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Project Execution

Project Execution. Experience of an Indian Refinery. Inception. CPCL owns two Refineries in southern part of India with 220 thousand Barrels Crude oil processing per Day Company established in 1965 as a JV of GoI, NIOC of Iran & AMOCO, USA

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Project Execution

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  1. Project Execution Experience of an Indian Refinery

  2. Inception • CPCL owns two Refineries in southern part of India with 220 thousand Barrels Crude oil processing per Day • Company established in 1965 as a JV of GoI, NIOC of Iran & AMOCO, USA • 50 thousand bbl / day grass root Refinery near Chennai, commissioned in 1969 in a record time of 27 months Now CPCL is a group company of IndianOil Slide 2 of 31

  3. Panorama of Growth

  4. Panorama 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

  5. Green Power Generation Project was completed in 6 months from order

  6. Water Management Projects 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 ’07 Slide 6 of 31

  7. Refinery Expansion Cum Modernisation Project 2004 A success story in Project Execution Licensor Selection Implementation Strategies Commissioning

  8. Process Licensor Selection

  9. Associated Utility & Offsite facilities

  10. Implementation Strategies • Project executed on a combination of Conventional and LSTK basis • CDU / VDU, OHCU and U&O executed on conventional basis • Hydrogen, NHT / CRU, VBU & SRU executed on LSTK basis • Entire LSTK (200 M US$) bidding process completed in 99 days

  11. Major Contractors Associated with the Project • EIL • BHEL • BHPV • L&T • Punj Lloyd / Petrofac • Bridge & Roof • Petron • Spicgel • Nicco • EPIL

  12. 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.

  13. 3D 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 extensively in the presence of Licensor, PMC, CPCL team comprising of experts from Operations, Process, Engineering and Contractor.

  14. Human 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.

  15. Pre-commissioning • 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

  16. 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

  17. High Pressure Reactors Pre-commissioning Important 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

  18. Focus on High Pressure circuit • Protocol established to check all flanges in HP circuit • Healthiness of flange face • Right gasket in place • Torque tension values • PSV Setting and validity • Spring support release

  19. 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

  20. Chevron Report on Commissioning ……This was a very successful and smooth commissioning. The entire CPCL staff should be credited for the many hours of hard work and preparation that went into this successful startup. When rating Commissioning of Hydro-crackers this one would be rated at the top and would be considered “WORLD CLASS”

  21. Thank You

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