ABUBAKAR TAFAWA BALEWA UNIVERSITY

P.M.B 0248, BAUCHI STATE, NIGERIA

JUNE 2019
ABUBAKAR TAFAWA BALEWA UNIVERSITY

P.M.B 0248, BAUCHI STATE, NIGERIA

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

CONDUCTED AT

POWER PLANT AND UTILITIES DEPARTMENT

KADUNA REFINING AND PETROCHEMICAL COMPANY (KRPC)

A SUBSIDARY OF NNPC

BY

APEH ISRAEL ALEWO

REG. No. 14/38620U/1
SUBMITTED TO

DEPARTMENT OF CHEMISTRY
FACULTY OF SCIENCE
ABUBAKAR TAFAWA BALEWA UNIVERSITY (ATBU), BAUCHI
IN PARTIAL FULFILMENT FOR THE AWARD OF B. TECH INDUSTRIAL CHEMISTRY

JUNE, 2019

ii
 DECLARATION
I, APEH ISRAEL ALEWO, declare that this technical report was written and prepared

by me, as a result of all the experience garnered during my one-year industrial training

and the content there in are true.

iii
 CERTIFICATION
I, certify that this technical report on industrial training as regards to partial fulfilment of

bachelor of technology in Industrial Chemistry was carried out and dully presented by

me, APEH ISRAEL ALEWO (14/38620U/1), Department of Chemistry, Faculty of

Science, Abubakar Tafawa Balewa University, Bauchi.

iv
 DEDICATION

This report is dedicated to Almighty God, who is my fountain of wisdom, focus and

dexterity, who directed me throughout my period of SIWES. I dedicate this also to my

bosom parents for their endless support at every phase of my life.

v
 ACKNOWLEDGEMENT
Firstly, my profound gratitude goes to the ever-sovereign God for giving me the

privilege, foresight, guidance and understanding, so as to remain focused and goal

oriented to achieve immensely throughout the course of my training. I wish to register

my unapologetic gratitude to my loving family, especially my amiable parents; Mr and

Mrs JOHN APEH (W02 rtd.) and my ever-loving siblings, for their love, patience,

tireless prayer, guidance, motivation, moral and financial support. You are loved and

cherished always and forever.

My special thanks also go to my industry-based supervisors, Engr. Opeyemi Ahmed,

Babangida Aliyu and the entire member of staff of the Kaduna Refining and

Petrochemical Company, for their professional guidance throughout my training. I also

acknowledge their painstaking and resilient efforts to teach, scrutinise, build and also

correct my shortcomings, despite their tight schedules and constraints, so as to ensure a

successful and excellent completion of my training. I will not fail to acknowledge my

fellow I.T students/colleagues; Alhamdu, Ahmed and Daniel.

My Sincere appreciation also goes to my friends; Sandra, Mercy, David, Raphael, Grace,

Theresa, Thankfulness, Dedah, Paul, Austin, Jennifer, Goodnews, Ogwuche, Darey and

all others, too numerous to mention, who in one way or the other have been of support.

May God bless you all.

Finally, to my institution-based supervisor, Mr Aminu Makama, my I.T coordinator, Mr

Tafida and all members of staff of the department of chemistry. I sincerely appreciate

and acknowledge you for your experienced and timely advice during your visit to my

place of industrial training and guidance as to the preparation of this technical report.

May you get to the apex of the academic echelon.

vi
 ABSTRACT
The power plant and utilities (PPU) department is responsible for the production and

supply of safe, reliable and secured utilities required for the consistent and continuous

operation of the plant and other facilities in K.R.P.C. PPU functions includes the

production\distribution of the following: Water (drinking, demineralized, service,

cooling and boiler feed), Dried steam (for Air facility and turbine systems), reliable

power supply, Instrument air (for pneumatic control system), Service air,

Liquid/Gaseous nitrogen. The production of these utilities cannot be overemphasized

as it is the working fluid for all process units. This department is basically divided into

two major sections; the power and utilities section. Other subsections include the LAB

plant, raw water intake plant and the wastewater treatment. This technical report gives

a detailed explanation of the major process flow and operations in the power plants and

utilities department in the refinery.

vii
 TABLE OF CONTENTS

Contents Page
Title page - - - - - - - - - ii
Declaration - - - - - - - - - iii

Certification - - - - - - - - - iv

Dedication - - - - - - - - - v

Acknowledgement - - - - - - - - vi

Abstract - - - - - - - - - vii

Table of Content - - - - - - - - viii

CHAPTER ONE – INTRODUCTION

1.1 Preamble - - - - - - - - 1

1.2 Aims and objectives of SIWES - - - - - 2

1.3 Aim and Objectives for Selecting the Area of SIWES - - 2

1.4 Motivation for Selection of the SIWES Place - - - 3

1.5 Training Methodology at the SIWES Place - - - - 4
1.6 Report Outline- - - - - - - - 4

CHAPTER TWO – THEORETICAL BACKGROUND OF THE SIWES AREAS

2.1 Introduction - - - - - - - - 5

2.2 Nigeria National Petroleum Corporation (NNPC/KRPC) - - 5

2.3 Power Plant and Utilities - - - - - - 9

2.4 The Control Room - - - - - - - 11

2.5 Process Parameters and Instrumentation - - - - 12

CHAPTER THREE – DETAILS OF TRAINING UNDERGONE IN THE SIWES

AREAS

3.1 Introduction - - - - - - - - 14

3.2 Fire and Safety Induction Course - - - - - 14

viii
3.3 Accident - - - - - - - - 14

3.3.1 Causes of accident - - - - - - - 14

3.3.2 How to prevent accident - - - - - - 14

3.3.3 Types of work permit - - - - - - - 15

3.3.4 Harmful substances - - - - - - - 15

3.3.5 Ways of contact - - - - - - - 16

3.3.6 Personal protective equipment - - - - - 16

3.4 Fire - - - - - - - - - 17

3.4.1 Classes of fire - - - - - - - - 17

3.4.2 Fire extinguisher - - - - - - - 18

3.4.3 General prevention - - - - - - - 18

3.4.4 Prevention objectives - - - - - - - 18

3.5 Unit 70 (Steam Generation) - - - - - - 18

3.5.1 Unit 81 (Raw Water Intake from the River) - - - - 19

3.5.2 Unit 73 (Demineralization of Water) - - - - - 20

3.5.3 Boiler Feed Water System - - - - - - 22

3.5.4 De-Aerators (70D01 & 70D02) - - - - - 23

3.6 The Raw water treatment plant (Unit 72) - - - - 24

3.6.1 Process Flow Description - - - - - - 25

3.6.2 Pressure Filters - - - - - - - 26

3.6.3 Drinking water filters - - - - - - - 28

3.6.4 The Clarifier - - - - - - - - 28

3.6.5 Water samples- - - - - - - - 29

ix
3.7 Unit 75 (The air facility unit) - - - - - - 29

3.7.1 Process Flow Description - - - - - - 30

3.7.2 Air compressors - - - - - - - 31

3.7.3 Air surge drums - - - - - - - 32

3.7.4 Dryers - - - - - - - - - 32

3.8 Unit 76 (Nitrogen plant/ facility) - - - - - 33

3.8.1 Process Flow Description - - - - - - 33

3.8.2 Chillers - - - - - - - - 34

3.8.3 Adsorbers/ buffer tanks - - - - - - 36

3.9 Unit 74 (Cooling Facility) - - - - - - 37

3.9.1 Process Flow Description - - - - - - 38

3.9.2 Cooling Water Draft System - - - - - - 39

3.9.3 Cooling Water Treatment - - - - - - 40

CHAPTER FOUR – EXPERIENCE GAINED AND APPLICATIONS IN FUTURE
CAREER
4.1 Introduction- - - - - - - 42

4.2 Experience Gained and Applications in Future Career - - 42

4.3 Air compressor Start Up and Shut down Processes - - - 42

4.4 Cooling water pumps start-up/shutdown Process - - - 43

4.5 Fire Fighting Techniques - - - - - - 44

4.6 Backwashing of pressure filters - - - - - 45

CHAPTER FIVE

5.1 Conclusion - - - - - - - - 47
5.2 Suggestions to Future SIWES Students - - - - 47
5.3 Difficulties Faced During the Training - - - - 48
5.4 Recommendation - - - - - - - 48
Reference

x
 LIST OF TABLES

Table 3.0 Personal protective equipments- - - - - 16

LIST OF FIGURES

Figure 2.0 The NNPC organizational flowchart - - - - 7

Figure 2.1 Organizational flowchart of PPUD - - - - 10

Figure 2.2 The PPU main control room - - - - - 12

Figure 3.0 Personal Protective Equipment - - - - 17

Figure 3.1 Steam generator - - - - - - 19

Figure 3.2 Process flow diagram of unit 81- - - - - 19

Figure 3.3 Cross Section of Demineralized water plant - - - 21

Figure 3.4 Demineralization of water - - - - - 22

Figure 3.5 Steam generation process - - - - - 23

Figure 3.6 A cross section of De-aerators - - - - 24

Figure 3.7 Cross section of raw water tank - - - - 25

Figure 3.8 Block flow Diagram for Raw Water Treatment- - - 27

Figure 3.9 Cross section of pressure filters - - - - 29

Figure 3.10 Cross section of Clarifiers - - - - - 30

Figure 3.11 Cross section of Compressed Air Facility - - - 32

Figure 3.12 A Compressor - - - - - - - 34

Figure 3.13 Cross section of Nitrogen Facility - - - - 36

Figure 3.14 Process Flow Diagram for Cryogenic Nitrogen Production- - 37

Figure 3.15 A Process Chiller- - - - - - - 38

Figure 3.16 Adsorbers - - - - - - - 40

Figure 3.17 Cross section of cooling water system - - - 41

Figure 3.18 A Cooling Water Tower - - - - - 42

Figure 3.19 Chemical dosing facility - - - - - 44

xi
 CHAPTER ONE

1.0 Introduction

1.1 Preamble

The Industrial Training Fund (ITF) designed Students Industrial Work

Experience Scheme (SIWES) in 1973 with respect to the yearnings of the Federal

Ministry of Industry. The scheme was basically initiated to supplement the

theoretical learning of students from their various institutions with exposure to

practical industrial activities in their various disciplines. The Student Industrial

Work Experience Scheme (SIWES) aim to solve the problems of inadequate

practical skills preparatory for employment in industries by Nigerian graduates of

tertiary institution. The SIWES also planned and supervised training intervention

based on stated and specific learning and career objectives, towards developing

the occupational competencies of the participants. It is a programme required to

be undertaken by all students of tertiary institution in Nigeria pursuing courses in

specialized Engineering, Technical, Business, Applied Science and Applied Arts.

It is quite obvious that growth in technology is a worldwide phenomenon

and Nigeria is not an exception. Therefore, there is a need for improvement in the

efficiency of the country's work force. To bridge the gap between formal

education and technical know-how, it became imperative to bring institutions of

higher learning and employers in the industries closer through SIWES.

Moreover, it is believed that SIWES will prepare Students and equip them

with the necessary skills upon graduation. Hence, the Federal Government

deemed it necessary to incorporate SIWES into the Industrial Training Fund

(ITF). This is because the ITF is involved in training workers in commerce and

industries as well as other establishments that need training for manpower

 development. Therefore, since SIWES is also involved in developing students for

manpower development in the industrial sector, the incorporation became a

Necessity.

1.2 Aim and Objectives of the SIWES

It is not correct to view SIWES as an ordinary vocational job for

moneymaking, but an avenue for aiding students to put into practice what have

been taught theoretically in School. It is a continuation for students' academic

pursuit. In addition, the following are some of the objectives of the SIWES:

 To bring into compromise, the theoretical learning of the practical work.

 To enhance the relationship between institution of higher learning and the

industrial sector.

 To encourage students to be responsible and Self-reliant after graduation.

 To provide an avenue for students to acquire industrial skills and prepare

them for industrial work situations, they are likely to meet after graduation.

 To expose students to work methods and techniques in handling equipment

and machinery that may not be available in schools.

1.3 Aim and objectives for selecting the area of SIWES

NNPC/KRPC/ Kaduna

The following are some of the objectives of selecting the Kaduna Refining

and Petrochemical Company as my Area of SIWES;

 To attend, witness and acquire knowledge together with practical experience

of the Industrial activities taking place in the Company, with a keen interest

in the chemistry of Industrial processes.

 To develop skills on how to use and operate industrial equipment’s

particularly Industrial chemistry equipment’s.

  To learn lessons and garner experience on organizational work ethics for

future career.

The aim and objectives of this technical report as regards my one (1) year

of Industrial Training are as follows:

 To give a precise account of my experience during the training.

 To show the importance of the SIWES in integrating practical training with

theoretical orientation learnt from school.

 To serve as a reference should the experience gained happens to be in line

with my final year project.

 To also serve as a reference point; for those willing to do a research on any of

the topics discussed.

1.4 Motivation for selection of the SIWES place

It was a great chance and opportunity to witness and gain experience of

the industrial operations taking place in KRPC (PPU). The organization is of

powerful, skilful and wide disciplines. Practical applications of what we learnt in

School (theoretical) are available, especially in the field of Water Treatment

particularly. The practical skills operations taking place in those organizations

are what motivated me to apply and undertake this exercise.

KRPC (PPU) Kaduna: The training involves the continuous operation of water

transportation, filtration, demineralization, steam production for driving turbine

which is couple to the generator through a reduction gear for electric power

generation. Electric power generated is distribute to the entire organization and

its suburbs for normal working operations.

1.5 Training methodology at the SIWES place

 During the course of the training, the following methodology was

adopted;

 Brief Lectures and discussions.

 Participation and involvement while conducting operations.

 Site Works (project and repair operations).

 Questioning and Answering.

1.6 Report outline.

This technical report comprises of the knowledge which was garnered in

the Industrial training I undertook in the Organization, It is fully indicated within

and according to subheadings. The technical report is organized into five (5)

chapters.

The first chapter contains the general introduction, the second chapter is

devoted to the theoretical background of the selected SIWES areas. The main

training undergone is detailed in chapter three. Chapter four is the experience

gained from the training and its application in future career. Chapter five goes for

the limitations, difficulties, recommendation and conclusion.

 CHAPTER TWO

2.0 Theoretical Background of The SIWES Area

2.1 Introduction

This chapter is concerned with the fundamental theoretical background of

the SIWES areas. It will aid better understanding for technical aspects of this

report. The general objective of this chapter is to discuss and as well as describe

main objective and the principle of operation of the organizations.

2.2 Nigeria National Petroleum Corporation (NNPC/KRPC)

The NNPC embarked on commercialization exercise the same year 1988

and it became necessary to merge the two plants (Refinery and Petrochemical

Plants) to form a single subsidiary company of NNPC known as Kaduna

Refining and petrochemical Co. Limited (KRPC), which was incorporated as a

limited liability Company on 3rd November, 1988. It occupies an area equivalent

to approximately 1.8 squares Kilometre. In 1988, the NNPC was commercialized

into 12 strategic business units, covering the entire spectrum of oil industry

operations: exploration and production, gas development, refining, distribution,

petrochemicals, engineering, and commercial investments. Currently, the

subsidiary companies include: 

 Nigerian Petroleum Development Company (NPDC)

 The Nigerian Gas Company (NGC)

 Nigerian Pipeline and Storage Company (NPSC) Formally known as

(PPMC)

 Integrated Data Services Limited (IDSL)

 National Engineering and Technical Company Limited (NETCO)

 Hydrocarbon Services Nigeria Limited (HYSON)

  Warri Refinery and Petrochemical Co. Limited (WRPC)

 Kaduna Refinery and Petrochemical Co. Limited (KRPC)

 Port Harcourt Refining Co. Limited (PHRC)

 NNPC Retail

 Duke Oil

In addition to these subsidiaries, the industry is also regulated by the

Department of Petroleum Resources (DPR), a department within the Ministry of

Petroleum Resources. The DPR ensures compliance with industry regulations;

processes applications for licenses, leases and permits, establishes and enforces

environmental regulations. The DPR, and NAPIMS, play a very crucial role in

the day to day activities throughout the industry.

 SECRETARY
GROUP
MANAGING
DIRECTOR

Autonomou Corporate
s Service
Business Units
Units
units

Figure 2.0: The NNPC Organizational Flowchart

Upstream Downstream Refining Ventures Gas & Power
Company Company Company Company Company

Finance and Corporate

accounts Services
 The Kaduna Refining and Petrochemical Company (KRPC) was built by the

Chiyoda Chemical Engineering and Construction Company Limited, Japan for the

Nigerian National Petroleum Cooperation (NNPC). KRPC was commissioned in 1980 as

NNPC Refinery Kaduna. Its initial capacity was 100,000 Barrels per Stream Day

[BPSD]. As the third Refinery in the country, it was established to cope with the

growing demand for petroleum products, especially in the Northern part of the country.

The Refinery was designed to process both Nigerian and imported crude oils into fuels

and lubes products. In December 1985, the Fuels section of the Refinery was

successfully DE bottle-necked from 50,000 BPSD to 60,000 BPSD, bringing the total

refinery installed capacity to 110,000 BPSD. In March 1988, the 30,000 MT per annum,

Linear Alkyl Benzene (LAB) Petrochemical Plant was commissioned. The

Petrochemical Plant, being a downstream of plant of the refinery, derives its entire raw

materials including utility supplies from the refinery.

Kaduna Refining and Petrochemical Co. (KRPC) was established to efficiently

and profitably process crude oil into refined petroleum products and manufacture linear

alkyl benzene (LAB) and tins and drums for domestic consumption and export. The

objectives of KRPC are to optimize the capacities of the existing plants, reduce the

plants' operating costs, develop new products from existing facilities for use in

downstream industries and extend refining services to the West African sub-region. Like

other subsidiaries of NNPC, KRPC is owned 100% by NNPC.

The Company consists of different Departments including; Power Plant and

Utilities (PPU), Production Planning and Quality Control (PPQC), Engineering and

Technical Services Department (ETSD), Linear Alkyl Benzene (LAB), Maintenance

Department, Wastewater Treatment Department (WWT) etc. All headed by their

 Managers. The Company therefore offers its combine resources with utmost confidence

in its ability to meet the demand of the nation.

2.3 Power Plant and Utilities

The Power Plants and Utilities (PPU) is one of the main Department in KRPC

that is responsible for providing safe, reliable and secured Electric Power, Steam, Water

(cooling, drinking, and boiler feed), Air (instrument, service), Nitrogen etc. that are all

required for the continuous operations in the company. The primary raw material for the

department is water, pumped from River Kaduna. PPUD complex of KRPC is saddled

with the responsibility of providing safe, reliable and secured electric power, steam,

water (cooling, drinking, service, and boiler feed), Air (instrument, plant), nitrogen etc

required for continuous operation of the Process Plants and other facilities in our

Refineries and Petrochemical Plants. PPUD also treats waste materials.

At present, PPU is one of the main functional departments in the Company. It has

a Manager, a Secretary and two (2) Deputy Managers, DM Utilities and DM Power.

There are also four (4) Superintendents in the Department.

 MANAGER,
PPU

DM, UTILITY
DM, POWER
UTILITIES SHIFT SUPT

Figure 2.1: Organizational flowchart of PPUD

The following are the key operations in the Department:

 Steam production process

 Power generation production process

 Raw water treatment process (refinery)

 Water Demineralization process

 Cooling water treatment process

 Compressed air production process

 Nitrogen (gas & liquid) production process

 Drinking water production sub-process

 Wastewater treatment process

 LAB utilities production processes & sub-processes

Power Plant Units

Unit 70 - Steam generating facilities

Unit 71 - Power generating facilities

Unit 78 - Fuel oil facilities

Utilities Units

Unit 62 - Waste water treatment plant

Unit 72 - Raw/filtered water treatment plant

Unit 73 - Demineralized water plant

Unit 74 - Cooling water facilities

 Unit 75 - Compressed air facilities

Unit 76 - Nitrogen facilities

Unit 80 - Caustic soda facilities

Unit 81 - Raw Water Intake

Unit 90 - Linear Alkyl Benzene Utilities

The primary source for the generation of almost all these utilities is water.

2.4 The Control Room

The control room is the heart of the power plant and utilities section of the Kaduna

refining and petrochemical company. It is also called the Operations Room. It is a room

serving as a central space where a large physical facility/equipment’s or physically

dispersed service can be monitored and controlled. Its main purpose is production and

process control. They are typically tightly secured and inaccessible to the general public.

Multiple electronic displays and control panels/ gauges are usually present to check out

process parameters. The control room is manned “24/7/365” basis and have multiple

people on duty at all times to ensure continuous vigilance. Control rooms are usually

found in the following establishments;

 Nuclear power plants and power generating stations

 Oil refineries and chemical plants

 Transport facilities

 Military facilities etc.

Note: Emergency alarms are put in place to trigger and inform the operator on duty,

whenever a particular process or instrumentation is Faulty or below the tolerance level.

Each emergency alarm set-up has an Acknowledge, stop and reset button.
 Figure 2.2: The PPU main control room

2.5 Process Parameters and Instrumentation

Process parameters are certain measures that refer to the status of a process; their

values indicate whether the process meets the plan/ specification or it needs adjustment.

An industrial chemist is so concerned about the process parameters in an industrial set-

up, this is borne out of the desire to have a first-hand idea about the process flow and

process instrumentation utilized in a particular unit operation. In order to obtain effective

execution of a process, its parameters should stay under continuous control. The major

process parameters an industrialist looks out for are;

a) Flow (measured in m3 /hr.)

b) Level (measured in %)

c) Temperature (measured in °C)

d) Pressure (measured in Kg/cm2)

Process instrumentation on the other hand, simply refers to the machines,

equipment’s and materials utilized in each unit operation through-out a particular

process. Some of the instrumentation includes Compressors, Pumps, Turbines, Dryers,

and Tanks etc.

Note: Each process parameter/instrumentation has a set-standard level and a tolerance

level. When the tolerance level is abridged, an emergency alarm is triggered. Constant

and careful manning of the control room makes up for this challenge.
 CHAPTER THREE

3.0 Details of Training Undergone in The SIWES Area

3.1 Introduction

The details of the training I undertook in Kaduna Refining and Petrochemical Co.

KRPC (PPU) are fully discussed in this chapter. The training method was based on the

following; Teachings during plant patrol, Lectures and discussions, Participation and

involvement of Questions and answering mode.

3.2 Fire and Safety Induction Course

In every working environment in which employees are operating in industries,

workshops or any offices, safety is very important so as to avoid or reduce accidents.

This is an obligatory program in NNPC/KRPC, Kaduna for every new employee,

Industrial Training (I.T) Students and contractors before they would be allowed to enter

any section of the plants. In general, safety means freedom from harm or injury. The

safety induction Course is conducted by the Safety and Fire Services Department of the

Company.

3.3 Accident

Accident is an unplanned sense of events that may lead to an injury of personnel,

death or damage to properties.

3.3.1 Causes of Accident

i. Unsafe act.

ii. Unsafe condition.

iii. Bad housekeeping.

iv. Breaking of safety rules.

3.3.2 How to Prevent Accident

i. Obtaining work permit for every work before execution.

 ii. Wearing personal protective equipment’s (PPE’s)

iii. Following safety rules strictly.

iv. Obtaining good housekeeping.

3.3.3 Types of Work Permit

i. Hot work (welding, heating).

ii. Cold work (admin, lesser work).

iii. Vessel entry (entry into a closed column).

iv. Acid area entry.

v. Excavation (digging).

vi. Electric works permit.

3.3.4 Harmful Substances

Harmful substances are the substances that are hazardous or dangerous to human

life which when in contact with body, causes temporary or permanent injury.

Some harmful substances are:

a) Acid: This includes H2SO4 and HCl. Acid, when in contact with tissue causes

severe burns. The first aid treatment for contact with H2SO4 is to wipe it from the

skin and then wash it off with a lot of water.

b) Gas: This is primarily NH3. Small amount of this gas is dangerous which causes

headache, mental dullness and unconsciousness. The first aid treatments for

exposure to NH3 are:

i. To move to fresh air area in a hurry.

ii. To keep quiet and warm.

iii. To practice artificial respiration.

c) Liquid: This includes Benzene and Toluene. Toluene is a colourless and flammable

liquid. Exposure to toluene causes headache, a bad taste, loss of appetite, anaemia
 and enlarged liver may be found in rare cases. The first aid treatment is to wash the

area affected with a lot of water.

d) Noise: This is a harmful condition, which when the 90 decibels limit for hearing is

surpassed, it can result to destruction of ear drums and eventually, being deaf.

3.3.5 Ways of Contact

a) Inhalation via noise.

b) Absorption via skin.

c) Direct contact or injection.

d) Ingestion via mouth.

e) Through the nose

3.3.6 Personal Protective Equipment’s (PPE’s)

Table 3.0 Personal protective equipments

Region(parts) of the body Equipment (s)

Head Helmet
Body Safety overall or lab coat
Hand Hand glove
Eye Eye goggles
Ear Earmuff or plug
Nose Dust canisters
Face Face shield
Heights Safety belt
Feet Safety boots
Acid Acid suit
Confined space Breathing apparatus
 Figure 3.0: Personal Protective Equipment

3.4 Fire

Fire is a rapid combination of combustible substances leading to the production

of heat, smoke or light. There are three major elements that makes up the fire triangle;

Oxygen, heat and Fuel source.

3.4.1 Classes of Fire

The classes of fire include the following;

CLASS A: These are the free combusting material such as paper, grass, wood, clothes

and rubber etc.

CLASS B: These are the liquids combusting materials such as petrol, kerosene, diesel oil

and palm oil etc.

CLASS C: Those are the gaseous combusting materials such as butane, propane etc.

CLASS D: These are the materials combusting materials such as sodium, magnesium,

potassium etc.

Note: Electric fire does not belong to any classes of fire; it depends on the nature of the

fire.
3.4.2 Fire Extinguisher

This is a device or equipment made to prevent or help in putting off fire during

eventual outbreaks. It is of various types depending on the class of fire, which will

determine the one to be used. Examples of fire extinguishers are:

i. Carbon dioxide extinguisher: It is used for classes B, C and D.

ii. Dry chemical power extinguisher: it is used for classes B, C and D.

iii. Foam dry extinguisher: It is used for class B only.

Note: Water is always used to extinguish class A.

3.4.3 General Prevention

i. Avoid careless smoking in inflammable environment.

ii. Lubrication of machines so as to allow free movement.

3.4.4 Preventive Objective

i. To save life.

ii. To save properties from damage and destruction.

3.5 Unit 70 (Steam Generation)

This is the unit where water is obtained from the water plant and converted into

steam. Steam is generated using a Boiler. We have three basic classes of steam, vizly;

i. High Pressure Steam (HPS); Generate at the pressure of 42.5 Kg/cm 2 and

temperature of 412 ℃. (Design generation pressure 47.6 Kg/cm2) used as motive

power.

ii. Medium Pressure Steam (MPS); Generate at 16.5 Kg/cm 2 and 275 °C used for

driving small turbine, processing, heating etc.

iii. Low Pressure Steam (LPS); Generate at 4.5 Kg/cm 2 and 175 ℃ used mostly for

heating.
 Figure 3.1: Steam generator

3.5.1 Unit 81 (Raw Water Intake from The River)

The main raw material used in Power Plant and Utilities Department is Water.

The Section gets the water from River Kaduna.

KADUNA RIVER

LIFT PUMPS
In-take Well
81POIABC
COAGULANT
DOSING PUMPS

CLARIFIES
81SO1AB COAGULANT AND
DOSING PUMPS

I SODIUM
RECEIVER TANKS HYDROXIDE
(81DO1)
PUMPS

TRANSFER PUMPS
81P02 ABCD

Water to KRPC
Raw Water Tank

Figure 3.2: Process flow diagram of unit 81

The process parameters and instrumentation for unit 81 include;

a) Diesel Generator
 b) Lift pump

c) Transfer pump

d) Flow

e) D05 (in and out)

3.5.2 Unit 73 (Demineralization of Water)

In this process, mineral ions present in the water are removed by Ion Exchange

Method. Example; Any salt can be split up into Cat ions and Anions, Sodium Chloride

(NaCl) can split up into Na+ and Cl- (ionic form). In demineralization process the

positive ions are removed in Cat ion exchanger and the negative ions are removed in

Anion exchanger. By the removal of cat ions and anions dissolved in water,

Demineralization is achieved.

The water charged to a demineralizing (Demine.) unit should be free from coarse

dispersed and colloidal impurities because these may precipitate on the resin surface

affecting the overall performance of the unit.

 Figure 3.3: Cross Section of Demineralized water plant

Schematically the process of demineralization involves 2 basic steps:

 Removal of metal cations (Ca2+, Mg2+, Fe2+, Na+, K+, Al3+) represented by M+ in the

cat ion exchanger.

 Removal of the anion (CO3-, HCO3-, SO4-, Cl- etc. represented by A- in the anion

exchanger.

The normal route of a Demineralization Unit is as follows:

Water à Filter à Cation Exchanger à De-gasifier à Anion Exchanger à Polisher à

De-aerator à Scavenging Chemical addition à Boiler feed water Pumps à Boiler.

CO2

Filtered water HSO4

HCL H-OH

Ca HCO3
Mg
Ca SO4
Mg

Anion Mixed Bed

CL Cation
Exchanger Ion
Exchanger Exchanger

Air (RH++ROH-)
Air

To Demineralised
Degassing Water tank en route
Chamber H-OH To the boilers
ROH- + HSO4 → R-SO4 + H-OH pH = 6.5~8.5
HCL CL (Water) Cond = < 1μscm-1
SiO2 = <0.02ppm
RH++ Ca - ANION R- Ca + HCO3
Mg Mg HSO4
Na Na HCL

Figure 3.4: Demineralization of water

The process parameters and instrumentation for unit 73 includes;

a) Demin in service
 b) Tanks level

i. Demineralized water tank level

ii. Condensate water tank level

iii. Boiler feed-water tank level

c) Mixed bed in service

3.5.3 Boiler Feed Water System

The purpose of the boiler feed water system is to give final treatment of the water

to de-mineralized water to make it suitable for feeding into the boiler. The process

involves duration of water, chemical treatment with Ammonia for PH control, Hydrazine

for oxygen scavenger and Sodium Phosphate for boiler internal treatment.

Demineralized
Water

De-aerator De-aerator
Hydrazine

Piping Ammonia Piping

Phosphate Boilers

Steam
Phosphate
 Figure 3.5: Steam generation process

The uses of steam in Company include:

i. As a source of motive power for driving generators, pumps, compressors etc.

ii. As heating for heat exchangers, line tracing, fuel oil tank etc.

iii. Processing as stripping steam, de-aeration an ionizing steam etc.

iv. Special purposes for firefighting e.g. in a furnace during tube burst. In emergency

cases e.g. failure of feed supply to catalytic cracker (FCC)

v. As driving fluid in ejectors, pump priming etc.

3.5.4 De-Aerators (70d01 & 70d02)

De-aeration is the removal of air molecules (usually oxygen) from a volume of

liquid or gas. The de-aeration process is carried out in de-aerators before water gets to

the boiler for heating and subsequent production of steam. It is important because

demineralized water contains little proportion of oxygen in it. De-aeration is essential

because the boilers are made from metals; oxygen reacting with air in these boilers

causes corrosion of it parts, consequently reducing its efficiency and effectiveness. Two

de-aerators are installed; Demineralized water is feed into each de-aerator with

individual water level controller 70-LIC-U01 and 70-L1C-U02. It is operated at equal

water level by common de-aerator outlet feed water pipe and similar for feed water

outlet piping.

De-aerators are tray type vertical cylindrical storage tank with 320 t/hr. capacity

and an operating pressure of 1.34 kg/cm2 along with a temperature of 125 °C.
 Figure 3.6: A cross section of De-aerators

3.6 The Raw Water Treatment Plant (Unit 72)

The unit 72 is called the raw water/filtered water treatment plant. This unit is

responsible for the whole process of water treatment before transfer to pumps for

drinking, service, demineralization and several other purposes/uses. This unit is made of

raw water tanks (72TK01A & B), with a capacity of 75 million litres each. The raw

water tanks serves as temporary reservoir of water directly from the Kaduna river source.

The water then flows through pumps (72P01A, B & C), to the water clarifiers (72S01A,

B & C). These clarifiers are mechanically built round settling tanks and Treatment

Avenue for raw water. The water is treated using Polyaluminium chloride aid (PAC aid),

coagulant aid and calcium hypochlorite [Ca(ClO)2]. Each clarifier has four floculators

and one rake.

 Figure 3.7: Cross section of raw water tank

The process parameters and instrumentation for this unit are;

a) Flow to refinery

b) Flow to clarifier

c) Tanks level

i. Raw water tank A level

ii. Raw water tank B level

iii. Filtered water tank level

3.6.1 Process Flow Description

Raw water is transferred through pumps from raw water tanks to the clarifiers,

before reaching the clarifiers, a portion of this is sent to the safety department as hydrant

water used for firefighting activities. The clarifiers are designed to be operated in full

capacity based on water received from raw water tanks. Its modus operandi is such that,

after chemicals are poured in the chemical mixers via manual chemical dosing, it is

transported to the floculattors which spreads it all through the water. The coagulant aid is

first introduced; these surrounds and solidifies dirt’s of low weights on the surface called
SCUM. The PAC aid then drags this scum to settle at the bottom alongside solid

impurities called SLUDGE. Calcium hypochlorite is then introduced to kill germs that

might be present. At the end of the chemical dosage, after 6hours, a sludge wash off is

carried out to drain the impurities present. The clarified water then moves to the clarified

water pit, subsequently to pressure filters for filtration. Upon filtration, the water is

pumped to the filtered water tank (72TK02). The filtered water is then transferred to

different units via electric driven pumps.

3.6.2 Pressure Filters

Pressure filters are steel tanks made of nozzles, regulators, pressure vessel used
solely for the water filtration process. The pressure filter uses high pressure water and air
for it filtration and backwashing activities. The main difference between pressure filters
and conventional rapid filters is that in the former, the filtering media is found within the
system in an enclosure termed, pressure vessel. It utilizes the biological media or
biological process in its operation. These media includes sand, gravel and anthracite in a
ratio of 40:30:30. During filtration, the materials are placed at the bottom at the bottom
of the filter in the pressure vessel; water comes from the clarified water pit and passes
through it, with the media serving as a form of sieve. In each filter, we have 360
strainers, these strainers are the media through which clean and quality water passes
before going into the filtered water tanks. The filters in KRPC are twelve (12) in number
coded, 72F01A-L. It is controlled by seven (7) valves, each serving a different function,
vizly;
 Valve 1 (service inlet): This regulates water flow from clarified water pits to
pressure filter.
 Valve 2: This regulates water flow from filtered water tanks back to pressure filters.
 Valve 3: This regulates water flow from filters to backwashing pits.
 Valve 4: This is used for draining and to reduce pressure in filters
 Valve 5: (service outlet): This regulates flow of clean and quality water from filter to
filtered water tanks.
 Valve 6: This is utilized for air bubbling and agitation; to sieve the filtration media
properly
 Valve 7: This is utilized for venting, that is to reduce pressure.
It is essential to wash these filters, since with time and constant usage it tends to get
dirty. This is carried out utilizing a process called BACKWASHING.
 Figure 3.9: A Cross section of pressure filters

3.6.3 Drinking Water Filters

The drinking water filters have unique codes 72FO2A & B. They are cylindrical
steel tanks which serves as final treatment avenue of filtered water before transfer to
drinking water tank (72D01) through electrical driven pumps (72PM04), and subsequent
use by end users for drinking purposes. The drinking water filters uses activated carbon
as its filtration media in an adsorption process. The main function of activated carbon is
to eliminate colour, odour and taste from water for drinking purposes. To initiate the
filtration process, the activated carbon B pump is manually started.
3.6.4 The Clarifier
Clarifiers are settling tanks built with mechanical means for continuous removal
of solids been deposited by sedimentation. A clarifier is generally used to remove solid
particulates or suspended solids from liquids by clarification and/or thickening.
Concentrated impurities, discharged from the bottom of the tank are known as sludge,
while the particles that flow on the surface are called scum. Before water enters the
clarifier, it is first treated with Coagulants and flocculants reagents. These reagents
cause finely suspended particles to clump together and form larger and denser particles
called flocs that settle more efficiently and easily; aiding in the conservation of energy.
After treatment, clarified and clean water is sent to the clarified water pit before going to
the filter for further filtration.
 Figure 3.10: Cross section of Clarifiers

3.6.5 Water Samples

Water samples are taken at strategic positions to ascertain the quality of water and to
check if proper water treatment/ filtration is carried out. The water samples are taken at
seven strategic points. Vizly;
 Clarifier water inlet
 Clarifier water outlet
 Cooling water outlet
 Drinking water inlet
 Pressure filter inlet
 Pressure filter outlet
 Filtered water inlet
The water samples are taken to check and test the following chemical parameters.
The parameters include;
 The Hydrogen ion concentration (pH)
 The ionic (silicate) content
 The water temperature
 The turbidity
 The conductivity
Note: The chemical dosing is done 30 minutes before taking water samples. The water
samples are taken twice for every 12 hours shift.
3.7 Unit 75 (The Air Facility Unit)
The air facility unit is solely responsible for the production of compressed air
used majorly for powering pneumatic control systems; system powered by air. This unit
provides instrument air and service air for usage in the refinery, with the latter utilized
for powering valves and the former for maintenance activities. The unit is made up of
Air compressors (75K01A-E), dryers (75D01A & B) and air surge drums (75S01A &
 B). After production, compressed air is sent to a common header from which different
units tap.
The process parameter and instrumentation for this unit are;

a) Compressor
b) Dryer
c) Instrument air
d) Service air
e) Air Surge Drums

Figure 3.11 Cross section of Compressed Air Facility

3.7.1 Process Flow Description

The most important set-up in this unit is the air compressor. The compressor sucks in

feed air from the atmosphere at ambient temperature and pressure of about 0.1 kg/cm 2.

The air goes through three (3) stages, each leading to an increase in temperature. At

stage 1, the pressure builds up to 1.1 kg/cm2, at stage 2 it increases to 3.5 kg/cm2 and

finally at stage 3 it builds up to 9.3 kg/cm2. This pressure at the final stage is excess and

compressed air cannot be sent to the air surge drums for storage, it is then regulated by a

pressure indicator and controller (PIC) to a range of about 8.0-8.5. After compressed air
 must have been produced, it is sent to the air surge drums; to remove and evacuate

moisture from air produced, serve as temporary storage for compressed air and as an

avenue for removing ripples. Compressed air is further channelled to dryers and then to a

common header where it gets to the end users. Compressed air is utilized by the

following units;

 Nitrogen plant

 Off-sites

 Power plant and utilities

 Lubes
 Fuels
 Instrument air
 Service air

3.7.2 Air Compressors

The air compressor is a device that converts power (using diesel, steam or
gasoline engine) into potential energy stored in pressurized air. It is made up of two main
parts, the driver and the turbine. By one of several methods, it forces more air into a
storage tank, increasing the pressure. The compressed air is then held in the tank until
called into use. The compressor in the Kaduna refining and petrochemical company is
coded 75KO1. Based on its design and principle of operation, it is a centrifugal
compressor; it takes air and spins it leading to a rise in its pressure. The KRPC have two
compressors, a steam driven and an electrical driven, the latter is set on standby mode
and cuts in when the steam driven drops to a pressure below the set mark at about 6.6
kg/cm2. The steam driven compressor utilizes the high-pressure steam and medium
pressure steam for powering it driver. The compressor has a flow/capacity of 6000
Nm3/hr. The mechanical parts of this device utilize cooling water and lube oil for cooling
and
lubrication of its
parts, the former is
 gotten from the unit 74(cooling facility) while the latter is supplied by an oil pump.

Figure 3.12: A Compressor

3.7.3 Air Surge Drums

An air receiver tank or air surge drum is an integral and important part of any

compressed air system. The air surge drum serves three main functions;

 It serves as a temporary storage tank/reservoir of compressed air for peak demands

 The air surge drums evacuate possible moisture from compressed air.

 It minimizes pulsation; acts as an avenue for removal of ripples, this ripple tends to

affect the free flow of stored air to the common header before it gets to final users.

Much like a water reservoir provides water during times of drought and stores water

during the wet times, an air surge drum compensates for peak demands and help balance

the supply of the compressor with the demand of the refinery.

3.7.4 Dryers

A compressed air dryer is a machine used for removing water vapour from

compressed air. The performance of dryer is typically defined by the dew point. A

regenerative desiccant dryer typically delivers a dew point of between -40 °C and -73
°C. A deliquescent dryer delivers a dew point suppression that fluctuates with air

temperature; typically, this suppression is 11°C below the compressed air temperature.

The process of air compression concentrates atmospheric contaminants, including

water vapour. This raises the dew point of the compressed air relative to free

atmospheric air and leads to condensation within pipes and the compressed air cools

downstream of the compressor. Excessive water in compressed air causes the following;

 Freezing of outdoor air lines.

 Corrosion in piping and equipment

 Malfunctioning of pneumatic process control instruments

 Fouling of processes and products

3.8 Unit 76 (Nitrogen Plant/ Facility)

The unit 76 is the nitrogen facility if the KPRC, this unit is solely responsible for

producing and providing liquid and gaseous nitrogen for consumption in major sections

of the refinery which includes the power plant, process plant and lubes. The unit is made

up of the following equipment’s;

 The Nitrogen compressor

 The Chiller

 The Carbon bed

 The Adsorbers

 The Buffer tanks

Fig 3.13 Cross section of Nitrogen Facility

The process parameters and instrumentation for this unit are;

a) Flow
b) Percentage purity
c) Compressor pressure
3.8.1 Process Flow Description
The Nitrogen production process is termed a cryogenic process. Cryogenics is a
branch of science and engineering that deals with low temperature reactions. In this
process, the constituent of air is separated when it is cooled and chilled to a very low
 temperature of about -180 °C. The nitrogen compressor sucks air at ambient temperature
and pressure with all the constituents of air present in it. The compressed air is then sent
to a chiller, the chiller cryogenically cools the air using cooling water from unit 74,
leaving only nitrogen and oxygen present. The chiller shows the level of separation when
it is up to the set mark designed. The nitrogen and oxygen present goes to an Activated
carbon bed which removes oil vapour and further impurities in the compressed air.
Upon leaving the carbon bed, it goes to the adsorbers. The main separation takes place at
the adsorbers, the remaining constituent of air present other than nitrogen is adsorbed
using carbon black as the adsorbing media. The percentage of oxygen present determines
the nitrogen purity; A 23 ppm of oxygen represents a 77 ppm of pure nitrogen. After all
these impurities must have been adsorbed, impure nitrogen goes off to the atmosphere.
The pure nitrogen goes to buffer tanks which serve as storage tanks awaiting transfer to
end users.
One of the most important use of this nitrogen gas is the flushing of Fractionating
columns, towers and pipes especially in production areas where little deposits of oil
fractions might be present upon discharge to pipelines for end users. Nitrogen is used
because it is defined as a simple asphyxiant; causing oxygen/carbon dioxide suffocation.
This inert quality of nitrogen is used in many applications where oxidation is not desired,
with oxygen forming part of a fire triangle and a causative agent of fire outbreak.

Figure 3.14: Process Flow Diagram for Cryogenic Nitrogen Production

3.8.2 Chillers
 A chiller is a machine that removes heat from a liquid via a vapour-compression

or absorption refrigeration cycle, chilled water is used to cool and dehumidify air. A

process chiller is a refrigeration system using halocarbon or ammonia refrigerants that

provide cooling for a process or industrial application. A process chiller may use an air

or water condenser in its cooling process. As the sub-cooled liquid refrigerant passes

from the condenser to the evaporator, a thermostatic expansion valve causes the pressure

and temperature to drop. The refrigerant then picks up the heat from the fluid flowing

through the evaporator, changing from a liquid to a vapour. It continues in a continuous

cycle continually cooling the process. The Mechanical Ejectors are included in the

system to retain high condensate vacuum by removing air or gases, which look into the

surface condenser and vent them to the air. Each process chiller incorporates the

following parts;

-Compressor -Condenser -Evaporator -Pumps -Pipes -High pressure refrigerant

-relief valves

Figure 3.15: A Process Chiller

Chillers rely on three basic principles.

  First when a liquid is heated it vaporizes into a gas, and when a gas is cooled it

condenses into a liquid

 Second- lowering the pressure above a liquid reduces its boiling point and increasing

the pressure raises it

 Third – heat always flow from hot to cold.

The basic cooling cycle is that the chiller utilizes a liquid refrigerant that changes

phase to a gas within an evaporator which absorbs heat from the water to be cooled.

3.8.3 Adsorbers/ Buffer Tanks.

Adsorption is the process by which molecules temporarily adhere to the surface
of materials they are in contact with. A nitrogen production facility consists of a two or
more adsorbers filled with Carbon-molecular sieve (CMS). CMS is produced
specifically to have pore sizes that correspond to the relatively small size of an oxygen
molecule (compared to the relatively larger nitrogen molecule). The adsorption process
is such that compressed air is drawn from a compressor and directed into one adsorber.
Under pressure, oxygen in the compressed air gets “stuck” in the pores of the CMS,
allowing the remaining constituent (mostly Nitrogen) to pass through the system
unhindered. However, there is one problem. Eventually, oxygen molecules separation
will no longer occur. This is called Saturation; where oxygen molecules completely
cover the surface of the CMS and there is no room for more to be adsorbed. Fortunately,
the adsorption process is reversed by depressurizing the adsorber, this is why two
adsorbers are used to overshadow this limitation. While the first adsorber is regenerating,
the second adsorber is actively producing Nitrogen. At the end of the cycle, the first
adsorber is once again ready to produce nitrogen and the second adsorber regenerates,
and so on. After Production, Pure nitrogen gas goes into buffer tanks for storage and
eventual consumption
 Figure 3.16: Adsorbers

3.9 Unit 74 (Cooling Facility)

The unit 74 is termed the cooling facility of the refinery; It is simply called the

cooling Tower. The role it plays is analogous to the radiator of a car engine. This unit is

solely responsible for the production and provision of cooling water, utilized in the

cooling of process fluids and equipment to specification. Owing to production activities

in the refinery at high temperature and pressure, it is always hot. So, this cooling water is

essential so as to reduce the temperature and hotness to make it moderate for working

conditions. The pumps responsible for the operation of this unit are steam driven and

electrical driven. There are three basic types of cooling water systems;

- The open system - The closed system - The once through system

The KRPC utilizes the open cooling water system. The once through system is majorly

utilized in the middle-east countries such as Kuwait and Saudi Arabia. These countries

are very humid with high concentration of salts in it water, as a result the cooling effect

is subdued due to excess heat. The cooling water system has the following parts/sub-

units;

-Cooling fans - Cooling water basins -Water (H2O) sprinkler –Stack –Riser

-Drifter

-Make-up water valve -Side filters -Cooling water pumps

 Figure 3.17: Cross section of cooling water system

The process parameters and instrumentation for this unit are;

a) Cooling pumps

b) Cells

c) Cooling fans

d) Cooling water pressure

e) Recirculation rate

3.9.1 Process Flow Description

The principle of operation of cooling tower is very similar to that of the

evaporative type of condensers, in which the warm water gets cooled by means of

evaporation. Water evaporates as a result of the hot water droplet coming in contact with

the air (pumped out by means of a cooling fan). This evaporating water also absorbs the

latent heat from the water surrounding it. By losing latent heat, the water is cooled.

Filtered water from the pressure filters is sent to the cooling water basins via Up-risers

with the aid of cooling water pumps (74PT01A-E). The water is first treated with

inhibitors and dispersants, the former is to prevent cooling water from coming in contact

with the walls of the transporting media so as to prevent corrosion while the latter is to

kill germs present. The cooling process is such that, water comes in through Up-risers

and since the system is open and exposed, hot air leaves the water at first. The cooling

fan now blows the water counter-current to the direction of downward flow, so as to

increase the evaporation rate and hence the cooling effect. This system is made of water

sprinkler which increases the surface area of water so that the heat exchange will be high
 from the bulk of water exposed to the air. The drifter gives direction to the water after

the fan helps blow the air counter-current to flow of water. After the water must have

been cooled, it is deposited in a cooling water basin from which it flows through down-

risers to the sections they are utilized.

Figure 3.18: A cooling water tower

3.9.2 Cooling Water Draft System

 According to the method adopted to circulate the air and bring about evaporation,

cooling towers may be classified as;

a) Natural Draft cooling tower: As the name implies, the air is circulated inside the

cooling tower by natural convection. The natural draft cooling towers are further

classified as; The Spray type and the Deck type. Capacity control is impossible in

this system because the volume of air cannot be controlled. They are located only in

open spaces, as they are dependent on atmospheric air.

b) Mechanical Draft cooling tower: It is simply to the natural draft system. As the name

indicates, air is circulated inside the tower mechanically instead of natural

circulation. Fans or centrifugal Fans may be used. This system is usually smaller

because of the increase in cooling capacity due to increase in volume of the air being

forced out by fan.

c) Forced/ Induced Draft cooling tower: This is a sub classification of the mechanical

draft system based on the location of the fan. In the forced draft system, the fan is

located near the bottom and on the side; it forces the air from bottom to top. An

eliminator is used to prevent loss of water droplets along with the forced air. In the

induced draft system, a centrally located fan at the top takes suction from the tower

and discharges it to the atmosphere.

3.9.3 Cooling Water Treatment

Water may be treated with chemical inhibitors to extend the saturation point of

insoluble materials and prevent Scaling/corrosion. When insoluble materials such as

calcium carbonate (CaCO3), Calcium phosphate, Magnesium salts and silica, precipitate

out of cooling water, they form deposits called Scale. This scale reduces heat exchanger

efficiency consequently leading to wasted energy and increased operational costs.

Dispersants are also used in in water treatment to kill germs that must have been present
after the chemical dosage for pre-treatment. The dispersant solution is injected into the

cooling water basin, prevents particles settling in the system. The inhibitor solution is

added to minimize corrosion in the pipes of the system. To prevent the growth of algae

and microorganisms in the cooling water system, hypochlorite solution is injected in the

basin. Sulphuric acid is added to control the pH of the water. To eliminate suspended

matter from the water a bleed of the water coming from the units is continuously passed

through three filters 74F 01 A-C which retains foreign substances. The water is then

returned to the basin. The filters must be backwashed periodically to remove the

substance they have retained. The backwash water is then to the waste water pit and

from there sent to the waste water unit.

Figure 3.19: Chemical dosing facility

 CHAPTER FOUR

4.0 Experience Gained and Applications In Future Career

iv.1 Introduction

The previous chapter highlights the detail of training undergone in the SIWES

areas. The chapter discusses and describes the avenue for acquiring industrial skills and

experience at Kaduna Refining and Petrochemicals Co. (PPU). This chapter illustrates

the experience gained during the course of the training.

Power Plant and Utilities Department is maintained and observed continuously at

every minute and 24 hours of a day. The operators are very hard working and

experienced. There is plant patrolling two (2) hourly readings of pressure and

temperature gauges and other normal routine operations of running equipment taking

place in the plant constantly.

In real world, the utility system is the back bone for modern technology. Areas and field

of specializations such as Process Science, Oil refining and production, Industries etc. all

requires and depend on the electric power for their operations. The provision of electric

power is a very complex system that requires the contribution of scientists, engineers and

good management.

4.2 Experience Gained and Applications in Future Career

The main experiences gained are from the work activities I have participated.

However, they are fully applicable in future carreer. The work (operation) activities

participates includes as below explain in the points and headings.

4.3 Air Compressor Start Up and Shut Down Processes

The air compressor is the major equipment (component) where compress air is

generated. The air compressor is started up by a process termed “COMMISIONING’’.

The steps in commissioning an air compressor are as follows;

 a) Carry out pre start-up checks by physical inspection.

b) Check lube oil level

c) Confirm if cooling water is commissioned in both inlet and outlet

d) Reset all alarms

e) Ensure all drains and steam traps are opened, Commission medium pressure steam

(MPS)

f) Open bye-pass (HPS valve) to control flow

g) Commission High pressure steam (HPS)

h) Open the Emergency Main Shut-off Valve (EMSV), until mechanical leakage comes

out meaning governor has taking control. The EMSV takes the turbine speed to about

2500 rpm, then the governor takes it to the desired speed of about 3100 rpm

i) Auto load the compressor

j) Open the discharge of the compressor

Note: When the discharge is at Zero, the blow off valve is at hundred (100), so when the

discharge is finally opened, the blow off valve returns to Zero. The process above is the

commissioning of the steam driven compressor.

4.4 Cooling Water Pumps Start-Up/Shutdown Process

The cooling water pump is the most important machine in the cooling water facility.

It is majorly steam driven turbine pumps. With an electrical driven pump on standby

mode, the KRPC has extra Four (4) steam driven turbine pumps coded, 74PT01A-E.

The commissioning of a steam driven turbine pump is as follows;

 Priming

 Pre-start up checks

 Check lube oil and Governor oil level

 Ensure all alarms are checked and all drains are opened
  Commission Low pressure steam (LPS)

 Open bye-pass

 Commission High pressure steam (HPS) gradually, then fully

 Commission EMSV gradually, then fully

 Start the Automated oil pump (AOP)

 Communicate with the process control room to ensure conformance

 Open the discharge

Note: The commissioning of low-pressure steam before high pressure steam is advised

so as to prevent hammering and thermal shocks. It is very important to keep constant

communication with the control room so as to ascertain the cooling water pressure,

before opening your discharge. The cooling water pressure has a tolerance level of 4.4

kg/cm2. Any pressure below this can cause a trip in the coo ling water pump.

4.5 Fire Fighting Techniques

One of the important experiences gained and skill acquired during my internship at

the KRPC is the practical firefighting experience. Fire as mentioned earlier in chapter

three is a rapid combination of combustible substances leading to the production of heat,

smoke or light. To understand the concept of firefighting techniques one has to have a

sound knowledge on the causative agents of fire. The causative agent of fire called the

FIRE ELEMENTS. They include;

 Heat

 Fuel

 Oxygen (O2)

The firefighting/ control mechanism aims at managing or subduing totally, one or all

of the fire elements, owing to the fact that these three factors must be present for a

possible fire outbreak. The fire control mechanisms are;

 a) Cooling: This is aimed at eliminating the heat source of a fire; it is practically done

by reducing the temperature. This is why water is a popular extinguishing material.

The fire will go out so long as the heat generated by the fire is less than that which is

absorbed by the water.

b) Starvation: While cooling aims at removing the heat/ignition element. Starvation

aims at removal of a fuel source leading to a fire outbreak. A fuel is anything that

can burn completely when lighted to it ignition temperature. Fuel doesn’t necessarily

mean petrol. A raging fire will burn itself out if it runs out of flammable materials.

c) Smothering: This aims at Shielding and choking the oxygen source. This is a

technique most applicable to solid fuel fires, although, some materials may contain

enough oxygen within their own chemical makeup to keep the blaze burning.

Note: Water is not an appropriate extinguishing material to use on electrical fires as

well as those caused by cooking oil/fats.

The firefighting technique is carried out using a fire extinguisher. It utilizes a

simple technique termed PARSS.

 P- PICK

 A-AGITATE

 R-REMOVE SAFE PIN

 S-SQUUEZE

 S-SWEEP AT THE BASE OF FIRE

4.6 Backwashing of Pressure Filters

Backwashing the pressure filter is cleansing the filter by reversing the flow of water

to remove any debris, build up and contaminants. It is simply pumping the water

backwards through the filtration media, including intermittent use of air during the

process. It is a form of preventive maintenance, so that the filter media can be reused.
The backwashing process utilizes both compressed air and water. It is an automated

process ran by programmable logic controller (PLC). But due to over usage, the

automatic backwashing process has developed faults and the manual backwashing

process has been resorted to. Manual backwashing is carried out utilizing the knowledge

of valves associated with pressure filters as explained in chapter three. The steps are as

follows:

 Shutdown filters; Close all service valves (1, 5), for about a minute.

 Venting; Open valve 7, for about 3minutes

 Blow down; Open valve (4, 3), then close.

 Air bubbling; Open valve 6, then close. For about 5minutes.

 Backwashing; Open valve (2, 3), then close. For about 30minutes.

 Water Filling; Open valve 1, close 7. For about a minute

 Start-up filters; Open all service valves (1, 5).

Note: In the manual backwashing process, the filtration media is retained and

available for usage after filtration.

 CHAPTER FIVE

5.1 Conclusion

The Student Industrial Working Experience Scheme (SIWES) is really an eye

opener, more importantly as it involves the use of equipment and materials that may not

be available in most institutions.

The SIWES have made provisions for practical application of theories gained in

the classroom. To a large extent, the scheme is an important skill-training programme for

undergraduates which has plays fundamental role in project works.

Apart from the academic field gains, it has really helped a lot to crystallize

attitudes and behaviours by improving our moral standard due to encouragement, advises

and criticism by the senior staff and leaders.

5.2 Suggestions to Future SIWES Students

Working under an encouraging and reputable organization during Industrial

Training, there is going to be much of experiences as well as moral, social and

academical empowerment. I therefore suggest that;

 Student should not miss this great opportunity which is once in lifetime.

 Students should go to the right places for their IT.

 Student should be regular and punctual.

 Student should be humble and obedient which I call ‘the requirement for learning’

 Students going for IT should be good ambassadors to the University by being

punctual in their activities and well behaved.

 Lastly, I sincerely commend the effort of the Staff and Operators in the PPU

Department of KRPC Kaduna

 Students should make themselves available during work hours, absconding and

abandonment of duty to visit friends is barbaric.

5.3 Difficulties Faced During the Training

During the period, some of the difficulties faced during my Industrial Training

include the following;

 Nature of the working hours, 2 days for morning shift (6am – 7pm) and 2 days for

night shift (6pm – 7am). It was very hard to stay adapted and withstand the stress.

Failure for not coming to work without any tangible reason may lead to withdrawal

from the Department.

 While mixing chemicals (NH3 and PO4). Ammonia is choking and irritating despites

the use of Google mask, hence very difficult to perform the work.

 It is very noisy environment because of heavy equipment’s operating continuously,

as such your ears are always covered with helmet and ear plug.

 Despites the insulation of the steam’s pipes within the plant, there are still leakages

along making the environment and other equipment so hot. The issue result to

difficulty to move around and observe.

5.4 Recommendation

The Student Industrial Work Experience Scheme (SIWES) has been a great

avenue of getting experience where students are exposed to practical aspects of learning.

Nevertheless, three (3) months of experience is not enough for one to get all the skills

perfectly and put into practice especially as regards to Process science and flow in

particular.

I therefore recommend that the period may be increase to about a year in such a

way to provide more chance for students learn a lot.

Finally, I commend the Department of chemistry for the effort and attention

given to the SIWES program. Realities, Skills, Services and applications of the

Department curriculum activities are everywhere applicable and versatile.

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