REPORT ON GRE – 421: STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

REPORT ON GRE – 421: STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

ABSTRACT

This report investigates and gives a detailed explanation of the processes involve in Bonny River Terminal (Exxonmobil) where the quality control and quality assurance analysis (laboratory analysis), feed fractionation, the storage of Liquefied Petroleum Gas (LPG) for Loading into nominated vessel for export and fire protection system.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE OF CONTENTS                                                                                   Page

 

Certification …………………………………………………………………i

Dedication …..…………………….…………………………………………ii

Acknowledgement ………………………………………………………………iii

Abstract…………………………………….………………………………….iv

Table of Content ………………….…………………………..…………….v-vii

List of Figures …………………………………………………………………………….vii

 

CHAPTER ONE

 

1.0 Introduction……..…………………………………….…………………1

1.1 Historical Background of SIWES……………………….………………1-2

1.2 Aims of Siwes………………………………………………………………………..2

1.3 JB Servicing Enterprise ……………………………………………………………..3

1.4 Services Rendered by the organization ……………………………………………3

1.5 Organization Chart ………………………………..…………………………3

 

CHAPTER TWO

 

2.0 Description of Bonny River Terminal (BRT)……………………………..4-5

2.1 Process Systems In Bonny River Terminal…………..…………………5

2.2 Feed Inlet and Preheating Section…………………………………………..6

2.2.1Operation Principles ………………………………..……………6-7

2.3 Fractionation Process……………………………………………………………8

2.3.1 Depropanizer Column……………..………………………………8-10

2.3.2 Debutanizer Column………….……………………………….11-12

2.4 Product Refigeration and Cooling…………………………………………..13

2.4.1 Butane Cooling……………….………………………………..13

2.4.2 Propane Compression System……………………………………13

2.4.3 Propane Compressor and Suction Scrubbers……………………14-15

2.4.4  Rundown To Storage………………………..…………………15

2.5 Product Storage……….………………………………….………………15-16

2.6 Hot Oil…………………………………………………………………………………17-18

2.7 Utilities………………………………………………………………………………..19

2.7.1  Instrument Air …………………………………..…………….19

2.7.2  Portable Water………………………………………………….19

2.7.3  Nitrogen………………………………………….……………19

2.7.4  Diesel Oil………………………………………….……………20

2.7.5  Fuel Gas System………………………………….……………..20

2.7.6  Oily Water Treatment System…………………………………20

2.8 Laboratory……………………………………………………………………………20

2.8.1 Gas Chromatography………………………….………..………20-21

2.8.1.1 Significance and Use…………………………………………21

2.8.1.2 Gas Chromatography System…………………………………21-22

2.9 Fire Protection System……………………………………………………………22-23

 

CHAPTER THREE

 

3.0 Practical Experience………………………………..…………………..28-30

                  

CHAPTER FOUR

 

4.0 Summary / Recommendation…………………………………………………..31

4.1 REFERENCES…………………………………………….…………….32

 

APPENDIX………………………………………………………………………………………..33-34

 

 

 

 

LIST OF FIGURES

 

Figure 1.1:  Department of Petroleum Resources Organogram

Figure 2.0:  Diagram Showing the Overview of Bonny River Terminal.            Figure 2.1:          Diagram Showing Feed Inlet and Preheating System.

Figure 2.2:  Diagram Showing the Depropanizer System.

Figure 2.3   Diagram Showing Debutanizer and Depropanizer

Figure 2.4:  Diagram Showing Propane Compressor.

Figure 2.5:  Diagram Showing the SuctionSrubbers.

Figure 2.6: Diagram Showing the Propane and Butane Storage Tank.

Figure 2.7:  Diagram Showing Pentane plus Storage Tank.

Figure 2.8: Diagram Showing Hot Oil Surge Tank.

Figure 2.9:  Diagram Showing Shematic of a Gas Chromatograph

Figure 2.10: Diagram Showing Loading Arms

Figure 2.11: Diagram Showing Fire Station

Figure 2.12: Diagram Showing Firewater Hydrant

Figure 2.13: Diagram Showing Ground and Stack Flare

Figure 2.14: Diagram Showing Product Coolers

Figure 2.15: Diagram Showing Loading Jetty

Figure 2.16: Diagram Showing Propane Circulation Pump

Figure 2.17: Diagram Showing Propane Loading Pump

Figure 2.18: Diagram Showing Hot Oil Heater

Figure 2.19: Diagram Showing Firewater Holding Pond And Residential Area

 

 

 

                                                               CHAPTER ONE

 

 

  •      INTRODUCTION

 

The Student Industrial Work Experience Scheme (SIWES) programme was established in 1973 to expose students to industrial culture that consists of professional work methods using machine and equipment complying with safety principles in the application of science and technology. The Scheme was established not only to provide an avenue for Nigerian undergraduates to acquire industrial skills and experience in their various disciplines but also provide students with an opportunity to apply their theoretical knowledge in real work situations thereby bridging the gap between university learning and actual practice. The short term benefit is that the transition from the university to the world of work is made easier while enhancing students contact for job placement. This programme, on the other hand, provides the employers with cheap manpower involvement while strengthening their involvement in the entire process of preparing Nigerian undergraduates for employment.

 

 

1.1     HISTORICAL BACKGROUND OF SIWES

As included in the national objective stated in the second national development plan in 1970, Nigerian felt the need for economic self-sufficient and the need to have skilled indigenous manpower. As a result, the Federal Government established the Industrial Training Fund (ITF) in 1971 under the Federal Ministry of Information. This comprises of 22 area offices with headquarter in Jos, Plateau state. In 1974, the ITF board initiated and designed the student industrial work experience scheme. ITF funded the scheme up to 1978, when it became apparent that the board could not shoulder the financial responsibility due to the increase in the number of students in the programme, until 1984 with the funding being borne by the Federal Government.

 

 

1.2     AIMS OF SIWES

 

  1. The main aim of the programme is to bridge the gap existing between theory and practical in engineering, technology, science and other programme in the Nigerian tertiary institution.
  2. The scheme is also aimed at exposing students to machine and equipment, professional work methods and ways of safeguarding the work areas and workers in industries and organizations.

 

 

 

The objective is to:

 

  1. Provision of an avenue for students in the Nigerian institutions to acquire industrial skills and experience in their course of study.
  2. Prepare students for the work situation they are likely to meet after graduation.
  • Enlist and strengthen employer’s involvement in the entire education process of preparing graduates for employment in industries.

 

In a bid to realize the objectives of SIWES and to get proper training which would prepare me for the world of work and broadens my knowledge, I decided to have my internship with JB Servicing Enterprise/Bonny River Terminal seeing the relationship with my course of study, I was convinced it would provide me with the wealth of experience, industrial skills and exposure to equipment and machineries as well as chemical processes/unit operations

 

 

 

 

 

 

 

 

 

JB SERVICING ENTERPRISE

 

JB SERVICING ENTERPRISE is an indigenous oil and gas servicing company, currently a contractor to ExxonMobil Producing Nigeria Unlimited, BONNY RIVER TERMINAL (BRT) facility.

The company was established in MARCH, 2011.

 

SERVICES RENDERED BY THE ORGANIZATION

The company is into Instrumentation and Electrical jobs, Supplies, General Contracts and Civil works, they do construction of shore line embankment and also into Fabrication and structural welding.

 

 

ORGANIZATIONAL CHART

 

MANAGING DIRECTOR
ADMINISTRATION
FINANCE
I.T
TECHNICAL
SAFETY
EXTERNAL RELATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER TWO

 

2.0     DESCRIPTION OF BONNY RIVER TERMINAL

 

Mobil Producing Nigeria Unlimited is one of the subsidiaries of Exxonmobil co-operation, Bonny river terminal is one of the terminal owned by Mobil Producing Nigeria Unlimited which is located at Bonny in Rivers State. The basic activities in Bonny River Terminal are; feeds fractionation, Exportation of process product, quality control and quality assurance analysis of products (laboratory analysis). BRT is a gas processing plant where Natural Gas Liquid (NGL) C3+ containing a mixture of propane, butane and pentane plus is separated by fractionation into its various components (propane, butane and pentane plus). Pentane plus exist as a liquid at atmospheric temperature but propane and butane which exist as gas at atmospheric pressure have to go through further liquefaction process of cooling, compression and condensation before they can finally be stored as liquid in tanks. The liquefied natural gases LPG (propane and butane), and Natural gas liquid (pentane) are then loaded from the tanks into ships for export.

 

The terminal is headed by Operations Management who coordinates all the activities of the Terminal. The terminal is supported by various departmental superintendents in order to run the activities of the terminal successfully. These departments include: Operations, NNPC/DPR, Logistics, Safety Health Environment (SHE), AC Maintaince, Global Real Estate and Facilities (GREF), Laboratory, Security, Medical and Maintenance sections

 

 

 

 

 

 

 

Fig. 2.0   Diagram Showing an Overview of Bonny River Terminal

 

 

2.1     PROCESS SYSTEMS IN BONNY RIVER TERMINAL (BRT)

Bonny River Terminal (BRT) on-shore plant receives propane plus feed (C3+) and fuel gas feed from offshore OSO RX and EAP GX platforms, processes it into different components which are: propane, butane and pentane plus products and stores them in their different designated tanks for loading operations. The description of BRT plant’s process systems is divided is divided into the following six sections.

  • Feed inlet and Preheating section
  • Fractionation section
  • Propane Refrigerating and product Cooling section
  • Propane compression section
  • Product storage
  • Hot oil system and utilities

 

 

 

2.2     FEED INLET AND PREHEATING SECTION

The purpose of the BRT feed inlet and preheating system is to receive and preheat the feed from offshore platform prior to entering the fractionation section.

 

2.2.1  Operation principles

The main feed to BT is propane which is part of the gas gathering project. Natural Gas Liquid (NGL) propane plus product is removed from the gas on the platform. Propane plus (C3+) product flows through a 140 kilometer 12 inch pipeline from platform and enters the propane surge drum. A propane plus product pipeline pig receiver from the platform is provided at the end of the pipeline for cleaning and checking line integrity using an intelligent pig. A scrape pig is launched from time to time from either offshore platform to clean the incoming subsial pipelines. Operational pigging is required on a regular basis for free water and corrosion management.

 

Propane plus product is sub-cooled, bubble point pressure of propane plus product is estimated to be 79psig at 80°F (26.70C). The operating pressure of the propane plus surge drum is maintained at 105psig by the addition of warm propane vapour from the depropanizer overhead or the release of excess vapours to flare. The propane plus liquid stored in the Propane plus Surge Drum is pumped by the Depropanizer Feed Pump. The propane plus product is divided into three streams which are heated by the Propane Product Cooler, Butane Product Cooler and Pentane plus Product Cooler respectively. Each of these liquids has been through the fractionation process and has been heated. This heat is used to increase the temperature of the Propane plus feed to the Depropanizer. After propane plus liquid is heated by each stream, the three streams are combined into one stream and enter atop the 21st tray of the Depropanizer.

 

Fig. 2.1   Diagram Showing the Feed Inlet and Preheating System.

 

 

 

 

2.3     FRACTIONATION PROCESS

The fractionation system uses a depropanizer and debutanizer column to separate the preheated propane plus feed into propane, butane and pentane plus product.

 

2.3.1  Depropanizer Column

The propane plus feed stream enters at the 21st tray of the depropanizer and is fractionated into an overhead product of essentially pure propane and a bottom product containing butane plus liquids. The required heat for fractionation is achieved by a hot oil supply to the depropanizer reboiler. The base of the depropanizer is divided into two sections by a dividing weir. Liquid from the seal pan bottom tray as of the depropanizer is directed into both sides of this tray. Liquid from one side of this dividing weir goes to the shell side of the reboiler. This liquid is heated in the reboiler producing a thermo siphon effect. The hot vapour liquid are returned to the bottoms of the tower is mixed with cooler inlet feed flowing into the tower. The hot vapour rises up the tower, vaporizing any light ends in the incoming feed. Any butane plus vapour rising up the tower with the hot vapour from the reboiler will be condensed from the cooler falling liquid and return to the bottom of the depropanizer. These butane plus liquids collected on the product side of the bottom weir make up the feed stream to the debutanizer. Overhead vapour leaves the top of the depropanizer as propane at a temperature of 124°F (approx. 51oC) and pressure of 225psig. This overhead stream is divided into three streams:

(a)    The first and largest stream passes through depropanizer pressure control valve and enters the air cooled depropanizer overhead condenser where the overhead vapours are condensed into liquid. The condensed liquid enters the depropanizer reflux accumulator at a temperature of120°F (48.9oC) through a submerged inlet distribution nozzle.

(b)     The second stream is the hot vapour bypass. This stream is used for the pressure control of the depropanizer reflux accumulator. This stream bypasses the depropanizer overhead condenser and enters the top of the depropanizer reflux accumulator through pressure control valve. Excess pressure in the depropanizer reflux accumulator is sent to flare.

(c)      The third stream is used for pressure control of the propane plus surge drum.

 

 

 

 

 

 

 

 

 

 

 

Fig. 2.2   Diagram Showing the Depropanizer System

 

 

2.3.2 Debutanizer column    

Debutanizer feed is sent from the bottom of the depropanizer through cascade control. The feed enters the debutanizers at 165°F(73.9oC) and 92.4psig.The mixed phase feed stream enters the debutanizer above tray 18 and is fractionated into an overhead vapour steam of butane and a bottoms stream of pentane plus liquids. The required heat for fractionation is achieved by the hot oil supply to the debutanizer reboiler. The base of the debutanizer is divided into two sections by a dividing weir. Liquid from the zeal pan tray of the debutanizer is directed into each of this tray. Liquid from one side of this dividing weir goes to the shell side of the reboiler. The liquid is heated in the reboiler. The hot vapour/liquids are returned to the bottom of the tower below tray 1. The hot vapour/liquid that is returned to the tower is mixed with the cooler inlet feed flowing into the tower.

 

The hot vapour rises up the tower vaporizing any light ends in the incoming feed. Any pentane plus vapours rising up the tower with the hot vapour from the reboiler will be condensed from the cooler falling liquid and return to the bottom of the debutanizer. The bottom stream leaves the debutanizer at 238°F (114.4oC), and passes through the pentane plus cooler where it is cooled to 96°F (35.6oC) by the incoming feed to the debutanizer. The stream then flows to the pentane plus rundown tank. The overhead vapour leaves the debutanizer at 124°F (approx.51oC) and 90psig and is divided into two streams:

  • The first and largest stream passes through debutanizer pressure control valve and enters the air cooled debutanizer overhead condenser where the overhead vapours are condensed into liquid. The condensed liquid enters the debutanizer reflux accumulator at a temperature of 120°F (48.9oC) through a submerged inlet distribution nozzle. The butane liquids leaving the reflux accumulator are pumped by the debutanizer reflux pumps and are split into two streams. The first stream debutanizer reflux returns to the column above tray 35.

 

  • The second stream butane product is sent to the butane product cooler.

The second is the hot vapour bypass. This stream is used for the pressure control of the debutanizer reflux accumulator. Excess pressure in the debutanizer reflux accumulator is sent to flare.

 

 

 

 

 

 

Fig. 2.3   Diagram Showing Debutanizer(Left) and Depropanizer(Right)

 

 

 

 

2.4     PRODUCT REFIGERATION AND COOLING

 

The refrigeration and cooling process uses the chillers, scrubbers and compressor for cooling the products.

 

2.4.1  Butane cooling

Butane product from the butane product cooler is chilled in the butane high level chillers tube side ad in the butane low level chillers tube side. The butane outlet temperature of the high level chillers depends on the propane pressure and temperature in the shell side of the exchanger. Chilling of the butane is accomplished by boiling off propane liquid at two different pressure levels, 116psig for the high level chillers and 46psig for the low level chillers. The boiling temperature at these pressures is 66°F (18.9oC) and 8°F (-13.3oC). After leaving the butane low level chillers the cooled butane product flows to the butane storage tanks. Normally, propane liquid from propane third stage suction scrubber is the supply to butane low level chillers.

 

2.4.2  Propane compression system

Propane rundown: Propane refrigeration is achieved by flashing off the rundown propane liquid to storage in the three different pressure stages, the flashed propane vapours from the three stages are recovered and compressed by the propane compressors. A portion of the propane liquid enters the butane high/low level chillers and acts as a refrigerant to cool the butane product rundown. The flashed propane vapours are recovered and recompressed in the propane compressors.

The control valve diverts part of the rundown propane liquid into the shell side of the butane high level chillers. The remaining propane flow is split evenly into two streams to the propane compressor third stage suction scrubbers.

 

 

 

Fig. 2.4   Diagram Showing the Propane Compressor

 

 

2.4.3  Propane compressors and suction scrubbers

Propane vapours from the butane high level chillers flow to the propane 3rd stage suction scrubbers. Vapours separated from the propane 3rd stage suction scrubbers are fed to the third stage suction of the propane compressors.  Propane liquid line from the Propane 3rd Stage Suction Scrubber bottom divides into two streams. A small portion of the propane liquid from the Propane 3rd Stage Suction Scrubber bottom is used as the cooling medium in the Butane Low Level Chillers. The propane liquid flows through a level control valve to the shell side of the Butane Low Level Chillers. Propane liquid is partially vaporized by pressure drop prior to entering the chillers. The remainder of liquid propane from the Propane 3rd Stage Suction Scrubber bottom is flashed across the level control valve, and flows into the Propane 2nd Stage Suction Scrubbers. These scrubbers operated at 30 psig. Vapours from 2nd scrubbers flow to the suction of the 2nd stage of compressor. Propane vapours generated in the low level chillers flow to the propane 2nd stage suction scrubber. The Propane 1st Stage Suction Scrubbers are also provided but will normally not receive any liquid or vapour. However, during recycle operation when the hot gas is being recycled from third stage compressor discharge to third, second and first stages through anti-surge valves, these vessels are used to receive the recycled hot gas from third stage discharge and act like a 1st stage suction drum, especially during start-up, turn-down or in an anti-surge event.

 

Fig. 2.5   Diagram Showing the Suction Srubbers

 

 

2.4.4  Rundown to storage

Liquid propane product from the bottom of the Propane 2nd Stage Suction Scrubbers flows to the BRT Propane Storage Tanks through the BRT run-down line.

 

2.5     PRODUCT STORAGE

Propane product is received into tank age from the bottom of the 2nd stage suction scrubbers on each propane compressor train. Rundown flow rate of the propane product is controlled with level control valves. The propane product flows to the tank and is spray injected into the propane tanks. The propane is also used for propane circulation via propane circulation pumps to keep the various loading equipment cool until it is used for offloading and being shipped out.

Sub cooled butane product is received into tank age from the butane low level chillers which is back pressure controlled. The butane product flows to the tanks and is spray injected. Pentane plus liquid product from the product cooler flows to the pentane plus rundown tank. Liquid from this tank is pumped via the pentane plus transfer pumps on flow control reset by level to the pentane plus storage tanks. The pentane plus storage tank is a floating roof tank.

 

Fig. 2.6   Diagram Showing the Propane and Butane Storage Tank.         

 

 

 

 

 

 

 

 

 

 

 

Fig. 2.7   Diagram Showing the Pentane plus Storage Tank.

 

 

2.6     HOT OIL

The hot oil circulation system is a closed loop system and is totally independent of the hot oil system in current operation at the BRT plant. The hot oil surge tank acts as a surge vessel to handle the thermal expansion in the system and store the circulating heat transfer media, MOBILTHERM 605. The normal pressure control for the hot oil surge tank is maintained by fuel gas. Hot oil from the hot oil surge tank flows to the hot oil circulation pumps where the pressure of the hot oil is increased by 190psig to overcome the pressure losses during circulation of the hot oil through the system.

 

From the discharge of the circulation pumps, the hot oil flows through the hot oil heater where it is heated to 4250F (218oC). Normally, the fuel gas system is used as fuel source for the burners and pilots of the hot oil heater. In case of a fuel gas trip, propane vaporizers and super heater is used as fuel. After the existing hot oil heater, the hot oil is sent to the depropanizer and debutanizer reboiler to provide the heat required for product fractionation in the columns. If required, the hot oil is routed to the propane vaporizer and super heater to provide the heating required for the proper vaporization and super heating of the propane that is to be used as an alternate fuel gas. All circulated hot oil returns back to the hot oil surge tank.

 

Fig. 2.8   Diagram Showing the Hot Oil Surge Tank.

 

 

 

2.7     UTILITIES

 

2.7.1  Instrument air: A packaged air compressor supplies compressed air to the instrument air dryer where air flows through two 100% desiccant filled chambers operated in parallel to absorb any entrained moisture.

2.7.2  Portable water: Portable water storage tank will be used to supply the plant with potable water for the eyewash and safety shower stations on BRT.

2.7.3  Nitrogen: An air/nitrogen membrane unit that is used to produce nitrogen and nitrogen receiver is installed. This aids in the purging of lines.

2.7.4  Diesel oil: Diesel oil is supplied to BRT for the fuel supply to the additional solar dual fuel power generator.

2.7.5  Fuel gas system: High pressure (HP) fuel gas is supplied to BT. The primary source of the fuel gas to BRT is a 12” dry gas pipeline flowing from OSO offshore. An additional fuel gas scrubber is added for the removal of any liquids prior to the fuel gas flowing to the additional power generator.

2.7.6  Oily water treatment system: The oily water is handled in the oily water treatment system. The oily water is fed into the oily water holding pond/API separator. The oil phase rises to the surface of the oily water holding pond/API separator where the oil is skimmed off and sent to the recovered oil sump.

 

2.8     LABORATORY

The laboratory is in charge of quality assurance and control. They verify the quality of the products loaded into ships and contribute to maintaining environmental quality by analyzing waste water to ensure that it is not contaminated before it is drained into the sea. In the lab, chemical analysis is carried out on feed and products of the plant to make sure they are within specification. Physio-Chemical Composition, Sulphur Content, and Detailed Hydrocarbon Analysis (DHA) are carried out on feed (RX and GX feed), fuel gas, C3 receiver, C3 rundown, C4 rundown, C5+ rundown samples, tank samples of C3, C4 and C5+ , portable water and  environmental water samples. Ship tanks are also tested to determine the amount of sulfur already in them before product is loaded in.

Analytical Procedure: Some of the test carried out in the laboratory and their procedures are listed below.

2.8.1     Gas Chromatography: Chromatography is a method of separating the components of a mixture between two immiscible phases: Which are Mobile Phase carried by a vector fluid and a Stationary Phase of separation column packing.

 

Gas analyses are mainly done with a gas chromatograph. The mixture to be analyzed is injected and vaporized by heating at the head of the column and is carried along the stationary medium by a neutral vector gas (helium, nitrogen, etc.) of very high purity. During the transfer, the phase equilibriums of the components determine the transit time and separation coefficients which result in complete separation of the components in the gas phase at the exit from the column. After separation, the components can be detected and analyzed separately.

 

For a compound to be suitable for gas chromatography, it must have sufficient volatility and thermal stability. This test method covers the determination of the composition of liquefied petroleum gasses (LPG) and natural gas liquid (NGL).

  • Significance and use:

The component distribution of liquefied petroleum gases and concentrations is often required as a specification analysis for end-use sale of this material. Its wide use as chemical feed stocks or as fuel, require precise compositional data to ensure uniform quality of the desired reaction products.

  • Gas Chromatograph system:
  • Detector: Two types of detectors found in a gas chromatograph are:
  • Thermal Conductivity Detector (TCD): Is simple and non-destructive. It is preferred for moderate sensitivity in all areas. It responds to both inorganic and organic compounds. In BRT, this detector is in GC-44, it is used in analyzing fuel gas, feed (both RX and GX feed), C5+ rundown because they have inorganic and multiple compounds in them.
  • Flame Ionization Detector (FID): is used for detecting hydrocarbons and gives a rapid, precise and continuous reading of the HC concentration. It has high sensitivity and reliability. Respond only to substances that produce charged ions when burned in a hydrogen/air flame, mostly organic compounds and few inorganic compounds. This detector is contained in GC-46 and is used in analyzing C3 rundown, C3 receiver and C4 rundown.
  • Recorder: a strip chart recorder and integrator with a full-scale range of 10mV or less are used. In BRT, a computer monitor is used.
  • Carrier gas: the instrument is equipped with suitable facility to provide a flow of carrier gas through the analyzer column at a rate that is constant. In BRT, helium gas is used as the carrier gas.

 

Fig. 2.9   Diagram Showing the Schematics of Gas Chromatography

 

 

2.9     FIRE PROTECTION SYSTEM

 

The fire protection system includes the following:

 

  • Firewater Holding Pond

 

  • Firewater Pump

 

  • Firewater Distribution System
  • Firewater hydrant
  • Fixed water monitor
  • Fixed water spray systems
  • Sprinkler systems
  • Indoor/outdoor hose reels

 

  • Foam Extinguishing Systems
  • Foam /water monitor
  • Foam/water sprinkler system
  • Portable/Mobile Equipment
  • Fire truck
  • Hose carbinets/fire blanket
  • Fire Detection System
  • Gas detectors
  • Fire alarm sirens
  • Outdoor manual call points

 

Fig. 2.10   Diagram Showing Loading Arms

 

 

 

 

Fig. 2.11   Diagram Showing Fire Station

Fig. 2.12   Diagram Showing Firewater Hydrant

 

 

Fig. 2.13   Diagram Showing Ground and Stack Flare

Fig. 2.14   Diagram Showing Product Coolers

 

Fig. 2.15   Diagram Showing Loading Jetty

 

Fig. 2.16   Diagram Showing Propane Circulation Pump                                  

 

 

  Fig. 2.17  Diagram Showing Propane Loading Pump

 

 

   Fig. 2.18  Diagram Showing Hot Oil Heater

 

                                                          CHAPTER THREE

 

3.0       PRACTICAL EXPERIENCE

 

During my industrial training with JB SERVICING ENT./Oso/BRT department in ExxonMobil, I was able to understand the Permit to work system, the operation of some firefighting equipment, how to use portable gas detectors,natural gas processing plant and the various unit operations carried out in the plant. I was also opportuned to see the different equipment and machines used and their driving force.

 

The internship afforded me the opportunity to understand the designers’ mind concerning the chemical processes and the operations used to get optimization as well as the separation techniques used to process propane, butane and pentane plus. It was a lifetime experience that made me to understand and appreciate chemical engineering and its processes. Indeed, time and space would not suffice me to exhaustively comment on the innumerable wealth of experience and knowledge gained. However, below is an outline of the major works carried out on some of the machines/equipment and knowledge gained.

FLANGES

Flanges are a common source of leak on a process plant, although the majority of leaks are “pin-hole” and are unlikely to result in a major hazard unless they are allowed to increase in size, or they result in escalation.  .

 

Process Piping

Only failures from the main body of the pipe, i.e. through the pipe wall, are considered, this includes welds in long pipe sections. Process piping may fail due to the following failure modes: Design error, material/construction defect, mechanical wear (including vibration), corrosion/erosion, fatigue, creep, operational overload, external loading (including impact), and operating error.

 

VALVES

I learnt about the three types of control valves used in the plant, namely; fail open, fail close and fail lock. I also learnt the different types of valves suitable for different purposes like the globe and the gate valves are used for flow control, i.e. to regulate flow rate while the butterfly valves are suitable for use in water and/or air flow in large diameters. I also learnt the operational principles of valves and can easily tell when a valve is opened or closed.

 

FRACTIONATING TOWERS

I learnt how to condition the fractionating column to achieve optimum fractionation product. This is achieved by taking the temperature, pressure, reflux ratio, and flow rate into consideration, knowing the standard which must be met.

 

OTHER EXPERIENCE GAINED

I learnt about thermosiphonic effect in the propane refrigeration section where liquid propane is used to cool gaseous propane/butane and the gaseous propane formed due to heat gained during heat exchange goes up to the compressors where is being compressed back to liquid and returned again as propane to continue chilling.

 

I got to understand the use of heat exchangers to achieve proper utilization of heat energy in the plant thereby minimising heat wastage, time and even human energy that will be required. The knowledge gained from the Distributive Control System (DCS) cannot be forgotten as I learnt how to make changes in the plant from the comfort of the Central Control Room, such changes include: opening/closing of valves, switching on/off of pumps, increasing/reducing flow rate, temperatures and pressures.

 

I worked as a lab analyst which exposed me to the different activities in the lab, few of such activities include:

  • Analysing hydrocarbon for product specification by testing for its percentage composition, sulphur content, its density, specific gravity, etc.
  • Portable water analysis to check its purity and compositions like chlorine iron content and the conductivity and pH.
  • Environmental and sewage water analysis to test for oil and grease, total suspended solute, and total dissolved solute before disposing into the sea.
  • Pre-loading checks on ship’s tanks to ensure the tanks are fit for lading, this check involve checking for the percentage of oxygen, hydrogen, and hydrogen sulphide in the tanks.

By doing all these, I improved in my capability to handle laboratory equipment/apparatus in the right manner.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER FOUR

 

4.0       SUMMARY/RECOMMENDATION

 

Having worked as a plant operator with the senior operator in BRT, I gained more understanding of gas processing, understood why certain things are done in certain ways, it was an unforgettable experience that I look forward to having more. Also, working as a lab analyst has exposed me to varieties of laboratory activities such as tests, analysis, equipment handling/maintenance, calibration checks, etc.

Having undergone the SIWES program, I strongly recommend it for all the undergraduates studying science, engineering and technological related courses as it will help to expose them to the real work situation in their different fields of study and bridge the gap between school work and actual practices. It is indeed an opportunity that must not be miss use by the undergraduates else, they will be left regretting their actions/inactions.

 

I also recommend that the Industrial Training Fund (ITF) embark on a program that will limit those factors (stated at the introductory section) which have impeded the growth of this SIWES program if not totally eliminated.

 

 

 

 

 

 

 

 

 

 

 

4.1            REFERENCES

 

  1. Department of Petroleum Resources Orientation manual; 1989.
  2. Technical Training Centre Operations manual; 1998.
  3. Coulson J.M and Richardson J.F; Coulson and Richardson’s chemical Engineering; volume 2; 5th edition; Butterworth-Heinemann; Oxford; 2002; pages 585-587. 1109-1111.
  4. Hobart H. Willard, Lynne L Merritt JR, John A, Jean and Frank A. Settle JR; Instrumental Methods of analysis; 6th Edition; Wadsworth Publishing Company Bedmont California; pages 454-485.
  5. Perry J.H; Chemical Engineer’s Handbook; Process Control; 6th edition; McGraw-Hill New York; 1984; pages 43-50.
  6. Routh E.J, Fuller A.T; Stability of motion; 1975.
  7. BRT Lab test method manual, ASTM methods by BRT
  8. BRT technical orientation manual.
  9. Instrumentation Engineering Technology; the northern Alberta institute of Technology; retrieved 17 October 2012.
  10. EAP Systems training manual BT2 NGL; 2007.
  11. Total training manual Course EXP-PR-EQ04

 

 

 

 

APPENDIX

SOME ABBREVIATIONS USED IN BONNY RIVER TERMINAL

  • MPN: Mobil Producing Nigeria
  • P&ID: Piping and Instrumentation Diagram
  • PFD: Process Flow Diagram
  • BRT: Bonny River Terminal.
  • BT1: Bonny Train 1.
  • BT2: Bonny Train 2.
  • NGL: Natural Gas Liquid.
  • LPG: Liquefied Petroleum Gas.
  • HC: Hydrocarbon.
  • P: High Pressure.
  • P: Low Pressure.
  • MOV: Motor Operated Valve.
  • PSV: Pressure Safety Valve.
  • MV: Manual Valve
  • PCV: Pressure Control Valve
  • GC: Gas Chromatograph.
  • BDV: Blowdown valve
  • SDV: Shutdown Valve.
  • LIC: Level Indicator Control
  • EAP: East Area Project
  • TIC: Temperature Indicator Control
  • FIC: Flow Indicator Control
  • PIC: Pressure Indicator Control
  • SHE: Safety Health Environment
  • SSHE: Safety Security Health Environment
  • PPE: Personal Protective Equipment
  • DCS: Distributed control system