugal pump designs offer simple and low-cost solutions to most low pressure, high-
capacity pumping applications including low viscosity fluids such as water, solvents and
chemicals.
This is a type of a level sensor, a device used to detect the level of liquid with in a tank. It
may be used to control a pump, as an indicator, an alarm, or to control other devices.
This is a machine used in a tank for mixing various process media (includes liquid types,
gases and solids) together. It imparts energy through mechanical means by rotating a shaft on
which there is an impeller designed specifically for the duty.
These control the movement and direction of feedstock in and out of the tanks of the system.
They are electromechanically operated valves and hence used wherever fluid flow has to be
controlled automatically.
These are containers which hold fluids for a short or long time.
This is an assembly of one or more wires running side by side which is used to carry electric
current.
(ELBSHIR, 2019)
Programmable logic controllers (PLCs) have been an integral part of factory automation and
industrial process control for decades. PLCs control a wide array of applications from simple
lighting functions to environmental systems to chemical processing plants. These systems
perform many functions, providing a variety of analog and digital input and output interfaces;
signal processing; data conversion; and various communication protocols. All of the PLC's
components and functions are centered on the controller, which is programmed for a specific
task.
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CHAPTER THREE
3.1 Introduction
This chapter describes, discusses and justifies the research approach, methods and techniques
used in this research work, project design, data analysis, data quality control and description
of the geographical area and where the project will exist.
PP-R pipes
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PP-R pipes are made of a plastic material called polypropylene-random copolymer (PP-R),
which is a type of polypropylene plastic that contains a random arrangement of copolymers.
Polypropylene is a type of plastic that is known for its durability, high temperature resistance,
and chemical resistance, making it well-suited for use in piping applications. The addition of
copolymers to the material helps to improve its flexibility and impact resistance, making it an
even better choice for use in pipes. PP-R pipes are commonly used in a variety of
applications, including plumbing, heating and cooling systems, and industrial piping systems.
Steel pipes
Steel pipes a hollow tube that are used in various applications. They a commonly used in the
transportation of various liquid such a water, natural gas and petroleum.
Steel pipes have many properties that make them useful for a wide range of applications.
Some of the most important properties of steel pipes include their strength, durability, and
ability to withstand high temperatures and pressures. Steel pipes are also resistant to
corrosion and can be easily welded or joined together to create longer lengths. Because of
these properties, steel pipes are often used in the construction of buildings, infrastructure, and
other structures. They are also commonly used in the transportation of liquids and gases, as
well as for mechanical power transmission.
Motor
The motor is made of steel due to its effect in performing characteristics such as efficiency
and power output. This steel made are strong and durable materials that is resistant to wear
and tear, making it an ideal choice. It is also resistant to corrosion and can withstand high
temperatures which makes it suitable for use in environments where these factors may be
present.
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Design and installation of the tanks
The tanks were designed using the stainless steel and mild steel of thickness 6mm. it was
made by cutting the sheet into 3 pieces using a shear machine to a specific measurement and
welded to form a round tanks.
The pipes used were PP-R pipes which were fitted using different components of it such as
the socket joints, reducers of ¾ “, T-joints, ……….
All these components connected to 2 solenoid valves which a controlled using the PLC
(programmable logical controller) allow the opening and closing during the process operation
and these valves are timed for the opening and closing.
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A centrifugal pump also connected at the end of the two fluid pipe joints, so as to pump the
mixed fluid with different additives into the third storage tank which mixes the fluids with the
help of a blade connected to a motor.
The motor is installed on the third tanks using a welded stand and bolted firmly so as to
prevent it from falling from the rapid vibration. The holes on the tanks were made using a
drilling machine. This motor makes
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Fig 5: installation of the motor
The machine was tested on the stability, safety and operation and it made a successful
approach to opening the valve and letting the fluid to flow.
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The motor also operated successful after the pumping of the fluid into the third storage tank.
This section involves the P and ID drawing and the interpretation of the whole process.
The Project designed is proposed to have three major systems i.e., Piping system (Pipes,
fitting, tanks and valves), Electrical control panel (start, stop button and electrical cables),
Sampling system (Measuring cylinder), Additives i.e., Anti-knocking additives e.g., Tetra
methyl Lead, Anti-oxidation e.g., Phenyl diamines and level switches in every tank.
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Tanks A contains the base material Gasoline, tank B contains Anti-oxidation additive and
Tank C containing Anti-knocking additive. The tanks are connected by the pipes to
centrifugal pumps connected in parallel for maintenance and also increase the pumping rate.
The pumps are then connected to the Mixing tank with an agitator motor comprising of a
propeller for mixing of additives as it rotates. The mixer flows through the discharge tube to
the sampling system opening from a solenoid valve to the measuring cylinder in-order to take
samples for laboratory test. The system also contains conductive sensors that detect
imperfections in the mixture whether it meets the required standards and this opens the valve
in the discharge line to cause flow of the mixture to the storage tank. In case the
homogeneous requirement is not met, the sensor opens the valve in the diversion line back to
the mixing tank for further mixing.
This section describes how to determine the required time for each action and the operation
of the entire program.
The system will be initiated by starting using the start button on a panel board connected to a
power supply. Valve A opens for a given time and the base material flows to the mixing tank
after which valve A closes and valve B opens for specific time period and this leads Anti-
oxidation additive i.e., Phenyl diamines or alkylated phenols into the mixing tank. Valve C
opens while valve B closes to allow Anti-knocking additive i.e., Tetraethyl Lead to be added
to the Mixing tank for a given time. When the set time for the tank to be fed with the different
feedstock elapses, the agitator motor begins to drive the rotor to cause the mixing in the
mixing tank for a specific time to achieve a homogeneous mixture. The discharge valve is
then opened to release the product, this activates the sampling section. On its way to the
storage tank, a conductive sensor determines whether the mixture is up to the required
standard. If it’s not the line leading to the storage tank is shut and the diversion line is opened
for the fluid to flow back to mixing tank. In case the required standard is achieved, the
diversion line is closed while the line to the storage tank is opened and the product is
discharged into the storage tank. When the time required to complete a cycle of the process
elapses, the process begins again by opening valve A and it continues as described earlier.
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3.4 Geographical area of the existence of the proposed project.
The proposed project will be implemented in Western Uganda, Kiryadongo district, Kigumba
Town Council at UPIK in the instrumentation workshop.
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CHAPTER FOUR.
Challenges
During the time of implementing this project, a number of challenges came up that did not
make the project smoothly and these challenges are as follows;
1. Leakages from the piping system which made the additives to leak out, due to lack of
PPR fittings.
2. Lack of materials for the connections, such as GI fittings and GI pipes instead of
uniform PPR which took time in connection.
3. Short time given, which composed of delay in bringing the right materials hence not
giving time to try the final output.
Conclusion.
The purpose of this research was to identify effective strategies for mixing the additives so as
to form a homogeneous product to reduce the emission of CO, HC, and CO2 better than when
using pure Gasoline, it would also improve engine brake torque and power for a low blending
fraction.
The objective of this project is to design and install a system that will automatically blend the
base materials and additives in a process tank.
However, this project was helpful as to me in such a way that I learnt some major ideas in the
electrical system, installations of the piping systems and good housekeeping as I
implemented the project making it precise and knit.
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REFERENCES.
Shaukat N., “PLC Based Liquid Filling and Mixing System,” IEEE Multi Topic Conference,
2002
YUDI IRWANTO, “Automation of mixing tank system in STTN-BATAN mini plant using
DCS Centum VP”, J. Phys.; Conf. Ser. 1436012128, 2020
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APPENDICES.
This chapter comprises of the budget, work plan/time frame and instruments.
Solenoid valve Automatic control of fluids 2pcs 500,000 1,500,000 Others available in
the workshops
Level switches Flow type liquid level switch for 1pcs Available in the
monitoring fluid levels workshops
PPR Plain elbow, 25mm (joining pipes in different 14pcs 4,000 56,000
Female elbow and trajectory)
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male elbow
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July-august Submission and writing proposal
December Testing
4.3 Instruments/tools
Thread seals-4pcs
Testers-1pcs
A pair of pliers-1pcs
Adjustable spanners-1pcs
MS plate (1mm)-1pcs
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