Parco Internship Report
Parco Internship Report
Parco Internship Report
Table of Contents
1 Preface.....................................................................................................................................4
2 Acknowledgement...................................................................................................................4
3 Introduction..............................................................................................................................5
4 Mission Statement...................................................................................................................6
5 History.....................................................................................................................................6
6 Parco major activities..............................................................................................................6
7 Administration.........................................................................................................................6
8 PARCO’s pipeline system.......................................................................................................7
9 Pipeline division......................................................................................................................7
10 S & T (Station and Terminal)..................................................................................................7
10.1 Keamari, Terminal Station (TS-1).................................................................................7
10.2 Korangi, Pumping Station (PS-1)..................................................................................8
10.3 Bubak, Pumping Station (PS-2)....................................................................................8
10.4 Shikarpur, Pumping Station (PS-3)...............................................................................8
10.5 Fazilpur, Pumping Station (PS-4).................................................................................8
10.6 Mahmood Kot, Station (PS-5) (TS-2)...........................................................................8
10.7 Faisalabad (PS-6) (TS-3)...............................................................................................8
10.8 Machhike (TS-4)...........................................................................................................8
11 FIRE FIGHTING SYSTEMS..................................................................................................9
11.1 Fire-fighting pump........................................................................................................9
11.2 Joke Pump.....................................................................................................................9
11.3 Jockey Pumps Working.................................................................................................9
11.4 Foam tanks....................................................................................................................9
11.5 Functions of Foam Tank..............................................................................................10
12 Assignment............................................................................................................................10
13 Cyclic Maintenance of Tank..................................................................................................10
13.1 Cyclical maintenance Define.......................................................................................11
13.2 API standard 653.........................................................................................................11
13.3 Vacuum box test..........................................................................................................12
13.3.1 ADVANTAGES......................................................................................................12
2
13.3.2 ACCEPTANCE CRITERIA....................................................................................12
13.3.3 REPAIRS AND RETEST........................................................................................12
13.4 Magnetic particle inspection.......................................................................................12
13.5 Magnetic flux leakage.................................................................................................12
13.5.1 Benefits....................................................................................................................13
13.6 Cathodic protection system.........................................................................................13
13.7 Sand blasting...............................................................................................................13
13.8 Epoxy primer...............................................................................................................14
13.9 Sump pit......................................................................................................................14
13.10 Dip tape.......................................................................................................................14
13.10.1 Specifications.......................................................................................................14
14 Introduction to Storage Tanks...............................................................................................14
14.1 Storage Tanks..............................................................................................................14
14.2 Types of storage tanks.................................................................................................15
14.2.1 Containment Basin...................................................................................................15
14.3 Fixed-Roof Tank.........................................................................................................15
14.4 External Floating Roof Tank.......................................................................................16
14.5 Internal Floating Roof Tank........................................................................................16
15 Conclusions............................................................................................................................17
3
1 Preface
The purpose of this report is to explain what I learned from my internship experience at Pak
Arab Refinery Limited. This report comprises the brief description of Pak Arab Refinery
Limited, pipeline, firefighting system and the assignment assign to me.
This wonderful experience of just 6 weeks proved to be a high inclination in the graph of my
personal learning.
2 Acknowledgement
Praise to Allah Almighty who bestowed me ability and potential to accomplish the task of work.
First of all I am very thankful to HR department for giving me an opportunity to visit Pak Arab
Refinery Limited. I would like to give special thanks to Pak Arab Refinery Limited to facilitate
me in well mannered.
I wish to express deep sense of gratitude to all the officials, specially my mentor Sir Imran
Mushtaq for supporting me throughout this internship period. I am also thankful to Sir Irfan for
sharing his knowledge and experience about SAP.
4
3 Introduction
Petroleum energy plays a pivotal role in the socio economic development of country, especially
for a developing country like Pakistan, where demand for petroleum products is fast increasing.
Incorporated in May 1974, Pak Arab Refinery Ltd. (PARCO) has now been inexistence for 27
years as a joint venture between the government of Pakistan (GOP) and Abu Dhabi. Its
authorized capital is Rs. 5 billion and paid up capital is Rs. 2160 million of which 60% is held by
the GOP and 40% by Abu Dhabi petroleum investments of Abu Dhabi. This long awaited project
has been setup despite facing numerous obstacles and hurdles during the 1998-99 period and
despite international sanctions.
5
4 Mission Statement
To enhance and establish a professionally sound corporate identity.
To operate the existing Pipeline System, Mid Country Refinery and marketing initiatives
in a manner that establishes it as a center of excellence in Pipeline, Refining & Marketing
Activities in the Country.
To embark upon Integrated Investment Program which takes cognizance of the existing
bottlenecks and long-term petroleum needs of the Country.
To provide a lead to the indigenous Petroleum Industry in finding of solutions to
Technical and Managerial problems.
To develop appropriate Human Resources for undertaking of large Energy Projects in the
Country.
5 History
For many years after the completion of the pipeline, the dream was to actualize the planning for a
Mid-Country Refinery at Mahmood Kot, near Multan. In September 2000, the dream became
reality with the start-up of the country's largest capacity refinery of 100,000 barrels per day,
costing US$ 886 million - commissioned well within budget and a month ahead of schedule. The
state-of-the-art refinery is based on the latest equipment and process technology and also serves
as a training resource for technologists from the region.
7 Administration
PARCO pumping stations exist in many areas such as Karachi, Keamari, Korangi, Bubak,
Shikarpur, Faisalabad, Fazilpur and Mahmood kot. These plants are controlled by administration
of head office at Karachi. The issues relate to their technical work, operations at Karachi and mid
country refinery are controlled and demonstrated by their own administrations.
6
8 PARCO’s pipeline system
PARCO’s pipeline system consists of 6 pumping stations namely
PS-1 Korangi
PS-2 Bobak
PS-3 Shikarpur
PS-4 Fazilpur
PS-5 Mahmood Kot
PS-6 Kot Bahadur Shah
PS-7 Faisalabad
TS-1 Keamari
TS-2 Mahmood Kot
TS-3 Faisalabad
TS-4 Machike
9 Pipeline division
Pipe line operation
Pipe line maintenance
S & T operation
S & T maintenance
Telecom/Scada
C & ES (coordination and engineering services)
7
PS-1 tanks. TS-1 also handles High Speed Diesel tankers berthed at Keamari port for
transporting Diesel to Korangi for onward transfer to Port Qasim and WOP.
10.2 Korangi, Pumping Station (PS-1)
With the local crude decanting facility at Korangi Pumping Station PS-1, the station plays a
strategic role by receiving local crude directly through decanting facilities, imported crude oil
and PAPCO’s High Speed Diesel from Keamari Terminal Station through PARCO’s 20 inch dia
18 km transfer line. High Speed Diesel from Pakistan Refinery Limited (PRL) and National
Refinery Limited (NRL) is also received here through three 8 inch dia. spur lines. The crude oil
pumped from Korangi Pumping Station is delivered to the Mid-Country Refinery, Gujrat
Terminal Station TS-2 through 16 inch dia. Karachi-Mahmood kot Pipeline, while the diesel is
pumped through KPLP into the White Oil Pipeline.
10.3 Bubak, Pumping Station (PS-2)
The Bubak Pumping Station receives crude oil from Korangi pumping station through 16 inch
dia. KMK mainline and increases its pressure / flow for onward pumping to Shikarpur Pumping
Station PS-3.
10.4 Shikarpur, Pumping Station (PS-3)
The Shikarpur Pumping Station receives crude oil from Bubak Station through 16 inch dia.
mainline and increases its pressure / flow for onward pumping to Fazilpur Pumping Station. Also
linked with OMC depots for transferring diesel from WOP System.
10.5 Fazilpur, Pumping Station (PS-4)
The Fazilpur Pumping Station receives crude oil from Shikarpur through 16 inch dia. mainline
and boosts its pressure / flow.
10.6 Mahmood Kot, Station (PS-5) (TS-2)
For onward pumping to Terminal Station-2 (TS-2), Mahmood kot. The crude received at
Mahmood kot, is then refined at the PARCO Mid Country Refinery.
10.7 Faisalabad (PS-6) (TS-3)
Faisalabad Pumping cum Terminal Station was initially used to receive and store HSD & SKO
from Mahmood kot through 18 inch dia. Mahmmod kot Faisalabad (MFM) line, boosting its
pressure / flow for onward pumping to Machikke through MFM Line. After commissioning of
the Gantry at Faisalabad, High Speed Diesel is partly supplied to Oil Marketing Companies
(OMCs) through this gantry and remaining HSD is pumped to Machhike.
Petroleum products from the Mid-Country Refinery are now also transported through Mahmood
kot Faisalabad Machhike (MFM) Pipeline. This also includes Kerosene which is now supplied to
Machhike from Mid-Country Refinery through MFM Pipeline.
10.8 Machhike (TS-4)
Machhike Terminal Station TS-4 receives HSD & SKO from Faisalabad, through 16 inch dia,
MFM pipeline to its Tankage, and delivers these products to Oil Marketing Companies (OMCs)
through spur lines.
8
11 FIRE FIGHTING SYSTEMS
A firefighting system is probably the most important of the tank services, as its aim is to protect
human life and production, strictly in that order.
It consists of three basic parts:
A large store of water in tanks, either underground or on top of the building, called fire
storage tanks
A specialized pumping system,
A large network of pipes ending in either hydrants or sprinklers (nearly all buildings
require both of these systems)
11.1 Fire-fighting pump
A fire-fighting pump is a centrifugal pump which is used for pumping fire-fighting water. Fire-
fighting pumps can be designed for transportable use (e. g. on fire-fighting vehicles or as
portable fire pumps) or for stationary use (e. g. hydrants, sprinkler systems.
4 Diesel Engine pumps
1 Joke pump
1 Foam tank
11.2 Joke Pump
A jockey pump, also known as a pressure-maintenance pump, is a small apparatus that works
together with a fire pump as part of a fire-protection sprinkler system. It is designed to keep the
pressure in the system elevated to a specific level when the system is not in use, so that the fire
pump doesn’t have to run all the time and the system doesn’t go off randomly. It can also help
prevent the system from damage when a fire happens and water rushes into the pipes.
11.3 Jockey Pumps Working
To understand how a jockey pump works, it’s important to understand how a fire sprinkler
system works. Sprinkler systems consist of pipes with pressurized water in them and heads that
are designed to open when they reach a certain temperature. When the heads open, the water
pressure in the pipes drops, since water is flowing out of them. When this happens, a large device
called a fire pump starts to send more water through the pipes so that the system can continue to
put out the fire.
The purpose of the jockey pump is to keep the water pressure in the pipes within a specific range
when there’s not a fire, so that the sprinklers won’t go off randomly. Since pipes leak, over time,
the water pressure inside them automatically goes down. The jockey pump senses this, and then
fills them back up to normal pressure. If a fire happens and the pressure drops dramatically, the
jockey pump won’t be able to keep up, and the drop in pressure will trigger the large fire pump
to start sending water.
11.4 Foam tanks
Foam Chambers and Foam Makers are air-aspirating foam discharge devices designed to protect
flammable liquid storage tanks by applying foam down the inside wall of the tank.
9
Foam Chambers are designed to generate foam and apply the expanded foam to the fuel surface
in a manner that lessens submergence and agitation as the foam contacts the fuel.
Foam Makers include High Back-Pressure, Floating Roof Foam Makers, and Rim Seal Foam
Pourers. High Back-Pressure Foam Makers are designed to generate expanded foam for the
purpose of subsurface injection into a cone-roof liquid hydrocarbon storage tank. Floating Roof
Foam Makers (FLR) and Foam Pourers are air-aspirating foam discharge devices that are
designed to protect floating roof, flammable liquid storage tanks.
Storage capacity of foam tank is 22700LT
11.5 Functions of Foam Tank
Reducing Heat
Reducing Oxygen
Removing Fuel
12 Assignment
To make SOP (Standard Operating procedure) of cyclic maintenance of product storage tank.
Removal of sludge
Vacuum Box test (VBT)
Magnetic Flux Leakage (MFL)
Magnetic Particle Inspection (MPI)
Cathodic production system (CP System)
10
13.1 Cyclical maintenance Define
Cyclical maintenance is work to maintain the general condition of tank and some communal
fittings. This usually happens every 10 years.
It includes:
External inspection
Internal inspection
Repairing and replacing
As a notified body, we provide you with trusted independent assessment, testing and verification
to ensure the safety of your storage tanks, helping you to:
Prevent accidental leaks and avoid costly decontamination with regular inspections
Gain a clear insight into the precise capacity and volume of your tanks with accurate
calibration
Assure the integrity of your storage tanks by complying with local regulations and the
relevant standards and codes
Storage tank owners usually hear the term API 653 Standard in the context of aboveground
storage tank inspections. This is rightly so, because API 653 is the internationally recognized
standard for inspecting aboveground welded storage tanks storing products at atmospheric
pressure.
However, the API 653 Standard covers more than the requirements for an API 653 inspection.
In addition to addressing inspection requirements, API 653 also addresses the repair, alteration,
relocation, and reconstruction of existing aboveground storage tanks built to the API 650
Standard.
11
13.3 Vacuum box test
Vacuum box testing is a non-destructive examination used when trying to locate weld seam
leaks. A vacuum box and a compressor create a high or low pressure vacuum while a detergent
solution is applied to the test area. The detergent bubbles, making leaks visible within the created
pressure envelope.
13.3.1 ADVANTAGES
Provides an immediate indication visual of the location of any leaks present
Can detect small leaks within a given area
Some large leaks may not be detected by bubble formation because the strong stream of air may
break the bubble film as soon as it forms. To avoid missing this type of leak, the pressure shall
be monitored for a variation (decrease).
12
(usually steel). Where there are defects — corrosion or material loss — the magnetic field
“leaks” from the steel.
MFL probes incorporate a magnetic detector placed between the poles of the magnet where it
can detect the leakage field. During inspection, a magnetic circuit of sorts forms between the part
and the probe. The magnetic field induced in the part saturates it until it can no longer hold any
more flux. The flux overflows and leaks out of the pipe wall and strategically placed sensors can
accurately measure the three-dimensional vector of the leakage field.
Because magnetic flux leakage is a vector and that a sensor can only measure one direction, any
given probe must have three sensors to accurately measure the axial, radial, and circumferential
components of an MFL signal.
13.5.1 Benefits
Using MFL can yield the following benefits:
One of the few methods used to inspect finned tubes (NFT is also an alternative)
Can be used on all ferromagnetic materials
A properly designed and maintained cathodic protection system will take up the remainder
resulting in a 100 % efficient cathodic protection system.
Cathodic protection systems protect a wide range of metallic structures in various environments.
Common applications are: steel water or fuel pipelines and steel storage tanks such as home
water heaters; steel pier piles; ship and boat hulls; offshore oil platforms and onshore oil well
casings; offshore wind farm foundations and metal reinforcement bars in concrete buildings and
structures.
13
13.7 Sand blasting
Abrasive blasting, more commonly known as sandblasting, is the operation of forcibly propelling
a stream of abrasive material against a surface under high pressure to smooth a rough surface,
roughen a smooth surface, shape a surface or remove surface contaminants. A pressurized fluid,
typically compressed air, or a centrifugal wheel is used to propel the blasting material (often
called the media).There are several variants of the process, using various media; some are highly
abrasive, whereas others are milder. The most abrasive are shot blasting (with metal shot) and
sandblasting (with sand).
Epoxy primers typically provide slightly better long term corrosion protection by creating a
harder and more chemically resistant coating. Epoxies also provide excellent water resistance
and minimal shrinkage
13.10.1 Specifications
Construction: Lightweight aluminum frame winder. High impact plastic handle.
Complete with graduated brass dip weight
Units: Black etched with raised markings. Graduated in mm on one side, with feet, inches
and 1/16ths on the reverse
Lengths: Available in 10, 20 & 30m versions
Accuracy: To EC Class II standard
14
14 Introduction to Storage Tanks
14.1 Storage Tanks
Storage tanks containing organic liquids, non-organic liquids, vapors and can be found in many
industries. Most storage tanks are designed and built to the American Petroleum Institute API-
650 specification. These tanks can have different sizes, ranging from 2 to 60 m diameter or more.
They are generally installed inside containment basins in order to contain spills in case of rupture
of the tank.
Industries where storage tanks can be found are: petroleum producing and refining,
petrochemical and chemical manufacturing, bulk storage and transfer operations, other industries
consuming or producing liquids and vapors.
Fixed-roof tanks
External floating roof tanks
Internal floating roof tanks
Domed external floating roof tanks
Horizontal tanks
Pressure tanks
Variable vapor space tanks
LNG (Liquefied Natural Gas) tanks
15
14.3 Fixed-Roof Tank
Of currently used tank designs, the fixed-roof tank is the least expensive to construct and is
generally considered the minimum acceptable equipment for storing liquids. A typical fixed-roof
tank consists of a cylindrical steel shell with a cone- or dome-shaped roof that is permanently
affixed to the tank shell. Storage tanks are usually fully welded and designed for both liquid and
vapor tight, while older tanks are often have a riveted or bolted construction and are not vapor
tight. A Breather Valve (pressure-vacuum Valve), which is commonly installed on many fixed-
roof tanks, allows the tank to operate at a slight internal pressure or vacuum.
This Valve prevents the release of vapors during only very small changes in temperature,
barometric pressure, or liquid level, the emissions from a fixed-roof tank can be appreciable.
Additionally, gauge hatches/sample wells, float gauges, and roof manholes provide accessibility
to these tanks and also serve as potential sources of volatile emissions.
External floating roof tanks are equipped with a rim seal system, which is attached to the roof
perimeter and contacts the tank wall. The rim seal system slides against the tank wall as the roof
is raised and lowered. The floating deck is also equipped with fittings that penetrate the deck and
serve operational functions. The external floating roof design is such that evaporative losses from
the stored liquid are limited to losses from the rim seal system and deck fittings (standing storage
loss) and any exposed liquid on the tank walls (withdrawal loss).
Tanks in which the fixed roof is supported by vertical columns within the tank
Tanks with a self-supporting fixed roof and no internal support columns
16
The fixed roof is not necessarily free of openings but does span the entire open plan area of the
vessel. Fixed roof tanks that have been retrofitted to employ an internal floating roof are
typically of the first type, while external floating roof tanks that have been converted to an
internal floating roof tank typically have a self-supporting roof.
An internal floating roof tank has both a permanently affixed roof and a roof that floats inside the
tank on the liquid surface (contact deck) or is supported on pontoons several inches above the
liquid surface (noncontact deck). The internal floating roof rises and falls with the liquid level.
15 Conclusions
PARCO as a leading and pioneer organization is doing very well. Their plans are very well
organized, managed, according to circumstances and they avail the opportunities very
effectively. I am pretty sure that company has ability to achieve its goals as stated in vision
statement. After analysis I reach at the same conclusion that they are “LEADERS ALL THE
WAY”.
17