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Project ExecutionProject ExecutionExperience of an Indian RefineryExperience of an Indian Refinery
Now CPCL is a group company of IndianOil
Inception
Slide 2 of 31
CPCL owns two Refineries CPCL owns two Refineries in southern part of India with in southern part of India with 220 thousand Barrels Crude 220 thousand Barrels Crude oil processing per Dayoil processing per Day
Company established in Company established in 1965 as a JV of GoI, NIOC 1965 as a JV of GoI, NIOC of Iran & AMOCO, USAof Iran & AMOCO, USA
50 thousand bbl / day grass 50 thousand bbl / day grass root Refinery near Chennai, root Refinery near Chennai, commissioned in 1969 in a commissioned in 1969 in a record time of 27 monthsrecord time of 27 months
YearYear CapacityCapacityMMTPAMMTPA
Major secondary processing Major secondary processing unitsunits
19691969 Initial CapacityInitial Capacity 2.52.5 Lube ,Cat Reforming,Diesel Lube ,Cat Reforming,Diesel Desulphurisation,Vis BreakerDesulphurisation,Vis Breaker
19801980 DebottleneckedDebottlenecked 2.82.8
19841984 Doubled (Refinery-II)Doubled (Refinery-II) 5.65.6 FCC ,WaxFCC ,Wax
1985-881985-88 Value Addition ProjectsValue Addition Projects Propylene,Food Grade HexanePropylene,Food Grade Hexane
19931993 DebotlleneckedDebotllenecked 6.56.5
19931993 CBR RefineryCBR Refinery 7.07.0
20022002 Debottlenecking-CBRDebottlenecking-CBR 7.57.5
20042004 3 MMTPA Expansion 3 MMTPA Expansion at Manali at Manali 10.510.5
Hydro Cracker, Hydro Cracker, Cat.Reforming,Soaker Cat.Reforming,Soaker
Visbreaker Visbreaker
Panorama of GrowthPanorama of Growth
• Refining capacity expanded by revamp of plants and addition of new units
• In 2004 Capacity expanded from 130 to 190,000 Bbls/day by addition of new Crude Distillation, Hydro-Cracker, Cat.Reforming, Soaker Visbreaker Units
Slide 4 of 31
Panorama of GrowthPanorama of Growth
Green Power Generation
Project was completed in 6 months from order
Plant Capacity 17.6 MW
Estimated Power Generation
36 Million KWHrs / Annum
Generator Capacity
800 KW each
No of WEGs 22Project Cost Rs. 89.8 Cr
In 1991, commissioned a 2.5 MGD City Sewage Reclamation plant
In 2001, commissioned RO Rejects Recovery plant
Additional City Sewage Treatment Project
Capacity: 2.5 MGD Project cost : Rs. 46.68 Cr Commissioned : Dec ’06
Sea Water Desalination Project Capacity: 5.8 MGD Project cost : Rs. 231.34 Cr Scheduled completion: Dec
’07Slide 6 of 31
Water Management Projects
Refinery Expansion Cum Refinery Expansion Cum Modernisation Project 2004Modernisation Project 2004
Licensor Selection Implementation Strategies Commissioning
A success story in Project ExecutionA success story in Project Execution
Process Licensor SelectionProcess Licensor Selection
Unit Licensor CapacityCDU / VDU EIL 3.0 MMTPA
Visbreaker Lummus, Netherlands 1.15 MMTPA
Hydrocracker Chevron Global Lummus, USA 1.85 MMTPA
CRU Axens, France 225,000 TPA
Hydrogen Technip Benelux, Netherlands 56,000 TPA
Sulphur Recovery EIL / Delta Hudson, Canada 180 TPD
LPG Merox UOP, USA 42,000 TPA
Kero Merox UOP, USA 600,000 TPA
Associated Utility & Offsite facilities
Facility Utility / Scope Vendor2 x 20 MW Gas Turbine Power BHEL130 tph Boiler Steam BPHVCryogenic Nitrogen Plant Inert Gas BHPVUtility & Offsite facility Design EILSour Water stripper, Amine Treating & Regeneration facilities
Design EIL
Project executed on a combination of Project executed on a combination of Conventional and LSTK basisConventional and LSTK basis
CDU / VDU, OHCU and U&O executed on CDU / VDU, OHCU and U&O executed on conventional basisconventional basis
Hydrogen, NHT / CRU, VBU & SRU executed Hydrogen, NHT / CRU, VBU & SRU executed on LSTK basison LSTK basis
Entire LSTK (200 M US$) bidding process Entire LSTK (200 M US$) bidding process completed in 99 dayscompleted in 99 days
Implementation Strategies
Major Contractors Associated Major Contractors Associated with the Projectwith the Project
EILEIL BHELBHEL BHPVBHPV L&TL&T Punj Lloyd / Punj Lloyd /
PetrofacPetrofac
Bridge & RoofBridge & Roof PetronPetron SpicgelSpicgel NiccoNicco EPILEPIL
Safety Management
Safety features were incorporated right from design basis stage itself and during
• Finalization of P&ID & process package, • Detailed engineering, • 3 D modeling review, • Hazop review etc.
Safety was given top most priority during construction and commissioning.
3D Model & Hazop Review3D Model & Hazop Review 3D Model (Plant Design Software package) was
reviewed by CPCL in two stages.
After the completion of 50 % & 100 % of engineering• Interference checks were carried out • Approach to equipments and valves for operation
and maintenance
After Engineering, Hazop review was carried out After Engineering, Hazop review was carried out extensively in the presence of Licensor, PMC, extensively in the presence of Licensor, PMC, CPCL team comprising of experts from CPCL team comprising of experts from Operations, Process, Engineering and Contractor.Operations, Process, Engineering and Contractor.
Human resourcesHuman resources
Developing the trained manpower Operators with experience in high pressure
units were positioned one year ahead. Blend of experienced operators from with in
the refinery and new recruits. Class room training for two weeks. On the job training for two weeks in similar
units. Simulator training for panel engineers. Interactive sessions for atleast one hour in a
day.
Chemical Cleaning and Pickling Pressure Relief Valve Registration, Tagging,
and verification of Relief Pressure Rotary Equipment & Instrument Checklist Check on Fire protection & Safety system Construction Safety Audit External Safety Audit by OISD team Construction area Turnover
Pre-commissioning
Pre-commissioning
Special Concerns unique to High Pressure Units
Makeup Hydrogen System
RGC & Auxiliary Systems
HP system - Reactor Internals
PEG and RTJ Flanges
Furnaces
HP Loop Leak Test
High Pressure Reactors Pre-commissioningImportant checks doneImportant checks done Reactors expand several feet when heated –
interference from piping and instrumentation Reactor internals marked before removing for easy
reinstallation Levelness and tight fit of internals. Deviation can
cause mal-distribution and poor radial spreads Coat the nuts and bolts with high temperature anti-
seize compound Installation of quench piping Positioning of Temperature instruments inside Catalyst loading
Focus on High Pressure circuitFocus on High Pressure circuit
Protocol established to check all Protocol established to check all flanges in HP circuitflanges in HP circuit
Healthiness of flange faceHealthiness of flange face Right gasket in placeRight gasket in place Torque tension valuesTorque tension values
PSV Setting and validityPSV Setting and validity Spring support releaseSpring support release
CPCL commissioned the entire process units without any setback and in a safe
manner within stipulated time.
Hydro cracker unit was commissioned in 35 days smoothly from pressure test of
HP system in line with the process licensor schedule
…………This was a very successful and This was a very successful and smooth commissioning. The entire CPCL smooth commissioning. The entire CPCL staff should be credited for the many staff should be credited for the many hours of hard work and preparation that hours of hard work and preparation that went into this successful startup. When went into this successful startup. When rating Commissioning of Hydro-crackers rating Commissioning of Hydro-crackers this one would be rated at the top and this one would be rated at the top and would be considered “WORLD CLASS”would be considered “WORLD CLASS”
Chevron Report on Commissioning
Thank YouThank You