7/23/2019 Detailed Feasibility Report - Bharat Oman Refineries Ltd http://slidepdf.com/reader/full/detailed-feasibility-report-bharat-oman-refineries-ltd 1/243 DETAILED FEASIBILITY REPORT FOR DEBOTTLENECKING OF BHARAT OMAN REFINERIES LIMITED REPORT NO: A439‐RP-02-41‐0001 VOLUME 1 OF 1 MARCH 2014 This report is prepared for M/s BORL and it is for use by M/s BORL or their assigned representatives/organizations only. The matter contained in the report is confidential.
243
Embed
Detailed Feasibility Report - Bharat Oman Refineries Ltd
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
7/23/2019 Detailed Feasibility Report - Bharat Oman Refineries Ltd
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
COPYRIGHT
This document is copyright protected by EIL and is produced for the clientM/S BORL. Neither of this document or any extract from it may beproduced, stored or transmitted in any form for any purpose by any partywithout prior written permission from EIL.
Request for additional copies or permission to reproduce any part ofdocument for any commercial purpose should be addressed as shownbelow:General Manager (PDD)Engineers India Limited1, Bhikai Ji Cama PlaceNew Delhi- 110066IndiaTelephone: 011-2676-3323
EIL reserves the right to initiate appropriate legal action against anyunauthorized use of its Intellectual Property by any entity.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
LIST OF TABLESTABLE NO. DESCRIPTION PAGE
1.1 Existing Unit Capacities and Post Revamp
Capacities
3 of Ch 1
1.2 Existing Product Pattern and Post RevampProduct Patterns
4 of Ch 1
1.3 Summary of Modifications Required in ProcessUnits to Achieve 7.8 MMTPA Crude throughput
4 of Ch 1
1.4 Summary of Modifications Required in UtilitySystems to Achieve 7.8 MMTPA CrudeThroughput
7 of Ch 1
4.1 Product Slate 9 of Ch 44.2 Product Specifications 10 of Ch 44.3 Existing & Post Revamp Units Capacity 14 of Ch 4
7.1.1 Maximum Achievable Capacity in Various Units 2 of Ch 7.17.1.2 Utility System 3 of Ch 7.17.1.3 Offsite Tanks 6 of Ch 7.17.3.1.1 List of Modified Equipments in CDU/VDU 3 of Ch 7.3.17.3.2.1 Theoretical Yields of DCU 3 of Ch 7.3.27.3.2.2 List of New/Modified Equipments in DCU 4 of Ch 7.3.27.3.4.1 List of New/Modified Equipments in NHT 4 of Ch 7.3.47.3.4.2 List of New/Modified Equipments in CCR 7 of Ch 7.3.47.3.4.3 List of New/Modified Equipments in Penex Unit 9 of Ch 7.3.47.3.5.1 List of New/Modified Equipments in HGU 5 of Ch 7.3.5
7.3.6.1 Modified/New Equipment list for LPG ATU 2 of Ch 7.3.67.3.6.2 Modified/New Equipment list for LPG CFC 2 of Ch 7.3.67.3.7.1 Modified/New Equipment list for SRU 5 of Ch 7.3.77.3.7.2 Modified/New Equipment List for Oxygen
Enrichment6 of Ch 7.3.7
7.3.7.3 Modified/New Equipment List for SWS I/II 7 of Ch 7.3.77.3.7.4 Modified/New Equipment List for ARU 13 of Ch 7.3.77.4.1 Overall Material Balance of Refinery 2 of Ch 7.47.4.2 Unit Capacities 2 of Ch 7.47.4.3 Euro IV MS Specification 3 of Ch 7.47.4.4 Properties of Blending Streams of MS Pool 4 of Ch 7.4
7.5.1 Treated Raw Water Requirement 3 of Ch 7.57.5.2 Cooling Water Consumption 5 of Ch 7.57.5.3 DM Water 6 of Ch 7.57.5.4 Instrument Air 8 of Ch 7.57.5.5 Plant Air 9 of Ch 7.57.5.6 Nitrogen Requirement of the Various Units 11 of Ch 7.57.5.7 HP Steam Consumption 12 of Ch 7.57.5.8 MP Steam Consumption 12 of Ch 7.57.5.9 LP Steam Consumption 13 of Ch 7.57.5.10 Estimated Power Consumption 13 of Ch 7.5
7.5.11 Estimated Steam & Power Supply 14 of Ch 7.57.5.12 BFW Consumption 15 of Ch 7.5
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.5.13 Condensate Balance 16 of Ch 7.57.5.14 Overall Fuel Gas Balance 18 of Ch 7.57.5.15 Overall Fuel Balance 19 of Ch 7.57.6.1 Adequacy of Offsite Pumps 6 of Ch 7.67.6.2 Existing Offsite Tanks 8 of Ch 7.67.6.3 Existing Offsite Pumps 8 of Ch 7.67.6.4 Feed and Intermediate Storage Tanks 9 of Ch 7.68.1 National Ambient Air Quality Standards 2009 3 of Ch 88.2 Emission Standards For
Furnace/Boilers/Captive Power Plants5 of Ch 8
8.3 Emission Standards For Sulphur Recovery Unit 6 of Ch 88.4 Emission Control For Raod Tank Truck/Rail
Tank Wagon Loading8 of Ch 8
8.5 VOC concentration 9 of Ch 8
8.6 Monitoring Requirements and Repair Schedule 10 of Ch 88.7 Ambient Air Quality Standards in Respect to
Noise12 of Ch 8
8.8 Standards for discharge of EnvironmentalPollutants from Petroleum Refineries
12 of Ch 8
8.9 SOx Emissions for Present RefineryConfiguration
17 of Ch 8
8.10 SOx Emission for Post Expansion RefineryConfiguration
18 of Ch 8
8.11 Year Wise Plantation Details 23 of Ch 88.12 Sapling Details 24 of Ch 89.1 Comparison Between Different Modes of
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
1.0 EXECUTIVE SUMMARY
1.1 INTRODUCTION
Bharat Oman Refineries Limited (BORL) is operating a 6MMTPA Refinerylocated at Bina, Madhya Pradesh, India, with associated crude receipt andhandling facilities, cross country pipelines, marketing terminal etc.
BORL intends to augment the processing capacity of the facilities from present6MMTPA to 7.8 MMTPA considering low cost debottlenecking. In order tominimize the cost and shutdown time for implementation of project, 30%increase in crude capacity is established and achieved in consideration ofminimizing hardware modifications using in-built design margin and no newprocessing facilities.
BORL presently has the following facilities:- 6MMTPA refinery configuration consisting of Crude and Vacuum
Distillation Unit (CDU/VDU), Delayed Coker Unit (DCU), Integrated FullConversion Hydrocracker unit (FCHCU) and Diesel Hydrotreating Unit(DHT), MS block comprising Naphtha Hydrotreating Unit (NHT),Continuous Catalytic Reformer (CCR) and Isomerization Unit (ISOM) andother associated facilities such as Hydrogen Generation Unit (HGU), SulfurRecovery Unit (SRU), Sour Water Stripper (SWS) etc.
- Crude Oil Terminal at Vadinar to receive crude from crude carriers- Cross country Vadinar –Bina Pipeline to transport crude from Vadinar to
Bina refinery.- Bina Dispatch Terminal adjacent to refinery to market the final products
produced from refinery
The existing refinery is producing MS and HSD conforming to Euro III/IVspecifications by processing of Arab Mix type crudes besides other petroleumproducts like LPG, Naphtha, Kero, ATF, Petcoke & Sulphur.
1.2 BASIC DESIGN PARAMETERS
Refinery Capacity: 7.8 MMTPA (30% increase in existing capacity of6.0MMTPA ), 8280 on stream hours.
The existing refinery capacity of 6MMTPA can be augmented to annualcapacity of about 7.8 MMTPA (about 30% increase over 6.0 MMTPA)considering 8280 hours (345 days) which can be achieved post expansion dueto reliability of operations.
Crude Blend : 100 % Arab Mix (A 65:35 weight blend of Arab Light and ArabHeavy Assay 2000)
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
1.3 OBJECTIVES OF THE STUDY
The objective of the DFR is to establish the adequacy of all existing majorequipment for 130% increase in throughput of existing refinery in consideration
of following:
Minimum hardware modifications utilizing available design marginsLow capital cost with the accuracy of ±20%Short shutdown time ( limited to 40-45days)
1.4 RESULTS OF ADEQUACY CHECK
The unit performance and adequacy of major and critical equipments areevaluated by respective unit’s licensor. The key findings for each unit are
summarized below:
1.4.1 PROCESS UNITS
Table 1.1 Existing Unit Capacities and Post Revamp Unit Capacities
Delayed Coker Unit 1.357 1.822 134Hydrogen Unit 0.077 0.098 127Naphtha Hydrotreater 1.0 1.45 145CCR Reformer Unit 0.54 0.787 146Isomerization Unit 0.31 0.56 181Sulphur Recovery Unit 2 x 180 MTPD 3 x 243 MTPD 202
SWS I & II
125 T/hr & 49
T/hr
162 T/hr/hr &
65 T/hr 130/132
Amine Regeneration unit470 T/hr of Lean Amine of 25 wt %MDEA
The product pattern post revamp corresponds to Arab mix crude slate and will
vary in case of heavier crudes like Kuwait, Basra light etc which have
comparatively higher pet coke yield and fuel & losses.
The equipment adequacy is based on revamp feasibility studies carried out byLicensors for the respective Licensed units and studies carried out by EIL for the
units designed by EIL. A summary of findings of adequacy check on critical
equipment in process units is summarized in table below:
Table 1.3 Summary of Modifications Required in Process Units to
Achieve 7.8 MMTPA Crude Throughput
Unit Modifications Required for Critical Equipment
CDU/VDU/NSU
A new additional first stage deslater parallel toexisting one and second stage desalter.Minor modifications in the internals of columns e.greplacement of trays with high capacity trays/change in deck plates/ change in packing .New amine column and pump for hot well offgastreatment facilities. Augmentation in heat transfer area and associatedmodification in the radiant section with additional 16no of tubes for the crude and vacuum heater.Replacement of existing pumps e.g crude booster
pumps and addition of cooling water booster pumpfor vacuum column.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Unit Modifications Required for Critical Equipment
Additional shells in existing exchangers like HVGOCR and additional bays in Ovhd naphtha maincondenser and tempered water.
NHT
New auxiliary heater in parallel for naphtha splitterheater.Tray replacement of naphtha splitter with UOPECMD trays Additional six shells of combined feed exchanger.New catalyst charge for the NHT reactor.
CCR
Additional Net gas compressor in parallel to exsiting
net gas compressor
Replacement of burners in charge heater and inter
heaters.
Additional shells in existing exchangers
PENEX
Additional facilities for achieving 181 % Penexcapacity : Lead Lag reactors(2 nos) DIH column and stabilizer column with its
Hot combined feed exchanger , cold combinedfeed exchanger charge heater.
Minor modification in existing reactor w.r.t VLD traywith additional catalyst .Replacement of DIH column with ECMD trays.Replacement of tube bundle with high flux tubes instabilizer reboiler, DIH column bottom and side drawreboiler.Replacement of exchangers with new largerexchanger e.g methanator heater, hot combinedfeed exchanger etc.New refrigeration package for balance capacity.
Integrated FCHCU
& DHDT
Change in catalyst in all the HCR reactors andDHT reactorReplacement of coils in all the Reactor furnacesand fractionators furnaceNew Recycle gas compressorNew pumps with PRT for the first stage HCRcharge pumpMotor and impeller replacement for the 2nd stageHCR and DHT charge pump with new PRTsReplacement of four exchangers in the HP section Additional banks in the 1st stage Feed filter andDHT feed filter Additional backwash oil system with vessel, air
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Unit Modifications Required for Critical Equipment
Unit
LPG CFC unit
New 1st stage CFC column , 2nd stage CFC column
and 2nd
stage CFC separatorNew CFC solvent wash contactor and solvent washseparatorNew water wash column and coalescer
1.4.2 Utility Systems
A summary of findings of adequacy check on utility systems are summarized
in table below:
Table 1.4 Summary of Modifications Required in Utility Systems toAchieve 7.8 MMTPA Crude Throughput
System Modifications required
Steam and
Power
Shortfall in power requirement will be met through grid. Anadditional Utility Boiler for 160 TPH capacity to supply HPsteam at 42 Kg/cm2g to refinery is under implementation.
Cooling Water
System
One additional cooling water cell of capacity 4000 m3/hrand one additional pump of capacity of 8000m3/hr arerequired..
Nitrogen
SystemOne additional chain of 500 Nm3/hr capacity is envisaged.
Raw Water
System
One additional Raw water intake pump similar to existing isenvisaged.Oil removal facility from Raw water feed to RO-DM isenvisaged.
Compressed
Air System
One additional LP Air compressor similar to existingcompressor is envisaged. Additional Instrument drier(5000Nm3/hr) is also considered.
Flare System No modifications are envisaged.
RO –DM plant One additional bank of RO-I, RO-II, UF, MB train areenvisaged.
CPU One additional chain of capacity of 50TPH is envisaged.
ETP One additional CRWS and SWS tanks are considered.
1.4.3 Offsite Storage system
All products run down lines from refinery to Dispatch terminal are found
adequate for 30% increase in flow of products. An additional 10” H2 line from
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
2.0 INTRODUCTION
Bharat Oman Refineries Limited (BORL), is operating a 6MMTPA Refinery locatedat Bina, Madhya Pradesh, India, with associated crude receipt and handling
facilities, cross country pipelines, marketing terminal etc.
Bharat Oman Refineries Limited (BORL) proposes to enhance the crude processingcapacity of the refinery from present 6 MMTPA to 7.8MMTPA through low costcapacity expansion utilizing the available design margins thus minimizing thehardware cost & shut down time for revamp.
The existing refinery is producing MS and HSD conforming to Euro III/IVspecifications by processing of high sulfur Arab Mix type crudes besides otherpetroleum products like LPG, Naphtha, Kero, ATF, Petcoke & Sulphur.
The processing facilities at the Bina refinery primarily consist of the following units:
• Crude and Vacuum Distillation unit• Integrated Hydrocracker and Diesel Hydrotreater unit• Delayed Coker unit• Hydrogen plant• MS block (NHT/CCR/ISOM)• Matching product Treating facilities• Sulphur recovery unit• Utilities & Offsites including Captive Power plant.• COT, VBPL and BDT
The refinery block diagram is as shown below:
The crude oil is received at the refinery through 24” dia, 937 Km long cross countrycrude pipeline from Vadinar, District Jamnagar, Gujarat.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
2.1 LOW COST DEBOTTLENECKING PROJECT
Under this project, BORL intends to augment the processing capacity of Binarefinery from present 6MMTPA to 7.8MMTPA considering low cost debottlenecking.
In order to minimize the cost and shutdown time for implementation of project,130% increase in crude capacity is established and achieved in consideration offollowings:
Minimizing hardware modifications using in-built design marginNo New processing facilities
As a first step to achieve the above objectives of project, preliminary feasibilityreport was prepared to establish the order of magnitude cost for debottlenecking ofrefinery. This was followed by maximum capacity test run conducted by BORL inthe existing process units to identify the hardware bottleneck and other operatingconstraints
In order to estimate the capital investment within accuracy of ± 20% and to establishthe implementation plan for 130% increase in crude processing capacity withminimum modifications, BORL has retained EIL’s services to prepare detailedfeasibility study report for low cost debottlenecking of Bina refinery.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
3.0 SCOPE OF WORK
The scope of Detailed Feasibility Report is to estimate capital cost of project with
accuracy of ± 20% and tentative schedule for overall project implementation toachieve the processing objective of sustained refinery operation at 7.8MMTPAcrude throughputs through low cost expansion. The design crude for the revamp ismaintained same as the original design crude i.e, 65:35 AL:AH (by wt).
In addition, environmental considerations and implementation philosophy for thisproject are studied and included in report.
3.1 DETAILED FEASIBILIT REPORT
The report consists of the following:
1. Design basis
2. Project configuration
3. Process description
4. Overall Material Balance
5. Process flow diagrams
6. Equipment lists
7. Requirement of raw material(crude), Utilities, Chemicals, Catalysts, Off-sitesand auxiliary facilities. Transportation logistics raw material & products
8. Environmental Considerations
9. Utilities and offsites facilities:
10. Identifying tankage, silo / warehouse requirement for intermediate and finalproducts including requirements for raw materials / feed streams. OSBL(Outside battery limit of process units) facilities including dispatch facilitiesfor products, effluent treatment facilities, power and steam generationsystem, fire-fighting system etc.
11. Project Capital Cost
Preparation of cost estimates with ± 20% accuracyEstimated basic design and engineering fees, License / know-how fees,list & estimated cost of proprietary items (if any), commissioning and
training fees based on quote from Licensors / Consultants’ in-house datafor similar projects in recent past.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Estimated consultancy fees for carrying out detailed engineering,procurement, inspection and expediting of equipment/materials,construction supervision, etc.Estimates for civil, electrical materials, piping, structural, instrumentation
materials.Capital cost breakup as foreign exchange component and indigenouscomponent.
12. Project implementation strategy and project schedule along with bar chart.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
In case this is not available,
whether a system is to be
designed /included in
execution.
The power requirement after post expansion is
proposed to be met through existing CPP and
from augmented grid (Grid augmentation for 220kV is envisaged to receive 125 MW power).This
shall be further reviewed during detailed
feasibility study.
4.1.10.3 Construction Power
Available Yes
Volts 415/230 V AC LT supplyKM away Within existing refinery
Contract Demand Charges Power available within the plant will be used as
construction power.Energy charges
Minimum energy charges (as
% of Contract Demand)
4.1.10.4 Construction Water
Available YesKM away Within existing refinery
4.1.10.5 Cooling water
The Refinery cooling tower capacity is inadequate as per prefeasibility report.
Cooling tower fill replacement shall be considered only if this option avoids additional
cooling tower. Cooling tower fill replacement shall be checked against requirement of
new cooling tower after additional cooling water requirement is worked out.
4.1.10.6 Nitrogen system
The nitrogen consumption is expected to change post refinery expansion to
7.8MMTPA. Hence one additional N2 chain of 500 Nm3/hr capacity is envisaged,
shall be confirmed during detail feasibility study.
4.1.10.7 Air System
In the post expansion scenario to 7.8 MMTPA, the instrument air and plant airrequirements are expected to increase marginally. One LP air compressor identical
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
to existing air compressors (8824.39 Nm3/h capacities) is to be evaluated for DFR.
Existing two number instrument air driers are being operated at 50% load. Additional
instrument air drier is to be considered.
4.1.10.8 Steam system
To meet the steam requirement during post expansion, steam balance will be worked
out during detail study. BORL is presently installing one additional 160TPH utility
boiler in view of revamp scenario. Capacity of existing CFBC boilers shall be
considered as 225 TPH.
4.1.10.9 DM Water
One additional bank for RO-DM plant (One additional bank of RO-I, RO-II, UF, MB
train) of existing capacity is considered to cater additional DM water requirement.
Additional oil removal facility from Raw water feed to RO-DM is considered. One
additional cooling tower blow down storage tank and one additional feeding pump for
blow down of cooling tower is considered.
4.1.10.10 Condensate system
No surplus capacity is available in condensate treating unit. Additional train ofcondensate treating unit shall be considered for the additional units.
4.1.10.11 Flare
Flare load mitigation strategies will be implemented during Basic engineering phase
to minimize any hardware modifications in the flare systems. Modification in existing
seal drum shall be considered for low flow scenario. Flare adequacy shall be
checked at 7.8MMTPA throughput
4.1.10.12 ETP
The adequacy of existing ETP will be checked for 7.8 MMTPA refinery operation as
per DFR study. One additional CRWS & SWS tank of existing capacity is considered.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
E. SUPERIOR KEROSENE
TEST SPECIFICATION
Acidity, inorganic NilBurning Quality :
a) Char value. mg/kg of oil consumed Max. 20
b) Bloom on glass chimney Not darker than grey
Colour (Saybolt), Min. +10
Copper Strip corrosion for 3 hrs. at 50°C Not worse than No. 1
Distillation :
a) Percentage recovery below 200°C Min. 20
b) Final boiling point,°C Max. 300Flash Point (Abel), °C Min. 39
Smoke Point, mm. Min. 18*
Total Sulphur, %wt. Max. 0.235**
Conforms to BIS : 1459 - 1974* For supplies of Defence & railway signal lamps, smoke point of the productshall be minimum 22 mm. Under the emergency IS Specifications forkerosene, smoke point for general supplies has been relaxed to minimum 18mm.** For supplies to Defence, total sulphur content percentage by weight of the
CONFORMS TO BIS SPEC IS:1571-2001 and DEFSTAN 91-91/ISSUE 4# The requirement to determine lubricity as per IS 1571-2001 applies only to
ATF containing more than 95% hydroprocessed material where atleast 20% ofthis is severely hydro processed. Defence requirement to be met at 0.65 mm,
Max. To meet this requirement, approved Lubricity Additive as mentioned in4.2.4 of IS:1571, 2001 to be added by appropriate agency before beinginducted into the aircraft.
4.4 EXISTING & POST REVAMP UNIT CAPACITIES
Design Capacities of existing units and expected capacities post revamp are
tabulate below in table 4.3:
Table 4.3: Existing & Post Revamp Units Capacities
Hydrogen Unit 0.077 0.098 TechnipNaphtha Hydrotreater 1.0 1.45 UOPCCR Reformer Unit 0.54 0.787 UOPIsomerization Unit 0.31 0.56 UOPSulphur Recovery Unit 2 x 180 MTPD 3 x 243 MTPD EILSWS I & II 125T/h &49 T/h 162 T/hr/hr & 65 T/hr EIL Amine Regenerationunit
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Details of existing storage tanks in BDT area is given as under
Sr.No.
Service Product
PumpableVolume in KL
(Vol in betweenLLL and HLL of
tank)
Typeof
tank*Tank Size
1 01A HSD - EURO III 14926 CR 34m x 18m
2 01B HSD - EURO III 14937 CR 34m x 18m
3 01C HSD - EURO III 14928 CR 34m x 18m
4 01D HSD - EURO III 14871 CR 34m x 18m
5 01E HSD - EURO III 14925 CR 34m x 18m6 01F HSD - EURO III 14880 CR 34m x 18m
7 02A HSD - EURO IV 14869 CR 34m x 18m
8 02B HSD - EURO IV 14880 CR 34m x 18m
9 02C HSD - EURO IV 14855 CR 34m x 18m
10 02D HSD - EURO IV 14934 CR 34m x 18m
11 02E HSD - EURO IV 14850 CR 34m x 18m
12 02F HSD - EURO IV 6885 CR 26m x 14.5m13 03A MS - EURO III 10200 FR 34m x 16m14 03B MS - EURO III 10200 FR 34m x 16m
15 03C MS - EURO III 10200 FR 34m x 16m16 03D MS - EURO III 10200 FR 34m x 16m17 03E MS - EURO III 10200 FR 34m x 16m18 03F MS - EURO III 5400 FR 26m x 14.5m
19 04A MS - EURO IV 10200 FR 34m x 16m20 04B MS - EURO IV 10200 FR 34m x 16m21 04C MS - EURO IV 10200 FR 34m x 16m22 04D MS - EURO IV 10200 FR 34m x 16m
23 04E MS - EURO IV 10200 FR 34m x 16m24 04F MS - EURO IV 5400 FR 26m x 14.5m
25 05A SKO 5300 FR 26m x 14.5m26 05B SKO 5300 FR 26m x 14.5m
27 05C SKO 5300 FR 26m x 14.5m
28 05D SKO 5300 FR 26m x 14.5m
29 05E SKO 5300 FR 26m x 14.5m
30 06A ATF 9900 CFR 33m x 16m
31 06B ATF 9900 CFR 33m x 16m
32 06C ATF 9900 CFR 33m x 16m
33 06D ATF 9900 CFR 33m x 16m
34 06E ATF 9900 CFR 33m x 16m
35 06F ATF 9900 CFR 33m x 16m36 07A NAPHTHA 5300 FR 26m x 14.5m
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
6.0 PROJECT LOCATION
The proposed project is expansion of Bharat Oman Refineries Limited (BORL),
located in Bina, Dist. Sagar in Madhya Pradesh. The site is located approximately atLatitude of 24◦10’48″N and longitude of 78◦12’0″E.
The site is well connected by state highways and road network. The nearestimportant town is Bina,, which is 9 Km from the site. The nearest airport to the sitelocation is Bhopal, which is 135 Km away from the Bina Refinery site and thenearest rail junction is Bina which is situated on the broad guage line between NewDelhi to Bhopal.
The power required after post expansion is proposed to be met by utilizing fullcapacity of existing CPP (99 MW) and balance from augmented grid (Grid
augmentation for 220 kV is envisaged to receive 125 MW power).
The expansion envisaged for various process units is proposed to be done withinthe battery limit or in immediate vicinity of the existing units. Thus the administrationbuilding and other associated facilities shall be kept same as that of existing one.
The overall plot plan prepared for this project is attached in Annexure-2.
BORL site can be visualised in Google map as attached below:
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.1 PROJECT CONFIGURATION
The capacity of Bina refinery can be increased from 6MMTPA to 7.8MMTPA
without replacement of any major equipment in any of the existing process units.The desired capacity increase is proposed to be achieved by exploiting the
available over design margins, limited hardware modifications in the existing
process units, utilities and offsites, low capital investment and reasonably short
shutdown time.
7.1.1 Process Units
The extent of augmentation which can be achieved by utilizing the in-built design
margins & with minimum hardware modifications and without replacement of major
equipment in capacities of major process units is tabulated below:
Table 7.1.1: Maximum achievable capacity in Various Units
UnitsExisting Capacity
(MMTPA)
Post Revamp
Capacity (MMTPA)
Crude / Vacuum Distillation
Unit6.0
7.8
Integrated Full Conversion
Hydrocracker and DieselHydrotreater 1.952/1.637 2.625/2.202
Delayed Coker Unit 1.357 1.822
Hydrogen Unit 0.077 0.098
Naphtha Hydrotreater 1.0 1.45
CCR Reformer Unit 0.54 0.787
Isomerization Unit 0.31 0.56
Sulphur Recovery Unit 2 x 180 MTPD 3 x 243 MTPD
SWS I & II 125 T/hr & 49 T/hr 162 T/hr/hr & 65 T/hr
Amine Regeneration unit470 T/hr of Lean Amine of 25 wt %
MDEA
468T/hr of Lean Amineof 40 % MDEA
ATF Merox 0.55 0.711
LPG treating unit 15.5 T/hr 21.66 T/h
7.1.2 Utilities Systems
The utility facilities for the Refinery consist of the following:
Steam, Power & BFW SystemRecirculating Cooling Water System
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
S no. Description Specification
capacity
B CPP-STG3 extraction cum condensing type of STG, 33
MW each
In design there is provision of importing 45 MW power from the National grid for
emergency and back up to refinery power generation system. To meet the
process units emergency requirements, an emergency DG set of 4.0 MW is
also available.
Shortfall in power requirement will be met through grid.
An additional Utility Boiler for 160 TPH capacity to supply HP steam at 42
Kg/cm2g to refinery is under implementation.
9. Flare SystemThe refinery flare system comprises of two flare systems. A hydrocarbon flare and
a sour flare system.
The HC flare size is 66” and has a design capacity of 946,973 kg.hr (peak
load)
The sour flare size is 20” and has a design capacity of 30,846 kg/hr (peak
load).
In order to minimize any hardware modifications in the flare systems, flare loadmitigation strategies will be implemented in the basic engineering phase.
10. Effluent Treatment Plan
Refinery has a full-fledged Effluent Treatment Plant (ETP) for treatment of the
following waste water generated from the refinery.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
In order to cater to the increased flow of crude (around 30% increase), pumping
facilities in existing 24” pipe line will require enhancement along with DRA injection
at the dispatch terminal and the intermediate pumping stations. Post
debottlenecking, additional booster pump and modifications in main line pumps at1st intermediate pumping station are envisaged to meet the revamp flow of crude
supply at the refinery.
7.1.5 BINA Dispatch Terminal
Bina dispatch Terminal adjacent to Bharat Oman Refinery for Marketing of
Finished Petroleum products produced in the Refinery is having facilities to market
MS ( Euro IV/Euro V equivalent Grades ), HSD ( Euro IV/V Grades), SKO,
Naphtha, ATF and LPG via Road, Rail and Pipeline. Products are received in the
Marketing Terminal from Refinery through piping.
7.1.6 Crude Oil Terminal
Crude oil terminal at Vadinar has facilities of Crude Oil receipt, storage and
pumping facilities to pump the crude to refinery via Vadinar Bina Pipeline (VBPL).
Under the expansion project of refinery additional crude storage tanks are
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
BORL has provided the test run report carried out at a capacity of 115-119 % and
a special study report carried out at 111 % capacity which has indicated certain
equipment limitations which has been looked into and suitable modifications has
been suggested. Cost provision of these modified or new equipments is kept in
the feasibility report.
Adequacy check has been limited to the critical equipments and adequacy check
of the line and instruments are not in the scope of the study.
An adequate margin to accommodate the flow conditions pertaining to Kuwait
crude processing has been considered for adequacy check of all the equipments.
7.3.1.2 EQUIPMENT ADEQUACY REPORT
Based on above mentioned basis and assumptions, the adequacy check hasbeen done and the findings of the adequacy check for all major/critical
equipments are summarized below in Table 7.3.1.1 and overall equipment list is
attached in Annexure -2.
Table 7.3.1 List of Modified Equipments
Crude Distillation Unit
S.NO TAG NO DESCRIPTION MODIFICATION
COLUMNS
111-CC-00-101(M)
Crude Column
Dia =6200mm, Type: Tray TowerTrays modifications:3 Nos (Trays 15-17) -Existing tray deck platesneed to be changed with new deck plates3 Nos(Trays 25-27) - Exit Weir to be changed &downcomer bottom clearance required to bechanged.3 Nos(Trays 36-38) - Exit Weir to be changed &downcomer bottom clearance required to be
changed
211-CC-00-103(M)
LGO stripper
Dia=1600 mm, Type: Tray TowerTrays modifications:6 Nos (Trays 1-6)- Existing deck plates to bechanged with new deck plates.
311-CC-00-104(M)
HGO Stripper
Dia=1600mm, Type: Tray TowerTrays Modifications:6 Nos (Trays 1-6)-Existing trays will need to bereplaced with new
EXCHANGERS
1 11-EE-00-
124A/B
KERO Product
Trim Cooler
Tube side Nozzle modifications. Inlet/Outlet nozzle
Sizesto be increased to 8‖/8‖ from existing 6‖/6‖.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
1 11-EA-00-125AH
Ovhd NaphthaMain Condenser
An additional bay, identical to existing 4 bays(5.8m*10.5m) to be considered.
VESSELS
1 11-VV-VI-119
Diesel Coalescer Replaced by new coalescer.
PUMPS 1 11-PA-CF-
101A/BCrude Pump Impeller change with motor replacement of 1MW
2 11-PA-CF-102 A/B/C
Crude BoosterPumps
Replaced by new pump( Flow:654m3/hr, Head:522 m, Motor rating:1200KW)
3 11-PA-CF-104 A/B
KERO CR Pump Impeller trimming
4 11-PA-CF-105 A/B
LGO CR Pump
Replaced by new pump(Flow:940m3/hr,Head:91.6m,Motor Rating:225KW)
5 11-PA-CF-106 A/B HGO CR Pump Replaced by new pump(Flow:482m3/hr,Head:98.4m, MotorRating:150KW)
6 11-PA-CF-107 A/B
KERO Pdt Pump Impeller change with higher dia.
7 11-PA-CF-108 A/B
LGO Pdt Pump Impeller change with motor replacement of 160KW
8 11-PA-CF-109 A/B/C
HGO Prdt Pump Motor replacement of existing pumps (PA-109 A/B)with 132kW motor & One new pump (PA-109 C)with flow 56 m3/hr, head 215m & motor rating 132KW.
9 11-PA-CF-110 A/B/C
RCO Pump Impeller change with higher diameter
10 11-PA-CF-111 A/B
Crude ColumnReflux pump
Impeller change with higher diameter
11 11-PA-CF-112 A/B
Ovhd NaphthaPump
Replaced by new pump(Flow:224m3/hr, Head:220.4m, Motor rating 150KW)
12 11-PA-CF-113 A/B
CDU Sour WaterPump
Impeller change with higher diameter
13 11-PA-CF-128 A/B
Recycle waterpump
Impeller change with higher diameter
FIRED HEATERS 1 11-FF-00-
101Crude Heater Additional 16 no tubes, Modification in fan and
burner, replacement of stack damperNEW EQUIPMENT 1 LGO Exchnager New Exchanger With following Specifications ,
No of Shells: OneSize: 650*6000mm Area: 80m2
2 HGO Exchanger New Exchanger With following SpecificationsNo of Shells: One
Size: 800*6000mm Area: 100m2
3 2nd StageDesalting
New pump(Cap: 104 m3/h ,Head :125m,Motor rating 75KW)
Pressure drop increase in trays is within the design limit.
Side strippers
The existing diameter and trays of all the side strippers ( Kero/LGO/HGO) are
found adequate for 130% of the design loads
However, as per special study report and the test run report, it was observed that
LGO is drawn at around 10% higher and HGO is drawn at around 64% higher
than design draw rates. In anticipation of similar operation post revamp, theadequacy check of the strippers have been carried out with these additional
overdesign margins over and above 30% increase in the design loads.
For these increased loads, the LGO stripper needs change in deck plates and
HGO stripper needs change in trays of new configuration.
Vacuum column
Vacuum Column is found to be adequate but to retain the existing column
allowable pressure drop value of 17.25mmHG, following modifications are
proposed
Replacement of Bed No.#2 & Bed No.#4 with new packed bed having more
open type of packing, but retaining the respective existing bed heights.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
VDU Heater FD fans (12-EA-FN-101A/B)
The fan is checked for following post revamp operating conditions as shown in
table below:
Maximum Normal Minimum
Two FanOperating
One FanOperating
Two FanOperating
One FanOperating
Existing
Revamp
Existing
Revamp
Existing
Revamp
Existing
Revamp
Capacity(Nm
3/s)
(Dry)8.9 9.8 17.8 19.6 7.7 8.5 7.7 8.5
DischargePressure(mm WC)
260
315
260 315 200 230 50 57
Findings Existing fan is adequate to deliver all operating condition except for maximumcapacity while one fan operating (i.e 19.6 NM^3/S flow @ 315 mm WCdischarge pressure). To achieve this condition too, existing 110 KW motorneeds to be replaced with new motor of power rating132 KW. In addition to thisreplacement/ rectification of some major component such as Fan Rotor, Seals,bearings, casing with inlet box & drain, outlet evase is also required.
It is presumed that the existing APH (for both CDU & VDU heater) is working as
per design and the existing flue gas temperature of 160 degC at APH outlet is
being achieved. The increase in flue gas flow rates/temperature for revampcondition is estimated to be absorbed in APH overdesign margins.APH shall be
checked for new loadings during detailed engineering.
The inlet box damper for the ID fan needs to be inspected for smooth operation.
Other performance parameters (TMT, BWT etc.) are under allowable limit.
Existing combined stack (ID & length) for CDU & VDU heater is adequate to
handle the revamp loads w/o any modification.
Exchangers
Preheat Network
The preheat network has been examined with 30% additional of design flow and
duty for the revamp scenario. All the exchangers in the preheat circuit are found
to be adequate for 30% additional design flow and duty and preheat
temperature of 307degC will be achievable in existing network.
However as per special operating study and the test run reports, the existing
operating preheat II temperature (295degC) is 15degC lower than designpreheat temperature of 310degC. To evaluate the lower operating preheat
temp, the design and operating data were compared as tabulated below:
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
*Combined LVGO & HVGO run down temperature: 83degC** Increase in steam generation by 25%.
Temper water System
In order to cool HVGO and VR+Slop to the rundown temperatures mentionedabove one additional bay identical to the existing 3 bays to be provided for the
Tempered water Air cooler 12-EA-109 to cool 468.6 m3/hr of tempered water to
60 deg c.
Vessels
All the vessels are found adequate for the revamp conditions with acceptable
reduced residence time and the hold up time
PumpsThe pump adequacy has been carried out based on the following assumptions:
The pumps have not been checked w.r.t NPSHA / NPSHR & downstream
design pressure as these aspects will be checked in the detail engineering .
Adequacy Check of the pump has been carried out based on existing pump
data sheets /predicted performance curves on the assumption that the actual
performance of the pumps are as per datasheets /curves
Adequacy Philosophy
Pump adequacy check has been performed with an objective of retaining the
existing pump with the following philosophy:
Minimum overdesign margin is provided for the rated flows of the pump over
and above 25 % increase in normal flow for the revamp
Head increase post revamp has been avoided by considering replacement of
line size, instruments , if required.
Adequacy Results
A summary of the adequacy results of the pumps are tabulated below.Majority of the pumps are found adequate with impeller replacement and /or
motor replacement.
Motor Replacement
If pump is found adequate and motor inadequate (Total 9 Pumps:3 in CDU & 6 in
VDU), replacement of motor with a higher rating is envisaged. Replacement of
motor may call the following changes :
a) Base plate modification/replacementb) Couplings need replacement,c) Foundation may require modification
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Modifications related to Motor shall be carried out by OEM only which mightinvite opportunity costs.Shut down time requirement is more as compared to implementation of newpumpsNormally motor related modifications are preferred by OEM at their workplace.
Shifting of pumps at OEMs works are mostly difficult, time consuming & costineffective. To carry out the motor related modifications at site, BORL shallcheck adequate facilities at their workshop.
Therefore , the ph i losophy of motor c hange f rom economica l feas ib i l ity and
execut ion po in t of v iews sha l l be rev iewed at design stage in consu l tat ion
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
PUMP ADEQUACY CHECK RESULTS
CRUDE DISTILLATION UNIT
PUMPDESCRIPTION
PRE-REVAMP POST-REVAMP
MODIFICATIONS/FINDINGSRATEDFLOW(m3 /hr)
DIFFHEAD(M)
RATEDFLOW(m3 /hr)
DIFFHEAD (M)
Crude Pump(11-PA-CF-101 A/B)
958.2 201 1197 254.2 Existing motor (Rated Power: 665 kW) to bereplaced by new (Rated Power: 1MWapprox).Impeller change with higher diameter
Crude BoosterPump(11-PA-CF-102
A/B/C)
523 391.3 654 522.1 New Pump. Existing Pump is insufficient for revamprated flow.
Desalting WaterPump(11-PA-CF-103 A/B)
70 183.1 80 180 Adequate
KERO CR Pumps(11-PA-CF-104 A/B)
663 99.2 853 82.2 Impeller Trimming
LGO CR Pumps(11-PA-CF-105 A/B)
758.0 73.2 940 91.6 New Pump. Existing Pump is insufficient for revamprated flow.
HGO CR Pumps( 11-PA-CF-106
A/B)
378 69.6 482 98.4 New Pump. Existing Pump is found inadequate due tomaximum achievable head of 70 m for the revampflow.
KERO ProductPumps(11-PA-CF-107 A/B)
211 152.2 220 155 Impeller replacement with higher diameter. (Inoperation since KERO Draw has been reduced to85%, this pump can be made adequate with impellerchange).
LGO Product Pumps(11-PA-CF-108 A/B)
154 207.4 188* 226.4 Existing motor (Rated Power: 110 kW) to bereplaced by new (Rated Power: 160 kW approx). .Impeller change with higher diameter
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
HGO ProductPumps(11-PA-CF-109 A/B)
56 215 112* 215 Existing motor (Rated Power: 75 kW) to bereplaced by new (Rated Power: 132 kW approx).One Additional pump (2W +1S) is required toaccommodate the revamp rated flow.
RCO Pumps(11-PA-CF-110
A/B/C)
306 173.2 336 175 Impeller replacement with higher diameter
Crude ColumnReflux Pump(11-PA-
CF-11 A/B)
275.3 102.5 315 112.6 Impeller replacement with higher diameter
Overhead NaphthaPumps(11-PA-CF-112 A/B)
187.4 205 224 220.4 New Pump. Existing Pump is only sufficient for flow of215 m3/hr (3% margin) which is very less.
CDU Sour WaterPumps(11-PA-CF-113 A/B)
21 68.5 24 72.6 Impeller replacement with higher diameter
Recycle WaterPumps(11-PA-CF-128 A/B)
10.3 42.6 13 48 Impeller replacement with higher diameter
VACUUM DISTILLATION UNIT
Vacuum DieselPump(12-PA-CF-101 A/B)
540 147.5 590 160 Existing motor (Rated Power : 250 kW) to bereplaced by new (Rated Power: 330 kW approx).Impeller change with higher diameter
LVGO IR + CR
Pump(12-PA-CF-102 A/B)
735 117.4 905 105 Impeller replacement with higher diameter
HVGO IR + CRPump(12-PA-CF-103 A/B)
934 136.6 1161 135 Existing motor (Rated Power: 390 kW) to bereplaced by new (Rated Power: 460 kW approx). Impeller change with higher diameter
SLOP RecyclePumps(12-PA-CF-104 A/B)
60 191.2 67 193 Impeller replacement with higher diameter
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Ejector System
The study has been performed on the existing ejector system for increase in
capacity by 30% by Ejector Vendor. Based on the adequacy study following two
options are suggested:
1) Replacing of existing ejector system to meet the revamped capacity of 30%.
With new ejector system
2) Installing an additional condenser with a three stage vacuum system for balance
30% load in parallel to existing system.
As per test run report, ejector performance for design conditions has not been
established due to non-availability of sufficient cooling water to condensers.
Ejector performance can be established after installation of dedicated cooling
water pumps to ejector system. Modifications in ejector system shall be firmed up
after accomplishing the performance of ejector on design conditions and
subsequently test run data at maximum achievable capacity of ejectors.
However for costing point of view replacement/modification of ejector elements,
new pre-condenser and modifications in inter condenser and after condenser are
considered.
7.3.1.4 NEW FACILITIES
BORL requested some of following facilities to be considered for post expansion
case based on their operating experience:
Hot well Off Gas Scrubbing section
As per operational feedback, there is considerable corrosion in the APH of thecrude heater due to sour gases from the Hot well. Hence a new amine basedabsorber system for treating hot well off gases have been conceived .The newhot well off gas treatment system shall employ 40 % MDEA and shall include thefollowing:
Hot well off gas amine absorber
Hot well off gas KOD (Existing caustic vessel 12-VV-VI-106 will be modified forthis service)
Rich amine pumps
Cooling water Pumps for Ejector’s System
Presently there is limitation in condensing duty of vacuum column OVHDcondensers due to improper cooling water flow. Cooling water flow to the unitbattery limit is 57% of design flow. To overcome the limitation of cooling water tocondensers additional CW pumps within unit shall be considered.
Coker Heaters: Lummus has carried out preliminary adequacy check of heater
and identified potential changes to the furnace and its auxiliary systems. Sincethe furnace rating was not included in the Lummus scope of revamp feasibility
report, detailed rating of the heater and interaction with the auxiliary equipment
suppliers will be performed during design stage. The modifications as reported in
revamp feasibility study are listed below:
Radiant Section: To meet the revamp duty of 41.98MMKcal/hr and to achieve
both EOR TMT and allowable pressure drop, replacement of all existing tubes
with higher metallurgy i.e. SS347H of sch 40. Additional 6 tubes per pass of
MOC SS347H of sch 40. Total no of passes are two per heater.
Subsequently it is found that SS347H MOC is not suitable for high content ofchloride ( around 20ppm as per BORL data) as exist presently in vacuum
residue feed, Lummus proposed to consider Inconel800 tubes in place of
SS347H.
Convection Coil: Use of two future rows is required. The use of future rows will
help reduce the radiant flux by shifting some duty to convection section and
also help in maintaining the heater efficiency.
Tube supports: Tubes supports will be adequate with reduced load of 40
schedule tubes. However tube supports need to be checked for revamp
conditions and thermal movements which might be controlling in tube supportdesign during design stage.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Convection intermediate Tube Supports: Flue gas temperature profile has
changed to 70°C from 50°C throughout convection. Design margin has
reduced from 110°C to 65°C. Mechanical check is required during design
stage to verify the design of supports for revamp conditions.
FD Fans: Two FD fans running at 50% capacity will be adequate for revampvolumetric flow and static pressure required. For fuel oil firing single FD fan will
not be adequate. Some reduction of load or combination of fuel oil with fuel
gas or reduction in excess air is required.
ID Fans: ID fans are adequate for fuel gas firing. But for fuel oil firing it is
marginally short. Adequacy of ID fans to be verified by vendor during detail
engineering.
Burner: Burner tips may need modification. To be confirmed by vendor during
detail engineering.
Stack: Stack is adequacy to be checked during detail engineering for ID fantrip and APH bypass. Load need to be reduced during natural draft operation.
Wet Gas Compressor: The adequacy for the WGC was checked by compressor
vendor for the process conditions provided by licensor. Vendor reported
maximum Possible flows with given operating conditions as given below in table :
Stage 1 31910 Kg/hr 20128 m3/hrCompressor is adequate subject to 1s stage discharge pressure isconsidered as 4.04 kg/cm2g instead
of 3.5 kg/cm2gStage 2 24322 Kg/hr 4521 m3/hr
Compressor is not found adequate for the required revamp flow rate of
40912*1.1 kg/hr for stage 1 and 31182*1.1 kg/hr for stage 2.
Therefore a new compressor of balance capacity in parallel to existing
compressor is considered to handle the revamp load. The new compressor is
envisaged of fixed rating of 1.3MW motor driven machine.
The adequacy and modifications suggested for other equipments as well as
requirement of new equipments as proposed in Lummus revamp feasibility studyreport are summarized below in Table 7.4.2 and overall equipment list is
tabulated in Annexure 2.
Table 7.3.2.2: List Of New/Modified Equipments
S.NO TAG NO DESCRIPTION MODIFICATION
FURNACE
114-FF-00-101A/B
Coker Heater
Radiant section: Replacement ofExisting Tubes change with Inconel800 material.Convection Section: Use of
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
additional two future rows.COLUMNS 1
14-CC-00-101 Coker Fractionator
Top trays (26-15): modification oftray panel with VG-10, modifyDowncomer width.
HCGO Frac (14-7) Trays: numberof valves to be increased.HCGO PA trays (6-1): modificationof panels with Pro-Valve andDowncomer width modification.
2 14-CC-00-102 LCGO Stripper Trays (2-6): Increase number ofvalves.
3 14-CC-00-104 Absorber Trays (1-30): Modification inDowncomer width and clearance.
4 14-CC-00-105 StripperTray (1-30): Modifiy Downcomerwidth and clearance along withincrease in number of valves.
5 14-CC-00-107 Debutanizer
Top Section: Increase in number ofvalves and Downcomer clearance.Bottom Section: Modification ofdowncomer width and clearancealong with increase in number ofvalves.
EXCHANGERS
114-EE-00-101A
Feed/HP StreamExchanger
New (Area: 597 m , No. of Shells: 1)
2 14-EE-00-107E/F
CompressorInterstage Cooler
New in parallel with exchanger 14-EE-00-107A/B/C/D. (Area: 147 m2,No. of shells: 2)
3 14-EE-00-109E/F
CompressorDischarge Cooler
New in parallel with exchanger 14-EE-00-109A/B/C/D. (Area: 278 m2,No. of Shells: 2)
414-EE-00-
115E/F
DebutanizerOverhead
Condenser
New in parallel with exchanger 14-EE-00-115A/B/C/D. (Area: 204 m2,
No. of Shells: 2)5
14-EE-00-118B Absorber IntercoolerNew in parallel with exchanger 14-EE-00-118B. (Area: 37 m2, No. ofShells: 1)
6 14-EE-00-119 Debutanizer SteamReboiler
Replaced with new 14-EE-00-121.
7 14-EE-00-120 Stripper Reboiler New (Area: 113 m , No. of Shells: 1)8
14-EE-00-121Debutanizer SteamReboiler
New (Area: 88 m2, No. of Shells: 1)
9
14-EE-00-123
Debutanizer Bottom
Water Cooler
New (Area: 126 m , No. of Shells: 1)
AIR COOLERS
1 14-EA-00-102A-L
Coker FractionatorOverhead Condenser
One additional Bay of 5.0m X10.0mto existing 6 bays. (Surface Area:
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
2,650 m )DRUMS 1
14-VV-00-103CompressorInterstage Drum
In situ increase the length of vessel(Note: 1).
2
14-VV-00-104 Recontact Drum
In situ increase the length of vessel
(Note: 1).3
14-VV-00-107DebutanizerOverhead Receiver
Replaced with new vessel. (Dia:2,500 mm and Length: 7,500 mm)
4 14-VV-00-122Feed/HP SteamExchangerCondensate Pot
New (Diameter: 910 mm and length1,700 mm)
514-VV-00-123
Stripper ReboilerCondensate Pot
New (Diameter: 910 mm and length1,700 mm)
PUMPS
1
14-PA-CF-101A/B Coker Unit FeedPump
Impeller change with larger
diameter and motor replacement(75 KW)2
14-PA-CF-105A/B
Debutanizer BottomPumps
Replaced with new pump of motorrating 95 KW. (Flow: 256.74 m3/hr,Head:152 m)
314-PA-CF-107A/B
Lean Sponge Oil/LCGO ProductPumps
Impeller change with largerdiameter and motor replacement(150 KW)
414-PA-CF-110A/B
FractionatorOverhead LiquidPumps
Impeller Change with largerdiameter
514-PA-CF-113A/B Stripper Feed Pumps
Replaced with new pump of motorrating 75 KW.(Flow: 256.25 m3/hr,Head: 99.73 m)
614-PA-CF-121A/B
Absorber BottomPumps
Replaced with new pump of motorrating 30 KW. (Flow: 195.9 m3/hr,Head:59.8 m)
714-PA-CF-122A/B
Absorber IntercoolerPumps
Replaced with new pump of Rating30 KW.(Flow: 220.88 m3/hr,Head:48.61 m)
COMPRESSOR 1
14-KA-CF-101B Wet Gas CompressorNew in parallel to existing 14-KA-CF-101. HT Motor Driven (1.3MW).
214-KA-CF-102
Blowdown RingCompressor
New. Motor Driven (45 KW).
NOTES
1. Replacement of vessel is not feasible from implementation/constructability point ofview. Licensor shall confirm the adequacy of this vessel in view of retaining the samediameter and increasing the length in situ.
Lummus recommended that it is feasible to increase the capacity of existingcoker up to 1.822MMTPA at 5vol% recycle rate with above mentioned additions
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.3.3.1 Hydrocracker and Diesel Hydro treating Unit
A debottlenecking study for increasing the capacity of HCU/DHT from its current
operation of 1.952MTPA for HCU & 1.637MTPA for DHT to 2.625 MMTPA HCU &
2.202 MMTPA for DHT has been performed by CLG. The revamp study done by
CLG includes the operating data at 115%, expected operating parameters & yield
structure, bottlenecks & necessary modifications for the key systems &
equipments at revamped capacity.
7.3.3.2 Revamp Feasibility Study
CLG performed revamp feasibility study to achieve 135% increase in existing
capacity by analyzing plant data along with rigorous simulation modelling in
consideration of followings:
Feed quality for HCU and DHT unit same as per original design.
Product yield pattern and quality for HCR and DHT are considered same as in
original design.
Battery limit conditions of all feeds and products have been considered same as
original design except feed streams will be a 80:20 mix of hot and cold feed
instead of 100% hot feed as considered in original design.
With the above basis, CLG carried out revamp study and stated post revamp
process data of all equipment. Based on CLG simulated process data of each
equipment adequacy of the unit was checked by CLG and EIL. The process flow
scheme as furnished by CLG in their report is attached in Annexure 3. CLG
furnished the results of adequacy check of the HP section in their report. EIL
carried out the adequacy check of the LP section with the data provided by CLG.
The key features and adequacy check of major equipment based on data given byCLG in their report are summarized below. The overall equipment list is attached in
Annexure 2.
1. Reactors
a) HCR Stage 1 Reactors (16-RB-00-101/102/103): No changes in reactor
internals except increase in sizes of orifice of reactor quench piping. New
generation catalyst ( ICR 180) is recommended having higher size i.e “NAQ”
from current” L” size. New catalyst system consisting of demet, treating and
cracking will provide higher activity, lower pressure drop and flexibility to shift
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
To achieve the revamped duty with reduction in the pressure drop, coilmodifications for the 1st stage HCR reactor Feed Heater, augmentation of heattransfer area and associated modification in the radiant section are envisaged.The modification details are summarized below:
Existing ConfigurationModified configuration based on
Preliminary findings
- No. of Cells: 2 (one each for eachpass)
- No. of coil passes: 2- No. of tubes per pass/cell: 12 (total
24 tubes)- Coil orientation: Horizontal
- Coil MOC: SS347H
- Coil OD: 8 inch (Non standard Coil)- Coil thickness: 17 mm (MWT)- Effective tube length: 12.8 m- Tube Spacing: 431.8 mm (Vertical)- Tube Supports: Ladder Type
- Calculated Pressure Drop: 4.9Kg/cm2
- No. of Cells: 2 (one each for eachpass)
- No. of coil passes: 2- No. of tubes per pass/cell: 10 (total 20
tubes)- Coil orientation: Horizontal
- Coil MOC: SS347H- Coil OD: 9 inch (Non standard Coil) - Coil thickness: 20 mm (MWT)- Effective tube length: 12.8 m- Tube spacing: 527.7 mm (Vertical)- Tube Supports: Tube supports to be
modified / replaced to suit new coilconfiguration.
Above feed section : 50% higher vapor &liquid load than existing design.Below feed section: 30% higher vapor &liquid load than existing design.Feed distributor: 33% higher vapor &liquid load than existing designLiquid re distributor: 30% higher vapor &liquid load than existing design
Dia =1370 mmTrays modifications:Existing 6 no of trays (Tray 1 to6) need to be replaced withnew high capacity trays .New feed distributor & liquidredistributor modifications.
16-CC-00-502Fractionator
Bottom section:30% higher vapor & liquidload than existing designTray no 11 to 54 except tray 20-22 & 28-30 : 33% higher vapor & liquid load thanexisting designTray 20-22 & 28-30: 33% higher vaporload than existing design &20% higherliquid load than existing designrespectively.
Dia =3050 mmTrays modifications:Existing 10 no of trays (Tray 1to 10) need to be replacedwith new high capacity trays.Dia =5180 mmTrays modifications:Existing 37 no of trays (Tray 11to 22 & Tray 28-54)) need to bereplaced with new high capacitytrays.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Columns Post Revamp Data Modifications
Debutanizer load than existing designFeed distributor: 33% higher vapor &
liquid load than existing design.Liquid re distributor: 33% higher vapor &liquid load than existing designBottom reboiler return & sump: 33%higher vapor & liquid load than existingdesign
Trays modifications:Existing 24 no of trays (Tray 1
to 24) need to be replacedwith new high capacity trays.
Dia. =1070 mmTrays modifications:Existing 17 no of trays (Tray 25to 42) need to be replaced withnew high capacity trays.New feed distributor & liquidredistributor modifications
Dia =2590 mmTrays modifications:Existing 12 no of trays (Tray 1to 12) need to be replacedwith new high capacity traysExisting 6 no of trays (Tray 21to 26) deck plates need to bereplaced with new tray deckplates with more no of valves.
Adequate, , Mechanical Integrity to bechecked with respect to vibrations
16-EE-00-304A-BDHT Reactor Feed/Effluent Exchanger Replacement with New for costpurpose, , Mechanical Integrity to bechecked with respect to vibrations
16-EE-00-305DHT Reactor Effluent/Feed Gas Exchanger
Adequate, , Mechanical Integrity to bechecked with respect to vibrations
16-EE-00-401DHT HHPS Vapor/CLPS Liquid Exchanger
New Heat Exchanger consideredbased on 20 % higher area thanexisting exchanger area. For costpurpose, , Mechanical Integrity to bechecked with respect to vibrations
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 7.3.4 Page 2 of 11
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.3.4.1 MS BLOCK (NAPTHA COMPLEX)
Naphtha complex (MS Block) of Bina refinery consists of Naphtha hydrotreater
(NHT) of capacity of 1.0MMTPA , Continuous catalytic reformer (CCR Platformingunit) of capacity of 0.54MMTPA, a Cyclemax CCR Regeneration section and a
Penex process unit of capacity of 0.31MMTPA. These units were designed by
UOP in the year 2006 for the production of Euro III and Euro IV grade gasoline.
Under this project, unit licenser M/s UOP carried out a process study to explore
technical feasibility of MS block for processing of additional naphtha due to
expansion of refinery and maximum processing of Hydrocracker heavy naphtha
with the objective of maximization of production of Euro IV grade gasoline and low
cost upgradation of existing units. To accomplish the objectives, UOP conducted a
MS blending and preliminary revamp feasibility studies. There after objective ofstudy was revised for 100% production of Euro IV/Euro V MS and the following
were concluded:
Revamp of existing MS Block
NHT - 145% increase in capacity (SRN + HCU HN)
Penex – 181% increase in capacity
CCR/Plaforming – 130% and 146% increase in capacity
Based on above, UOP has carried out detailed Revamp feasibility study whichincluded evaluation of operating process parameters, identification of the
bottlenecks, modification in major equipment and requirement of new equipments.
Also, UOP carried out assessment of MS blending for total production of 100%
Euro IV/Euro V MS utilizing available naphtha streams. UOP evaluated and
presented various cases which involved revamping of Penex and CCR units and
MTBE blending etc. Based on techno- commercial evaluation the option wherein
revamp of Penex unit to 181% and CCR revamp capacity of 146% was selected.
The revamp of Penex to 181% capacity is comparatively simpler and can be
implemented with minimum shutdown time and low capital cost.
UOP performed high level assessment for 181% increase in capacity of Penex unit
and provided additional new equipments along with cost estimates to be
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 7.3.4 Page 4 of 11
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
duty of 7.21MMKcal/hr. To avoid the modifications of the existing stripper reboiler,
the convection section of the Auxiliary Naphtha Splitter Reboiler Heater will
provide the heat (~1.26 MMKcal/hr ) to Stripper bottoms first and then routed to
the existing Stripper Reboiler Heater.
Splitter Reboiler Heater (19-FF-00-103) and Auxilliary Naphtha splitter Reboiler
Heater (19-FF-00-103B): The required process duty of the Naphtha Splitter
Reboiler for the revamp case is 15.75 MM Kcal/hr. The existing heater is
inadequate to handle the revamp process duty even with modifications.
UOP recommends adding an Auxiliary Naphtha Splitter Reboiler Heater in parallel
to the existing heater to supplement the required process duty for the revamp
operation. The convection section of the auxiliary heater will be utilized for heating
both Stripper bottoms and Naphtha Splitter bottoms.
The maximum duty from the existing Naphtha Splitter Reboiler Heater will be11.35 MM Kcal/hr without the burner modification and the remaining duty of 4.4
MMKcal/hr will be provided by the auxiliary Naphtha Splitter Reboiler Heater.
The adequacy and modifications suggested for other equipments as well as
requirement of new equipments as proposed in UOP revamp feasibility study
report are summarized below in Table 7.3.4.1 and overall equipment list is
tabulated in Annexure 2.
Table 7.3.4.1.: List Of New/Modified EquipmentsSLNO
TAG NO DESCRIPTION MODIFICATION
COLUMNS
119-CC-00-101 Stripper
Existing 20 No of trays of bottomsection to be replaced with new trays
2
19-CC-00-102 Naphtha Splitter
Existing 24 No of bottom section traysto be replaced with 28 Nos. of ECMDtrays
VESSELS
1 19-VV-HW-106 Water Break Tank Existing tank to be replaced by new.Dimensions dia*length:0.8m*1.9m
REACTORS
1 19-RB-00-101 Reactor As existing with New catalyst
EXCHANGERS
1
19-EE-00-101A-FCombined FeedExchanger
6 Additional shells to be installed inparallel Area-4074 m2Size: 1125mm*6000mmNo of shells : 6
One Auxiliary Heater in parallel fornaphtha splitter and convection sectionto be used for naphtha splitter reboiler.Duty (Absorbed) - 4.4 MMCkal/hr
2Product Trim Condenser
New exchanger Area-158.4 m2No of shells : 2
2. Continuous Catalytic Reforming Unit (CCR)
UOP performed revamp feasibility study report of CCR unit for 130% (678859
MTPA) and 146% ( 793,113 MTPA) increase in existing capacity considering feed
composition as derived by NHT unit yield estimate and simulation work for the
naphtha splitter. The CCR REGENERATOR section assessment had been
performed by UOP previously and was excluded from the scope of current study
of UOP.
Since the additional modification required in the case of 146 % from 130 % is very
minimal, the 146 % case is pursued for detail feasibility report and considered asrevamp case. The process flow scheme as provided by UOP in their report is
attached in Annexure 3.
The key features and modification as reported in UOP Revamp feasibility report,
are summarized below:
The CCR unit shall produce 98C5+RONC reformate as in the original design.
Reactors: The existing reactors were evaluated for the new revamp conditions
with R-264TM catalyst and found to be adequate. The revamp operating
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 7.3.4 Page 6 of 11
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
conditions are within the limits in terms of reactor design temperature and
pressure. The catalyst volume specified for the new operating conditions is also
the same as the originally specified volume.
Net Gas Compressors (20-KA-RP-102A/B/C): The existing Net Gas Compressors
are adequate for the revamp operating condition for both 130% and 146%
operating case based on implementation of suggested revamp to recontact section
exchangers. The compressor spillback would be limited to 5% during revamp
operation. The adequacy of the compressors has been checked by UOP based on
the vendor as built documents and the revamp conditions.
BORL has decided to consider one more Net Gas compressor based on actualperformance of the compressors and cost provision has been kept for the same. .
Recycle Gas Compressor (20-KA-CF-101A/B): The existing Recycle Compressorappears to be adequate for the revamp process requirements for both 130% and
146% operating case. For the 146% operating case, the Separator pressure has
been increased from original design of 2.46 Kg/cm2g to 2.81 Kg/cm2g to enable
Recycle Compressor operate within existing performance curve. The compressor
is estimated to run at about 102% of its original design speed for the revamp
operation.
Recovery Plus: Post revamp the net gas flow is around 39 KNM3/h for 146% and
the existing Recovery Plus unit which is designed for 25 KNM3/h is not adequate
to handle the revamp net gas flow for both 130% and 146% operating cases. A
parallel new Recovery Plus unit was proposed by UOP to handle the total net gas
for the revamp operating conditions.
The new Recovery Plus system will have a design net gas processing capacity of
approximately 15KNm3/h.
UOP provided a cost estimate for the new recovery plus and considering theprevailing LPG ,naphtha and fuel gas price at BORL, the payback worked out tobe ~9 yrs. Hence it is decided not to install the new recovery plus system.
The heaters have been checked considering only fuel gas firing in the heaters post
revamp.
For both 130% and 146% operating cases, burner replacement is required for allthe reactor section heaters. The extent of modification will require further analysis,but it will range from simple replacement of fuel gas tips with larger orifice drillings(probably possible for 125% design case) to the replacement of burners withburners that have greater heat release capabilities than current model sizesinstalled (likely for 146% design case).The common stack for the NHT and the Platforming heaters seem to be adequatefor the revamp process condition.
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 7.3.4 Page 11 of 11
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
UOP will attempt to optimise the scheme to reduce some of equipment count (if
possible) at the time of basic engineering.
7.3.4.3 CONSTRUCTABILITY
The existing plot was considered for all the proposed modifications and it was
determined that there is sufficient space for new/modified equipment.
A joint site visit was made by EIL and BORL team to assess the extent of
modification work involved in the revamp as well as to locate space for the new
equipments.
The modifications /new facilities as tabulated above were checked for and found
feasible from construction and implementation point of view with the following
observations:
NHT Unit
The space for new naphtha splitter reboiler auxillary heater (19-FF-00-103B) isidentified adjacent to the existing heater (19-FF-00-103).Two stacked shells of new Combined feed exchanger (19-EE-00-101 G/H) to be
located near existing (19-EE-00-101 A/B).Two stacked shells (19-EE-00-101 I/J) to
be located at the grade level on north of (19-EE-00-101 E/F) and for other two
shells (19-EE-00-101 K/L) additional structure(7m*4m) to be made.
CCR UnitNew net gas compressor can be located on north of 20-KA-RP-102. Presently this
space is reserved for dropout. New dropout shall be created at the southern end of
the shed
PENEX Unit
The new refrigeration package shall be located towards east of existing
refrigeration section (15-XZ-00-205).
In addition, structural work is envisaged for carrying out these modifications ( likemaking of new tech structures to accommodate new bays of air coolers, relocationof staircase etc.). Also piping rerouting/modifications shall be required wherevernew vessels/exchangers/air cooler/pumps are to be accommodated.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.3.5.0 HYDROGEN GENERATION UNIT
77,000MTPA of Hydrogen has been operating at Bina refinery to cater the H2requirement of hydrocracker unit, DHDT and MS block. The unit wascommissioned in the year 2010.
The unit consists of Naphtha Dechlorination / Desulphurisation, Steam Naphthareformer, HT shift Reactor and a Pressure Swing Adsorption (PSA) for Hydrogenpurification. The unit is designed for hydrocracker naphtha and hydrotreated mixpentane as a feed & fuel to the reformer.
Under this project, Technip has been awarded to conduct a revamp study forincrease in capacity of hydrogen unit to meet the requirement of hydrogen forexpansion of HCU, DHDT and MS Block.
7.3.5.1 REFINERY HYDROGEN BALANCE
To establish the revamp capacity of unit, the refinery hydrogen balance is workedout based on the followings:
35% increase in capacity of HCU/DHDT 45% increase in NHT 81% increase in ISOM 46% increase in CCR capacity
Existing(KTPA)
Revamp(KTPA)
Hydrogen Consumption
HCU/DHT 86.7 114.7NHT+ISOM 4.9 10.56
Total 91.6 125.3Hydrogen Generation
H2 from ROGPSA
24.5 32.16
H2 from HGU 67.0 93.15
H2 plant capacity 77
% Revamp ~21
Post revamp, the Hydrogen requirement may increase by 27% to cater the H2requirement n the case of CCR shutdown operating at lower load.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
FEASIBILITY STUDY REPORT
M/S Technip carried out revamp feasibility study for following cases consideringnaphtha feed with FBP of 184 degC (which is heavier naphtha than the plant isdesigned for):
15% increase in hydrogen design capacity (i.e. margin over 77KTPA ofhydrogen).27% increase in hydrogen design capacity (i.e. margin over 77KTPA ofhydrogen).
In order to achieve a capacity increase of 15% or more, Technip proposed thefollowing two combinations which are economically most feasible.
Case 1: incorporation of Prereformer + LT shift (15% capacity increase)Case 2: Incorporation of Prereformer + TPR + LT shift (27% capacity increase)
Technip performed a study to identify the adequacy of existing equipment anddetermine new/modified equipment with the level of investment associated foreach case considering no up-gradation of reformer.
Based on post revamp H2 requirement as stated in section 7.3.5.1 above, BORLopted to pursue the Case 2 which enhances the design capacity by 27% .
The process flow scheme for Case2 as given by Technip in their report is attachedin Annxure-3.
The key features and modification as reported in Technip Revamp feasibility reportare summarized below:
Steam Reformer (18-FD-00-11): Existing reformer is adequate for increased plantcapacity with integration of pre-reformer and LT shift reactor. However mainheader of the inlet system needed to be replaced with new material (SS 347H) dueto higher inlet temperature. Reformer burners are on limits and shall be checkedwith vendor in detailed phase.
Also the convection section of existing steam reformer needs to be modified tohandle the revamp load. The details of modifications required are summarized
below:
a) Feed/Steam Superheater (18-EE-00-22): Due to higher inlet temperature,bottom three rows need to be replaced with three rows of SS 347H. MOC ofoutlet header shall be changed to SS 347H.
b) Naphtha Feed Superheater (18-EE-00-25): The coil arrangement needs to bechanged (stream distribution change to 28 from existing 8) to reduce thepressure drop across the coil. Also the inlet and outlet manifold size shall beincreased to 12” from existing 8”.
c) Pre-reformer Preheat Coil (18-EE-00-26): To preheat the feed for pre-reformer, an additional coil needs to be incorporated in convection section of
steam reformer. New coil with 5 rows of MOC P22 and 3” ID shall be providedin between 18-EE-00-22 and 18-EE-00-23.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Pre-Reformer (18-RB-00-10A/B): The Pre-reformer needs to be installedupstream of TPR because direct naphtha reforming in TPR is not favourable dueto following reasons:
a) The potential for potash fouling on the shell side migrated by primary reformereffluent leading to poor heat transfer within the TPR in longer term
b) The potential for condensation of heavy hydrocarbon where the tube sheetmeets the refractory.
Therefore in heavy hydrocarbon based plant, a pre-reformer must be installedbefore TPR can be used. Two pre-reformer reactors (1W+1S) will be installed inplant to provide flexibility of on line replacement of the pre-reformer catalyst forplant operation.
TPR (18-FD-00-12): For increased plant capacity, a TPR is provided in parallel to
the existing reformer. An add on TPR provides extra plant capacity withoutmodifying the steam reformer.TPR is a tubular reformer in which heat of reaction is supplied by hot processstream at the shell side of the reactor. It is placed in parallel to the steam reformerin such a way that hot effluent from the steam reformer is used as heat source forTPR.
LT Shift Reactor (18-RB-00-14): For additional conversion of carbon monoxideand to improve hydrogen yield, LT shift reactor shall be provided downstream ofHT shift reactor.
H2 Booster Compressor :
M/s Technip has worked out a battery limit pressure of17.52 kg/cm2g as against 21.5kg/cm2g required based on the hydraulic study andsuggested a booster compressor to boost up the pressure from 17.52 kg/cm2g torequired 21.5 kg/cm2g.
EIL reviewed the pressure profile submitted by M/s Technip and based on thehydraulic check in both ISBL and OSBL system, the followings are suggested toM/s Technip for elimination of H2 product booster compressor:
A parallel product Hydrogen line will be laid to HCU/DHDT block.
Set point of Pressure controller located at downstream of dechlorinator /desulfurization reactor was increased from the existing design value of 31.3kg/cm2g as was considered by Technip to 33.1kg/cm2g which will meet thedesired battery limit pressure of 20.2 kg/cm2g.
This results in increase in mixing point (Mixing point is defined as the pointwhere the recycle gas from the recycle gas compressor and naphtha from thefeed pump mixes) pressure which provide additional pressure required in thecircuit.
The pressure controller set point is maintained by controlling the dischargepressure of the naphtha feed pump.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
The adequacy of the recycle gas compressor and naphtha feed pumps werechecked and found feasible to ensure higher mixing point pressure as35.2kg/cm2g.
EIL submitted above modifications along with detailed hydraulic study to Technipfor their confirmation. M/s Technip accepted that elimination of the boosterhydrogen compressor is possible and recommended the same to BORL.
The adequacy and modifications suggested for other equipments as well asrequirement of new equipments as proposed in Technip revamp feasibility studyreport are summarized below in Table 7.3.5.1 and overall equipment list istabulated in Annexure 2.
Table 7.3.5.1: List of modified Equipments in HGU
SLNO TAG NO DESCRIPTION MODIFICATION
REACTORS
1 18-RB-00-11 Comox Reactor Modification in inlet distributor2
18-RB-00-12A/BDechlorinator/Desulphuriser Reactor
Modification in inlet distributor
VESSELS
1 18-VV-VI-14Cold CondensateSeparator
Replaced by new vessel withspecificationDia(mm)*Height(mm) :2900*4600
REFORMER/CONVECTION COILS
1 18-FD-00-11 Steam Reformer Modification in inlet system.2 18-EE-00-22 Feed/Steam
SuperheaterReplacement of 3 Nos of rows ofcoils of SS347H
3 18-EE-00-25 Naphtha FeedSuperheater
Modification in coil arrangement andnew manifolds
EXCHANGERS
118-EE-00-11B
Naphtha FeedVaporiser-2
Replaced by new exchangerNo of shells: 1; Area/shell:102m2
218-EE-00-27
Hydrogen ProductCooler
Replaced by new exchangerNo of shells: 1; Area/shell:155m2
FANS 1
18-KA-CF-12 Flue Gas FanImpeller change with motorreplacement of rating 1250 KW.
PACKAGE EQUIPMENTS 1
18-LZ-00-12Hydrogen GenerationPSA
Additional adsorber vessels andpurge gas drum required
218-LZ-00-41
Hydrogen RecoveryPSA
Additional adsorber vessels andpurge gas drum required
NEW EQUIPMENTS
1 18-RB-00-10A/B Pre Reformer New equipmentDia(mm)*Height(mm) :2600*3900
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Tube length 14m3 18-RB-00-14 LT Shift Reactor New equipment
Dia(mm)*Height(mm) :5100*49004 18-EE-00-28 Boiler Feed Water
Exchanger
New equipment
No of shells: 1; Area/shell:420m25 18-EE-00-26 Pre Reformer Preheat
CoilNew coil 5 rows with 20tubes/row
6 18-EA-00-13 Nitrogen CirculationCooler
New equipmentNo of bundles:1; No of tubes 298;
7 18-EE-00-29 Nitrogen CirculationHeater
1500 KW electric heater
7.3.5.2 CONSTRUCTABILITY
The existing plot was considered for all the proposed modifications and it wasdetermined that there is sufficient space for new/modified equipment. A joint site visit was made by EIL and BORL team to assess the extent ofmodification work involved in the revamp as well as to locate space for the newequipments.
The modifications /new facilities as tabulated in Tables 7.3.5.1 were checked forand found feasible from construction and implementation point of view.
Modifications in Convection Section of Reformers: The modifications requiredin convection section of reformer have been studied in detail from construction and
implementation point of view as follows: The convection section of Reformer consists of 5 nos of Heat exchangers with tagnos. EE-21,EE-22, EE-23,EE-24 & EE-25, from El.12370 to El.16630.The inlet andoutlet headers are provided inside the header box i.e. outside ETS and the pipeconnections from headers are provided at the road side and plant side of theconvection section.Structural platforms and pipe supports are provided at the road side of theconvection box. Length of the tube is approx 17 m.There are 7 nos of ITS (Intermediate Tube Supports) and 2 ETS(End TubeSupport).( Ref Drg: Technip drg no. 745-18-DW-013-083 Sh 1 of 1 Rev.0)
Exchangerno
Dia and No ofrows of tubes
Inlet Headersize withelevation
Outlet Headersize withelevation
Remarks
EE-21 60.3 mm dia X 2 rows 22” dia : EL.11950 24” dia EL 12370 Header on eitherside
EE-22 3” dia X 6 rows 22” dia : EL123873
20” dia EL 13815 Header on sameside
EE-23 60.3 mm dia X 4 rows 20” dia EL 15237 20” dia EL 14387 Header on sameside
EE-24 60.3 mm dia X 2 rows 24” dia EL 15786 24” dia EL 16200 Header on eitherside
EE-25 60.3 mm dia X 2 rows 8” dia EL 16973 8” dia EL 116630 Header on eitherside
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Proposed Modification
1. MOC of 3 bottom rows of EE-22 need to be changed to SS-347 H.
2. One new heat exchanger with 5 no of rows of metallurgy (2 1/4 Cr + 1 Mo)
with inlet and outlet headers to be installed between EE-22 and EE-23. Size of
inlet and outlet headers and metallurgy is not available in the referred drawing.
3. Raising the elevation of header and coil location of EE-23 to a safer height to
accommodate the new exchanger.
4. Pitch of tubes of EE-25 to be increased to 3D from the existing 2D.
Methodology of Execution: EIL proposed following methodology of executionwhich shall be confirmed during detail engineering stage
The total height of the convection box is 6.517 m (Header bottom El is 11220 andHeader top El is 17737).Since there is no adequate space available for coilremoval / insertion at the plant side, it is proposed to pull out the coil from the roadside.
Sequences of activities involved are as below:
1. Cutting and removing of structural members provided for pipe supports and
walk way platforms on the road side.
2. Connected pipe with exchanger headers need to cut and remove.
3. Header box on either side of the convection box to be removed.
4. Inlet and outlet Header provided on the road side of EE-22 , inlet header ofEE-24, and outlet header of EE-25 need to be cut and removed.
5. Cutting of all bends provided on plant side.
6. Tube connections to inlet header of EE-25, outlet connection of EE-24, Inlet
and outlet connection of EE-23 to cut to enable pulling out of the coil.
7. Pulling out of coils of all exchangers except EE-21 from the road side.
8. Removal of ITS of EE-25,24 & 23. This is required to accommodate the new
coil between 22 & 23, elevation change of coils of EE-23 and pitch change
of EE-25.
9. Insertion of SS-347 H coil for EE-22. It is to be noted that, prefabrication ofpipe to pipe connection of the coil is only possible and all return bends
needs to be welded in-situ only, as there is no space available on plant side
for coil insertion.
10. Subsequent coil of EE-22 can be inserted only after completion of welding
/NDT of bottom layers.
11. Erection of inlet and outlet header. Welding and NDT of the coil with the
headers.
12. Erection of ITS and ETS of all exchangers.
13. Erection, welding and NDT of pre-fabricated coil, header of the new
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
14. Complete the erect ion of the coils, header, welding & NDT of the
subsequent exchangers. It may be noted that welding and NDT of the
bottom layer to be completed before insertion of the top layer.
15. Hydro test of all the coils including header of all exchangers.
In order to perform coil pulling and insertion, suitable structure arrangement to bemade on the road side. The structural arrangement may consist of extending thetwo columns of the pipe rack available on the road side up to top elevation ofconvection box ie up to a height of 17737 mm. Intermediate columns withfoundation may be provided on road and tie up with reformer columns.
Suitable capacity and requisite nos of chain pulley blocks/ trolley arrangement tobe provided on the temporary structures. Chain pulley blocks needs to be installedinside the convection box also to enable removal / insertion of the coils.
Crane needs to be positioned for lowering the structures, headers and coils. After hydro test of the coils, complete the piping outside the convection section,structural etc , which are cut and removed for coil removal/insertion.
Inference
A structural analysis and constructability check was conducted by Technip onconvection section and it was concluded that the proposed modifications can bedone with the existing structure. In order to keep the shutdown revamp time ofabout 45 days, it is recommended that a modular design be applied for the
modification in convection section.
Technip have reviewed the observation and comments regarding modifications inthe reformer convection section. Technip has also confirmed that estimation of sitework/ work duration for the Hydrogen plant modifications remains as indicated forthe Revamp, as 45 days based on their experience for other revamps.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
7.3.6.0 TREATING UNITS
In this section, adequacy check of following units are addressed:LPG Amine Treating Unit (LPGATU)LPG CFC
Fuel Treating Unit (FGATU)
7.3.6.1 LPG Amine Treating Unit (LPG ATU)
The existing capacity of LPG ATU is 15.5 T/hr and 25% MDEA solution is used foramine treatment of LPG.
Post revamp the capacity of LPG treating unit as tabulated below is worked outconsidering:
LPG produced from 7.8MMTPA of AM ( 65:35::AL:AH) crude processing in
existing CDU/VDULPG produced from DCU which is augmented for 135% of existing capacity.LPG yield is considered as furnished by Licenser for 1.52 kg/cm2g CokerDrum Overhead Pressure
UNITEXISTING FEED
(KG/HR)POST REVAMP FEED
(KG/HR)
CDU/VDU 10225 12750DCU 5268 8950Total 15493 21700
Post revamp 40% MDEA solution shall be used for amine treatment of LPG andloading of lean and rich amine are considered same as existing.Simulations have been done for 40% increase in the unit capacity by our eResearch and Development department keeping the feed composition same asexisting design and for 40% MDEA solution. The process flow scheme for this unitis given in Annexure 3.
Equipment Adequacy Report
Based on above mentioned basis, the adequacy check has been performed andthe findings of the adequacy check for all major/critical equipments are summarized
in Table 7.3.6.1and overall equipment list is attached in Annexure 2..
Table 7.3.6.1 Modified/New Equipment List for LPG ATU
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Equipment wise Adequacy Report
COLUMN
The adequacy check of existing columns has been carried out based on thefollowing assumptions:
No modifications of trays/internals have been carried out by BORL. Adequacy findings of internals are based on in-house information (packagedetails) of internals.
LPG Amine Absorber (21-CC-AS-101): The column is adequate with replacementof exiting 10 trays with new configuration trays.
VESSEL Amine Settle Drum (21-VV-HI-101): Adequacy check for this vessel is not done atthis stage as it is a vendor furnished item. Cost for new Vessel is taken considering40% increase in vapor load.
EXCHANGERSLPG Amine Cooler(21-EE-AS-101): Adequacy of LPG cooler was checked for dataas tabulated below:
ExchangersCooing waterm3/hr Outlet Temp(Process Side) °C DutyMMKCal/Hr
ExistingPostrevamp
ExistingPostrevamp
Existing Postrevamp
LPG aminecooler
13.13 21.21 40 40.3 0.07 0.1059
It was found that Cooling water flow rate will increased from 13 X 1.1 TPH to 21 X1.1 TPH post revamp. Process stream can be cooled from 45°C to 40.3°C which isa acceptable deviation from existing LPG amine cooler outlet temperature of 40°C.
PUMPS
The pump adequacy has been carried out based on the following assumptions:The pumps have not been checked w.r.t NPSHA / NPSHR & downstream designpressure as these aspects will be checked in the detail engineering . Adequacy Check of the pump has been carried out based on existing pump datasheets /predicted performance curves on the assumption that the actualperformance of the pumps are as per datasheets /curves.
Adequacy Philosophy
Pump adequacy check has been performed with an objective of retaining theexisting pump with the following philosophy:Minimum overdesign margin is provided for the rated flows of the pump overand above 25 % increase in normal flow for the revamp
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Head increase post revamp has been avoided by considering replacement of linesize, instruments, if required.
Lean Amine Booster Pumps (21-PA-CF-102A/B):
7.3.6.2 LPG CFC Unit
Post revamp capacity of LPG CFC will be corresponding to LPG treating unit i.e.21.7T/hr. The process flow scheme of this unit is given in Annexure 3.
The adequacy of this unit is performed in consideration of followings:Mercaptan in Feed LPG : Increased by 48 %Crude Blend : 100 % Arab Mix (A 65:35 weight blend of Arab Light and ArabHeavy Assay 2000)Since Crude blend considered same as existing design crude blend, LPGcomposition and properties are kept same as existing. Adequacy check has been carried out based on the as-built details of theequipments and with the following philosophy :It is presumed that all existing equipments are in good health and workingcondition. Health check of existing equipments is excluded from existing scopeof work.No de-ration of the equipment is considered for establishing adequacy.Cost provision of modified or new equipments is kept in the feasibility report. Adequacy check has been limited to the critical equipments and adequacycheck of the line and instruments are not in the scope of the study.
Equipment Adequacy Report
Based on above mentioned basis, the adequacy check has been performed andthe findings of the adequacy check for all major/critical equipments are summarizedin Table 7.3.6.2 and overall equipment list is attached in Annexure 2.
.Table 7.3.6.2: Modified/New Equipment List for LPG ATU
SLNO
TAG NO DESCRIPTION MODIFICATION
COLUMNS
1 21-CC-00-201 Prewash Column LPG distributor to be changed
221-CC-00-202 Regeneration Column
Replaced with new (Dia: 1980mm and height: 12000 mm)
PUMP DESCRIPTION
EXISTING POST-REVAMP
MODIFICATIONS/FINDINGSRATEDFLOW(m
3 /hr)
DIFFHEAD(M)
RATEDFLOW(m
3 /hr)
DIFFHEAD(M)
Lean AmineBooster Pumps
24 109 25.1 130 Impeller need to bechanged with higherdiameter.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
CFC CONTACTOR AND SEPARATORS
1st Stage CFC Contactor and separator (21-RB-00-201 & 21-VV-HW-201): 1ststage CFC column and separator is checked for post revamp flow and majormodifications required are as follows:
Due to increase in LPG flow , new CFC column is required
For separator , 2nd stage CFC separator will be used after increasing
the CFC column nozzle from 600mm to 680 mm.
2nd Stage CFC Contactor and separator (21-RB-00-202 & 21-VV-HW-202): 2nd
stage CFC column and separator is checked for post revamp flow and major
modifications required are as follows:
Due to increase in LPG flow, both CFC column and separator are found
to be inadequate and new are required.
CFC Solvent wash Contactor and separator (21-RB-00-203 & 21-VV-HW-203):
CFC Solvent wash contactor and separator is checked for post revamp flow and
major modifications required are as follows:
Both CFC column and separator are found to be inadequate and new are
required.
SAND FILTER
LPG Sand filter (21-VV-VI-204): LPG Sand filter is checked for post revamp flow
and found inadequate, new is required.
EXCHANGERS
LPG Cooler & Caustic Heater (21-EE-AS-201 & 21-EE-DP-202): The exchangersLPG Cooler and Caustic heater have been found adequate with minor increase/decrease in outlet temperature and / or increased utility flow rate as tabulatedbelow:
Exchangers Findings/Modifications
Cooing waterm3/hr / Steam ,
Kg/hr
OutletTemperature degC
Existing Postrevamp
Existing Postrevamp
LPG cooler Tube side inlet /outlet nozzle sizeto be increased to3” / 3” from 2” / 2”
11 13.45 40 41.2
CausticHeater
135 152 52 49.5
PUMPS
The pump adequacy has been carried out based on the following assumptions:
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
The pumps have not been checked w.r.t NPSHA / NPSHR & downstreamdesign pressure as these aspects will be checked in the detail engineering. Adequacy Check of the pump has been carried out based on existing pumpdata sheets /predicted performance curves on the assumption that the actualperformance of the pumps are as per datasheets /curves
Adequacy Philosophy
Pump adequacy check has been performed with an objective of retaining theexisting pump with the following philosophy:
Minimum overdesign margin is provided for the rated flows of the pump overand above increase in normal flow for the revampHead increase post revamp has been avoided by considering replacement ofline size, instruments, if required.
Adequacy Results
A summary of the adequacy results of the centrifugal pumps are tabulated below.Majority of the pumps are found adequate with impeller replacement. For thepumps used in intermittent service the operating hours will increase.
PUMP ADEQUACY CHECK RESULTS
The metering pumps used in intermittent service are found adequate with increasein the operating hours.
New facilities As per operational feedback, there is intermittent caustic carryover in LPG-CFCwhich results in Cu strip corrosion failure. To avoid this, provision of Water washcolumn followed by Coalescer in LPG-CFC unit has been considered. Followingequipment shall be included:
The post revamp capacity increases to 18.7 T/hr. Adequacy check was done for 50% increase in capacity and based on 40 wt% MDEA instead of 25 wt% MDEA. Theprocess flow scheme of this unit is given in Annexure 3.
Equipment Adequacy Report
Based on the above post revamp conditions, adequacy check has been performedfor and it has been found that all the equipments are adequate without anymodification. The overall equipment list is attached in Annexure 2.
Equipment Wise Adequacy
COLUMNS:
The adequacy check of existing columns has been carried out based on the
following assumptions:No modifications of trays/internals have been carried out by BORL. Adequacy findings of internals are based on in-house information (packagedetails) of internals.
Fuel Gas Amine Absorber (22-CC-00-101): The column is checked for loading of0.4 kmol of H2S/kmol of MDEA (100%) and is found to be adequate for the revisedconditions without any modification.
VESSELS
All the vessels are found adequate for revamp conditions with acceptable reduced
residence time and hold up time.
HEAT EXCHANGER
Adequacy PhilosophyNo overdesign margin has been considered for the adequacy check ofexchangers.5% de-rating factor has been considered.
Fuel Gas Cooler (22-EE-AS-102): Existing exchanger shall cool the process streamfrom 45 degC to 41.5 degC (instead of 40 degC). The corresponding duty shall be0.0376 MMKCAL/hr and cooling water flow shall be same as existing (12.1 T/hr).
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
7.3.7.0 SULFUR BLOCK
Sulfur block consist of following units:
Sulfur Recovery Unit (SRU)
Sour Water Stripping Unit I/II (SWSI/II) Amine Regeneration Unit (ARU)
7.3.7.1 SULPHUR RECOVERY UNIT
The process objective of Sulphur Recovery unit is to convert hydrogen sulphidepresent in feed gas streams i.e. acid gas from Amine Regeneration unit, sour gasfrom Sour Water Stripper Unit and to recover it as sulphur product in order tominimize pollution. Tail gas containing residual sulphur species is incinerated in
thermal incinerator and vented to atmosphere.
Under this project, the revamp of all process units are envisaged for the capacityexpansion of 30-40% which will result the expansion/ revamp of sulphur recoveryunit to sustain the allowable SOx limit of refinery post expansion.
Existing SRU Configuration
Design Sulphur production rate, MTPD : 360 (Total)In existing configuration,
Two parallel Claus trains, each of capacity 180 MTPD sulphur productionTail Gas Treatment unit (TGTU) to enhance overall sulphur recovery
New SRU configuration (Post Expansion of Refinery)
SRU capacity post expansion is worked out as 488.5 TPD in consideration offollowings:
Refinery capacity : 7.8 MMTPACrude : 100 % Kuwait crude same as existing design caseSulphur in crude : 2.704 %*
DCU pet coke sulfur : 8%*Sulphur as SOx not included.
*Data as furnished by BORL
Capacity increase has been checked for the same feed quality as per the originaldesign basis i.e. Kuwait feed case. For other crudes like Arab Mix crude(AL:AH:;65:35) and for mix of Arab Mix and Kuwait ( 60% Arab Mix, 40% Kuwait),the capacity worked out as 382 and 420 MTPD respectively.
As a part of DFR, various options as detailed below have been worked out to arrive
optimal configuration of SRU to meet the revamp requirement of sulphur recovery of488.5 MTPD.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Option-1 No Standby SRU TrainUnder this option, revamp of existing train to its maximum achievable capacityconsidering O2 enrichment and no additional train shall be considered.
Case A: Revamp of existing train to achieve SRU capacity of 488.5MTPD
SRU shall run all the time meeting full capacity with both trains operating. This willimply:Max capacity of train: 245 MTPD (0.5*488.5)For Kuwait crude case :
Existing trains of capacity shall be revamped for 245MTPD i.e. 36% increase incapacityTGTU revamp requirement i.e. 36% increase in design capacityOperating capacity of each train will be :100%With outage of one train, achievable crude throughput : 50%
Case B: Revamp of existing train to Maximum achievable SRU capacity
The revamp of existing train can be done upto 50% increase in capacity consideringO2 enrichment.For Kuwait crude Case
The maximum achievable revamp capacity of SRU train is: 270MTPD.TGTU revamp requirement i.e. 36% increase in design capacityOperating capacity of each train will be :90%With maximum achievable revamp capacity (270MTPD) of SRU consideringoutage of one train, the crude throughput of refinery for different crudes are
tabulated below:
Crude CaseMaximum achievablecapacity of refinery
Kuwait 55% Arab mIx 71%60% Arab Mix and40% Kuwait
64%
Case C: Revamp of Existing Train based on 80% minimum crude throughput
The revamp capacity of SRU train shall be based on 80% minimum crudethroughput equivalent sulfur recovery capacity available in event of an outage of onetrain.In consideration of above SRU revamp capacity for different crude cases aretabulated below
Crude Case
Capacity of SRU trainconsidering 80% crudethroughput with outage ofone train in MTPD
% RevampRequired
Kuwait 390.8 217% Arab mIx 305.6 170%60% Arab Mix and40% Kuwait
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
The revamp of existing train is not feasible for such high capacities i.e. 170-200% ofexisting capacity. Therefore this option shall be ruled out.
Option-2 Consideration of Standby SRU Train
Case D: Additional Train with Revamp of Existing Train
One additional Sulfur train without TGTU, SRU shall run all the time meeting fullcapacity with 2 trains operating and one standby. This will imply
Max capacity of train: 245 MTPD ( 0.5*488.5)
For Kuwait crude case :Existing trains of capacity shall be revamped for 245MTPD i.e. 36% increase incapacityNew train capacity : 245 MTPDTGTU revamp requirement i.e. 36% increase in design capacity
Case E: Additional Train without Revamp of Existing Train
Additional train of same capacity as existing and no revamp in existing SRU, themaximum achievable capacity with standby train will be as follows:
Crude CaseMaximum achievablecapacity of refinery
Kuwait 74%
Arab mIx 94%60% Arab Mix and 40%Kuwait
86%
Conclusion
1. It is evident from option C that BORL’s need to achieve minimum 80% crudethroughput in the event of one train down could not be met.
2. All SRU conceivable configurations are tabulated below:
Case A Case B Case D Case E
Standby Train No No One OneRevamp of existing train 35% 50% No
revamp35%
SRU Train capacity in MTPD 245 270 180 245TGTU revamp 35% 35% 35% 355Refinery throughput ( Kuwaitcrude case ) with outage of onetrain
50% 55% 73 100
Final SRU Configuration
Case D is selected i.e.One additional standby train of 180 MMTPD along with 35% capacity by oxygenenrichment.Enhancement of existing two trains to 243 MMTPD by oxygen enrichment.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
List of all the equipments required for new SRU train are tabulated in Table7.3.7.1.The process flow schemem is attached in Annexure 3and overall equipmentlist for new train of 243TPD is attached in Annexure 2.
Table 7.3.7.1 Modified/New Equipment List for SRUSLNO
TAG NO DESCRIPTION MODIFICATION
VESSEL 1
29-VV-00-007C Tail Gas CoalescerNew (Diameter: 2400 mm and Height:3250 mm)
REACTORS 1 29-RB-00-
001C Converter-INew (Diameter: 3390 mm and Height:4800 mm)
6 29-EE-00-006C Reheater-II New7 29-EE-00-007C Acid Gas Preheater New
Oxygen Enrichment System
The existing SRU uses plant air. For post revamp scenario, oxygen enriched airshall be used instead of plant air which will increase the plant capacity by 35%.
The following options have been looked for Oxygen enrichment of plant air:
Vaporised Oxygen injection: The liquid oxygen will be procured and stored in astorage vessel. The vaporized oxygen from liquid oxygen storage vessel will be
injected to the combustion air line.Enriched air will be used in the main burner
of SRU.
Waste Nitrogen Utilisation: Waste nitrogen vented from the nitrogen plant will
be routed to the main burner of SRU.Make up vaporized oxygen will be
injected from liquid oxygen storage facilities. The typical composition of waste
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
S.No Component Mole%
1 O2 29.02 N2 62.93 H2O 8.1
MW 28.4
To cater the balance oxygen required to achieve the desired oxygen
enrichment of air, the following two options are envisaged:
a) Membrane system:It involves the generation of 35%(v) Oxygen enriched air from air by usingair separation membrane unit. Oxygen enriched air will be routed to themain burner of SRU.
b) VPSA System:Vacuum Pressure Swing Adsorption (VPSA) is a technology used forselective separation of a component from a mixture of gases by means ofadsorption. The process is similar to Pressure Swing adsorption except thatit is carried out at very low pressure.Following are the specifications of O2 from VPSA plant:
Average O2-content of product : 92 vol%Dew point at 1.013 bar approx. :-40 degCProduct Pressure @ B/L : 5 bar(a)
Selected O2 enrichment system
BORL has opined for waste Nitrogen option for the oxygen enrichment. The totalwaste N2 requirement for two trains will be 24000Nm3/hr(12000 Nm3/hr for eachtrain) .The waste N2 available from the existing N2 plant is 2640 Nm3/hr. With installationof an additional new N2 plant of 500 Nm3/hr capacity, additional 880Nm3/hr ofwaste N2 shall be available.
The following facilities for O2 enrichment using waste N2 as tabulated below inTable 7.3.7.2 are envisaged in N2 plants and these facilities shall be confirmedduring detail engineering phase:
Table 7.3.7.2: Modified/New Equipment List For Oxygen Enrichment
Sl.No TAG No. DESCRIPTION MODIFICATION
1 XX-VV-00-001 Waste NitrogenSurge Vessel
New (Diameter: 2500 mmand 7500 mm, Qty: 2)
2 29-K-00-001 A/B Waste Nitrogen
Blower
New (motor Driven of rating16 KW)
3 Option 1 Membrane Unit New4 Option 2 VPSA Unit New
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
To meet balance requirement of waste N2 i.e. 24000-2640-880=20480Nm3/hr whichis equivalent to 142 TPD or 4148 Nm3/h of oxygen (based on 100 % oxygen), VPSAsystem is considered.
7.3.7.2 SOUR WATER STRIPPING UNIT I/II (SWS I/II)
CAPACITY: The existing capacity of SWS I is 125 T/hr and that of SWS II is 49 T/hr.The following is the total Sour Water flow to SWS I the unit:
UNITEXISTING FEED
(KG/HR)POST REVAMP FEED
(KG/HR)
CDU/VDU 71200 89000DCU 30300 39400 ARU 4400 5720SRU/TGTU 11500 17250
FLARE KOD 7600 10260TOTAL 125000 161620
The total Sour Water Flow to SWS II unit:
UNITEXISTING FEED
(KG/HR)POST REVAMP FEED
(T/HR)
HCU/DHT 41500 58367NHT 7500 7516TOTAL 49000 65883
In the post revamp scenario SWS I/II is checked for increased flow of 30% overoriginal Capacity.
Equipment Adequacy Report
Based on above mentioned basis and assumptions, the adequacy check has beendone and the findings of the adequacy check for all major/critical equipments aresummarized in Table 7.3.7.3 and overall equipment list is attached in Annexure 2.The Process Flow scheme is attached in Annexure 3 .
Table 7.3.7.3: Modified/New Equipment List For SWS I/II
S.NO TAG NO DESCRIPTION MODIFICATION
VESSELS 1 28-VV-HI-101 Sour Water Surge
Drum-IInternal modification includingshifting of baffles and nozzles.
228-VV-HI-201
Sour Water SurgeDrum-II
Internal modification includingshifting of baffles and nozzles.
COLUMNS 1
28-CC-00-2022nd Stage Sour
Water Stripper
Tray (25-32): Existing Trays need to
be replaced by high capacity trays.AIR COOLERS 1
28-EA-00-103Single Stage PA AirCooler
Existing 6 fan motors replaced bynew motors of 50 HP per fan.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
2
28-EA-00-2072nd Stage PA AirCooler
One new bay in addition to existing3 bays of area 6.4 m X 10.5 m.(Surface Area: 3244 m2/bundle)
PUMPS 1
28-PA-CF-101 A/B
Single Stage StripperFeed Pumps
Impeller change with larger
diameter and change in motor ofrating 90 KW.
2 28-PA-CF-102 A/B/C
Single Stage StripperPA Pumps
Impeller change with largerdiameter.
328-PA-CF-103 A/B
Single Stage StripperBottom Pumps
Impeller change with largerdiameter and change in motor ofrating 90 KW.
428-PA-CF-203 A/B
2nd Stage StripperBottoms Pumps
Replaced with new pump of motorrating 55 KW. (Flow: 79.5 m3/hr andHead: 123.8 m)
TANKS 128-TT-CR-101A
Sour Water StorageTank-IA
New Tank. (Diameter: 22,500 mmand Height: 14,000 mm)
228-TT-CR-201C
Sour Water StorageTank-IIA
New Tank. (Diameter: 15,000 mmand Height: 11,600 mm.
Equipment wise adequacy Report
COLUMNThe adequacy check of existing columns has been carried out based on thefollowing assumptions:
No modifications of trays/internals have been carried out by BORL. Adequacy findings of internals are based on in-house information (packagedetails) of internals.
Single Stage Sour Water Stripper (28-CC-00-101): The column ID and Tray Spacingare adequate for handling the revamped loads with existing conventional valve trays.
1st Stage Sour Water Stripper (28-CC-00-201): The column ID and Tray spacing arefound adequate for handling the revamped loads with conventional valve trays.
2nd Stage Sour Water Stripper (28-CC-00-202): Tray 1-24: The column ID and Tray
spacing are found adequate for handling the revamped loads with conventionalvalve trays.Trays 25-32: (i) The column ID and Tray spacing are found adequate for handlingthe revamped loads with conventional valve trays when feed is at tray No 24.(ii) The column ID and Tray spacing are found to be inadequate for handling therevamped loads with conventional valve trays when feed is at tray no 32 (alternatefeed location). This section needs to be replaced with high capacity trays for theaccommodating alternate feed case.Trays 34-39: The column ID and Tray spacing are found adequate for handling therevamped loads with conventional valve trays.
VESSELS:Sour Water Surge Drum-I/II (28-VV-HI-101/201): BORL informed that separation ofhydrocarbon is not taking place properly in existing vessels and oil is getting slipped
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
to Sour water storage tanks. Keeping in view of above issue and based on postrevamp flows adequacy of SWS I/II Surge Vessels were checked and found thatexisting vessels are not adequate for post revamp flow. Two options were envisagedfor feasibility study:
Option 1: Replacement of both the existing vessels with new vessels.Option 2: Internal Modifications of baffles and nozzles to increase the separationlength in existing vessels.
During site visit, it was confirmed it is not feasible to take out existing vessels forreplacements. Therefore, option 2 of in situ modification of exiting vessels shall beconsidered.
EXCHANGERS
Adequacy check for the exchangers is done for duty and outlet temperatureconditions as tabulated in table below. Findings of the study are summarized below:
TAG ServiceDuty (MMKcal/hr)
Outlet Temp(degC)
ExistingPost
revampExisting
Postrevamp
Exchangers
28-EE-00-101A/B
Sour Water (TubeSide)
6.63 8.52
99.65 99
Stripper Sour Water
(Shell Side)
74 74.5
28-EE-00-104A/B Stripped WaterCooler-I
4.23 5.447 40 41
28-EE-00-201A/B 1s stage Feed MixCooler
0294 0.3822 37 37
28-EE-00-202A/B Sour Water (TubeSide)
2.567 3.3371 89.8 89.8
Stripper Sour Water(Shell Side)
70 70
28-EE-00-203A/B
Sour Water (TubeSide)
2.407 2.951 138 136
Stripped Sour Water(Stripped SourWater)
123.5 125.9
28-EE-00-208A/B Stripped water 1.352 1.729 40 41Reboilers 28-EE-00-102A/B Single Stage
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
28-EA-00-205 1s Stage StripperPA Cooler
0.296 0.3848 65 65
28-EA-00-207 2n Stage StripperPA Cooler
7.6 10.67 65 65
Exchangers:
Single Stage Feed Exchanger (28-EE-00-101A/B): It has been found that the tubeside (sour water) maximum achievable outlet temperature is 99 degC instead ofexisting 99.65degC and shell side fluid (stripper sour water) would get cooled from126.8 degC to 74.5 degC (instead of existing 74 degC). Also the tube sidecalculated pressure drop is 0.6 kg/cm2 and velocity is more than 1m/sec.
Stripped water cooler-I (28-EE-00-104A/B): Existing exchanger can cool the strippedwater (shell side fluid) from 74.5 degC (existing 74 degC) to 41 degC (existing 40degC). Cooling water flow rate shall be increased to 459069 kg/hr from existing405950 kg/hr. Also the tube side calculated pressure drop is 0.9 kg/cm2 and velocityis more than 1m/sec.
1st stage Feed Mix cooler (28-EE-00-201A/B): Existing exchanger is adequate forthe post revamp conditions but cooling water flow rate shall be increased to 60060kg/hr from existing 50600 kg/hr. Also tube side calculated pressure drop shall be 0.9kg/cm2.
2nd Stage Feed Bottom Exchanger (28-EE-00-202A/B):It has been found that theexisting exchanger is adequate for the post revamp conditions without any
modification..However the tube side calculated pressure drop is 0.55 kg/cm2 andvelocity is more than 1m/sec.
1st Stage Feed/Bottom Exchanger (28-EE-00-203A/B): It has been found that theTube side (sour water) maximum outlet temperature is 136 degC instead of existing138 degC and shell side fluid (stripper sour water) would get cooled from 166.2degC to 125.9 degC (instead of existing 123.5 degC).
2nd Stage Trim water cooler (28-EE-00-208A/B): Existing exchanger can cool thestripped water from 70 degC to 41 degC (instead of 40 degC) and cooling water flowrate shall be increased to 15990 kg/hr from existing 129567.05 kg/hr.Aso the tube
side pressure drop shall be 1kg/cm2
Reboilers:
Single Stage Stripper Reboiler (28-EE-00-102A/B): Exchanger is adequate for the130% increase in flow & duty without any modification. However the stripper bottom(shell side) velocity is greater than 1m/sec.
1st Stage Stripper Reboiler (28-EE-00-204A/B): Exchanger is adequate for 130%increase on flow & duty without any modification.
2nd Stage Stripper Reboiler (28-EE-00-206A/B): Exchanger is adequate for the130% increase in flow & duty without any modification. However the stripper bottom(shell side) velocity is greater than 1m/sec.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Air Coolers:
Single Stage PA Air Cooler (28-EA-00-103): Existing air cooler shall cool the stripperPump Around to 68degC (instead of 65 degC) from 90 degC. To cool the stripper PA
to the desired temperature of 65 degC, existing motors of power rating 40 HP for allthe six fans needs to be replaced with new motors of power rating 50 HP.
1st Stage PA Air Cooler (28-EA-00-205): Existing Air cooler is adequate to handlethe post revamp conditions without any modification.
2nd Stage PA Air Cooler (28-EA-00-207): Existing air cooler is inadequate to coolthe stripper PA to 65degC from 92degC. To achieve the same, one additional baysimilar to existing would be required.
Tanks:Existing two sour water storage tanks are insufficient to handle post revamp storagecapacity. Thus one new sour water storage tanks (similar to existing) is required foreach of the unit.
Pumps:The pump adequacy has been carried out based on the following assumptions :
The pumps have not been checked w.r.t NPSHA / NPSHR & downstreamdesign pressure as these aspects will be checked in the detail engineering . Adequacy Check of the pump has been carried out based on existing pump datasheets /predicted performance curves on the assumption that the actual
performance of the pumps are as per datasheets /curves
Adequacy PhilosophyPump adequacy check has been performed with an objective of retaining theexisting pump with the following philosophy:
Minimum overdesign margin is provided for the rated flows of the pump overand above 30 % increase in normal flow for the revampHead increase post revamp has been avoided by considering replacement ofline size, instruments, if required.
Adequacy Results A summary of the adequacy results of the pumps are tabulated below.Majority of the pumps are found adequate with impeller replacement and /or motorreplacement.
Motor ReplacementIf pump is found adequate and motor inadequate (Total 2 Pumps), replacementof motor with a higher rating is envisaged. Replacement of motor may call thefollowing changes :a) Base plate modification/replacementb) Couplings need replacement,
c) Foundation may require modification
Modifications related to Motor shall be carried out by OEM only which mightinvite opportunity costs.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Shut down time requirement is more as compared to implementation of newpumpsNormally motor related modifications are preferred by OEM at their workplace.Shifting of pumps at OEMs works are mostly difficult, time consuming & costineffective. To carry out the motor related modifications at site, BORL shall
check adequate facilities at their workshop.
Therefore, the philosophy of motor change from economical feasibility and executionpoint of views shall be reviewed at design stage in consultation with OEM.
7.3.7.3 AMINE REGENERATION UNIT (ARU):
The existing capacity of ARU is 470 T/hr. The existing unit is working on 25% wtMDEA and rich amine loading of 0.45 moles of H2S per mole of MDEA (except for
PUMP DESCRIPTION
EXISTING POST-REVAMP
MODIFICATIONS/FINDINGSRATEDFLOW(m3/hr)
DIFFHEAD(M)
RATEDFLOW(m3/hr)
DIFFHEAD(M)
28-PA-CF-101 A/B(Single stagestripper feedpumps)
139.2 74 181.2 90 Impeller change of higherdiameter an new motor ofpower rating 90KW
28-PA-CF-102 A/B/C( Singlestage stripper PApumps)
254 64.7 302.5 68.9 Impeller change with largerdiameter.
28-PA-CF-103 A/B( Single stage
stripper bottompumps)
146 106 189.7 113.8 Impeller change of higherdiameter an new motor of
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
LPG ATU, loading is 0.34) and Lean Amine Loading is 0.015 moles of H2S per moleof MDEA.
The post revamp adequacy check is based on 40 wt% MDEA and rich amineloading of 0.4 moles of H2S per mole of MDEA for FGATU, 0.436 moles of H2S per
mole of MDEA for HCU/DHDT and 0.015 moles of H2S per mole of MDEA for LPG ATU.
The following is the feed from different units:
As the concentration has increased and loading remaining almost the same, the richamine feed flow to the unit is within the existing flow to the unit. Therefore all theequipments are adequate except for the Amine Generation Reflux Drum becausethe vapor load has increased. Overall Equipment list is attached in Annexure-2 andProcess Flow Schemes are given in Annexure 3.
Table 7.3.7.4: Modified/New Equipment List for ARU
SL NO TAG NO DESCRIPTION MODIFICATION
VESSELS 1 27-VV-VI-102
AMINE REGENERATORREFLUX DRUM
Replaced by New
7.3.7.4 CONSTRUCTABILITY
The existing plot was considered for all the proposed modifications and it was
determined that there is sufficient space for new/modified equipment.
A joint site visit was made by EIL and BORL team to assess the extent of
modification work involved in the revamp as well as to locate space for the new
equipments.
The modifications /new facilities as tabulated in Tables 7.3.6.1 to 7.3.6.4 were
checked and found feasible from construction and implementation point of view with
the following observations:
1) The space for additional train of SRU has been identified towards the south
side of existing Sulfur Block.
2) Space for New Sour Water Storage tanks 28-TT-CR-101A and 28-TT-CR-201C is not available near the existing tanks. The space for these tankshas been identified in the space available for new SRU train. .
3) Also the area required for oxygen enrichment facilities (i.e. Vessels,Blowers, VPSA) has been identified near existing Nitrogen plant4) The existing Surge Drums (28-VV-HI-101/201) cannot be taken out for
replacement. It is advisable to go for internal modification.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Streams KTPA Wt%
NHT-Heavy Naphtha 20 1.6Isomerate 502 40.2
Reformate 696 55.8HCU Hy Naphtha 29 2.3Total 1247 100
The production of 100% Euro IV MS as explained above is based on UOPpreliminary study. The followings shall be needed to taken up during design stage:
The properties of hydrocracker light naphtha and heavy naphtha for higheryields than present design yields.Processing of hydrocracker light naphtha in Penex unit by-passing hydro-
treatment (via Sulphur Guard Bed), processing directly to Penex and its impacton Isomerate yield and quality.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.5.0 UTILITY SYSTEM
This chapter provides the details of increased utility requirements and descriptionof additional facilities required for various utility systems envisaged for the refinerypost revamp for the detailed feasibility report.
The following utility systems are reviewed for DFR:1. Raw water system2. Cooling water system3. DM water system4. Compressed air system5. Nitrogen system6. Steam, power and BFW system7. Condensate system
8. Internal fuel oil and fuel gas system9. Flare system
The revised utility consumption and the additional facilities required post revampof the above facilities have been done based on estimation of utility consumptionof the process units based on the following:
Estimated requirement post expansion unit wise from the utility design valuesfor 6 MMTPA.Operating data of the existing units at increased capacity of the unitsLicensor utility figures for the post revamp
7.5.1 REFINERY UTILITIES SUMMARY
Sl.No
System Units Existing Value Revamp Value
1 CW System m3/hr 21729 25430DM Water
2 Process m3/hr 152 162.8Utility Block m3/hr 347 447.3
3 Raw Water m3/hr 2516 2630
4 Nitrogen Nm3/hr 1169 2557Instrument Air5 Process Nm3/hr 6370 5680
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Sl.No
System Units Existing Value Revamp Value
9 Condensate
SurfacePureSuspect
TPHTPHTPH
52.867.732.8
81.2116.746.3
7.5.2 RAW WATER SYSTEM
Raw water is available at the refinery battery limit from Betwa via Raw WaterPumping facility. To meet the refinery complex demand raw water reservoir ofcapacity 96,200 m3 (2 no’s - 33450 & 62750 m3 capacity) is provided. The rawwater from the reservoirs is pumped, treated and filtered in raw water treatmentplant (RWTP). The treated water is stored in two reservoir (holding capacity of
each reservoir is equivalent to 6 hrs of max treated water requirement of therefinery project) from where the supplies is pumped to the various consumers inthe refinery to meet its process and other requirements.
Treated water shall be used as follows:1. Cooling water make-up2. Service water3. DM Plant feed4. Bearing Cooling water5. Drinking water system6. Fire water system
Raw Water Reservoir
To meet the refinery complex two raw water reservoirs are available.
Treated Water Reservoir
Treated water is stored in one reservoir with two compartments designed forcatering to approximately 12.0 hrs of max treated water requirement of therefinery.
Treated water requirement
The revised estimated treated water requirement for various purposes in thecomplex is given below in Table-7.5.1.
Table-7.5.1: Treated Raw Water Requirement (m3/hr)
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
3 DM Plant/RO plant feed 250 600
4. Service Water 85 240
5. Pump Bearing Seal cooling 112 135
6. Drinking Water 87 204
7. Fire water make up 10 180
Total Treated water Demand 1947
Total raw water Demand 1957 2630
Capacity of Raw water treatment Plant
The raw water system consists of the following:
Raw water reservoir capacity : 96,200 m3 (2 no’s, 33450 & 62750 m3 Capacity)Treated water reservoir Capacity : 22,800 m3RWTP capacity : 2 X 1,500 m3/hr.
Normal raw water demand for the refinery complex for post revamp is 1957 m3/hr.against existing 1891 m3/hr.Maximum raw water demand for the refinery complex for post revamp is 2630m3/hr. against existing 2516 m3/hr.Since no major augmentation is required for Refinery Cooling Tower and minoraugmentation is required in RO-DM system, the existing raw water system will be
adequate for 25% increase in crude throughput with an additional raw water intakepump similar to existing capacity.No change in RWTP, except Oil removal facility to be considered.Treated water pumps (service water/BCW/CW make up/DM feed pumps) areadequate for revamp peak requirement of 2246 m3/hr.
Service water
Existing service requirement is 63 (nor) m3/hr and 210 (max) m3/hr .New servicewater requirement is 85 (nor) m3/hr / 240(max) m3/hr. No modification in servicewater system is envisaged.
7.5.3 COOLING WATER SYSTEM
The existing cooling water facilities are classified into two systems, namely,Refinery cooling water and CPP cooling water system. The existing facilities forthese two cooling water systems are as follows:
Refinery Cooling Tower : 24000 m3/hr
CPP Cooling Tower : 30000 m3/hr
The unit wise cooling water demand for the refinery post expansion is tabulated intable 7.5.2.The cooling water system envisaged for the refinery complex is fresh water
recirculation type. The Refinery cooling water system includes cooling towers,pumps, cooling water treatment facilities, distribution network supply to various
Note 1: Value taken as per Client from original utility summary given by EIL
(Licensor).
Cooling Tower
CPP CTThere is no change in power generation capacity of CPP; hence no increase inCW consumption of CPP is envisaged. 4000 m3/hr was allocated for otherconsumers of CPP CT against the final estimate of 1500 m3/hr pre revamp.Hence, the additional CW requirement of about 300 m3/hr for proposed new N2plant and LP Air compressor can be catered within this allocated 4000 m3/hr.
Refinery CT
New cooling water requirement post revamp for refinery cooling tower works out tobe 28000 m3/hr as against the existing system of 24000 m3/hr. One additionalcell same as existing Cells (6W+1S) of capacity 4000 m3/hr will be required for
augmentation of refinery cooling tower. Hence total no of cells in post revamp willbe (7W+1S) of capacity 4000 m3/hr.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Recirculating cooling water pumps
A new cooling water circulation pump same as existing (3W+1S ) of capacity8000 m3/hr is to be installed in refinery cooling tower .So total no of pumps post
revamp will be 4W+1S with capacity of each pump as 8000 m3/hr.Type : Horizontal centrifugalType of Drive : Electric motorNo. Of additional pumps : oneCapacity : 8000 m3/hrThe existing header sizes of the cooling water are 72”/66”/54”/38”. For theincreased cooling water a new header of 36 “/28”/20 “ shall be laid in the offsite tomeet the unit battery limit pressures. This can be further optimised during detailengineering.
Bearing Cooling Water
Existing BCW requirement is 760 m3/hr. BCW is taken from Raw water headerand BCW return is sent to cooling water headers as Cooling tower make up.
Recirculation system of BCW in all process units is being implemented by BORLto prevent overflowing of cooling tower sump .Hence only 10% of original BCWconsumption to be considered in Process units.
Hence BCW make up to cooling tower reduces to 112.5 m3/hr and no modificationin bearing cooling water system is envisaged.
7.5.4 DM WATER SYSTEM
DM water in the refinery complex is required as Boiler feed water make-up forsteam generation and as process water for dilution, reaction and washing. DMwater for the refinery is produced in RO system which is part of ETP.The demand summary of DM water in various units and utilities is given below inTable-7.5.3
Table-7.5.3:DM WATER (m3/hr)
UNIT Existing Post Revamp
CDU/VDU 5 6.3
NHT/NSU 0 6
HGU 132 132 (Note-2)
ARU 0 2.5
SRU 15 15
TGTU 0.5 1.0
Total process 152 162.8
Utility BlockCaustic Dilution 15 18.8
CPP 332 428.6
TOTAL- Utility 347 447.3
TOTAL- Process & Utility 499 610
Total process and utility with 10 % margin 548.9 671
Note 1: Condensate has been considered for DM water make up. Condensaterecovery is based on 60 % recovery of suspect condensate & 85% recovery ofpure & surface condensate.
Note-2: As per Licensor data.
DM water storage
Two DM water tanks of 16 hr storage are provided .Normally one tank receivesDM water from the RO plant and the second tank supplies DM water toconsumers.New DM water requirement is around 486 m3/hr In post revamp DM water storage
tank hold up will reduce to 14.8 hrs.
Total Flow 486 m3/hrCapacity of each tank (80 % filling) 7200 m3Number of tanks 1+1Hold Up Time 14.8 hrs
DM water transfer pumpIn present scenario for CPP (2W+1S) DM water transfer pumps of capacity 185m3/hr are present.Since the requirement of the utility block is 447.43m3/h, the adequacy of the
transfer pumps shall be checked during design stage. For process units existingDM water transfer pumps of 250 m3/hr (1W+1S ) are adequate since the processrequirement is worked out to be 197 m3/hr.
DM water transfer pumps to process users:Type : Horizontal centrifugalType of Drive : Electric motorNo. of pumps : 1 operating + 1 stand byCapacity : 250 m3/hr each
To meet the additional DM water requirement .One additional bank for RO-DM
plant of existing capacity is considered to cater additional DM water requirement.One new cooling tower blow down storage tank and one set of feeding pump isconsidered for feeding cooling tower blowdown to RO DM plant.
Details of the blow down tank and pump:TankTank size : Vertical Fixed cone roof tank, 18 m (Dia) x15 m
(HT)PumpType : Horizontal centrifugalType of Drive : Electric motorNo. of pumps : 1 operating + 1 stand byCapacity : 300 m3/hr each, 15 m Head
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Total air requirement (as per design) : 11200 Nm3/hTotal air requirement Post revamp(with 10%margin) : 13600 Nm3/h Additional air requirement : 2400 Nm3/h
Air requirement of new N2 plant : 6000 Nm3 /hTotal additional air requirement : 8400 Nm3/h
LP Air Compressor
One additional LP air compressor similar to existing compressor capacity of 8825
Nm3/hr) is considered to meet the additional air requirement post expansion. This
LP air compressor will be common for N2 plant and the Plant air /instrument air
plant.
Type : Centrifugal, non-lubricatedDrive : Electric motorCapacity of compressor : 8825 Nm3/hrNo. : 1(one)Discharge Pressure : 8.0 Kg/cm2 (g)
Additional Instrument air requirement will be met by additional air dryer of 5000Nm3/hr in addition to existing two no of dryers each of capacity 5000 Nm3/hr.
A new instrument air header of size 6” in parallel to existing 10” shall be laid toconform to the battery limit pressure of the offsites and utility due to considerableincrease in post revamp requirement.
Existing Emergency instrument air: 2 HP storage vessels for 30 minutes I.Arequirement for safe shut down (1 vessel for HCU+DHT unit + 1 vessel for balancerefinery facilities).The adequacy of the existing instrument system has beenchecked w.r.t the post revamp requirement and found adequate.
7.5.6 NITROGEN SYSTEM
High purity Nitrogen is required in the refinery for the following purposes:
A) Continuous Requirement During catalyst regeneration Blanketing of surge drums and storage tanks Purging of compressor seals
B) Intermittent Requirement Purging of systems during start-ups and shut-downs Catalyst Regeneration
The process related activities such as reactor section dry out, system purging,catalyst regeneration, etc. require high purity nitrogen (>99.5% purity). Accordingly, a existing nitrogen plant based on cryogenic air separation cater to
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
The nitrogen requirement post revamp against the existing consumption istabulated in the table 7.5.6
Table-7.5.6 Nitrogen requirements of the various units.
The total nitrogen demand post expansion considering design margin and marginfor leakage is ~ 3000 Nm3/h .
The existing Cryogenic Nitrogen plant capacity is as follows:
Gaseous Nitrogen : 1,500 Nm3/hr
Liquid Nitrogen : 225 Nm3/hr (Gaseous equivalent)
The requirement of 3000Nm3/hr of gaseous nitrogen Post revamp will be met byadditional new N2 chain of 500 Nm3/hr capacity.Liquid N2 storage capacity is adequate as there is no change in start up,regeneration etc data.
7.5.7 STEAM, POWER AND BFW SYSTEM
The steam is produced in the captive power plant. The fuel to CPP is coal. Thereare three levels of steam in the refinery viz: HP, MP and LP. The steam is beinggenerated / consumed in process units at these levels. The steam consumption inthe various units for different purposes such as:
Process use (Chemical reaction, Stripping steam, etc.)Steam drives for some of the compressors/pumps
As heating medium for steam heated exchangersFuel oil atomisation. Internal fuel oil atomization,
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Steam tracing of lines (congealing service)Tankage heatingDeaeratorIntermittent requirement like snuffing, decoking, soot blowing, purging etc. Air conditioning units for the Control rooms and the administrative building
Steam Requirement
Tables 7.5.7, 7.5.8 and 7.5.9 give the consumption / generation figures for steamin various units at HP, MP & LP levels of steam respectively under normaloperating conditions which corresponds to case-I in the original utility steamdesign basis.
The unit-wise net steam consumption /generation for the existing as well as postrevamp is tabulated below:
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Table 7.5.9:LP Steam consumption (TPH)
Units Existing Post Revamp
CDU/VDU 10 12.5
PENEX 0.5 1.2 (Note-1)CCR -2.8 -5 (Note-1)
HGU 0.5 3.7 ( Note-1)
HCU/DHDT 7.5 13.3 (Note-1)
DCU 9.6 9.6
SRU -36.3 -25 (note-3)
ARU 49 49 (Note2)
SWS-1 24.6 33SWS-2 15.8 19
Utilities & Offsite 5 6.8NET TOTAL 83.4 118
With 10% margin 92 ~130
-ve sign indicates generation
Note-1: As per Licensor data.
Note-2: In ARU simulation, duty of reboiler remains same as in post revamp
scenario so LP steam consumption taken same as in existing. However
same will be confirmed during design stage
Note-3:, LP steam generation as expected post revamp in SRU based on
operational feed backs.
The existing LP steam header in the offsite is 26”/22/18”. A new LP steam headerof size 20” shall be provided in the offsite in parallel to the existing header forrevamp requirement. However same will be confirmed during design stage.
Power Requirement
Table 7.5.10 gives the power requirement of the various units under normal
operating conditions. Table 7.5.11 gives estimated steam and power summary forexisting and post revamp scenario.
Table 7.5.10: Estimated Power Consumption (kW) (Normal)
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Units Existing Post Revamp
SRU 7388 9973.8Utilities & Offsite 24299 30373.8
Total (Normal) 89388 114904
Table 7.5.11: Estimated Steam & Power Summary
Existing Post Revamp
RefineryNormal/RatedPower demand(MW)
(Including CPP)
Normal: 90 Normal: 114.9
Rated : 126.39
(with 10% margin on normal
requirement)
Refinery SteamNormal/Rateddemand (TPH)
Rated Flows with
10%
margin
HP : -3.6,
MP:84
LP : 92
Total Rated: 172.4
Rated Flows with 10% margin
HP : 67
MP : 89.4
LP : 118
Total rated : 260
The existing steam and power generation facilities consist of:
CFBC : (2W+1S ) boilers of capacity 225 TPH each (VHP
Level)
STG : 3 X 33 MW each (Extraction type)
Grid back-up : 20 MW(As per design) (Currently BORL is
withdrawing
47 MW power from grid)
DG set : 4.0 MW (to meet emergency power)
Total power requirement post revamp will be 115 MW (all units running normally) As per BORL operating data post revamp comes out to be 94 MW only ascompared to 115 MW estimated based on original power requirement of units.Post expansion power available from CPP will be same as existing as 47 MW.The balance power 68 MW shall be available from Grid power.
Total steam requirement for all units post revamp running normally: 260 TPHSteam available from CPP post revamp (as per BORL operating data): 228 TPH.
Presently one additional 160 UB boiler is under implementation by BORL. This willcater to the additional requirement of steam. The existing 225 TPH boiler will be
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
common standby for both existing and the revamped system. Hence no newfacility is required for steam.
Steam balance of refinery in conjunction with new and existing boilers shall be
worked out during design stage from energy optimization point of view likeconsideration of back pressure turbine type pumps in some services etc.
Boiler Feed Water Requirement
Boiler feed requirement of various units and Captive Power Plant (CPP)is given inTable-7.5.12.
Table 7.5.12: BFW consumption (TPH)
Units Level ExistingPost
RevampCDU/VDU MP 21.9 27.4
CCRLP 1.3 4.6 (Note-2)MP 8.7 12.9 (Note-2)
ISOCRACKING MP 80 125 (Note-2)
PENEX HP 1 1.5 (Note-2)
DCUHP 7 3 (Note-1,2)MP 23.6 14.9(Note-2)
TOTAL
HP 8 4.5MP
134.2 180.5LP 1.3 4.6
NET TOTAL 143.5 189.5
Note-1: The HP BFW requirement in DCU is intermittent and for spalling of the
heater considered for total requirement of BFW .
Note-2: As per Licensor data.
The MP+LP BFW import system from CPP is designed for 170 m3/hr on continuous
basis as per existing and HP BFW is supplied by HGU.
In post revamp MP +LP BFW requirement is around 185 m3/hr.HP BFW requirement = 4.5 m3/hr.
Since MP+LP BFW pump rated flow is 197m3/h, no change in BFW system and
pump is envisaged.
7.5.8 CONDENSATE SYSTEM
Steam is being used in the refinery as process steam motive fluid for the steamturbine drives, ejectors, heating etc. Condensate results from the condensingsteam turbine drives, steam re-boilers and ejector condensers. Within the each
individual units suspect condensate and pure condensate is segregated. During
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
normal operation, suspect condensate is treated in centralised condensatepolishing unit before use.However, the pure condensate and surface condensate is directed to polishedcondensate tanks.
Condensate generation summary for various units is given below in Table-7.5.13.
Design capacity of existing chains is 50TPH. Two chains of 50 TPH capacity(1W+1s) is provided for treating suspect condensate and tracer condensate..
Post expansion Total condensate generation will be 244.2 TPH .The break up ofcondensates for the post revamp scenario is as follows:Surface Condensate : 81.2 TPH
Pure Condensate : 116.7 TPHSuspect Condensate : 46.3 TPH
The total suspect condensate including tracer condensate works out to be52.55(6.25+46.3). Although the post revamp requirement is marginally higher thanthe existing train capacity one additional chain of CPU in parallel to existing chainwith capacity same as existing capacity of 50 T/hr has been considered based onBORL requirement.
Feed Condensate tank (Unpolished Condensate)
The feed condensate tank(1+1) was originally designed for 16 hrs(total flow =106TPH) equivalent storage of continuous suspect(37.8TPH) and largest pure/surface
condensate flow (67.7 TPH). Post revamp the Feed condensate tank hold upreduces to 11 hrs for a total condensate flow of 163 TPH.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
CPU Feed Pumps
In existing two no’s (1W+1s) unpolished condensate transfer pumps of 50 m3/hreach are provided. No additional unpolished condensate pump is considered for
the additional chain of CPU.
Polished Condensate tank
The feed condensate tank was originally designed for 16 hrs (total flow =170.5TPH) equivalent storage of continuous polished condensate(50TPH), Surfacecondensate from unit (52.8 TPH)and pure/surface condensate flow(67.7 TPH).Post revamp the Polished condensate tank hold up reduces to 11.4 hrs for a totalcondensate flow of 244.2 TPH.
Polished Condensate/Preheat exchangers and Polished condensate pumps
Both the preheat exchangers in CPU are sized for 182 TPH of total condensate(suspect +pure+ surface condensate).The adequacy of the preheat exchangerswill be established during the engineering for the revised polished condensate andfeed condensate flow.The existing three polished condensate transfer pumps(2W+1S) are of capacity 95m3/h each with total flow of 190 m3/h. The adequacy of these pumps for 30%increase in flow will be checked during detail engineering.
7.5.9 FUEL GAS AND FUEL OIL SYSTEM
The fuel requirement for the BINA Refinery post revamp would continue to be metby fuel oil & fuel gas generated internally from various process units.
Furnaces within process units would operate partially by fuel gas system andpartially by fuel oil systems. For CPP the CFBC boilers are presently operated onIndonesian coal instead of pet coke and HSD will continue as start up fuel. Twotypes of fuel oil is being used, IFO for only CDU/VDU heaters with 0.5 % sulphur,RFO for remaining consumers with 0.5 % sulphur.
Fuel Demand
The total fuel demand in MMKCal/hr of respective units of BINA Refinery project,considering all units running is indicated in the following table. The followingconsumers in the complex are considered to be on fuel gas only.
101/201 heaters in HCU unit.NHT Charge heater 19-FF-00-101(as per Licensor report)NHT Auxiliary Heater 11-FF-00-103BCCR heaters 20-FF-101/102/103(as per Licensor report)Pilot burners in all heaters, SRU and Flare.Fuel gas purging for flare networkDCU, WGC seal purging.Incinerator in SRU.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Overall Fuel Gas Balance
A) Fuel gas balance in the BINA refinery complex for 100% fuel gas firing in
various units operating scenarios is as follows:
Table-7.5.14: Overall Fuel Gas Balance
UNITFG Generation
KG/HRFG Consumption
KG/HR(100%firing)
CDU 0 6640.12
VDU 0 3940.51
HCU/DHT 6146.8(NOTE-2) 7687.28
3146(NOTE-3)
DCU 14519.7 4302.83NHT 1169 3105.00
CCR 3212 (NOTE-4) 4778.76
PENEX 931
HGU 0 50.00
SRU 0 2900.00
HOT OIL HTR 3088.94
Pilot Burner 0 557.00
Flare Purging 0 500.00
Total 29124.5 37550
Note -1: 100 % fuel gas firing is not possible as the fuel gas generation is less than the consumption.
Note -2: 6146.8 kg/hr of fuel gas from Off Gas of HCU/DHDT after hydrogenrecovery from recovery PSA in HGU. This will be updated after receiving datafrom PSA vendor.
Note- 3: 3146 kg/hr after H2S removal in amine treating within CDU/VDU.
Note -4: 3212 kg/hr of fuel gas from Net Gas of CCR after hydrogen recoveryfrom recovery PSA in HGU. This will be updated after receiving data from PSAvendor.
B) Since fuel gas is not available for 100 % firing fuel balance in the BINArefinery complex is distributed between fuel gas and fuel oil. The ratio of fuelgas and fuel oil is based on the splits provided by BORL during PFR study forvarious units:
Note -1: Excess of fuel gas ~7028 kg/hr is available when fuel oil is fired alongwith fuel gas.
7.5.10 FLARE SYSTEM
The existing flare system is provided for safe disposal of combustible, toxic gaseswhich, are relieved from process plants and off sites during start-up, shutdown,normal operation or in case of an emergency such as:
Cooling water failureGeneral Power failureExternal fire case Any other operational failureBlocked outletReflux failureLocal power failureTube rupture
The refinery complex shall have two flare systems, one for Hydrocarbon flare forprocess units & off-sites handling hydrocarbon and the other for the sulphur blockhandling sour flare.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Of the above emergencies defined for flare system, the complex power failurewas the governing load for sizing the flare system.The existing design flare load and the flare load in revamp for the general powerfailure is tabulated below:
HC Flare Existing Capacity : 946,973 kg/hrHC Flare Post Revamp Capacity : 1217133.4 kg/hr
The adequacy of the existing Flare system has been checked for the revised flareload ,mol wt and temperature.The flare loads of DCU and MS block are as per the Licensor data and the load forHCU-DHT is based on the estimated value post expansion .
The major findings of the flare system for the revised flare load conditions are asbelow:
a) Flare Stack: The Existing flare stack is adequate for the Post Revamp load.b) Flare KOD: The Existing flare KOD is adequate for the Post Revamp load.c) Water Seal Drum: Water Seal drum is adequate for the post revamp
conditions .However as suggested by BORL internal modifications in waterseal drum is envisaged due to low flow of flare gas during normal conditions.
d) Flare Header : The existing flare header is found adequate for the revampload.
Since the governing case for sour flare is fire case for TGTU which remainsunchanged post revamp thus existing sour flare is adequate for the post revampconditions.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.6.0 OFFSITE SYSTEM
The offsite facilities of existing refinery consists ofa) Tank Farm
b) Interconnection of process lines between process unitsc) Product Run down lines from refinery to Dispatch Terminal.
7.6.1 TANK FARM
Tank Farm facilities are designed to store and transfer feed, intermediate andfinished products. The storage capacities are based on the crude, intermediateand finished products material balance vis-à-vis number of days of stockrequirements. The summary of existing feed and intermediate storage tanksand their pumps are tabulated in tables 7.6.2 & 7.6.3, given at the end of thechapter. Adequacy check has been done for the existing feed and intermediate storagetanks based on the revised capacities of the units for refinery expansion from6 MMTPA to 7.8 MMTPA. Details of Storage tanks considered for feed andintermediate services are attached in Table 7.6.4 (at the end of the chapter) asper the basis given below.
7.6.1.1 Crude storage and transfer
The refinery has three storage tanks (51-TT-FR-01A/B/C) which weredesigned originally for 6.5 days of operation. The holdup time available will get
reduced from 6.5 to 6.3 days with existing tanks. One additional crude storagetank is considered which will provide 8.3 days of hold up post revamp.The existing crude water Tank (52-TT-CR-15) will be sufficient to collect drainwater from additional Crude tank and no new tank is considered.The existing pumps 51-PA-CF-01A/B/C have been checked for the revisedduty conditions and the pumps have been found adequate with the change inimpeller and replacement of motor.
7.6.1.2 Intermediate Feed Storage and Transfer
For all intermediate services the holdup time available in the intermediate
feed/storage tanks based on post revamp scenario has been reviewed asagainst the holdup time originally envisaged for each service. Additional Tanks have been proposed in the intermediate services wheneverthere is a considerable reduction in hold up time post revamp.
a) Naphtha Hydro Treater (NHT) Unit Feed Storage and Transfer
The feed to NHT storage tank (52-TT-FR-06) consists of full range stabilisednaphtha from CDU/VDU. The existing tank was designed to provide storagerequirement of 5.9 days production of Naphtha from CDU/VDU operating@60% when NHT is down. For the post revamp scenario, the no of day
storage reduces to 4.8 days. One additional tank has been proposed whichwould provide storage for 9.6 days.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
The existing feed pump 52-PA-CF-06 A/B has been checked for the revampduty conditions and found adequate with replacement of impeller with higherdiameter.
b) Continuous Catalytic Reforming (CCR) Feed Storage Tank and Transfer
The feed to CCR feed tank (52-TT-CR-07) is HDT heavy naphtha from NHTUand HCU heavy naphtha. The existing tank (1 no) was designed to providestorage requirement of 2.5 days@60% throughput when NHT is down. For thepost revamp scenario, the number of storage days reduced to 1.1 days. Oneadditional tank has been proposed which would provide storage for 2.2 days.The existing pumps 52-PA-CF-107 A/B have been checked for the postrevamp scenario and found adequate for the revamp duty conditions.
c) Reformate Storage and Transfer
Normally reformate from CCR will be routed to both Euro-V and Euro-IVPremium Gasoline blending pools. The existing reformate tank (52-TT-FR-12)is designed for supplying 4.8 days of reformate for MS blending when CCRunit is shutdown. In the post revamp scenario the no. of days reduces to 3.2days. Hence one additional tank has been proposed which would increase theavailable storage to 6.3 days.The existing pumps (51-PA-CF-12A/B) will be adequate with impeller change.
d) Isomerate Storage And Transfer
The existing 2 no. of tanks (52-TT-DR-11A/B) are designed for 5.6 days ofproduction for isomerate of MS blending. For the post revamp flow theisomerate , hold up available will be for 4.6 days in the existing tanks. No newtank is proposed for Isomerate.The existing pumps 52-PA-CF-11A/B are not adequate for the revamp flowsand needs impeller to be replaced with higher diameter along withreplacement of motor.
e) Hydrogen Generation Unit Feed Storage Transfer
The HGU feed storage tank (52-TT-DR-08) receives mixed Pentane(Depentanizer Overhead) from PENEX unit. The existing tank is designed tocater HGU for 2.5 days @60% throughput when Penex Unit is shutdown.Since the no. of days will reduce to 2.0 days of storage for the post revampscenario, one additional tank has been considered.The existing feed pumps 52-PA-CF-08 A/B for HGU is adequate for the postrevamp scenario.
f) Coker Naphtha
Coker Naphtha produced in DCU will be stored in Coker Naphtha Tank (52-TT-CR-19). The existing tank is designed to store 8.5 days of production ofCoker Naphtha from DCU operating at 60% throughput when HCU is
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
shutdown and to cater the HCU unit operating at 60% throughput for 2.3 dayswhen DCU is shutdown. The storage requirement reduces to 7.1 days(whenHCU down)and 1.9 days (when DCU down)in post revamp scenario. Sinceone tank is already under construction in addition to the existing tank, no new
tank is proposed.The existing pumps 52-PA-CF-19A/B are adequate for the revamp dutyconditions.
g) Diesel Hydrotreating Unit (DHDT) Feed Storage and Transfer
A combined stream of light gas oil, heavy gas oil, vacuum diesel fromCDU/VDU is to be stored in DHDT feed tank (52-TT-CR-05A/B/C). Theexisting 3 tanks (52-TT-CR-05A/B/C) are designed for storage of 11.8 days ofproduction of diesel form CDU/VDU operating at 60% throughput and 3 daysof feed to DHDT @60% throughput when CDU/VDU is shutdown. Since 11.8days and 3 days storage reduces to 9.4 days and 2.3 days for diesel fromCDU/VDU and feed to DHDT, one additional tank has been considered andwith additional tank the no. of days will increase to 12.6 and 3.0 days.The existing DHDT feed pumps 52-PA-CF-05A/B have been found adequatefor the revamp scenario.
h) Light Coker Gas Oil
In existing refinery one LCGO tank (52-TT-CR-17) has been provided for 16.3days of production of LCGO from DCU operating at 60% throughput when
DHDT is shutdown.For post revamp flow, the storage days reduces to 12.5 from 16.3 days. SinceLCGO is normally routed hot from DCU to DHDT, 12.5 no. of days areacceptable and no new tank is proposed.The existing LCGO pumps 52-PA-CF-17A/B have been found adequate forthe revamp flows.
i) Hydrocracker Unit Feed Storage and Transfer
The feed from Hydrocracker unit (HCU) consists of vacuum gas oil (VGO)from CDU/VDU, Heavy Coker Gas Oil (HCGO) and coker Naphtha from DCU.
VGO, HCGO and Coker Naphtha will be stored separately. Vacuum Gas OilThe existing three tanks (52-TT-CR-02A/B/C) for VGO are sized for storing 12days of production of VGO from CDU/VDU operating at 60% throughput whenHCU is shutdown as well as for catering the HCU operating at 60% throughputfor 3.5 days when CDU/VDU is shutdown.For post revamp flows, hold up available in the tank reduces to 9.5 days from12 days and to 2.3 days from 3.0 days. One additional tank has beenconsidered similar to existing 3 tanks. The additional tank would providestorage for 12.7 days (when HCU is shutdown) and 3.1 days (when CDU/VDU
is shutdown) respectively for VGO.The existing pumps 52-PA-CF-02A/B are adequate for the revamp flows.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Heavy Coker Gas OilThe existing two tanks (52-TT-CR-03A/B) are designed to store 11 days ofproduction of HCGO from DCU operating at 60% when HCU is shutdown or tocater the HCU for 3.5 days operating at 60% when DCU is shutdown. For post
revamp scenario, the holdup reduces to 8.7 days for HCGO from DCU and 3.0days for HCGO to HCU unit. Since already one tank is under construction, nonew tanks are proposed.The existing HCGO pumps 52-PA-CF-03A/B are not adequate for the revampduty conditions and impeller to be replaced with impeller of higher diameter.
j) Vacuum Residue (VR) Storage and Transfer
VR from VDU will be stored in VR (DCU) feed storage tank (52-TT-CR-04A/B).The existing two tanks were designed for 8.2 days of production of VR fromCDU/VDU operating at 60% throughput when DCU is shutdown as well as tocater DCU operating at 60% throughput for 2 days when CDU/VDU isshutdown. Since already one tank is under construction and with new tank,storage requirement of 9.9 days(VR from CDU) and 2.3 days(feed to DCU) aremet, no new tank is envisaged.The existing pumps 52-PA-SC-01A/B/C are adequate for the revamp dutyconditions.
Miscellaneous Offsite Storages
a. CDU/VDU Internal Fuel Oil (1wt% Sulfur) Storage and Transfer
No additional tank is proposed as consumption of fuel oil in CDU/VDU isenvisaged to be reduced in post revamp scenario. The existing pumps will beadequate for post revamp case.
b. Refinery Fuel Oil (2% wt Sulfur) Storage and transfer
No additional tank is proposed as consumption of fuel oil in refinery isenvisaged to be reduced in post revamp. The existing pumps will be adequatefor post revamp case.
c. Dry Slop Storage and Transfer
The storage requirement of the existing tank (52-TT-FR-09) is to store 8 houroff spec production from CDU/VDU at 60% of normal throughput during startup. In the post revamp scenario, the holdup time available will be 6.4 hours.However since a new tank is already under construction no new tank isconsidered. Accordingly, the existing pumps are adequate for post revamp.
d. MTBE Storage
MTBE is uploaded from the truck tankers and stored in MTBE Storage tank.Existing tank (52-TT-DR-18) has holdup time of 8.3 days. As per the post
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
revamp requirement of MTBE, one new tank to be considered. The existingMTBE pump (52-PA-CF-18) and MTBE blowdown pump (52-PA-CF-20A/B)will be adequate for post revamp conditions.
Miscellaneous Offsite Pumps
The remaining pumps consisting of Flushing Oil Pump (52-PA-CF-21A/B),White oil Blowdown Pump (52-PA-CF-22A/B), Black Oil Blowdown pump (52-PA-CF-23A/B), Crude Surge Storage pump (52-PA-CF-24A/B) and BCWpump (52-PA-CF-25A/B) will be adequate for post revamp flow.
The adequacy report of all offsite pumps is tabulated in Table 7.6.1 as below:
Table 7.6.1: Adequacy of Offsite Pumps
S.NO PUMP TAG NUMBER SERVICE MODIFIACTIONS
1 51-PA-CF-01A/B/C CRUDE
Impeller change of largerdiameter and motorreplacement of rating 320KW.
Crude Oil Terminal/PipelineDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev A
Ch 7.7 Page 2 of 7
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.7.1 CRUDE OIL TERMINAL
System Description
Crude oil will be received and stored in the crude storage tanks in Crude OilTerminal. Free water associated with crude, which settles down duringintermediate storage period, will be drained and treated in the Effluent TreatmentPlant (ETP) located within COT. After settlement and draining of water, crude willbe transferred to the Refinery crude storage tanks through 935 KM Vadinar BinaPipeline.
The system consists of Crude Oil receipt, storage and pumping facilities.
Receipt of crude
Crude from SPM will be directly received in tanks located in COT (Crude pumpingrate from SPM to COT will be approximately in the order of 6600 m3/hr to 9000m3/hr depending on pressure available at ship tanker end), through a 48" ODpipeline in the subsea portion as well as onshore portion.
Storage of crude
The crude oil storage terminal is designed on the basis of import of crude oil byship tankers of parcel size 3,60,000m3 as the largest tanker capacity. The storage
requirement at the COT is based on the following criteria:
1. Stored capacity of each crude storage tank shall be 60,000m3.2. Though different types of crudes such as Arab Mix, (50:50), Kuwait and
Oman shall be received, the present design is based on the Arab Mix (50:50/ AL: AH) only.
3. Crude pumping with drag reducing agent injection to the refinery shall be atthe rate of 1078 M3/hr (corresponding to crude density of 870kg/m3 of AMcrude) to meet the demand of 7.8 MMTPA.
4. There shall be common storage tanks for all crudes.5. Slippage time of tanker arrival is considered as 2 days.
6. Ship tanker can arrive 1 day in advance.7. Received parcel will ready for pumping in 48 hours or 2 days (tankpreparation time after receiving crude for any one tank). First tank receivingthe parcel will be ready for pumping after one day after unloading iscompleted from a VLCC parcel
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
ATF
5FIXED CUM
FLOATING ROOF10450
29.5 29.5
1
FIXED CUM
FLOATING ROOF 10450
SLOP (OFF
SPEC
PRODUCT)
2 FIXED ROOF 858 NA NA
TOTAL 41 TANKS 414886 M3
LPG
5MOUNDED
STORAGE1400 MT
13.8 10.7
1
MOUNDED
STORAGE (off
spec LPG)
1400 MT
TOTAL 6 MOUNDED STORAGE 8400 MT
Notes:
1. Normally smaller capacity tank (as indicated for individual products in the above
table) is used for product dispatch through Road & Rail loading system. Howeverflexibility is provided for dispatching product from any of the tank. Products
cannot be received from the refinery directly in the small tanks. Product are
transferred to smaller capacity tanks using inter tank transfer line.
2. Split of product is not available between Euro-III and Euro-IV grade for Gasoline
and Diesel production. There is a common receipt header for Euro III and Euro
IV Regular Gasoline, hence total production of gasoline is considered for both
the grade.
3. There are separate headers for Euro-III and Euro-IV grade Diesel. Productions ofboth the diesel grades have been assumed in the same proportion of existing
production.
CONCLUSION
With respect to product receipt rate, present storage facility is found adequate.
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.8.2 PRODUCT DISPATCH FACILITY
Existing product dispatch facility is based on loading points in the bays of
Marketing Terminal. The products are dispatched through Road and Rail loadingfacility as well as through pipeline transfer. Road and Rail loading facility satisfies
local demand while pipeline transfer is utilized for satisfying demand from other
regions of India.
7.8.2.1 Road Loading Facility
For white oil, tanker capacity is considered as 12 KL where as for LPG tanker
capacity is 18 MT. Two separate weigh bridges in existing facility are provided for
weighing of the empty and filled LPG and Naphtha at the entry and exit point.
Custody transfer of other while oil products are through PD meter.
Road Tanker loading facility can be utilized to maximum extent on the following
basis:
1. Design Basis for white oil road gantry:
345 days per year shall be considered for loading operation.
Loading is done in two shifts operation per day.
Working hours per shift shall be 8 hours.
Effective working hours per shift shall be 6 hours.
Minimum time considered to fill 12 KL white oil tanker is 10 minutes. (For Top
& bottom loading). Minimum time considered for connection/disconnection is
10 minutes.
Maximum loading rate in case of top loading will be 72 M3/Hr. (1200 L/m)
while for bottom loading maximum rate will be 144 M3/Hr. (2400 L/m).
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
7.9.0 LOGISTICS
This chapter deals with movement of crude, finished products and utiltites.
7.9.1 Crude
Crude carried by Ocean Tanker is off loaded at Single Point Mooring (SPM) ofCALM type near Vadinar, Gujarat, at a distance of about 15 KM offshore.
From SPM crude is conveyed by sub sea line and onshore (approx 3.5 KM fromLand fall point (LFP)) pipeline to Crude Oil Terminal (COT) battery limits.
Crude oil is recieved and stored in the crude storage tanks in Crude Oil Terminal.
From COT tanks, crude is pumped to Refinery through Vadinar Bina Pipeline(VBPL) which is 935 Km long cross country crude pipeline from Vadinar to Bina.
7.9.2 FINISHED PRODUCTS
The final products from refinery as listed below are dispatched through Road and
Rail loading facility
LPG
Naphtha
Euro III/ Euro IV Gasoline
Kerosene
Aviation Turbine fuel
Euro III/ Euro IV Diesel
Coke
All final liquid products are sent to Marketing terminal from refinery via piping.
Sufficient facilities for road and railway loading/ unloading at marketing terminal
are provided to meet the local demand. Facilities for pipeline transfer of multi
products are also available for satisfying demand from other regions of India.
Coke produced within refinery is transported by road to nearby places and by
railway to other parts of India.
The utility systems are an integral part of the refinery and constructed on the
Refinery site. All utilities required for the plant shall be generated inside the
complex The refinery is self-sufficient in all its utility requirements except raw water
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 2 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
8.0 ENVIRONMENT CONSIDERATIONS
8.1 INTRODUCTION
Industrial development is essential for growth and betterment of the living
conditions of the society. Industrial development, however, is endemic with its
effect on the environment. It is essential that even while the industrial
development is spurred for growth, the environment is conserved and protected. It
has been considered essential to adopt environmental protection measures and
adhere to legislations such that the ecology and the habitat of the area are not
disturbed.
Various pollution control measures required to meet the prevailing environmentalstandards are planned at the different stages of execution of the project, viz.,
design, construction and operational phases.
8.2 POLICY AND LEGAL FRAMEWORK
Government of India has made many legislations/rules for the protection and
improvement of environment in India. Various environmental legislations/rules
applicable to the proposed project facilities are as follows:
Indian Environmental Legislation
The Environment (Protection) Act, 1986.
The Environment (Protection) Rules, 1986
Environment (Protection) Third Amendment Rules, 2002
Coastal Regulation Zone-Notification dated May 21, 2002
The Public Liability Insurance Act, 1991
The Public Liability Insurance Rules, 1991
The Water (Prevention and Control of Pollution) Act, 1974, and itssubsequent notifications.
The Water (Prevention and Control of Pollution) Cess Rules 1977 and its
subsequent notifications.
The Air (Prevention and Control of Pollution) Act 1981 and its subsequent
notifications.
Hazardous Wastes (Management and Handling) Rules, 1989, and its
subsequent notifications.
Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 and
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 3 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Noise Pollution (Regulation and Control) Rules, 2000 and its subsequent
notifications.
The proposed project shall be designed taking into account the above-referredlegislations/rules. Besides this the proposed effluent and emission standards for
Refineries will also be complied for this Project.
A brief description of the environmental protection measures proposed to be
adopted in the project with respect to the various components of the environment
like air, water, noise, land, etc., is given in the subsequent sections.
8.2.1 Air Environment
The gaseous emissions from the proposed project will be controlled to meet all the
relevant standards stipulated by the regulatory authorities.
8.2.1.1 Ambient Air Standards
The ambient air quality around the premises will be limited to those limits as per
National Ambient Air Quality Standards, which are given below in Table- 8.1.
Table 8.1: National Ambient Air Quality Standards 2009
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 7 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
8.2.1.3 Standards For Fugitive Emission, Leakages & Voc Emissions
Storage of Volatile Liquids: General Petroleum Products
1. Storage tanks with capacity between 4 to 75m3 and total vapor Pressure (TVP)
of more than 10 kpa should have Fixed Roof Tank (FRT) with pressure valve
vent.
2. Storage tank with the capacity between 75 to 500 m3 and total vapor Pressure
(TVP) of 10 to 76 kpa should have Internal Floating Root Tank (IFRT) of
External Floating Root Tank (EFRT) or Fixed Roof Tank with vapor control or
vapor balancing system.
3. Storage tanks with the capacity of more than 500 m3 and total vapor Pressure(TVP) of 10 to 76 kpa should have Internal Floating Roof Tank or External
Floating Roof Tank or Fixed Roof Tank with vapor control system.
4. The tanks with the capacity of more than 75 m3 and total vapor Pressure (TVP)
of more than 76 kpa should have Fixed Root Tank with vapor control system.
5. Requirement for seals in Floating Roof Tanks:
(i) (a) IFRT and EFRT shall be provided with double seals with minimumvapor recovery of 96%.
(b) Primary seal shall be liquid or shoe mounted for EFRT and vapor
mounted for IFRT. Maximum seal gap width will be 4 cm and
maximum gap area will be 200 cm2/m of tank diameter.
(c) Secondary seal shall be rim mounted. Maximum seal gap width will be
1.3 cm and maximum gap area will be 20 cm2/m of tank diameter.
(d) Material of seal and construction shall ensure high performance and
durability.
(ii) Fixed Roof Tanks shall have vapour control efficiency of 95% and vapour
balancing efficiency of 90%
(iii) Inspection and maintenance of storage tanks shall be carried out under
strict control. For the inspection, API RP 575 may be adopted, In-service
inspection with regard seal gap should be carried out once in every six
months and repair to be implemented in short time. In future, possibility of
Sampling connections, Equipment and line sizes more than 1.875 cm or ¾
inch are to be covered.
3. Applicability: LDAR programme would be applicable to components (given at 2
above) for following products/compounds: (i) hydrocarbon gases; (ii) Light
liquid with vapor pressure @ 20o C > 1.0 kPa; and (iii) Heavy liquid with vapor
pressure @ 20o C between 0.3 to 1.0 kPa.
4. While LDAR will not be applicable for heavy liquids with vapor pressure < 0.3kPa, it will be desirable to check for liquid dripping as indication of leak.
5. Definition of leak: A leak is defined as the detection of VOC concentration
more than the values (in ppm) specified below at the emission source using a
hydrocarbon analyzer according to measurement protocol (US EPA – 453/R-
95-017, 1995 Protocol for equipment leak emission estimates may be referred
to) :
Table 8. 5
Component General Hydrocarbon(ppm)
Benzene (ppm)
Till 31s Dec
2008
w.e.f Jan
1, 2009
Till 31s
Dec 2008
w.e.f Jan
1, 2009
Pumps / Compressor 10000 5000 3000 2000
Valves / Flanges 10000 3000 2000 1000
Other Components 10000 3000 2000 1000
6. In addition, any component observe to be leaking by sight, sound or smell,
regardless of concentration (liquid dripping, visible vapor leak) or presence ofbubbles using soap solution should be considered as leak.
7. Monitoring Requirements and Repair Schedule: Following frequency of
monitoring of leaks and schedule for repair of leaks shall be followed as per
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 13 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
3 BOD 3 days, 27oC 15
4 COD 125
5 Suspended Solids 20
6 Phenols 0.35
7 Sulphides as S 0.5
8 Cyanide (CN) 0.2
9 Ammonia as N 15.0
10 TKN 40.0
11 Phosphorus (P) 3.0
12 Chromium (Cr) Hexavalent 0.1
13 Chromium (Cr) Total 2.0
14 Lead (Pb) 0.1
15 Mercury (Hg) 0.01
16 Zinc (Zn) 5.0
17 Nickel (Ni) 1.0
18 Copper (Cu) 1.0
19 Vanadium (V) 0.2
20 Benzene 0.1
21 Benzo (a) – Pyrene 0.2
Notes:
1. Concentration limits shall be complied with at the outlet, discharging effluent
(excluding discharge from sea water cooling systems) to receiving
environment (surface water Bodies, marine systems or public sewers). Incase of application of treated effluent directly for irrigation/horticulture
purposes (within or outside the premises of refinery), make-up water for
cooling systems, fire fighting, etc., the concentration limits shall also be
complied with at the outlet before taking the effluent for such application.
However, any use in the process such as use of sour water in Desalter is
excluded for the purpose of compliance.
2. In case of circulating seawater cooling, the blow-down from cooling systems
shall be monitored for pH and oil & grease (also Hexavalent & total
chromium, if chromate treatment is given to cooling water) and shall conformto the concentration limits for these parameters. In case of reuse of treated
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 14 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
effluent as cooling water make-up, all the parameters (as applicable for
treated effluent) shall be monitored and conform to the prescribed standards.
3. In case of once through cooling with seawater, the oil & grease content in the
effluent from cooling water shall not exceed 1.0 mg/l.
8.3 EMISSION DETAILS
8.3.1 Liquid Effluents
A comprehensive waste water management system already exists in the refinery
to treat the liquid effluent to meet the EC / State Pollution Control Board
requirements for existing refineries. The waste water treatment plant at BORL is
designed based on combining physical, chemical and biological treatment systems
to effectively control the quality of effluent. The effluent treatment plant hasadequate capacity to treat this additional load (max. 50 m3/hr) generated from the
proposed facility.
The main sources of waste water generation due to proposed project are:
(i) Cooling Tower - Cooling tower blow down (due to addition of cooling water
cell of capacity 3000 m3/hr.
(ii) Sour Water Stripper Unit - Stripped sour water.
(iii) Desalter in CDU/VDU
Other sources (minor) of waste water generation are:
(i) Hydrogen Generation Unit
(ii) Boiler blow down, and
(iii) Sulphur Recovery Unit - water sprayed for solidification.
Water Balance for the Refinery Post Expansion is shown in Fig 8.1
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 20 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
(i) In-plant or Pretreatment Technology
(ii) End of Pipe treatment
These steps are discussed separately below.
In-plant Control Measures
Provision of appropriate segregation and collection philosophy for various
effluents depending on individual stream characteristics.
The process waste water will be segregated and thereafter treated further
in the existing waste water treatment plant within refinery complex.
Closed blow down system shall be incorporated for all hydrocarbon liquid
discharges from the process units which in turn reduce the effluent to ETP
both in terms of quantum and quality.
Paving the process areas to avoid contamination of soil/sub soil/ ground
water in case of accidental spills/leakage of hydrocarbon liquids.
Removal of hydrogen sulphide and ammonia which are toxic, odorous and
exhibit high oxygen demand by stripping the process sour water.
Reuse of treated effluent to the extent possible.
End of Pipe (EOP) Treatment
A comprehensive waste water management system already exists in the refinery
to treat the liquid effluent to meet the EC / State Pollution Control Boardrequirements for existing refineries. The waste water treatment plant at BORL is
designed based on combining physical, chemical and biological treatment systems
to effectively control the quality of effluent. The existing waste water treatment
plant is working efficiently as confirmed by the water analysis carried out during
the study period. The effluent treatment plant has adequate capacity to treat this
additional load (max. 50 m3/hr) generated from the proposed facility.
8.4.3 Noise Environment
The statutory national standards for noise levels at the plant boundary and atresidential areas near the plant will be met. The selection of plant equipment will
be made with specification of low noise levels as a major consideration. The
design will be undertaken with the aim of minimizing noise at source. Noise
suppression measures such as enclosures and buffers will be used to limit noise
levels in areas frequented by personnel to below 85 dB(A). Areas with high noise
levels will be identified and segregated where possible and will be provided with
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 24 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
8.4.5 Monitoring of Emissions and Effluents
8.4.5.1 Stack Monitoring
In order to keep a check on the emissions of SO2, NOx, SPM and CO from all the
point sources, all stacks shall be monitored as per statutory regulations.
8.4.5.2 Ambient Air Quality Monitoring
At present ambient air quality of the refinery and the surrounding area is measured
on continuous/periodic basis with four number of monitoring stations which are
identified on the basis of micro-meteorological conditions and human settlement
data as susceptible zones. The pollutants monitored are SPM, SO2, NOx, and HC(non methane). The monitoring of these pollutants will be continued in future also.
For regular monitoring of the operation of various pollution control facilities, a
laboratory with sophisticated instruments and well-trained manpower exists. A
separate Environment Cell with qualified Chemical Engineers/Scientists also
exists, which will ensure that all pollution control measures are effectively
operating and to carry out day-to-day checks, trouble shooting and further
improvements wherever necessary
8.4.5.3 Micro Meteorological Monitoring
In order to effectively co-relate the stack emissions and the real time ambient air
quality, the real time micro-meteorological data is also needed. A permanent
meteorological data monitoring station within the plant site area, to measure
parameters like wind speed, wind direction, ambient temperature, Relative
Humidity, Cloud cover, rainfall etc. is already existing.
8.4.5.4 Water Quality Monitoring
The monitoring of raw influent, the intermediate stages of Effluent Treatment Plant,
the treated effluent, the receiving water body and the ground water quality in the
surrounding areas is not only because of statutory compliance with the regulatory
authorities but also helps in reflecting the overall water management of the
Environmental ConsiderationsDFR for Debottlenecking of
Bharat Oman Refineries Limited
Document No.
A439-RP-0241-0001
Rev B
Ch 8 Page 26 of 26
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
Toxic and hazardous HC processing/handling areas shall be clearly identified
and regular health monitoring for the people working in these areas shall be
carried out.
All the employees shall be trained in Health, Safety and Environment (HSE)aspects related to their job.
Exposure of workers to noise, particularly in areas housing equipment which
produce 85dB (A) or more will be monitored by noise desimeters.
Periodic compulsory health check up will be carried for all the plant
employees. Particular attention will be given to respiratory and hearing
disorders. The yearly statistics along with observations will be reported each
year to the chief executive of the plant.
8.4.9 Environmental Audit
Records of quality and quantity of air emissions and liquid effluent will be
maintained. Details of quantity of solid waste disposed will be recorded on regular
basis. Details of waste storage area in the refinery complex will be maintained, this
will include details of the type of waste and the quantity stored. Addresses of
buyers of refinery wastes and details of proposed use of wastes will also be
maintained.
Data on influent to the effluent treatment plant and treated effluent quality and
stack emissions will be used to ascertain compliance with stipulated standards.The quantity of waste generated from various units will be compared with previous
years' data and efforts will be made to minimize wastes for more efficient utilization
of resources.
8.4.10 Environment Cell
M/s. BORL is already having an Environment Cell under its technical services
department which is headed by a well qualified and experienced technical person
from the relevant field. He is directly reporting to the Head of the plant operations.
The cell carries out number of activities related to effluent treatment andmonitoring of treated effluent, ambient air quality and stack emissions. The cell
also has an analytical laboratory under its control to carry out the analysis of air &
water samples. The lab has requisite technical staff to carry out these analyses.
The existing set-up shall be utilised for Debottlenecking of BORL project also.
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 9 Page 2 of 8
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
9.0 INTRODUCTION
The main purpose for realization of implementation strategy for Low Cost
Debottlenecking of BORL, Bina Refinery Project is to define a natural approach to asequence of planned events to allow the progress of the work to be achieved in the
set time frame and within the planned budget.
There are various modes of project implementation namely:
Conventional Mode of Execution (EPCM : Engineering, ProcurementContract Management)
Lump Sum Turnkey / Open Book Estimates (LSTK/OBE)
Based on the merits and de-merits of the above mentioned mode of execution of
the project. BORL shall review and finalise the mode of execution.
9.0.1. Engineering, Procurement Contract Management (EPCM) mode of
Implementation
In this mode of execution, Owner line up a CONSULTANT to perform the following
activities and Owner has responsibility for placement of orders and contracts.
Residual Process Design
Detailed Engineering
Contracts and Purchase
Inspection
Shipping
Construction Supervision
Commissioning Assistance
Overall Project Management and control
Advantages:
Minimal Investment Risk
Paralleling of activities with Front End Design for upstream Schedule advantages
Disadvantages:
Diffused responsibilities leading to high Schedule risk
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 9 Page 3 of 8
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
9.0.2. Engineering, Procurement and Construction (EPC) mode of Implementation
In this mode of execution, there are two type of contract implementation
philosophy:Lump sum Turn Key (LSTK)
Open Book Estimate (OBE)
9.0.2.1 Lump Sum Turn Key (LSTK) / Open Book Estimate (OBE) mode ofImplementation
In this mode of execution, OWNER engages a CONTRACTOR to implement the
job on EPCM basis with fixed commitment on Project Schedule at an agreed fee
/Cost. In case of LSTK contract, contractor has to complete work within agreedschedule and Cost. In case of OBE mode, the Contractual arrangement provides
for the commitments to be made by contractor & shared with the owner
transparently till an agreed commitment level of 65-70% of the target cost is
achieved (at the point of time when majority of orders and contracts are awarded,
while services cost quoted in lump sum and service fees as percentage at the time
of bidding), however single Point responsibility lies with the Contractor to deliver
the project as per agreed schedule. There may be option for conversion of the
contract to LSTK mode after typically 65-70% of the commitment of the Target
cost has been achieved.
Advantages:
Minimizes Contractor/client risks - Optimizes the Project Investment.
Enables start of Implementation from Process Package resulting in
significant Schedule gains. No need of formal FEED.
Transparent working arrangement between Owner and Contractor.
Owner gets the combined benefits of EPC and EPCM under the ambit of
PSU procedures for optimal cost and Fixed time frame advantage.Option of Converting the OBE Contract to LSTK available with Owner
based on a pre agreed arrangement.
Significant Cost advantage accrual out of minimisation of Financial risks of
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 9 Page 5 of 8
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
o DCU- 35%
o LPG Amine Treating Unit, only tray replacement in LPG Amine Absorberwith new Amine settler drum.
o LPG CFC Unit.
o FG Amine Treating Unit.
o Amine Regeneration Unit.
Increase in Capacity with major modification in Reformer:
o HGU- 27%
Increase in SRU capacity:o Modifications in existing Sour water Stripping (SWS–I & II) with addition
of 2 nos. Sour water storage Tank- 34%
o SRU New Train + Modification in existing 2 trains - 102%
Increase in MS Block :
o Naphtha Hydrotreating Unit- 45%
o Continues Catalytic Reforming Unit- 46%
o Penex Unit- 81%
Utility & Offsite (Exact Capacity to be finalised based on licensors input)
o 1 Cooling Tower (Cap: 4000 m3/ Hr. with 1 Pump Cap. 8000 m3/ Hr.)
o Pre-treatment facility for Treated water before feeding to RO DM Planto DM Water - 1 additional Bank and CPU - 1 Additional Chain
o N2 Plant - 1 additional unit- 500 Nm3/ hr
o Compressed Air system – 1 CF LP Air Compressor & 1 Dryer
o Additional tank for CRWS and SWS.
o Product Storage Tank – 8 Nos. and related product lines.
o Flare system: No modification.
9.1.2 Outside Refinery
Crude Pipeline – Addition of Pumps and DG at intermediate Pumping stations.
COT – 4 Nos. with Fire water network.
Betwa River Weir – Increase in wall height + additional pump.
7. For Electrical system, only modifications in existing Electrical panels & Sub-stationare considered to cater requirement of expansion. Requirement of New Sub-stationand additional panels are not considered.
8. Post expansion, Power requirement will be drawn from Grid. Hence no addition or
capacity expansion in Power Plant & Switchyard is considered.
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 9 Page 6 of 8
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
9. For modification in Recycle gas Compressor and Makeup Gas Compressor inHCU, Original Equipment Manufacturers (OEM) are to be ensured.
10. Modification in heater including supply or additional requirement shall be done byHeater Vendor.
11. Supply of DCS & erection shall be done by Original Equipment Manufacturer(OEM).
12. Procurement of Tank Plates and Structural Steel shall be kept under scope ofrespective contractors.
13. Graded site shall be made available on effective start date.
14. Piling work is not envisaged.
15. All civil work and major structural work shall be completed during pre-shutdown.
Foundation or major civil work is not considered during the shutdown.16. All Piping Fabrication/ Spools for pre-shutdown and shutdown requirement shall be
carried out during pre-shutdown only.
17. All Instrument calibration shall be completed during pre-shutdown period only.
18. During pre-shutdown refinery work, round the clock permit is required with priorintimation.
19. All work related to Crude Pipeline & work related to facility outside refinery isconsidered as pre-shutdown activity.
20. Total work for New SRU Train shall be carried out as pre-shutdown activity by
isolating physical area by properly barricading from existing 2 trains.
21. Work related to pre- reformer and shift reactor (LT) in Hydrogen unit shall becarried out during pre shut down by isolating area.
22. 2 agencies are considered for carrying out composite work for all unit areas.Demarcation of work shall be done based on staggering of various units takingworkload in to consideration.
23. Dispatch terminal and rail gantry related work shall be carried by BORL directly.
24. All statutory approvals for establishment of new facilities have been considered inthe scope of BORL.
Shutdown related:
25. Start date for shutdown is considered as permission to start hot work by BORLafter Refinery shut down.
26. Shutdown duration of 45 days considered is based on feedback/ assessmentreceived from M/s Technip KTI for HGU.
27. Shutdown related work in HGU shall be carried out through M/s Technip KTI.
28. All units are planned for shutdown at same time in the schedule.29. Possibility of completing some of hook ups and tie-in during intermediate shutdown
as part of Plant Maintenance shall be discussed & finalized with BORL.
DFR for Debottlenecking ofBharat Oman Refineries Limited
Document No.
A439-RP-02-41-0001Rev B
Ch 9 Page 7 of 8
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
30. No. of agencies for Mechanical/ Piping, Electrical/ Instrumentation and Insulation/Painting work during shutdown shall be decided at later stage based on workloadof Construction and hook ups based on detail Engineering.
9.3 OVERALL PROJECT IMPLEMENTATION SCHEDULE IS GIVEN IN BELOW
S.No Activity Schedule
1 Award of Contract to EIL Zero Date.
2 Discussions & agreement with
Licensor
1 Month from zero date.
3 Receipt of datasheet of
critical/long lead equipment
3 months from zero date progressively.
4 Final Process package inputsfrom licensor
5 months from agreement withLicensors.
5 Process package from licensor 6 months from zero date progressively.
6 Effective Start date Receipt of Process package from
Licensor.
7 Land free from encumbrance
for new SRU and agreed plan
for handing over of areas within
various units of Refinery &
Offsite area
On effective start date.
8 Basic Engineering for non-
licensed units
Starting from zero date with a duration
of 7 months.
9 Detailed Engineering Detailed Engineering for Procurement:
To commence 2 months after receipt of
critical equipment datasheet of licensed
unit or 1 month after receipt of critical
equipment datasheet of non-licensed
unit with duration of 17 months
excluding bal. Vendor Engg.
Detailed Engineering for Construction:
To commence 1 month after receipt of
input data of licensed unit or
immediately after receipt of input data of
non-licensed unit with duration of 23
months (17 months for Major
engineering + 6 months for balance
Vendor Engineering).
10 Procurement To commence 2 months after receipt of
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
10.0 PROJECT COST ESTIMATE
10.1 PROJECT COST
Project cost estimate for the identified scope of works is Rs 2518.99 Crore.
Validity of Cost estimate is as of 4th
Qtr 2013 price basis.This Project cost estimate shall be read along with Key assumptions and
Exclusions listed at Para 10.2 & 10.3
10.2 KEY ASSUMPTIONS
The basic assumptions made for working out the Project cost estimate are as
under:
Project Cost estimate is on conventional mode of execution.
Cost estimate is valid as of 4
th
Qtr 2013 price basis. No provision has been made for any future escalation.
No provision has been made for any exchange rate variation.
Existing land is adequate for expansion project and no site development is
required.
Piling is not required.
Existing infrastructure facilities are adequate and no cost provision has
been made for the same.
All costs are reflected in INR and all foreign costs have been converted into
equivalent INR using exchange rate of 1USD=Rs 61.0 Existing township is adequate and no cost provision has been made for the
same.
10.3 EXCLUSIONS
Following costs have been excluded from the Project cost estimate:
Forward escalation
Exchange rate variation
Construction site facilities Working Capital Margin
Interest During Construction
10.4 ESTIMATION METHODOLOGY
As indicated in para 10.3, the estimated Project cost for the identified scope and
technical details, Project cost works out to be Rs 2518.99 crores including foreign
component of Rs 522.23 crores
New equipment / augmentations / modifications required in equipment of existingprocess units to achieve 7.8 MMTPA crude throughputs have been identified to
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved
firm up the scope of work. Cost estimate for these equipment / facilities are based
on equipment lists / specifications provided by Process Department and in-house
cost data base. Cost estimate for Utilities & Offsites including Tankages is based
on information provided by Process department and in-house cost data base.
Executed cost data base for Bina refinery project has been used to the extentpossible using present exchange rate and economic indices. Suitable cost
provision has been made for Piping, Electricals and Instrumentation items. Cost
provision has been made for construction cost on factor basis. Applicable duties
and taxes have been added.
Cost estimate for new equipment & facilities is based on equipment list and
technical specifications developed for this project and cost estimate is based on
in-house cost data base. Cost of Proprietary items in MS Block, HGU & LPG CFC
have been considered based on the information provided by the Licensors.
Cost estimation for one new train of Sulphur recovery unit is based on analogousreference for similar type of unit executed and cost has been updated to present
date price level considering conventional mode of execution. Cost provision has
been made for Oxygen Enrichment Facilities also.
Cost is considered for 30% capacity enhancement of ATF Merox Unit.
Based on available preliminary technical information, above assumptions &
exclusions and methodology adopted for cost estimation, it is targeted to achieve
an overall accuracy of these estimates at ± 20%.
10.4.1 Modification / Replacement / Additional Items for Expansion Project
CDU/VDU unit
Column Internals, Vessels, Desalter Vessels & Internals, Pumps, Exchangers, Air
Cost provision has been made towards the EPCM services for the project based
on in-house information. Service tax has been considered @ 12.36%.
10.4.8 Pipeline
Cost provision for Pipeline has been made as per available inputs.
10.4.9 COT & BDT
Cost provision for COT & BDT has been made based on information provided by
the Process department.
10.4.10 Roads & Buildings
No new Road & Building has been envisaged for the project and no cost
provision has been kept in the Project cost.
10.4.11 Effluent Treatment Plant
Two new Tanks & Two new Pumps have been considered for ETP modification.
Cost for the same has been included under Utilities & Offsites cost.
10.4.12 Infrastructure facilities
It has been assumed that existing infrastructure facilities shall meet therequirement of expansion project and no cost provision has been made under thishead.
10.4.13 Construction Site FacilitiesExisting construction site facilities such as construction power, construction water,