A New Model For Reliability Centered Maintenance In Petroleum Refineries

Refiners today operate their equipment for prolonged periods without shutdown. This is primarily due to the increased pressures of the market resulting in extended shutdown-to-shutdown intervals. This places extreme demands on the reliability of the plant equipment. The traditional methods of reliability assurance, like Preventive Maintenance, Predictive Maintenance and Condition Based Maintenance become inadequate in the face of such demands. The alternate approaches to reliability improvement, being adopted the world over are implementation of RCFA programs and Reliability Centered Maintenance. However refiners and process plants find it difficult to adopt this standardized methodology of RCM mainly due to the complexity and the large amount of analysis that needs to be done, resulting in a long drawn out implementation, requiring the services of a number of skilled people. These results in either an implementation restricted to only few equipment or alternately, one that is non-standard. The paper presents the current models in use, the core requirements of a standard RCM model, the alternatives to classical RCM, limitations in the existing model, classical RCM and available alternatives to RCM and will then go on to present an ‗Accelerated‘ approach to RCM implementation, that, while ensuring close conformance to the standard, does not place a large burden on the implementers

SUPPLY CHAIN MANAGEMENT IN INDIAN PETROLEUM REFINING INDUSTRY

Model development for selection of location for refinery in India and identification of characteristics to be looked into when configuring it and to develop models for integrated supply chain planning for a refinery. Locating and removing inbound, internal and outbound logistic problems in an existing refinery and overall design of a logistic information system for a refinery are the main objectives of the study. A brief description of supply chain management (SCM), elements of SCM and their significance, logistics cost in petroleum industry and its impacts, and dynamics of petroleum its logistic practices are also to be presented. Scope of application of SCM in petroleum refinery will also be discussed. A review of the investigations carried out by earlier researches in the area of supply chain management in general and with specific reference to petroleum refining.

Investigations on the Effects of Petroleum Hydrocarbons on the Marine Bivalves Perna viridis (Linnaeus) and Sunetta scripta (Linne')

The thesis deals with different aspects connected with the distribution and toxicity of PHC in crude oils in the aquatic environment and marine molluscs. Information has been gathered and presented on the present status of research in the field based on a thorough review of recent literature. It is seen from the literature that the resident time of PHC becomes lesser and lesser when crude oil is discharged in large quantities into the coastal waters where excess oxygenation light penetration, temperature availability and strong tidal currents persist. This results in the reduction of the onslaught of oil pollution. This probably shows that taxic insult of crude oil in tropical shores will be relatively lesser than that occurring in temperate and boreal waters. However, there is no record of major episodal oil pollution comparable in quantum and extent to that of Torrey Canyon or Amoco Cadiz which prevents a more reliable analysis on the issue. Considerable controversy exists on the method of estimation of PHC in seawater. However, Ultra-violet fluorescence spectroscopy has been widely recommended as an analytical tool for the determination of total hydrocarbons. Similarly representation of values as chrysene equivalents has been recognised as the most reliable method of Quantum representation.

INVESTIGATIONS ON THE STRESS EFFECTS OF PETROLEUM HYDROCARBONS ON METAPENAEUS DOBSON (MIERS)

The present investigation has addressed the effects of PHC contaminated culture medium on the morphology, physiology and behaviour of shrimps. The shrimp Metapenaeus dobsoni is an important member of the crustacean animal community abounding the oil contaminated benthic regions of Cochin backwater system. Since it is known that true pollutants can disrupt the sustainability of ecosystems by its effect on species, populations and communities,a representative species was used for the study. The results discussed in this work is bound to help in understanding the ecotoxicant resistance that the animal may display under toxic conditions compared to dynamic steady-state systems in nature.

Bioremediation of petroleum sludge through Phytoremediation.Land farming and Microbial enhanced oil separation

The objective of this research is to study the feasibility of bioremediating the oily sludge from a refinery site. Three different methods of waste treatment were tried i.e. phytoremediation, land farming and microbial enhanced oil separation in laboratory scale treatment systems. A multiprocess approach by combination of phytoremediation, biostimulation and microbial enhanced oil separation is also presented. The methods of analysis, experimental procedure, and results are incorporated into five chapters of this thesis entitled "Bioremediation of petroleum sludge through phytoremediation, land farming and microbial enhanced oil separation.

Algae in industrial effluent treatment

The present research is based on two broader aspects of pollution assessment ,and treatability of petroleum and petrochemical effluents by algae. The objectives of the investigation are to study the algal ecology and trophic status of an oil refinery effluent holding pond , isolate and identify pure cultures of algae, study the role of algae in petroleum and petrochemical effluent treatment, develop strains of algae tolerant to toxic effluents, study the biotreatment potential of the tolerant algal strains developed The thesis comprises of six chapters. The first chapter gives the significance and objectives of the present study. The second chapter describes the methodology, and results of studies on the algal ecology, and trophic status of the effluent holding pond of Cochin Refineries Ltd., Ambalamugal, Kochi. The third chapter deals with the isolation, and development of pure cultures of algae, the algal bioassay of the refinery effluent, and the analyses of Chitrapuzha river water. The analysis, and assessment of the algal growth potential of the petrochemical effluent of Hindustan Organic Chemicals Ltd., Ambalamugal, Kochi. are summarised in the fourth chapter The fifth chapter deals with the algal growth potential in phenol and phenolic effluent, and subsequent absorption of phenol and total dissolved solids. The summary and conclusion of the present study are given in the sixth chapter.

Biochemical Effects of Petroleum Hydrocarbons on the Tropical Teleost Oreochromis mossambicus (Peters)

The present work is a base—|ine attempt to investigate and assess the toxicity of water-accommodated fractions (WAF) of Bombay High crude oil. The experimental animal selected for the present study is a euryhaline teleost, Oreochromis mossambicus (Peters), adapted to fresh water. The fish has been selected on account of its economic valve, abundant availability, experimental feasibility, ease of rearing and maintenance and also because it is one of the commonly cultured species in the South-East Asian countries.

Investigations on the stress effects of petroleum hydrocarbons on Metapenaeus dobsoni (Miers)

The present investigation has addressed the eflects of PHC contaminated culture medium on the morphology, physiology and behaviour of shrimps] The shrimp Metapenaeus dobsoni is an important member of the crustacean animal community abounding the oil contaminated benthic regions of Cochin backwater system. Since it is known that true pollutants can disrupt the sustainability of ecosystems by its eflect on species, populations and communities, a representative species was used for the study. The results discussed in this work is bound to help in understanding the ecotoxicant resistance that the animal may display under toxic conditions compared to aynamic steaay-state systems in nature

Investigations on Eco-friendly Natural Insecticides

Instead of developing easily degradable, and low-priced insecticides, we are going after highly sophisticated chemicals. Here, an attempt is being made to develop safer formulations of insecticides of botanical origin. Different parts of the plants were chosen based on their use in countryside and villages The dried plant materials were extracted with petroleum ether, and were applied on Tribolium castaneum. The results were statistically analysed. The active principles from Croton tigilium and Leea sambucina, the most potential plants, were isolated using Column Chromatography, TLC, and Hydrolysis. The isolated principles were analysed spectroscopically ( UV-Vis., IR, NMR, and MS ) to identify their chemical nature. The active principles from Leea and Croton were identified as a cholisterate derivative and a phorbol derivative respectively. In order to ascertain the environmental combatibility of the principles, degradation by soil bacteria was studied. The isolated principles were made into three type of formulations using stabilizers .The formulations were applied on Snake gourd semilooper, Pulse beetle, and mosquito larvae. Also the biocidal activity of the formulations was studied. Both Leea derivative and Croton derivative could be formulated effectively and were effective against a variety of pests. They are eco-friendly, as there is no artificial chemicals involved.

Transition metal and rare earth metal modified sol-gel titania: a versatile catalyst for organic transformations

Catalysis is a mature field with extensive practical applications in today's society.indeed,the catalysis of petroleum refining,fine chemical synthesis and emission control demands the production of catalysts in bulk quantities.Future improvement of these well established processes is likely to be incremental.On the other hand,the continuous demand for new products will require additional novel and innovative processes.The need for pollution abatement and prevention also imposes new demands on catalysis, and new processes are periodically advanced for the control of emission of gases as well as for remediation processes such as the cleaning of underground waters. The number of problems where catalysis can have a big impact is constantly growing.In general,science stimulated by the technology has enriched the field of catalysis in a way that has had broad and lasting value.The thesis"Transition metal and rare earth metal modified sol-gel titania: a versatile catalyst for organic transformations" accounts the preparation and characterization studies of both transition metals and rare earth metals modified sol-gel titania and its applications in industrially useful organic reactions.

Studies on new processing aids and other compounding ingredients in special purpose rubbers

In the first part of the study we probed the effectiveness of rice bran oil as a multipurpose compounding ingredient for nitrile (NBR) and chloroprene (CR) rubbers. This oil has already been successfully employed in the compounding of NR and SBR in this laboratory.In this context we thought it worthwhile to try this oil in the polar rubbers viz, NBR and CR also. The principle of like dissolves like as applicable to solvents is equally applicable while selecting a plasticiser, elastomer combination. Because of the compatibility considerations polar plasticisers are preferred for polar rubbers like NBR and CR. Although plasticisation is a physical phenomenon and no chemical reaction is involved, the chemical structure of plasticisers determines how much physical attraction there is between the rubber and the plasticiser. In this context it is interesting to note that the various fatty acids present in rice bran oil have a long paraffinic chain, characteristic of waxes, with an acid group at the end of the molecule. The paraffinic end of the molecule contributes lubricating effects and limits compatibility whereas the acid end group contributes some polarity and is also chemically reactive. Because of absorption of acid group on the surface of pigments, these acids will have active pigment wetting characteristics also. These factors justifies the role of rice bran oil as a co-activator and lubricating agent for NBR and CR. In fact in our study we successfully replaced stearic acid as co-activator and aromatic oillDOP as processing aid for CR and NBR with rice bran oil.This part of the study has got special significance in the fact that rubber industry now heavily depends on petroleum industry for process oils. The conventional process oils like aromatic, naphthenic and paraffinic oils are increasingly becoming costlier, as its resources in nature are fast depleting. Moreover aromatic process oils are reported to be carcinogenic because of the presence of higher levels of polycyclic aromatic compounds in these oils.As a result of these factors, a great amount research is going on world over for newer processing aids which are cost effective, nontoxic and performanance wise at par with the conventional ones used in the rubber industry. Trials with vegetable oils in this direction is worth trying.Antioxidants are usually added to the rubber compound to minimise ageing effects from heat, light, oxygen etc. As rice bran oil contains significant amount of tocopherols and oryzanol which are natural antioxidants, we replaced a phenolic antioxidant like styrenated phenol (SP) from the compound recipe of both the rubbers with RBO and ascertained whether this oil could function in the role of antioxidant as well.Preparation and use of epoxidised rice bran oil as plasticiser has already been reported.The crude rice bran oil having an iodine value of 92 was epoxidised in this laboratory using peracetic acid in presence of sulphuric acid as catalyst. The epoxy content of the epoxidised oil was determined volumetrically by treating a known weight of the oil with excess HCI and back titrating the residual HCI with standard alkali solution. The epoxidised oil having an epoxy content of 3.4% was tried in the compounding of NBR and CR as processing aids. And results of these investigations are also included in this chapter. In the second part of the study we tried how RBO/ERBO could perform when used as a processing aid in place of aromatic oil in the compounding of black filled NRCR blends. Elastomers cannot have all the properties required for a particular applications, so it is common practice in rubber industry to blend two elastomers to have desired property for the resulting blend.In this RBO/ERBO was tried as a processing aid for plasticisation, dispersion of fillers, and vulcanisation of black filled NR-CR blends.Aromatic oil was used as a control. The results of our study indicate that these oils could function as a processing aid and when added together with carbon black function as a cure accelerator also.PVC is compatible with nitrile rubber in all proportions, provided NBR has an acrylonitrile content of 25 to 40%. Lower or higher ACN content in NBR makes it incompatible with PVC.PVC is usually blended with NBR at high temperatures. In order to reduce torque during mixing, additional amounts of plasticisers like DOP are added. The plasticiser should be compatible both with PVC and NBR so as to get a homogeneous blend. Epoxidised soyaben oil is reported to have been used in the compounding of PVC as it can perfonn both as an efficient plasticiser and heat stabilizer.At present DOP constitute the largest consumed plasticiser in the PVC compounding. The migration of this plasticiser from food packaging materials made of PVC poses great health hazards as this is harmful to human body. In such a scenario we also thought it worthwhile to see whether DOP could be replaced by rice bran oil in the compounding of NBR-PVC blends Different blends of NBR-PVC were prepared with RBO and were vulcanized using sulphur and conventional accelerators. The various physical and mechanical properties of the vulcanisates were evaluated and compared with those prepared with DOP as the control plasticiser. Epoxidised rice bran oil was also tried as plasticiser for the preparation of NBR-PVC blends. A comparison of the processability and cure characteristics of the different blends prepared with DOP and ERBO showed that ERBO based blends have better processability and lower cure time values. However the elastographic maximum torque values are higher for the DOP based blends. Almost all of the physical properties evaluated are found to be slightly better for the DOP based blends over the ERBO based ones. However a notable feature of the ERBO based blends is the better percentage retention of elongation at break values after ageing over the DOP based blends. The results of these studies using rice bran oil and its epoxidised variety indicated that they could be used as efficient plasticisers in place of DOP and justifies their role as novel, nontoxic, and cheap plasticisers for NBR-PVC blends.

Development of Free Space Method for Material Characterisation and GPR Study & A Case Study on Biological Samples

The thesis mainly focuses on material characterization in different environments: freely available samples taken in planar fonn, biological samples available in small quantities and buried objects.Free space method, finds many applications in the fields of industry, medicine and communication. As it is a non-contact method, it can be employed for monitoring the electrical properties of materials moving through a conveyor belt in real time. Also, measurement on such systems at high temperature is possible. NID theory can be applied to the characterization of thin films. Dielectric properties of thin films deposited on any dielectric substrate can be determined. ln chemical industry, the stages of a chemical reaction can be monitored online. Online monitoring will be more efficient as it saves time and avoids risk of sample collection.Dielectric contrast is one of the main factors, which decides the detectability of a system. lt could be noted that the two dielectric objects of same dielectric constant 3.2 (s, of plastic mine) placed in a medium of dielectric constant 2.56 (er of sand) could even be detected employing the time domain analysis of the reflected signal. This type of detection finds strategic importance as it provides solution to the problem of clearance of non-metallic mines. The demining of these mines using the conventional techniques had been proved futile. The studies on the detection of voids and leakage in pipes find many applications.The determined electrical properties of tissues can be used for numerical modeling of cells, microwave imaging, SAR test etc. All these techniques need the accurate determination of dielectric constant. ln the modem world, the use of cellular and other wireless communication systems is booming up. At the same time people are concemed about the hazardous effects of microwaves on living cells. The effect is usually studied on human phantom models. The construction of the models requires the knowledge of the dielectric parameters of the various body tissues. lt is in this context that the present study gains significance. The case study on biological samples shows that the properties of normal and infected body tissues are different. Even though the change in the dielectric properties of infected samples from that of normal one may not be a clear evidence of an ailment, it is an indication of some disorder.ln medical field, the free space method may be adapted for imaging the biological samples. This method can also be used in wireless technology. Evaluation of electrical properties and attenuation of obstacles in the path of RF waves can be done using free waves. An intelligent system for controlling the power output or frequency depending on the feed back values of the attenuation may be developed.The simulation employed in GPR can be extended for the exploration of the effects due to the factors such as the different proportion of water content in the soil, the level and roughness of the soil etc on the reflected signal. This may find applications in geological explorations. ln the detection of mines, a state-of-the art technique for scanning and imaging an active mine field can be developed using GPR. The probing antenna can be attached to a robotic arm capable of three degrees of rotation and the whole detecting system can be housed in a military vehicle. In industry, a system based on the GPR principle can be developed for monitoring liquid or gas through a pipe, as pipe with and without the sample gives different reflection responses. lt may also be implemented for the online monitoring of different stages of extraction and purification of crude petroleum in a plant.Since biological samples show fluctuation in the dielectric nature with time and other physiological conditions, more investigation in this direction should be done. The infected cells at various stages of advancement and the normal cells should be analysed. The results from these comparative studies can be utilized for the detection of the onset of such diseases. Studying the properties of infected tissues at different stages, the threshold of detectability of infected cells can be determined.

Combined toxic effects of oil and pesticides on selected marine invertebrates

In recent years, pollution in general and sea water pollution in particular, has become an important topic for national and international considerations. Because of its impact on society, marine pollution has attracted great attention from politicians, administrators, natural scientists and technologists all over the world. To save our environment from further deterioration, it is essential to have an assessment of this problem This thesis involves investigation of the lethal and sub lethal effects of four pesticides and two petroleum oil, individually and in combinations on two commercially important bivalves. Among the four pesticides used two are organophosphates and the other two are organochlorines. Synthetic Pesticides, especially organophosphates and organochlorines have become increasingly important additions to chemical wastes polluting natural aquatic Communities special attention is given in the present investigation to delineate the combined toxic effect of oil and pesticides. The results are presented under different sections to make the presentation meaningful.

Dynamics of some Environmentally Significant Pesticides in a Tropical Waterway - A Toxicological Approach

Industrial pollutants, consisting of heavy metals, petroleum residues, petrochemicals, and a wide spectrum of pesticides, enter the marine environment on a massive scale and pose a very serious threat to all forms of aquatic life. Although, earlier, efforts were directed towards the identification of pollutants and their major sources, because of a growing apprehension about the potential harm that pesticides can inflict upon various aquatic fauna and flora, research on fundamental and applied aspects of pesticides in the aquatic environment has mushroomed to a point where it has become difficult to even keep track of the current advances and developments. The Cochin Estuarine System (CES), adjoining the Greater Cochin area, receives considerable amounts of domestic sewage, urban wastes, agricultural runoff as well as effluent from the industrial units spread all along its shores. Since preliminary investigations revealed that the most prominent of organic pollutants discharged to these estuarine waters were the pesticides, the present study was designed to analyse the temporal and spatial distribution profile of some of the more toxic, persistent pesticides ——— organochlorines such as DDT and their metabolites; HCH-isomers; a cyclodiene compound," Endosulfan and a widely distributed, easily degradable, organophosphorus compound, Malathion, besides investigating their sorptional and toxicological characteristics. Although, there were indications of widespread contamination of various regions of the CBS with DDT, HCH-isomers etc., due to inadequacies of the monitoring programmes and due to a glaring void of baseline data the causative factors could not identified authentically. Therefore, seasonal and spatial distributions of some of the more commonly used pesticides in the CES were monitored systematically, (employing Gas Chromatographic techniques) and the results are analysed.