00 VRMP Overall

Engineers India Limited
LESSONS LEARNT WORKSHOP BY

PROCESS 2
VIZAG REFINERY MODERNIZATION PROJECT
October 2020
1
BRIEF INTRODUCTION
PROJECT DETAILS:
Project Location: Visakhapatnam, Andhra Pradesh
Crude Refining Capacity: Revamp to increase capacity from

8.33 to 15.0 MMTPA
Design Crudes:
For New CDU-4 (9.0 MMTPA):-

Design Case-1: 87.5 wt% Basara Light +13.3 wt% Doba
Design Case-2: 92.5% wt% Arab Hy +7.5 wt% Dar blend
October 2020 2
BRIEF INTRODUCTION
Existing Facility:
The Visakh Refinery of HPCL (8.33 MMTPA refinery) is one of the most
integrated refineries with:
 Three crude distillation units,
 MS Block (NHT/ISOM/CCR),
 Diesel Hydro Desulphurization unit,
 Two Fluid Catalytic Cracking units, ,
 Visbreaker Unit,
 Bitumen Blowing unit and
 Propylene Recovery unit
The Refinery has installed Diesel Hydrotreater unit to comply with the Auto
Fuel policy to meeting the BS-IV product specifications for MS and HSD.
October 2020 3
BRIEF INTRODUCTION
New Facility:
S.No. Facility Capacity UOM
1 CDU/VDU-IV 9 MMTPA
2 SR LPG Treater (ATU & CFC) 196.8 KTPA
3 Naphtha Isomerisation Unit 0.352 MMTPA
4 Full Conversion Hydrocracker Unit 3.053 MMTPA
5 Residue upgradation facility 3.55 MMTPA
6 Hydrogen Generation Unit I & II 2 x 113 KTPA
7 Fuel Gas PSA 36 KTPA
8 Sulfur Recovery Unit I & II 2 x 360 TPD
9 SWS-I (Hydroprocessing) 270 TPH
10 SWS-II (Non- Hydroprocessing) 270 TPH
11 ARU I & II 2 x 540 TPH
October 2020 4
BRIEF INTRODUCTION
Existing Units requiring Revamp:
S.No. Facility Capacity UOM Remarks
Revamp capacity at the

1 NHT 1.5 MMTPA
rate of 30% revamp.
CCR/ CCR Revamp capacity at the

2 1.038 MMTPA
PSA rate of 35% revamp
Revamp capacity at the

3 DHDT 2.86 MMTPA
rate of 30% revamp.
No capacity
enhancement. But
4 Prime G 0.893 MMTPA
quality upgradation
considered.
October 2020 5
BRIEF INTRODUCTION
Utility Facilities:
Raw Water System(Includes the service water and the drinking water
system)
Re-circulating Sea Cooling Water System
Bearing Cooling Water System
Demineralised Water System
Captive Power Plant(BFW, Steam and Power generation system)
Condensate Polishing System
Compressed Air System (PA & IA) and Nitrogen System
Flare system
Integrated effluent treatment system
Internal Fuel oil and Fuel gas system
FLO system (existing)
Caustic storage & preparation system
Natural gas facility
October 2020 6
BRIEF INTRODUCTION
Offsite and Other Facilities:

FEED RECEIPT FACILITIES
PRODUCT DESPATCH FACILITIES
OFFSITE FACILITIES
 Crude storage, intermediate tanks, blending product storage and shipping
 Marketing Terminal connecting piping
 Inline blending system
 Utility interconnecting piping
 Fire water system
 Sulphur storage and handling
 Pitch handling system
 Process interconnecting piping
 SRV facilities at ISPRL cavern
INFRASTRUCTURE
October 2020 7
GENERAL LESSONS LEARNT
• Based on inputs received from the various groups working

on VRMP Units, it is noticed that few issues faced and their
corresponding suggested lessons learnt are common for
several facilities.
• These common issues are presented in this section for

discussion and resolution.
October 2020 8
S Issue Faced Background Resolution Lesson Learnt
N
o
1 Finalisation of utilty Changes in Utility conditions at Included in Utility design basis

design basis and late B/L, design pressure of Service Technical shall be attempted
revisions in Design water, DM water; DM water Amendments. to be finalised
Basis Part-B by Client . quality, FG properties. upfront so as to
avoid
amendments
during feed stage .
Finalisation of Design Basis of
Fuel Oil (new compositions
were added later)
Quality of circulating BCW

revised later
Fuel gas composition revised

considering various scenarios.
October 2020 9
N
o
2 Licensor did not In revamp job, for EIL emphasized that these For revamp Jobs,
used as built Updation of P&IDs for P&ID Updation has to be use of “As built”
P&ID’s for revamp revamp Licensor used done using “As built” P&IDs for base
Job original Licensor BDEP P&IDs as base for revamp of revamp P&IDs
P&IDs and did not used job. with suitable
the “As built” P&IDs HPCL also agreed the scope should be
Stating the reason that same. advised to client
Licensor is not responsible Later Licensor agreed to to be included
for changes by DEC in use “As built” P&IDs as in NIT/contract
Licensor P&IDs and base P&IDs for revamp scope in case EIL
backed the same with with suitable note to is not involved.
contract with HPCL. identify the scope and
responsibility of Licensor
based on changes done by
DEC in original Licensor
P&IDs
October 2020 10
N
o
3 Changes post BEDP In FC-HCU and NIU unit PMC identified PSV’s PMC identified
Submission : licensor has considered segregation and PSV’s segregation
Segregation of HP/LP only LP flare header. included in FEED as and included in
flare header Accordingly the PSV per Flare Design at
sizing has been later stage which FEED as per Flare
provided. However as caused PSV Design at later
per design basis backpressure change stage which
requirement, two flare and deviation request caused PSV
headers HP and LP to be to licensor backpressure
considered. change and
informed to
licensor through
deviation request.
October 2020 11

00 VRMP Overall

Uploaded by

Copyright:

Available Formats

00 VRMP Overall

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

00 VRMP Overall

Uploaded by

Copyright:

Available Formats

Engineers India Limited

LESSONS LEARNT WORKSHOP BY

Project Location: Visakhapatnam, Andhra Pradesh

Crude Refining Capacity: Revamp to increase capacity from

For New CDU-4 (9.0 MMTPA):-

Revamp capacity at the

CCR/ CCR Revamp capacity at the

Revamp capacity at the

Offsite and Other Facilities:

• Based on inputs received from the various groups working

• These common issues are presented in this section for

1 Finalisation of utilty Changes in Utility conditions at Included in Utility design basis

Quality of circulating BCW

Fuel gas composition revised

You might also like