1. Experience of an Indian Refinery
Project Execution
Experience of an Indian Refinery

2. Now CPCL is a group company of IndianOil
Inception
CPCL owns two Refineries in southern part of India with 220 thousand Barrels Crude oil processing per Day
Company established in 1965 as a JV of GoI, NIOC of Iran & AMOCO, USA
50 thousand bbl / day grass root Refinery near Chennai, commissioned in 1969 in a record time of 27 months
Before my collegues on the dias make presentation on Project execution ,let me give you an Indian Refiring Company's experience on project execution.
Now CPCL is a group company of IndianOil
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3. Major secondary processing
Panorama of Growth
Year
Capacity
MMTPA
Major secondary processing
units
1969
Initial Capacity
2.5
Lube ,Cat Reforming,Diesel
Desulphurisation,Vis Breaker
1980
Debottlenecked
2.8
1984
Doubled (Refinery-II)
5.6
FCC ,Wax
Value Addition Projects
Propylene,Food Grade Hexane
1993
Debotllenecked
6.5
CBR Refinery
7.0
2002
Debottlenecking-CBR
7.5
2004
3 MMTPA Expansion at Manali
10.5
Hydro Cracker,
Cat.Reforming,Soaker Visbreaker
CPCL has grown from a small 2.5 MMTPA refinery in 1969 to a Refining capacity of 10.5 MMTPA now.
Its Manali Refinery is one of the most complex refineries in the country
It’s the first refinery in the country to have two major secondary units i.e. FCC and Hydrocracker , coupled with mega LOBS production capability of several grades.
It may be noted CPCL has cracked into the prestigious list of S & P . CPCL is one amongst the seven companies from India in the Global list of 300.
CPCL has also leap fogged into rank no 6 from a position of 20 in 04 of Dun and Bradstreet amongst Oil and Gas sector .

4. Panorama of Growth
Refining capacity expanded by revamp of plants and addition of new units
In 2004 Capacity expanded from 130 to 190,000 Bbls/day by addition of new Crude Distillation, Hydro-Cracker, Cat.Reforming, Soaker Visbreaker Units
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5. Green Power Generation
ENERCON
Suzlon
RRB Vestas
NEC Micon
Pioneer Asia
GE, India
Project was completed in 6 months from order

6. Water Management Projects
In 1991, commissioned a 2.5 MGD City Sewage Reclamation plant
In 2001, commissioned RO Rejects Recovery plant
Additional City Sewage Treatment Project
Capacity: 2.5 MGD
Project cost : Rs Cr
Commissioned : Dec ’06
Sea Water Desalination Project
Capacity: 5.8 MGD
Project cost : Rs Cr
Scheduled completion: Dec ’07
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7. Refinery Expansion Cum Modernisation Project 2004
A success story in Project Execution
Licensor Selection
Implementation Strategies
Commissioning

8. Process Licensor Selection

9. Associated Utility & Offsite facilities

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

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

12. Safety Management
Safety features were incorporated right from design basis stage itself and during
Finalization of P&ID & process package,
Detailed engineering,
3 D modeling review,
Hazop review etc.
Safety was given top most priority during construction and commissioning.

13. 3D Model & Hazop Review
3D Model (Plant Design Software package) was reviewed by CPCL in two stages.
After the completion of 50 % & 100 % of engineering
Interference checks were carried out
Approach to equipments and valves for operation and maintenance
After Engineering, Hazop review was carried out extensively in the presence of Licensor, PMC, CPCL team comprising of experts from Operations, Process, Engineering and Contractor.

14. Human resources Developing the trained manpower
Operators with experience in high pressure units were positioned one year ahead.
Blend of experienced operators from with in the refinery and new recruits.
Class room training for two weeks.
On the job training for two weeks in similar units.
Simulator training for panel engineers.
Interactive sessions for atleast one hour in a day.
Pre-requisite for smooth commissioning is placing engineers right from beginning
Operators with experience in high pressure units were recruited one year ahead.
Blend of experienced operators from with in the refinery. (40:60)

15. Pre-commissioning Chemical Cleaning and Pickling
Pressure Relief Valve Registration, Tagging,
and verification of Relief Pressure
Rotary Equipment & Instrument Checklist
Check on Fire protection & Safety system
Construction Safety Audit
External Safety Audit by OISD team
Construction area Turnover
Chemical cleaning – pickling for compressor suction lines
Construction safety audit – CPCL IOC Team

16. Pre-commissioning Special Concerns unique to High Pressure Units
Makeup Hydrogen System
RGC & Auxiliary Systems
HP system - Reactor Internals
PEG and RTJ Flanges
Furnaces
HP Loop Leak Test
Interconnecting piping must be chemical cleaned and flushed thoroughly with nitrogen.
Keep the RGC Dry Gas Seal System CLEAN
Availability of spare MUG
Reliable Recycle Gas compressor

17. High Pressure Reactors Pre-commissioning
Important checks done
Reactors expand several feet when heated – interference from piping and instrumentation
Reactor internals marked before removing for easy reinstallation
Levelness and tight fit of internals. Deviation can cause mal-distribution and poor radial spreads
Coat the nuts and bolts with high temperature anti-seize compound
Installation of quench piping
Positioning of Temperature instruments inside
Catalyst loading

18. Focus on High Pressure circuit
Protocol established to check all flanges in HP circuit
Healthiness of flange face
Right gasket in place
Torque tension values
PSV Setting and validity
Spring support release
HP flange box-up
Orifice plate
Control valve stroke check
Direction of High pressure valves
PSV setting & validity
Spring support release
Vessel box up
Column internals & Seal pan test
Exchanger bundle pulling (Random

19. CPCL commissioned the entire process units without any setback and in a safe manner within stipulated time.
Hydro cracker unit was commissioned in 35 days smoothly from pressure test of HP system in line with the process licensor schedule

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

21. Thank You