REPORT

ON
TECHNICAL SERVICES DEPARTMENT

Submitted By: - SAAD MANSOOR

P# 5504
Trainee Engineer Chemical

Overview of TSD
Mission Statement
It Support production targets and meet future challenges in industry, while ensuring
trouble free economical operations in all instances by adopting best practices and
improvements in technology on sustainable basis.
Main Functions of TSD:It supports the operation of refinery to actually meet the targets of production at
optimized cost. Cost factor is the major concern while taking any decision to
operate the plant at steady state conditions. For this it involves the quality control
of intermediate & product streams. If the Plant is not achieving steady state
conditions by Process department than TSD will troubleshoot the problem by
technical study of different operating variables. TSD plans the Turnaround of the
Plant & the execution of various different activities. In case of any plant
modifications, TSD advice & assist in technology upgrades. Technical review
meetings for CRs and QRI system have to be reviewed by TSD. Monthly progress
reports of Refinery overall performance have to be prepared by TSD.
Technical Services Department is categorized into four major sections:1.
2.
3.
4.

Process Engineering
Production Planning
Laboratory
Research & Development

1. Process Engineering:-

The Process Engineering department first of all monitors all the

Parameters of refinery on daily basis. If there is any problem in
the operations i.e. operations department is not achieving the
desired set point of the process variables than process
engineering department provides technical support to Process
Operations. Troubleshooting of the problem by consulting the
simulation software and the previous history to overcome that
problem. Evaluate technically the catalyst performance i.e. its
cycle length, yield pattern etc. If there is requirement of any
modifications than they will review the overall design i.e. review
of impact of modification on overall design. After the review of
overall design they will conduct HAZOP studies. If they require
any further support than they liaison with Licensors & Vendors.
Turnaround Planning & coordination is also in the scope of
process engineering department. They maintains a library section
for any codes & standards, reference books, reference books,
technical magazines
2. Production Planning:Their purpose is to meet the targets as per Market & Commercial
plan according to market demand. Within the approved budget
by management, production planning have to control the own
use and loss. Improvement in white to black oil ratio i.e. obtains
the maximum conversion to obtain more valuable products. New
crudes of different countries are evaluated by this department to
obtain maximum profitability. The objectives of Production
planning department is to:-

a) Planning & Scheduling

This department does planning & scheduling of crude oil i.e.
weekly, monthly and annually crude receiving, charging &
procurement plan. The load & inventory of the refinery is
planned on weekly and monthly basis. If the catalyst active
sites reduced than this department plans the regeneration of
catalyst. it ensures availability of product by tank management
on daily basis. Scheduling of sales & production on weekly
basis and monthly production forecast is also done by this
department.
b) Refinery economics
The cost of raw material including crude price & sea freight is
very much important to evaluate. This evaluation is the sole
responsibility of this department. The feasible yield pattern of
product is carried out according to the prices of the products in
the market. If any unit is shut down than its impact in overall
economics is done by this department. A different recipe of
product blending to obtain the required specifications of
product is done by this department.
c) Reports for management
Reports prepared for management on daily basis includes daily
saleable report, daily production report according to the sales
own use and loss data. Daily crude composition report
according to type and percentage of crude available in
tankage. Weekly reports include crude receiving and charging
plan for advance planning of refinery feedstock, production

and sales schedule, inventory management plan and unit load

management plan.
3. Laboratory:The main functions of laboratory includes:

Testing of intermediate and finished products streams.

Testing of utilities and ETP samples.
Certification of finished product quality for export and local marketing.
Analysis of chemicals received in warehouse for acceptance.
Air / stack emission monitoring.
Analysis of sludge / deposits samples and lubricating oils.
Potable water and effluent water testing.
Evaluation of crudes and condensates.
Special analysis during test runs conducted by Process Engineering Section.
Testing of the different samples during turnarounds.
Finished and Intermediate Product analysis plus certification.
Inventories of Chemicals, Glassware and Spare parts.
Budget, IMS Documentation, Special Analysis
Calibration and Maintenance of Equipments, Standardization of Chemical

solutions.
Emission Monitoring, Crude Assay.
4. Research & Development:Objective:To explore opportunities for new product development & design, process
improvement, and review of engineering documents leading to new project
formation.

Research and development usually requires significant time, effort and manpower
to become successful. Despite the significant resources spent on R& D projects,
only 5-10% of the projects statistically believed to be successfully commercialized,
in terms of both timing and technological advances. Many projects fail because
they cannot achieve the desired results on timing of commercialization &
licensing.
Types of R & D: Basic research
New application research
New product development
In R & D department the techno economic analysis, cost saving,
proposals for basic process improvement, feasibililty preparation,
cost evaluation and budget estimation have been carried out.
They prepare TOR (terms of references) for awarding of contract
for feasibility study, consultant hiring for FEED package review.
They liaison with vendors and concerned departments for
engineering reviews of projects.
Current Assignments of R & D department:

Indigenization of Lubricity Improver for DHDS Diesel

Project feasibility study for 500 MW IPP project
Crude oil sludge cleaning methodologies
Fin Fan Tubes External Cleaning with indigenized resources
Techno-Economic study for the Utilization of D-max bottom as lube base

oils
Technical study report for the installation of Flare Gas Recovery System at
MCR
Study for Uniflex Process For Bottom Upgradation

 Study for the Benzene Reduction in Gasoline pool. (In-progress)

Installation of VFD & VSDs for Energy Conservation. (In-progress)
Prepared a conceptual design for Decanting facility at MCR