detailed feasibility report - bharat oman refineries ltd

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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.

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DETAILED FEASILBLITY REPORTFOR

DEBOTTLENECKING

OFBHARAT OMAN REFINERIES LIMITED

BHARAT OMAN REFINERIES LIMITED(BORL)

PREPARED BYENGINEERS INDIA LIMITED

NEW DELHI

EIL JOB NO: A439

REPORT NO: A439-RP-0241-0001

VOLUME 1 OF 1MARCH 2014





CopyrightDFR for Debottlenecking of

Bharat Oman Refineries Limited

Document No.

A439-RP-02-41-0001Rev A

Page 1 of 1

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.






Table of Contents ofDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev C

Page 1 of 1


TABLE OF CONTENTS

SECTION CONTENTS PAGE

1. EXECUTIVE SUMMARY 1 of Ch 1

2. INTRODUCTION 1 of Ch 2

3. SCOPE 1 of Ch 3

4. DESIGN BASIS 1 of Ch 4

5. MARKET STUDY 1 of Ch 5

6. PROJECT LOCATION 1 of Ch 6

7.

7.1

7.2

7.37.3.1

7.3.2

7.3.3

7.3.4

7.3.5

7.3.6

7.3.7

7.4

7.5

7.6

7.77.8

7.9

PROJECT DESCRIPTION

PROJECT CONFIGURATION

TECHNOLOGY OPTION

PROCESS DESCRIPTIONCDU/VDU

DCU

HCU/DHDT

MS BLOCK

H2 UNIT

TREATING UNITS

SULPHUR BLOCK

MATERIAL BALANCE

UTILITIES DESCRIPTION

OFFSITES DESCRIPTION

COT/PIPELINEBINA DISPATCH TERMINAL

LOGISTICS

1 of Ch 71 of Ch 7.11 of Ch 7.2

1 of Ch 7.3

1 of Ch 7.3.11 of Ch 7.3.21 of Ch 7.3.31 of Ch 7.3.41 of Ch 7.3.51 of Ch 7.3.61 of Ch 7.3.7

1 of Ch 7.41 of Ch 7.5

1 of Ch 7.61 of Ch 7.71 of Ch 7.81 of Ch 7.9

8. ENVIRONMENTAL CONSIDERATIONS 1 of Ch 8.0

9.PROJECT IMPLEMENTATION AND

SCHEDULE

1 of Ch 9.0

10. PROJECT COST ESTIMATE 1 of Ch 10.0

11. RECOMMENDATIONS 1 of Ch 11.0

ANNEXURE No of Sheets

1 OVERALL PLOT PLAN 1

2 EQUIPMENT LIST 48

3 PROCESS FLOW SCHEME 74






List of TablesDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev A

Page 1 of 2


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






List of TablesDFR for Debottlenecking of


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A439-RP-02-41-0001Rev A

Page 2 of 2


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

Implementation9 of Ch 9






Executive SummaryDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001

Rev C

Page 1 of 9

A 18.01.2010 Issued for DFR SK VS VS

Rev. No. Date Purpose Prepared by Checked by Approved by


SECTION 1

EXECUTIVE SUMMARY








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Ch 1 Page 2 of 9


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)








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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

UnitsExistingCapacity(MMTPA)

Post RevampCapacity(MMTPA)

% Increasein Capacity

Crude / Vacuum

Distillation Unit

6.0 7.8 130

Integrated FullConversion Hydrocrackerand Diesel Hydrotreater

1.952/1.6372.625/2.202 135/135

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

468T/hr ofLean Amine

of 40 %MDEA

ATF Merox 0.55 0.711 129LPG treating unit 15.5 T/hr 21.66 T/h 140


http://www.borl.in/technology.aspx#cduvdu


http://www.borl.in/technology.aspx#fchcdht


http://www.borl.in/technology.aspx#dcu

http://www.borl.in/technology.aspx#hgu

http://www.borl.in/technology.aspx#nhtnsu

http://www.borl.in/technology.aspx#ccr

http://www.borl.in/technology.aspx#penex

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Table 1.2 Existing Product Pattern and Post Revamp Product Pattern

Existing CasePost Revamp

case% Increase

inProduction6 MMTPA 7.8 MMTPA

Products ('000TPA)

LPG 222 344 55Naphtha 241 189 (-) 21Euro III RegularGasoline

385 0 -

Euro IV regular/Euro VEquivalent Gasoline

400 1242 210

Aviation Turbine Fuel 550 722 31Kerosene 487 396 (-)18.6Euro III Diesel 1610 0 -

Euro IV/V Diesel 1181 3641 208Total diesel 2791 3641 30Coke 410 523 27Sulfur 109 152 39

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.








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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

associated systems ( Separator, condenser,reboiler, reflux pump, S/D pump, bottom pump)

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








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cooler and pump in parallel to existing backwash oilsystem.Replacement of existing exchangers with newexchangers or provision of additional shells.

Delayed Coker

Replacement of existing tubes of heater with higher

metallurgy Inconel800.

New parallel motor driven WGC for the balance

capacity

New blowdown ring compressor for blowdown

system

Tray modification in coker fractionators, LCGO

stripper , absorber, stripper and debutanizer.New Feed exchanger, new reboilers for stripper

,debutanizer and additional shells for compressor

intermediate cooler and discharge cooler .

Additional coke transfer conveyor and additional

coke storage facility equivalent to existing capacity.

HGU

New Pre-reformer and LT shift reactor

New Technip Parallel Reformer

Modifications in convection section of reformer with

replacement of coils and new preheat coil for pre-

reformer.

Two additional vessels in the SMR PSA and ROG

PSA.

New nitrogen circulation heater and cooler

SRU

One additional sulfur train of capacity 180 TPD with

Oxygen enrichment. O2 enrichment is provided with

VPSA as source of oxygen enriched air.

O2 enrichment facilities for existing trains toenhance capacity to 243 TPD

SWS-I & II

Replacement of trays with high capacity trays in 2nd

stage sour water stripper

Additional sour water tanks in both trains.

ARU Replacement of amine regenerator reflux drum.

LPG Amine

Treating Unit

Replacement of existing trays with new

configuration trays LPG Amine absorber

Replacement of mine settler drum with new drumFG Amine Treating No Modification envisaged








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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

H2 unit to Hydrocracker is envisaged.








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Storage capacities of all existing feed and intermediate tanks are not sufficient

for 30% increase in throughput of refinery i.e. from 6.0MMTPA to 7.8 MMTPA.

Total 8nos. of additional tanks in crude, intermediate products and other

service like MTBE are considered.1.4.4 Bina Despatch Terminal

Additional spur with full rake loading facility in existing rail gantry for Naphtha,

HSD Euro IV/ EURO V, MS Euro IV/V, ATF and SKO are considered. Facilities

are provided to load from both (existing + new) the spurs. For HSD Euro IV,

new rail loading facility is considered with rail loading transfer pumps (4

working + 1 standby each with capacity of 300m3/hr), separate header and

master meter in the rail gantry.

1.4.5 Crude Transport Facilities (Vadinar Bina Pipeline)

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 mainline and the intermediate pumping stations. Post

debottlenecking, additional booster pump and modification in main line pump

at 1st intermediate pumping station are envisaged to meet the revamp flow of

crude supply at the refinery.

1.4.6 Crude Oil Terminal

Four additional crude tanks, each of 60000 m3 capacity and associated

facilities are envisaged at the crude oil terminal.

1.5 ENVIRONMENTAL EMISSIONS

The stipulated SOx emission limit is 30 TPD for Bina refinery. For the

enhanced capacity of 7.8 MMTPA, SOX emissions are estimated to remain

within the maximum limits. This is possible as a result of various measures

taken-up during the design of the project, such as fuel gas maximization, use

of only low sulphur fuel oil in furnaces, upgrading of sulphur recovery facility,

increase of amine strength etc.

1.6 CAPITAL COST ESTIMATE

The estimated capital cost for the revamp of refinery is Rs.` 2518.99 Crores’.

The costing indicated as above is based on the following

The above cost estimates have an accuracy of ± 20%.

Validity of the above cost is as of 4th Qtr. of 2013.

The project has been assumed to be executed on conventional mode.








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1.7 RECOMMENDATIONS

The Bina refinery capacity can be increased from 6MMTPA to 7.8 MMTPA

considering modifications as enumerated in the report. The desired capacityincrease 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 of

40-45 days.

The total estimated capital cost for the project is Rs. `2518.99 Crores’.

The cost estimates has an accuracy of ± 20% & the validity of the above cost

is as of 4th Qtr. of 2013.

Overall project implementation is scheduled within 36 months from zero date

(date of award of contract to EIL) with refinery shutdown period of maximum

45 days.

Refinery revamp for capacity increase beyond 7.8 MMTPA will require major

modifications in practically all the process units namely CDU/VDU, HCU/DHDT &

DCU besides augmentation of the existing Utilities and Offsites facilities and may

also warrant evaluation of new plants.






IntroductionDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev B

Ch 2 Page 1 of 3


SECTION 2

INTRODUCTION








Document No.

A439-RP-02-41-0001Rev B

Ch 2 Page 2 of 3


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.








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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.






ScopeDFR on Debottlenecking of


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A439-RP-02-41-0001Rev B

Ch 3 Page 1 of 3


SECTION 3

SCOPE








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Ch 3 Page 2 of 3


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.








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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.

13. Conclusion & Recommendations.

14. Overall Plot plan.






Design BasisDFR for Debottlenecking of


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Ch 4 Page 1 of 19


SECTION 4

DESIGN BASIS








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Ch 4 Page 2 of 19


4.0 DESIGN BASIS

Design basis considered for Debottlenecking of Bina Refinery project is detailed

in Section 4.1.

4.1 BASIC DESIGN PARAMETERS FOR DEBOTTLENECKING OF BINA

REFINERY PROJECT

Study to be Done by EIL FR DFR Other

Execution Methodology for Project LSTK CONV HYBRID

Project Duration required in Months Shall be Evaluated

4.1.1 Other Studies

By EIL By Others Remarks

1 Rapid Environmental impact study Not the part of DFR. Being done

under separate job by EIL.

2 Site evaluation/selection Existing refinery area.

3 Evaluation/Selection of licensors Study report for units prepared by

individual unit licensors /designers.

4 Rapid Risk analysis RRA study and data collection are

included in EIL scope but not in

scope of DFR. RRA and EIA

studies are being done by EIL as a

separate job.

5 Route survey (for transport of ODC

materials from various ports / industrial

areas of the country.)

As per existing data.

Marine Survey-effluent dispersion study As per existing data.

6 Downtime assessment report (For

Revamp)

Only one Shutdown is envisaged

and shutdown time is targeted to

be approximately 45 days for all

modifications.








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4.1.2 Plant Location

Village City State Nearest Railway

Station

Agasod BINA M.P Bina

4.1.3 Land Availability Details (Refer existing plot plan)

Plot Area Road

1. Khasra Map, Land Survey

map to be furnished.

Length of connecting road

(between site and existing

main road). Kms

As per existing

plant

2. Soil investigation, site detailslike Extent/cost of land filling/

piling data, if available may be

furnished.

Rerouting Requirement

Rerouting of any existing

facilities like road, power

lines, drains etc. required/ not

required (if required, details of

the same may be furnished).

Rerouting of

existing facility

shall be

considered as

required

3. Land Rate (Rs per acre) Not

applicable

Met Data As per existing

plant

4. Land availability: Not

Applicable

Grid power

availability

Nearest Dist

Sagar

Grid

augmentation for220 kV is

envisaged to

receive 125 MW

power

Level

220kV

4.1.4 Raw Material

Name A. Design case: Crude Mix

For Overall Material balance across the refinery: The Arab Mix (65:35: AL: AH) crude based on Assay 2000 of

AL&AH is considered

Feed for specific units shall be as per the existing

design basis of the corresponding unit.

Source Pipeline








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Ch 4 Page 4 of 19


4.1.5 Products

Name

Product names, its slate post revamp and their

specifications are detailed in Section 4.2, and 4.3.

Annual Capacity

Market Place

(preferred)

4.1.6 Plant Units

Process

Units

Capacity Utilities to

be

generated

Capacity Catalyst / chemicals

Name Quantity Unit Rate

a) Existing unit capacity and post revamp capacities are given in Table

4.3 at the end of this chapter.

b) New utilities to be generated for post revamp capacity are detailed in

section 4.1.10. Catalyst and chemicals consumption will increase

proportionately depending on post revamp capacity

4.1.7 Offsite, Raw Material/ Product And Other Storages

Optimal storage for new facilities will be considered based on existing bestpractices in refinery project.

Details of existing tanks data is detailed in Annexure 4.1 at the end of this

chapter.

Materials

Raw Material Intermediate Products Finished Products

Name State

Liquid/

solid

No of

days of

storage

Name State

Liquid/

solid

No of

days of

storage

Name State

Liquid/

solid

No of

days of

storage

4.1.8 Hook Up Connection

Name Distance of connection from existing facilities

Not Applicable as not in DFR scope. (Shall

be done during design stage)








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4.1.9 Product Evacuation by Railway / Truck/ Pipeline

Product

Name

% of product

to be moved

by rail

% of product to

be moved by

road

% of product to

be evacuated

through Pipeline

% of product to

be evacuated

through Coastal

movement sea

tankers.

As per existing plant, Details are given in Annexure 4.1 at the end of this

chapter. However new pet coke rail and truck loading facility is considered

Length of rail to be laid/ distance between plant and railway

siding

As per existing

Details of any major crossing (river/road/rail) coming on the way

to Railway station to be considered as part of Project cost.

As per existing

4.1.10 Utilities

For Debottlenecking of Bina Refinery Project, New utility facilities are consideredwhich will be integrated with existing utility facilities.

4.1.10.1 Raw Water For Plant Operation

Source As per existing plant

Distance from river/sea As per existing refinery

Raw water Analysis (if

available)

As per existing plant

The existing raw water system will be adequate

for 30% increase in crude throughput with

additional pump similar to existing capacity.

4.1.10.2 Electric Power For Plant Operation

Source CPP+GridVolts At Design Stage

Frequency At Design Stage

Captive Power to be

generated

As required

Level of Generation As per existing








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Ch 4 Page 6 of 19


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








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Ch 4 Page 7 of 19


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.








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Ch 4 Page 8 of 19


4.1.11 Environmental Requirement

4.1.11.1 Effluent Specifications

Liquid Effluent MINAS ( Minimum National Standards)/State

Pollution Board Standards. Required facilities

for Zero Liquid effluent discharge shall be

considered.

Gaseous Effluent MOEF ( Ministry of Environment and Forest)

guidelines/State Pollution Board.

As per BORL Input max SO2 emission : 30 TPD

After expansion as per PFR SOX emissions are

estimated as 29.95 TPD which is in the limits ofmaximum permitted SOX emission from Bina

Refinery. This shall be further worked out during

detail feasibility report.

Soild Waste Disposal of hazardous waste as per guidelines

Stack height (Limitation to be

specified)

As per existing

Location of effluent discharge

& its distance from B/L of plant

As per existing refinery standard

Note: Details to be furnished below in case State Pollution Board specificationsexist

4.1.11.2 Green Belt Requirement

As advised by State

Government during site

selection visit.

The Green belt forms an integral part of the

approach to improve the environmental quality

and aesthetics of the plant area. As

debottlenecking would not require additional

area to be acquired, existing green belt area

shall be maintained.

4.1.12 Township

No new facility envisaged.








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4.2 PRODUCT SLATE

After implementation of the low cost expansion of refinery, the product slate

considering present products specifications is tabulated below:

This product slate will be further optimized and estimated based on yields

received from licensors for revamp case as well as test runs data received from

BORL.

Table 4.1: Product Slate (Shall be confirmed in DFR)

Product Existing Case(6 MMTPA)Capacity

KTPA

Post RevampCase

(7.8 MMTPA)Capacity

KTPA

% Increase

inProduction

LPG 222 344 55Naphtha 241 189 (-) 21Euro III Regular Gasoline 385 0 -Euro IV/V Regular Gasoline 400 1242 210 Aviation Turbine Fuel 550 722 31Kerosene 487 396 (-)18.6Euro III Diesel 1610 0 -

Euro IV /V Diesel 1181 3641 208Coke 410 3641 30Sulfur 109 523 27

4.3 PRODUCT SPECIFICATIONS

The product specifications (Manufacturing Specifications) adopted for this

Project are given as under.








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A. Liquefied Petroleum Gas (LPG):

Note:1. "Pass" test indicates Hydrogen Sulfide not more than 5 ppm.2. Product shall contain minimum 10 ppm Mercaptans as Sulphur at the first

dispatching location to ensure the detection of odour.

B. Naphtha

TEST SPECIFICATION

Vapour Pressure @ 40°C, KPa Max. 1050 (152 psi)

Free-Water Nil

Hydrogen Sulphide, ppmw (1) Pass

Mercaptan sulphur, ppmw (2) Max. 150

Copper Strip Corrosion (Bomb) 1 hr.@ 38°C

Max. No. 1 Strip

Volatility : Evaporation Temperaturefor 95%v, °C Max. 2

TEST UNIT SPECIFICATION

Distillation IBP, Min Deg. C 40 - 45

FBP, Max Deg. C 160

Sulphur (Total), Max ppm 100

Aromatics, Max % vol. 10

Olefins, Max % vol. 0.2

Density @ 15 deg.C gm/ml 0.66-0.72

Lead Content, Max ppm 1

Residue on Evaporation,

Max 100 ml 2RVP @ 37.8 Deg. C, Max. Kg/cm2 0.7

Net Cal Value, Min Kcal/kg 10200

Chlorides, Max ppm 0.2

Arsenic & Other (Sb,V,Hg,P)Catalyst Poisons

ppm Absent

C/H ratio - 5.3 - 5.6

Paraffins + Naphthenes % vol. 80 - 90

Water Content ppm Absent









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C. EURO IV/V Gasoline

*For Rail and Road dispatch

CHARACTERISTICS UNIT REQUIREMENTS

Unleaded

Regular Euro IV

BS 4+ ( Equivalent

to EURO V)

Colour, visual Orange Orange

Density @ 150C kg/m3 720-775 720-775

Distillation :

a) Recovery upto 700C (E 70) % volume 10-45 10-45

b) Recovery upto 100 C (E 100) % volume 40-70 40-70

c) Recovery upto 150 C (E150) % volume 75 min. 75 min.

d) Final Boiling Point (FBP), max C 210 210

e) Residue, max. % volume 2 2

a) Research Octane Number (RON), min 91.7/91.4* 91.7/91.4*

b) Motor Octane Number (MON), min. 81 85

Gum content (solvent washed), max. mg/100 ml 5 5

Oxidation stability, min. minutes 360 360

Sulphur, total, max. mg/kg 50 10

Lead content (as Pb), max. g/l 0.005 0.005

Reid Vapour Pressure (RVP), max. kPa 58 60

Vapour Lock Index (VLI)

a) Summer, max 750 750

b) Other months, max 950 950

Benzene Content, max. % volume 0.96 0.96

Copper strip corrosion for 3 hr. @ 500C,max.

rating Class 1 Class 1

Olefin content, max. % volume 21 18

Aromatics content, max. % volume 34 34

Oxygen content, max % mass 2.7 2.7

Oxygenates Content : % volumea) Methanol, max % volume 3 3

b) Ethanol, max. % volume 5 5

c) Iso-propyl alcohol, max. % volume 10 10

d) Iso-bytyl alcohol, max % volume 10 10

e) Tertiary-butyl alcohol, max % volume 7 7

f) Ethers containing 5 or more carbonatoms per molecule, max

% volume 15 15

g) Other Oxygenates, max % volume 8 8









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D. EURO IV/V Diesel

CHARACTERISTICS UNIT REQUIREMENTS

EURO IV EURO V Ash, max. % mass 0.01 0.01

Carbon residue(Ramsbottom) on 10%residue, max.

% mass0.3 withoutadditives

0.3 withoutadditives

Cetane number (CN), min. 51 54

Cetane Index (CI), min. 48 51

Distillation :

96% vol. Recovery at 0C,

max.

0C 360 360

Flash point :

a) Abel, min. C 35 35

Kinematic viscosity @400C

cst 2.0-4.5 2.0-4.5

Density @ 15 C kg/m3 822.5-845 822.5-845

Total sulphur, max. mg/kg 50 10

Water content, max. mg/kg 200 200

Cold filter plugging point(CFPP)

a) Summer, max C 18 18

b) Winter, max 0C 6 6

Total contaminations, max. mg/kg 24 24

Oxidation stability, max. g/m3 25 25

Polycylic AromaticHydrocarbon (PAH), max.

% mass 11 8

Lubricity, corrected wear

scar diameter (wsd 1,4) @600C, max. microns 440 440

Copper strip corrosion for3 hrs. @ 500C, max.

rating Class-1 Class-1









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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

product shall be 0.20 max.

F. AVIATION TURBINE FUEL

TEST SPECIFICATION

Density @ 15°C, kg/m3 Min. 775

Max. 840

Appearance Clear

Mercaptan Sulphur, %w Max. 0.0020

Copper Strip Corrosion(2 hr@ 100°C) Max. No.1 stripSulphur, Total %w Max. 0.235

Flash Point (Abel), °C Min. 39

Viscosity (Kinematic) @ -200C, MM2/S Max. 8.0

Freezing Point, °C Max. -47

Total Acidity, mg KOH/g Max. 0.015

Aromatics, %v Max. 20.6

Olefins, %v Max. 5

Smoke Point, mm Min. 19Naphthalene content, %v Max. 3.0









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Calorific Value, net Cals/kg Min. 10,225

Existent Gum (Steam Jet), mg/100 ml Max. 7

10% volume recovered @ °C Max. 205FBP, °C Max 300

Anti-Oxidant (Active Ingredient) mg/litre Max. 24.0

Doped Fuel, pico-siemens/meter Max. 450

Lubricity Max. 0.77 #

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

UnitsCapacity(MMTPA)

Post RevampCapacity(MMTPA)

Licensor

Crude / VacuumDistillation Unit

6.0 7.8EIL

Integrated FullConversionHydrocracker andDiesel Hydrotreater

1.952/1.6372.625/2.202

CLG

Delayed Coker Unit 1.357 1.822 ABBLummus

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

470 T/hr ofLean Amine

468T/hr of Lean Amine of 40 % MDEA

EIL

ATF Merox 0.55 0.711 UOPLPG treating unit 15.5 T/Hr 21.66 T/hr

EIL































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Ch 4 Page 15 of 19


Annexure 4.1

OFFSITE FACILITIES









Document No.

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Ch 4 Page 16 of 19


1. EXISTING STORAGE TANKS

Details of existing storage tanks in Refinery area is given as under

S No. Service

PumpableVolume( Volin between

LLL andHLL ofTank)

Type ofTank**

Tank SizeD X H

Curr ent

M3 Meter

1 CRUDE 3 54500 FR 68 X 20

2 VGO 3 15797 CR 40 X 143 HCGO 2+1 5220 CR 26 X 114 VR (DCU

FEED)2+1 12721 CR 40 X 12

5 DHDT FEED 3 12825 CR 38 X 13.56 NHT FEED 1 25971 FR 52 X 15.37 CCR FEED 1 3857 CR 24 X 118 HGU FEED 1 3813 DR 20 X 149 DRY SLOP 1+1 2116 FR 18 X 1210 BLACK

SLOP

1 1830 CR 14 X 13.3

11 ISOMERATE 2 3813 DR 20 X 1412 REFORMAT

E1 8418 FR 30 X 15

13 CDU/VDUIFO

2 1293 CR 14 X 10

14 REFINERYIFO

2 1615 CR 14 X 12

15 CRUDE/WATER

1 1200 CR 14 X 10

16 HCU LT

NAPHTHA

1 3813 DR 20 X 14

17 LCGO 1+1 4565 &12825

CR 24 X 12 &38 X 13.5

18 MTBE 1 3813 DR 20 X 1419 COKER

NAPHTHA1+1 3850 CR 24 X 11

** FR: Floating Roof, CR: Cone Roof, DR: Dome Roof

(Two MS tanks of existing capacity are envisaged after post revamp)









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Ch 4 Page 17 of 19


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









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Ch 4 Page 18 of 19


Sr.

No.

Service Product

PumpableVolume in KL

(Vol in between

LLL and HLL oftank)

Typeof

tank*

Tank Size

37 07B NAPHTHA 5300 FR 26m x 14.5m

38 07C NAPHTHA 5300 FR 26m x 14.5m

39 07D NAPHTHA 5300 FR 26m x 14.5m

40 08A SLOP 5300 CR 11m x 11m

41 08B SLOP 910 CR 11m x 11m

42

DU1H(UG

Tank) HSD - III/IV 95 UG 11m x3.2m

43

DU2M(UG

Tank) MS - III/IV 84 UG 11m x3.2m

44

DU3S(UG

Tank) SKO 95 UG 11m x3.2m

45

DU4A(UG

Tank ) ATF 95 UG 11m x3.2m

46

DU5N(UG

Tank) NAPHTHA 84 UG 11m x3.2m

47UG

Tank ETHANOL 84 UG 11m x3.2m

48UG

Tank ETHANOL 84 UG 11m x3.2m

49UG

Tank SLOP 18 UG 6.5m x2m

2. FEED RECEIPT AND PRODUCT DISPATCH FACILITIES

2.1 Existing Crude Receipt facilities

The project also involves a crude supply system consisting of a Single Point

Mooring system (SPM), Crude Oil Storage Terminal (COT) at Vadinar, District

Jamnagar, Gujarat and 24” diameter and 935 Km long cross country crude

pipeline from Vadinar to Bina. To transport the crude at desired pressure two

intermediate pumping stations are provided between cross country crude pipe

lines.









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Ch 4 Page 19 of 19


2.2 Proposed Augmented Crude Receipt facilities

Four crude tanks, each of 60000 m3 capacity are envisaged at the crude oil

terminal.

2.3 Product Dispatch Facilities

a. Pipelines for MS blend Component

One rail wagon unloading facility along with unloading pump, unloading pipeline

(10” size, of length of about 1-1.5 km) and transfer facility from BDT upto

Blendnig station/MTBE tank at refinery .

b. Rail Dispatch facility

As per existing. Post Debottlenecking additional facilities are envisaged.

c. Road Dispatch:

As per existing.







Market StudyDFR for Debottlenecking of


Document No.

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Ch 5 Page 1 of 2


SECTION 5

MARKET STUDY






Market StudyDFR for Debottlenecking of


Document No.

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Ch 5 Page 2 of 2


This section is excluded from the report as per the scope of work.






Project LocationDFR for Debottlenecking of


Document No.

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Ch 2 Page 1 of 2


SECTION 6

PROJECT LOCATION






Project LocationDFR for Debottlenecking of


Document No.

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Ch 2 Page 2 of 2


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:






Project DescriptionDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev A

Page 1 of 1


SECTION 7

PROJECT DESCRIPTION






Project ConfigurationDFR for Debottlenecking of


Document No.

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Ch 7.1 Page 1 of 7


SECTION 7.1

PROJECT CONFIGURATION








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Ch 7.1 Page 2 of 7


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




























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Ch 7.1 Page 3 of 7


DM water System

Condensate system

Fuel Gas and Fuel Oil System

Compressed Air SystemNitrogen System

Raw Water system

The utility systems are an integral part of the refinery and constructed on the

Refinery site. The refinery is self-sufficient in all its utility requirements except raw

water is brought from outside (Betwa River) the refinery.

Major utility systems of refinery are summarized below in table 7.1.2.

Table 7.1.2: Utility System

S no. Description Specification

1. Recirculating Cooling Water System

Post revamp, the design capacity of Refinery cooling water system : 28000m3/hr.

A Cooling TowerOne new and (6+1) existing cells of 4000 m3/hr

capacity each

B Cooling Water Pumps

One new and (3+1) existing Pumps of 8000

m3/hr capacity each.In addition to Refinery cooling water system, there is 30000m3/hr of cooling water

system in CPP which supplies cooling water to CPP and 4000m3/hr of cooling

water to refinery utilities blocks.

2. DM Water System

A RO DM Plant Post revamp capacity: 515m3/hr

BDM Water storage

Tanks2 nos. of 9000m3 cap. each

CDM Transfer Pumps

to Process (1+1) pumps of 250 m3/h cap. each

DDM Transfer Pumps

to CPP(2+1) pumps of 185 m3/h cap. each

3. Condensate System

ACondensate Polishing

unit

One new and existing two numbers (1w+1s)

each of 50m3/hr capacity

B

Condensate storage Feed tank 2 numbers of capacity 1700m3 each

and for suspect condensate.

For Polished condensate- 2 nos. 2800m3

capacity each








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A439-RP-02-41-0001Rev B

Ch 7.1 Page 4 of 7



C Condensate pumps (2+1) pumps of 95 m3/hr cap. each

4. Compressed Air System

Post Revamp Compressed air system comprises of :

Plant air capacity = 3530Nm3/hr

Instrument air capacity = 8810 Nm3/hr

One new + Three( 2 operating + 1 standby) existing Compressor of capacity

of 8825 Nm3/hr

Instrument air driers = One new and two existing of capacity of 5000 Nm3/hr

each

Emergency instrument air = 2 HP storage vessel for 30 minutes I.A

requirement for safe shut down (1 vessel for HCU+DHT unit + 1 vessel for

balance refinery facilities).

5. Nitrogen System

Nitrogen is required during catalyst regeneration, purging, blanketing etc.

One new and one existing Cryogenic Nitrogen plant capacity of

Gaseous Nitrogen = 1500 Nm3/hr existing and New plant will be of capacity

of 500Nm3/hr

Liquid Nitrogen = 225 Nm3/hr (Gaseous equivalent) and for new 75

Nm3/hr

6. Fuel Gas and Fuel oil System

Four Cone roof tanks for Fuel oil are situated in OSBL area, Two for CDU IFO

and other two for Refinery IFO.

For both CDU and refinery IFO, separate surge vessels each of 30 minutes hold

up are in Fuel oil system.

CDU IFO pumps : 1W+ 1S of 20m3/hr capacity each

Refinery IFO pumps : 1W+ 1S of 30m3/hr capacity each

7. Raw Water System

A Raw Water reservoir

2 Reservoir of Capacity 33450 & 62750 m3

(two days equivalent storage).

BRaw water treatment

plant

2 Raw water treatment plant of capacity 1500

m3/hr each

CTreated Water

Storage

Total capacity 22800 m3 equivalent to 12hrs of

normal demand.

D Treated water pumpsTotal 6 pumps, 4 operating and 2 Standby of

550m3/hr each

8. Captive Power Plant ( Fuel to CPP is coke )

A CFBC Boilers Three numbers (2w+1s) each of 225 TPH








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Ch 7.1 Page 5 of 7



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.

Oily effluent flow : 198 m3/hr (avg.)/ 375 m3/hr (design)

Sanitary flow : 25 m3/hr

Spent caustic flow : 7 m3/hr

CRWS : 25 m3/hr in dry weather and 1400 m3/hr in wet weather

7.1.3 Offsite Systems

The offsite systems in existing refinery comprises of:

Tank farm

Interconnection of process lines between process units

Product run down lines from refinery to Dispatch Terminal








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A439-RP-02-41-0001Rev B

Ch 7.1 Page 6 of 7


The tank farm which is integral part to the refinery caters to (i) Storage tanks of

crude feedstock, received through the crude pipeline, (ii) intermediate and

component storage needed for routine operations and blending.

The summary of feed and intermediate storage tanks and their pumps are

tabulated below:

Table 7.1.3 Offsite Tanks

S No. ServiceNos of Tank* /

Type of Tank**

Nos of Pump

( operating + standby)

FEED Storages

1 CRUDE 3 (E) + 1(N) / FR 2+1

Intermediate Storages

2 Vacuum Residue 2 (E)+1 (C) / CR 2+1

3 VGO 3(E)+1(N) / CR 2+1

4 HCGO 2(E)+1(C) / CR 1+1

5 DHDT FEED 3(E)+1(N) / CR 1+1

6 LCGO 2(E) 1+1

7 NHT FEED 1 (E)+1(N) / FR 1+1

8 CCR FEED 1 (E)+1(N) / CR 1+1

9 HGU FEED 1 (E)+1(N) / DR 1+1

10 HCU LT NAPHTHA 1 (E) / DR 1+1

11 COKER NAPHTHA 1 (E)+1(C) / CR 1+1

12 ISOMERATE 2(E) / DR 1+1

13 REFORMATE 1 (E)+1(N) / FR 1+1

14 CDU/VDU IFO 2(E) / CR 1+1

15 REFINERY IFO 2(E) / CR 1+1

16 CRUDE/WATER 1 (E)/ CR 1+1

17 DRY SLOP 1 (E)+1(C) / FR 1+1

18 BLACK SLOP 1 (E)/ CR 1+1

19 MTBE 1 (E)+1(N) / DR 1+1

*E: Existing, C: Under Construction, N : New

** FR: Floating Roof, CR: Cone Roof, DR: Dome Roof

7.1.4 Crude Receipt & Transport Facilities

The project also involves a crude supply system consisting of a Single Point

Mooring (SPM), Crude Oil Storage Terminal (COT) at Vadinar, District Jamnagar,

Gujarat and 24” diameter and 937 Km long cross country crude pipeline from

Vadinar to Bina. To transport the crude at desired pressure two intermediate

pumping stations are provided between cross country crude pipe line.








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A439-RP-02-41-0001Rev B

Ch 7.1 Page 7 of 7


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

envisaged.






Technology OptionsDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev A

Ch 7.2 Page 1 of 2


SECTION 7.2

TECHNOLOGY OPTIONS






Technology OptionsDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev A

Ch 7.2 Page 2 of 2


Since this project is debottlenecking of existing Bina refinery, technology options

are not considered. Same Technology is adopted for revamp of existing units.






Process DescriptionDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 1 of 19


SECTION 7.3.1

CRUDE VACUUM & NAPTHA STABILIZERUNITS








Document No.

A439-RP-02-41-0001Rev B


Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

7.3.1.0 CRUDE /VACUUM AND NAPHTHA STABILIZER UNITS

Crude Distillation Unit (CDU) of capacity 6MMTPA and Vacuum Distillation Unit

(VDU) and Naphtha Stabiliser unit of corresponding capacity of the Crude unit

capacity were successfully commissioned on 29 th June 2010. CDU unit consists

of Crude Preheat Section & single stage Electrostatic Desalter, atmospheric

column section. Vacuum distillation section and naphtha stabilization section

exist to process atmospheric residue and unstablised naphtha of atmospheric

column respectively. The schematic flow diagrams of CDU/VDU and naphtha

stabiliser are attached in Annexure-3.

This unit has been operated consistently at higher throughput and test run was

performed in Aug 2012 at 115% and 119% throughput to establish the unit

performance and identify the debottlenecks of the unit.

Under Debottlenecking of Bina refinery project, the capacity of CDU/VDU unit

shall be increased by 130% i.e. 7.8 MMTPA and therefore to explore technical

feasibility of 125% operation, the revamp process study is executed by EIL.

The revamp feasibility study as described in this section is performed to evaluate

unit performance and identify bottlenecks and necessary modifications for the

key systems and equipments.

The results of the preliminary adequacy check as described in this section shallbe further evaluated in details and confirmed during design stage.

7.3.1.1 BASIS OF REVAMP STUDY

Crude Throughput: 7.8 MMTPA (30% increase in existing capacity of 6MMTPA),

8280 on stream hours (345 days)

Crude Blend : 100 % Arab Mix (A 65:35 weight blend of Arab Light and Arab

Heavy Assay 2000)

Since Crude blend considered same as existing design crude blend, yield

patterns and product properties are kept same as existing.

Adequacy check has been carried out based on the as-built details of the

equipments and with the following philosophy :

It is presumed that all existing equipments are in good health and working

condition. Health check of existing equipments is excluded from existing scope

of work.

No de-ration of the equipment is considered for establishing adequacy.








Document No.

A439-RP-02-41-0001Rev B



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‖.

AIR COOLER








Document No.

A439-RP-02-41-0001Rev B



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


13 11-PA-CF-128 A/B

Recycle waterpump


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)








Document No.

A439-RP-02-41-0001Rev B



Water Pump4 Crude Desalter

1st stageNew crude desalter (similar to existing) to beinstalled in parallel to existing desalter.

5 Crude Desalter2nd Stage

New equipment

Vacuum Distillation Unit

S.NO

TAG NO DESCRIPTION MODIFICATION

COLUMNS

1 12-CC-00-101Vacuum

Column

Packing modifications: Replacement of Bedno2 and Bed no 4 with new packed bedBed No. Dia(mm) Height of bed in mm2 6000 20004 9200 1000

Replacement of the existing removable typechimney trays with new welded type chimneytrays with high riser area.

For Bed #1 - Bed #2 , CT dia is 5000m and Bed#3 to #6 is 9200mm.

VESSELS

1 12-VV-VI-106 CausticVessel

Dismantling of spray ring

EXCHANGERS

1 12-EE-00-105A/BHVGO

Cooler

One additional shell, identical to existing(size:850mm*6000mm,approx area 243m2/shell)

to be provided in series with existing 2 shells.

2 12-EE-00-106A/BVR+ SlopCooler

Two additional shells, identical to existing (size:575mm*6000mm, approx area 104 m2/shell) tobe provided in parallel to existing 2 shells.

AIR COOLERS 1 12-EA-00-109A-F Tempered

WaterCooler

One Additional Bay (same as existing size:5.8m*10.5m) to be provided.

FIRED HEATERS 1 12-FF-00-101 Vacuum

Heater

Additional 16 no tubes, Modification in fan and

burner, Replacement of stack damper.PUMPS 1 12-PA-CF-101A/B Vacuum Diesel

PumpImpeller change with new motor of ratedpower 330 kW

2 12-PA-CF-102A/B (LVGO IR+CR)Pump


3 12-PA-CF-103A/B (HVGOIR+CR) Pump

Impeller change with new motor of ratedpower 460 kW

4 12-PA-CF-104A/B Recycle Pump Impeller change with higher diameter5 12-PA-CF-105A/B (VR+ Quench)


6 12-PA-CF-106A/B Slop Oil Pump Impeller change with higher diameter7 12-PA-CF-107A/B Sour Water

PumpImpeller change with higher diameter








Document No.

A439-RP-02-41-0001Rev B



8 12-PA-CF-108A/B TemperedWater Pump


9 12-PA-CF-109A/B Vacuum DieselIR Pump


10 12-PA-CF-110A/B LVGO IR

Pump

Impeller change with new motor of rated

power 55 kW13 12-PA-CF-112A/B LVGO Product


14 12-PA-CF-113A/B HVGO ProductPump

Impeller change with new motor of ratedpower 160 kW

EJECTOR SYSTEM 1 12-LZ-101 Vacuum

Ejector systemEjector system needs modification (Note 1)

NEW EQUIPMENTS 1 Vacuum

Column OvhdCooling WaterBooster Pump

New pump ,

Capacity: 3782 m3/hr ,Head :61m, Motorpower 672 KW

2

Hotwell OffGas Amine Absorber

Dia=1500 mm Height(T/T)=18801 mmColumnType=Packed bedPacking:No of Beds Height2 Nos 4250 mm for each bed

Weight of column : 27000 Kg3 Rich Amine

Pumps

New pump

Capacity: 30m3/hr, Head :76.2m ,Motorpower 15 KW

NOTES 1. Replacement/modification of elements may be required along with new/modification

in precondenser, condensers and after condenser. Shall be confirmed during detailengineering.

Naphtha Stabilizer Section

SNO


COLUMNS

13-CC-00-101 Naphtha Stabiliser

20 Nos (Trays 1-20) of dia of 1600mm, Replaced with high capacitytrays23 Nos (trays 21-43) of dia of 2800mm Replaced with high capacitytrays.

Pumps

13-PA-CF-101 A/B

Stabiliser RefluxPumps


13-PA-CF-102

A/B

Sour LPG Pumps Impeller change with higher diameter








Document No.

A439-RP-02-41-0001Rev B



7.3.1.3 EQUIPMENT WISE ADEQUACY REPORT

Equipment wise adequacy is as detailed below:

Desalter

The existing unit has a single stage Desalter. To meet desalted crude saltcontent of 1.0ptb and BS&W of 0.05vol%, an additional first stage desalter

parallel to existing one and second stage desalter along with associated facilities

(new desalting water pump etc) are considered.

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 (package

details) of internals.

Crude Colum

The existing column diameter and trays are adequate to handle the revised

vapour/ liquid loadings except the following modifications:

Tray section # 15—17- Existing trays deck plates need to be changed with

new try deck plates with more number of valves.

Tray section # 25—27 & #36-38- Adequate after changing exit weir anddown-comer bottom clearance required.

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.








Document No.

A439-RP-02-41-0001Rev B



Riser area of chimney trays CT#1 to CT#6 (Chimney trays below Bed#1 to

Bed #6) to be increased from existing chimney tray area of 25% to 30% to

lower the pressure drop across chimney trays. In order to achieve this

increase in area, existing removable type of chimney trays need to bereplaced with new welded type chimney trays with higher riser area.

Naphtha stabilizer

The column is found adequate with replacement of existing trays with highcapacity trays.

Furnaces

The adequacy check of the furnaces has been carried out with the followingassumptions:

Clean heat transfer surface and performance of heater as per original

design with no deterioration in furnace/ heat transfer surface dimensions, no

tube bulging/ bowing etc.

No adverse operating feed back / limitation on the performance of rotating

equipment.

Burner performance is satisfactory (no flame impingement, no flame

overlapping etc.).

Crude Heater

Crude heater is checked for post revamp conditions as tabulated below:

Flow

TPH

Duty

MMkcal/hr

Temp Deg C

In Out

Existing Design 751.8 43.848 310 371

Post Revamp 751.8* 1.25 67.53 280 371

Vacuum Heater

Vacuum heater is checked for post revamp conditions as tabulated below:

Flow

TPH

Duty

MMkcal/hr

Temp Deg C

In Out

Existing Design 407.3 32.6 341.4 427.9

Post Revamp 407.3* 1.25 40.075 341.4 427.9

Modifications in Crude and Vacuum Heaters

The major modifications required in the crude heater and the vacuum heater forthe above post revamp conditions are as follows:

Augmentation of heat transfer area and associated modification in the radiant

section is envisaged. Additional 16 no. tubes (2 tubes per pass) with coil








Document No.

A439-RP-02-41-0001Rev B



size/MOC/Thickness/elevations same as existing are required to be provided in

the existing firebox (at heater arch and side walls connected with bridge floor).

Existing burners of the CDU/VDU heaters are found adequate to handle the

revamp loads for ―APH-inline‖ operation. For ―APH bypa

ss‖ operation burnersare required to be studied with OEM for modification/replacement to cater for

additional 5 % loadings.

Replacement of existing stack damper with new stack damper of existing details

(based on operating feedback from BORL)

The calculated coil side pressure drop of the crude and vacuum furnace shall

be of the order of ~16 Kg/cm2 and 10 kg/cm2.

Existing FD fans of the CDU/VDU heaters are found adequate to handle therevamp loads for ―APH-inline‖ operation.

For ―APH bypass‖ operation FD fans adequacy are as follows:

CDU Heater FD fans (11-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(Nm3/s)(Dry)

13.1 15.0 26.2 30.1 10.9 12.5 10.9 12.5

DischargePressure

(mm WC)

270 355 270 355 185 245 45 60

FindingsExisting fan is adequate to deliver all operating conditions except for maximum

capacity while one fan operating (i.e 30.1 NM3/S flow @ 355mmWC discharge

pressure). To achieve this condition too, existing 150KW motor needs to be

replaced with new motor of rated power 250 KW. In addition to this replacement/

rectification of some major component such as fan rotor, seals, couplings,

bearings, casing with inlet box & drain, evase, drive end side base frame is alsorequired.








Document No.

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Ch 7.3.1Page 10 of 19


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:








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A439-RP-02-41-0001Rev B

Ch 7.3.1Page 11 of 19


It is evident from above data that there is lot of deviation in operating and

design flow and duty particularly for HVGO PDT and LVGO/ HVGOPA whichare most contributing for preheat train II outlet temperature.

Adequacy of preheat train for operating and test run data shall be established

during design stage.

As per operational feedback, steam generation is on higher side due to higher

product withdrawal temperatures of LGO and HGO from column (280 degc as

against design temp of 265 degc for LGO and 339 degC as against design temp

of 319 degC for HGO). In anticipation of similar operation post revamp, new

exchangers LGO/Crude and HGO/Crude in the preheat circuit have been

considered for utilizing excess duty with maintaining existing steam generationquantities.

Feed/Bottom Stabilizer Exchangers are found to be adequate for 25 %

additional design flow and duty. Shell side and tube side pressure drop will be

1.5kg/cm2 and 0.7kg/cm2 respectively for revamped conditions.

Reboilers

The Kero reboiler(11-EE-00-117) and the Stabilizer reboiler(13-EE-00-104) are

found adequate for 25 % margin on design flow and duty.

Service

Design Actual % change

Flow

(T/hr)

Draw off

Temp.degC

Duty

(Gcal/hr)

Flow

(T/hr)

Draw offTemp.

degC

Duty

(Gcal/hr)

Flow/duty

CRUDE COLUMN

Col. Ovhd. 270 159 14.1 201 153 10.54 -25/-25

KERO 118 234 13.47 103 244 12.31 -12.7 /-8.6

LGO 87 254 4.59 97 278 6.53 11.5/ 42

HGO 35 308 3.0 58 336 6.05 65/ 100

KERO PA 372 198 13.4 314 201 12.55 -15.6 /-6.3

LGO PA 432 265 16 386 280 16.2 -10.6 /1.2

HGO PA 217 319 9 198 339 10.9 -8.7/21

VACUUM COLUMN

LVGO 95 254 4.94 62 246 2.94 (-34.7)/(-40)

HVGO 102 333 10.089 145 327 13.71 42/36

VD(PA+PD

274 126 8.19 180 136 6.26 (-34.3)/(-23.56)

LVGO PA 393 254 12.68 282 246 7.33 (-28.2)/(-42.19)

HVGO PA 500 333 17.71 354 327 19.4 (-29.2)/9.5

VR+ SLOP 167 350 16.42 148 350 14.56 (-11.4)/(-11.3)

VR 91 350 5.52 53 350 3.79 (-41.7 )/(-31.3)








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 12 of 19


Overhead circuit

The overhead and run down exchangers have been checked with 25 %

additional flow and duty. The overhead air cooler has been checked with design

air temperature of 45.6 deg C.

Crude Column Over head exchangers

The crude column reflux condenser(11-EE-00-101A/B) is found adequate but the

overhead naphtha main condenser (11-EA-00-125) is found thermally and

hydraulically limiting . One additional bay have been considered for the naphtha

main condenser and with reduced inlet temperature of trim condenser (11-EE-

116 A/B), exchanger is found adequate for the revamp load with cooling water

increase from 460m3/hr to 527.5m3/hr.

Stabilizer overhead Exchangers

Stabilizer overhead condenser (13-EE-AS-103 A/B) is found adequate for the

revamp duty with increased cooling water flow rate from 520 m3/hr to 690 m3/hr.

Products Run down Exchangers

The rundown circuit shell and tube exchangers and the air coolers have been

found adequate with minor increase in rundown temperatures or increased

cooling water flow rate as tabulated below:

Product Exchangers Findings/Modifications

Cooing water

m3/hr

Rundown Temp

degCExisting

Postrevamp

ExistingPost

revamp

StabilizedNaphtha

13-EA-00-10113-EE-102 A/B

Adequate 124.2 204.5 40 40

Kero 11-EA-00-128EE-00-124A/B

Adequate 150.4 230 40 42.5

LGO 11-EE-00-11811-EE-00-12111-EA-00-12611-EE-00-122

Adequate 97.2** 110 40 46

HGO 11-EE-00-11911-EE-00-120

11-EA-00-12711-EE-00-123

Adequate 41.7** 47.0 40 43

VacDiesel 12-EA-00-10712-EE-00-107

Adequate 237 237 40 39

LVGO 12-EE-00-10812-EA-00-108

Adequate NA NA 80 89*

HVGO 12-EE-105 A/B Adequate with oneadditional, identicalshell as existing

291.6 291.6 80 78*

VR+slop 12-EE-106A/B. adequate withadditional two extrashells identical tothe existing shells in

parallel to theexisting two shells

177 177 160 176

DesalterEffluent cooler

Adequate 159 239 60 60








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 13 of 19


*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








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 14 of 19


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

with OEM.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 15 of 19


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








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 16 of 19


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)


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)









Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 17 of 19


*Flow as per operational feedback (25% margin over operating flow based on Test Run Report)

VR + QuenchPumps( 12-PA-CF-105

A/B)

380 242 472 270 Existing motor (Rated Power: 385 kW) to bereplaced by new (Rated Power: 490 kW approx). Impeller change with higher diameter

Slop Oil Pumps(12-PA-CF-106 A/B)

11.8 178.1 12.5 184.3 Impeller replacement with higher diameter

Sour Water Pumps(12-PA-CF-107 A/B)


Tempered Water

Pumps(12-PA-CF-108 A/B)


Vacuum Diesel IRPump(12-PA-CF-109 A/B)


LVGO IR Pumps(12-PA-CF-110 A/B)

129 73.7 155 75 Existing motor (Rated Power: 37 kW) to bereplaced by new (Rated Power: 55 kW approx). Impeller change with higher diameter

LVGO PDT Pumps(12-PA-CF-112A/B)

135 189.7 161 214 Existing motor (Rated Power: 110 kW) to bereplaced by new (Rated Power: 132 kW approx).Impeller change with higher diameter

HVGO PDT Pumps(12-PA-CF-113 A/B)

147 238.1 176 261 Existing motor (Rated Power: 132 kW) to bereplaced by new (Rated Power: 160 kW approx). Impeller change with higher diameter.

NAPHTHA STABLIZER UNIT

Stabiliser RefluxPumps(13-PA-CF-101A/B)


Sour LPG Pumps(13-PA-CF-102A/B)

21.2 253 27 268.1 Impeller replacement with higher diameter








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 18 of 19


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.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.1Page 19 of 19


7.3.1.5 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 7.3.1 were checked for

and found feasible from construction and implementation point of view.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.2 Page 1 of 7


SECTION 7.3.2

Delayed Coker Unit








Document No.

A439-RP-02-41-0001Rev B



7.3.2.0 DELAYED COKER UNIT

A debottlenecking study for increasing the capacity of DCU from its current

operation of 1.36 MMTPA to 1.822 MMTPA of fresh vacuum residue feed is

performed by CB&I Lummus. The revamp study done by CBI Lummus includes

benchmarking of current operation, determining key revamp operating

parameters and yield structure and identification of bottlenecks and necessary

modifications for the key systems and equipments.

Delayed Coker Unit which is licensed by CBI Lummus includes Coker Heaters,

composed of two separate cabins with their own convection sections, common

APH, common stack, common ID/FD Fans; two Coke Drums; and a Coker

Fractionator with Side Strippers and a Vapor recovery section. The Vapor

recovery section consists of a Wet Gas Compressor, Stripper/Absorber, Sponge

Absorber and Debutanizer. The DCU Area features three auxiliary facilities: CokeDrum Blowdown System, Coke Cutting System including Water Circulating

Facilities and coke handling system. Process flow diagram as furnished along

with study report are given in Annexure 3.

7.3.2.1 FEASIBILITY STUDY REPORT

CB&I Lummus carried out revamp feasibility report for 134% increase in unit

throughput considering vacuum residue feedstock quality same as FEED case 2

( VR of 65% AL & 35% AH crude) of design package and feed CCR as

23.99wt% & API as 4.18.

For specified feed and considering no modifications in existing coke drums, the

confidential coking yield correlations were fine-tuned and simulation model was

updated to bench mark unit operation based on the results of the test run data

that has been performed in August 2012 in order to closely match plant

performance.

Lummus envisaged following operating parameters for 34% expanded capacity

due to system hydraulics and other design considerations.Coke Drum Pressure = 1.52-2.5 kg/cm2g

Main Fractionator inlet pressure = 1.17-2.15 kg/cm2g

Wet Gas Compressor Discharge pressure = 14.3 kg/cm2g

Wet Gas Compressor first stage inlet pressure = 0.16-1.5 kg/cm2g

Recycle ratio = 5%

Coke Drum Cycle = 18 hours

C3+C4 recovery = 90%

The remaining operating parameters are close to the original design case.

Revamp feasibility study submitted by Lummus comprises process evaluation

including key revamp operating parameters, yield structure and required








Document No.

A439-RP-02-41-0001Rev B



modifications along with preliminary engineering for two options i.e. i) coke drum

overhead pressure of 1.52kg/cm2g and ii) coke drum overhead pressure of 2.5

kg/cm2g.

In order to minimize fuel gas yield and coke make, option 1 of coke drumoverhead pressure of 1.52kg/cm2g is pursued for revamp of 34% increase in unit

capacity.

The key features and modification as reported in Lummus Revamp feasibility

report which are considered under this project are summarized below:

Post revamp yield pattern for coker overhead pressure of 1.52kg/cm2g are

tabulated below in Table 7.3.2.1.

Table7.3.2.1: Theoretical Yield (Wt% of Fresh Feed)

Coker Gas 6.57LPG 4.05Coker Naphtha (C5-140°C) 8.74LCGO (140°C-370°C) 31.58HCGO (370°C Plus) 19.18Coke 29.88

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.








Document No.

A439-RP-02-41-0001Rev B



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


FURNACE

114-FF-00-101A/B

Coker Heater

Radiant section: Replacement ofExisting Tubes change with Inconel800 material.Convection Section: Use of








Document No.

A439-RP-02-41-0001Rev B



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:








Document No.

A439-RP-02-41-0001Rev B



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

and alternations.








Document No.

A439-RP-02-41-0001Rev B




For the feasibility of implementation and constructability of all new/ modified

equipment were evaluated at site and following are the findings:

Wet Gas Compressor: There is space to locate shed of 8m width for new

WGC at the north side of existing shed & to accommodate it, existing staircase

on northern side of existing compressor shed will be needed to be relocated.

Blowdown Ring Compressor: The location of new blowdown ring

compressor is identified in west side of northern battery limits of pipe rack.

Vessels: Replacement of Recontact drum due to its size cannot be taken out

and replaced with new one. Therefore diameter of existing recontact drum

shall be retained ( To be confirmed by licenser during design stage) and length

of Recontact drum can be increased in situ.

It is more economical to increase the length of Compressor Inter-stage vessel

as required post revamp, at site instead of replacement with other vessel.

Debutanizer Overhead Receiver can be replaced with new vessel.

Other Equipments: Implementation/ constructability of all other equipments

(modified or new) were checked and found feasible.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 1 of 19


SECTION 7.3.3

HCU/DHDT








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 2 of 19


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

more conversion in Stage1.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 3 of 19


b) HCR Stage 2 Reactors (16-RB-00-201/202) : No changes in reactor internals

are expected. New generation catalyst ( ICR 250 is recommended having

higher size i.e “NAQ” from current” L” size.

c) DHT Reactor (16-RB-00-301) : No changes in reactor internals except

increase in sizes of orifice of reactor quench piping. New generation catalyst is

recommended having higher size i.e “NAQ” from current” L” size. New catalyst

system will provide lower activity with a lower hydrogenation and lower

pressure drop for higher capacity operation. Quench valve size to be increased

2. Make up Hydrogen Compressors (16-KA-RP-801A/B/C)

The adequacy of the makeup gas compressor has been checked by

compressor vendor based on the revamped operating conditions provided byLicensor. However, mechanical adequacy check of the subject compressor and

its associated system needs to be carried out and shall require the necessary

component modifications. This check will be carried out by vendor during

detailed engineering stage.

3. Recycle Gas Compressor (16-KA-CF-401A/B)

Since the adequacy for the RGC based on revamped conditions i..e flow: 496

KNm3/hr, suction / discharge pr: 150.3/ 186.3kg/cm2gas provided by licensor

could not be established by compressor vendor, the same shall be checked

during detail engineering. Cost provision for new RGC has been kept in the

feasibility report.

4. Heaters

The adequacy of hydrocracker furnaces have been checked based on the flow,

duty and inlet/outlet temperatures provided by CLG for each of the furnaces.

CLG has provided the preliminary adequacy of the heaters with respect to coil

change for reduction in pressure drop. EIL carried the detailed adequacy of the

furnaces to assess the constructability of the coil change and associated

changes in the auxiliaries.

1st Stage HCR Reactor Feed Heater (16-FF-00-101): 1st Stage HCR Reactor Feed

Heater is checked for post revamp conditions as tabulated below:

Flow

Kg/Hr

Duty

MMkcal/hr

Temp DegC DP

kg/cm2In Out

Existing Design 277743 8.4 370 402 4.9

Post Revamp 355106*1.

1

8.03 (10% overdesign

margin on revampduty of 7.2 MMKcal/hr

360 382 4.2








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 4 of 19


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.

- Calculated Pressure Drop: ~4.2Kg/cm2

2nd Stage Reactor Feed Heater (16-FF-00-201): 2nd Stage HCR Reactor Feed

Heater is checked for post revamp conditions as tabulated below:

Flow

Kg/Hr

Duty

MMkcal/hr

Temp DegC DP

kg/cm2In Out

Existing Design 208280 6.5 348 379 4.2

Post Revamp 239920 7.15 (10% overdesign

margin on revamp

duty of 6.5 MMKcal/hr

348 376 3.3

To achieve the revamped duty with reduction in the pressure drop, coil

modifications for the 2nd stage HCR reactor Feed Heater, augmentation of heat

transfer area and associated modification in the radiant section are envisaged.

The modification details are summarized below:








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 5 of 19


Fractionator Feed Heater (16-FF-00-501): Fractionator Feed Heater is checked for

post revamp conditions as tabulated below:

Flow

Kg/Hr

Duty

MMKcal/hr

Temp DegC DP

kg/cm2In Out

Existing Design 397378 44 300 393 5.2

Post Revamp 488950

44.75 (10% overdesign

margin on revamp duty of

40.68 MMKcal/hr

310 393 5.2

To achieve the revamped duty with reduction in the pressure drop coil

modifications for the Fractionator feed Heater augmentation of heat transfer area

and associated modification in the radiant section are envisaged.

The modification details are summarized below:



- No. of Cells: 2 (one each for

each pass)

- No. of coil passes: 2

- No. of tubes per pass/cell: 12

(total 24 tubes)

- Coil orientation: Horizontal

- Coil MOC: SS347H

- Coil OD: 7 inch (Non standard

Coil)- Coil thickness: 14.9 mm (MWT)

- Effective tube length: 12.8 m

- Tube Spacing:431.8 mm

- Tube Supports: Ladder Type

- Calculated Pressure Drop: 4.2

Kg/cm2

- No. of Cells: 2 (one each for each

pass)


- No. of tubes per pass/cell: 12 (total 24

tubes)


- Coil MOC: SS347H

- Coil OD: 8 inch (Non standard Coil)

- Coil thickness: 17 mm (MWT)- Effective tube length: 12.8 m


- Tube Supports: Tube supports to be

modified / replaced to suit new coil

configuration.

- Calculated Pressure Drop: ~3.3

Kg/cm2








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 6 of 19


DHT Fractionator Reboiler (16-FF-00-701) : For the revamp conditions as tabulated

below as per Licensor data there is no change expected in the heater duty as

column is modelled utilizing design margins available in furnace.

Flow

Kg/Hr

Duty

MMkcal/hr

Temp DegC DP

kg/cm2In Out

Existing Design 252734 9 321 351 5.3

Post Revamp 278000 9.0 303 338 5.3

5. Columns

The trays / packing of the all columns have been checked based on the loads

provided by Licensor in the report & subsequent discussions & correspondences

with Licensor. Findings for each column are tabulated below:

Columns Post Revamp Data Modifications

16-CC-00-401 High

Pressure H2S Absorber

Tray 1-10: 16% higher vapor & liquid load

than existing design

Dia =2440 mm

Trays modifications:Existing 10 no of trays (Tray 1 to




pass)


- No. of tubes per pass/cell: 20

(total 80 tubes)


- Coil MOC: SS347H

- Coil OD , Coil thickness& Tube

spacing : (20 nos. tubes per

pass) 8”NB SCH40 coils spaced

on 2D/3D spacing.



- Tube Supports: Ladder Type

- Calculated Pressure Drop: 5.2

Kg/cm2


pass)


- No. of tubes per pass/cell: 18 (total 72

tubes)


- Coil MOC: SS347H

- Coil OD , Coil thickness & Tube

spacing :7 nos. per pass of 8”NB

SCH40 and 11 nos. per pass of

10”NB SCH40 spaced on 2D/3Dspacing



- Tube Supports: Tube supports to be

modified / replaced to suit new coil

configuration.

- Calculated Pressure Drop: ~5.2

Kg/cm2








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 7 of 19



10) need to be replaced withnew high capacity trays as per

Licensor16-CC-00-402 LowPressure H2S Absorber

Packing; 30% higher vapor load thanexisting design & liquid load is same asexisting design.

As Existing

16-CC-00-403 LP Ammonia and WashWater Column

Packing:30% higher vapor & liquid loadthan existing design

As Existing

16-CC-00-501 HCRProduct Stripper

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.

16-CC-00-503Kerosene side cutStripper

Tray 1-10: 50% higher vapor & liquid loadthan existing design

Dia =1680 mmTrays modifications:Existing 10 no of trays (Tray 1to 10) need to be replacedwith new high capacity trays.

16-CC-00-504 LightDiesel side cut

Stripper


Dia =2740 mmTrays modifications:

Existing 10 no of trays (Tray 1to 10) need to be replacedwith new high capacity trays.

16-CC-00-505 HeavyDiesel Stripper


Dia =1680 mmTrays modifications:Existing 10 no of trays (tray 1 to10) need to be replaced withnew high capacity trays.

16-CC-00-601Deethanizer

Tray 1- 34: 33% higher vapor & liquidload than existing design

As Existing

16-CC-00-602Sponge Oil Absorber

Packing: 33% higher vapor & liquid loadthan existing design

Packing modifications:Replacement of Bed # 2 of dia

760 mm & height 6400 mm.16-CC-00-603 Tray 1-42 : 33% higher vapor & liquid Dia =1680 mm








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 8 of 19



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

16-CC-00-604Naphtha Splitter

Tray 1-32 : 33% higher vapor & liquidload than existing design.

Dia =2290 mmTrays modifications:Existing 32 no of trays (Tray 1 to32) need to be replaced withnew high capacity trays.

16-CC-00-701 DHTProduct Stripper

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 design.Liquid re distributor: 30%higher vapor &liquid load than existing design.

Dia =920 mmTrays modifications:Existing 5 no of trays (Tray 1 to5) deck plates need to bereplaced with new tray deckplates with more no of valves.

16-CC-00-702 DHTFractionator Bottom section: 30% higher vapor & liquidload than existing design. Above flash zone: 30% higher vapor &liquid load than existing design.

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.

16-CC-00-703 DHTKerosene side cutStripper

Tray 1-8 : 30% higher vapor & liquid loadthan existing design.

Dia =1060 mmTrays modifications:Existing 8 no of trays (Tray 1 to

8) need to be replaced withnew high capacity trays.

6. Vessels

Adequacy of vessels has been checked based on operation feedbacks and from

process point of view. All vessels are adequate from process point of view except

replacement of the caustic washer (16-VV-VW-603) and LPG coalescer (16-VV-VW-

605) with larger vessel. The other modifications of vessels as tabulated below are

based on operational feedbacks:








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 9 of 19


Vessels Post Revamp Modifications

16-VV-VI-401Cold High Pressure Separator 401

New Generation Coalescer pad to beconsider (typical York pads)

16-VV-VI-404Cold Low Pressure Separator New Generation Coalescer pad (typicalYork pads) to be considered16-VV-VI-603Caustic Washer Drum

Replaced by new drumShell dia.* height: 2000mm*6000mmWT=11 MTNew Generation Coalescer pad (typical York

pads) to be considered16-VV-VI-604Water Washer Drum

New Generation Coalescer pad (typical Yorkpads) to be considered.

16-VV-VI-605LPG Coalescer

Replaced by new vesselShell dia.* height: 2000 mm*6000 mm

Wt=11.5 MT.16-VV-HW-607Naphtha Splitter Reflux Drum

New boot added of dia. 610 mm & length1400 mm

16-VV-HW-714DHT Fractionator Overhead Accumulator

Boot replaced with higher dimension of dia.610 mm & length 1400 mm

7. Pumps

The adequacy of pumps has been checked based on process data provided by CLG

in their report,HP pump vendor inputs ,hydraulics done by EIL for LP section pumps

& various discussions & correspondences’ with CLG. The adequacy report is

summarized below:

Pumps Post Revamp Data Adequacy Results

16-PA-CF-101A1stStage HCR ReactorFeed Pumps

Existing: Flow: 311.5 m3/hr.Diff. Head: 2405 mPost RevampFlow: 405 m3/hrDiff. Head: 2402 m

Replaced with New (Flow:445 m3/hr, Head: 2415m,Motor Power: 3685 Kw) &new PRT.

16-PA-CF-101 B 1stStage HCR Reactor

Feed Pumps

Post RevampFlow: 405 m3/hr

Diff. Head: 2402 m

New

16-PA-CF-102A/BBackwash OilPumps

Same as existing As Existing

16-PA-CF-201A/B2nd Stage HCRReactor FeedPumps

Existing: Flow: 272 m3/hrDiff. Head: 2714 mPost RevampFlow: 327m3/hr.Diff. Head: 2998 m

Impeller change with motorreplacement of 2800 KW

16-PA-CF-301A/BDHT Reactor FeedPumps

Existing: Flow: 282 m3/hr.Diff. Head: 2318 mPost RevampFlow: 367 m3/hr.

Impeller change with motorreplacement of 2700 KW.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 10 of 19



Diff. Head: 2370 m16-PA-RP-401A/B

Injection WaterPumps

Same as existing As per Licensor, one New

Pump 401 C added(Flow:12 m3/hr,Head:1626m, Motor Power :160 Kw)

LP Lean AminePumps16-PA-CF-402A/B

Existing: Flow: 32.2 m3/hr.Diff. Head: 297 mPost RevampFlow: 35.42*1.1 m3/hr

Diff. Head: 297 m

As Existing

16-PA-CF-403A/BHP Lean Amine HP

Pumps

Existing: Flow: 299.2 m3/hr.Diff. Head: 1559 m

Post RevampFlow: 299.2*1.1m3/hr.Diff. Head: 1560.9 m

As Existing

16-PA-CF-404A/BWash Water Pumps

Existing: Flow: 4.6m3/hr.Diff. Head:271 mPost RevampFlow: 6 m3/hr.Diff. Head: 277 m.

Impeller change with motorreplacement of 8 HP

16-PA-CF-501A/BProduct StripperReflux Pumps

Existing: Flow: 70.7 m3/hr.Diff. Head: 27 mPost Revamp

Flow:115 m3/hr.Diff. Head: 76 m

Replaced with New(Flow: 116.6 m3/hr, Head:73 m, Motor/ turbine Power

: 37 KW)

16-PA-CF-502A/BNaphtha RefluxPumps

Existing: Flow: 326 m3/hr.Diff. Head: 102 mPost RevampFlow: 424*1.1 m3/hr.Diff. Head: 85.3 m

Adequate

16-PA-CF-503A/BFractionatorOverhead Water

Pumps

Existing: Flow: 11.1m3/hr.Diff. Head: 61 mPost Revamp

Flow: 14.43*1.1m3/hr.Diff. Head: 63 m

Adequate

16-PA-CF-504A/BKerosene ProductPumps

Existing: Flow: 22.1 m3/hr.Diff. Head: 98 mPost RevampFlow: 33.15*1.1 m3/hrDiff. Head: 140.1 m

Impeller change

16-PA-CF-505A/BLight Diesel Pumparound Pumps


Flow: 336*1.1 m3/hr.Diff. Head: 109.2 m

Impeller change with motorreplacement of 110 Kw








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 11 of 19



16-PA-CF-506A/BLight Diesel Product

Pumps


Post RevampFlow: 197 m3/hr.Diff. Head: 140.2 m

Impeller change

16-PA-CF-507A/BDiesel Pump aroundPumps

Existing: Flow: 449.9 m3/hr.Diff. Head: 152 mPost RevampFlow: 540*1.1 m3/hr.Diff. Head: 147.5 m

Impeller change

16-PA-CF-508A/BHeavy Diesel

Product Pumps B


Post RevampFlow: 132*1.1 m3/hrDiff. Head: 208 m


16-PA-CF-509A/BFractionator BottomsPumps

Existing: Flow: 289.9 m3/hr.Diff.Head: 163 mPost RevampFlow: 348*1.1m3/hr

Diff. Head: 172 m

Impeller change with motor& Turbine replacement of300 Kw .

16-PA-CF-601A/BSponge AbsorberBottoms Pumps


Flow: 35.5*1.1 m3/hr.Diff. Head: 67 m

Replaced with New(Flow: 39.1 m3/hr, Head: 67m ,Motor Power :15 Kw)

16-PA-CF-602A/BDeethanizer RefluxPumps

Existing: Flow: 79.8 m3/hr.Diff. Head: 87 mPost RevampFlow: 107.8*1.1 m3/hr.Diff. Head: 87.2 m

Impeller change

16-PA-CF-603A/BDeethanizerBottoms Pumps

Existing: Flow: 91.1 m3/hrDiff. Head: 43 mPost Revamp


Impeller change

16-PA-CF-604A/BDebutanizer RefluxPumps

Existing: Flow: 41.3 m3/hr.Diff. Head: 234 mPost RevampFlow: 56*1.1 m3/hr.Diff. Head: 241 m

Impeller change

16-PA-CF-605A/BNaphtha SplitterReflux Pumps

Existing: Flow: 90 m3/hr.Diff. Head: 159 mPost RevampFlow: 121*1.1 m3/hr.

Diff. Head: 160 m

Impeller change

16-PA-CF-606A/B Existing: Flow: 92.6 m3/hr. Impeller change with motor








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 12 of 19



Naphtha SplitterBottoms Pumps

Diff. Head: 300 mPost Revamp


replacement of 125 Kw

16-PA-CF-608A/BSponge Oil AbsorberReflux Pumps

Existing: Flow: 23.6 m3/hr.Diff. Head: 57 mPost RevampFlow: 30.7*1.1 m3/hr.Diff. Head: 71 m

Impeller change

16-PA-CF-609A/BMake Up CausticPumps

Same as Existing As existing

16-PA-CF-610A/B

Caustic WasherCirculation Pumps

Existing: Flow: 10 m3/hr.

Diff. Head: 41 mPost RevampFlow: 13*1.1 m3/hr.Diff. Head: 45 m

Replaced with New

(Flow: 14.3 m3/hr, Head: 45m ,Motor Power : 5.5 Kw)

16-PA-CF-611A/BWater Washer FeedPumps


16-PA-CF-612A/BDegassed CausticPumps

Same as Existing Adequate

16-PA-CF-701A/B

DHT ProductStripper RefluxPumps

Existing: Flow: 14.2 m3/hr.

Diff. Head: 75 mPost RevampFlow: 23.4 *1.1 m3/hr.Diff. Head: 87 m

Replaced with New

(Flow: 23.4 m3/hr, Head:87.7 m Turbine & MotorPower : 37 Kw))

16-PA-CF-702A/BDHT Naphtha RefluxPumps

Existing: Flow: 60.8 m3/hr.Diff. Head: 81 mPost RevampFlow: 79.04*1.1 m3/hr.Diff. Head: 81m


16-PA-CF-703A/B

DHT FractionatorOverhead WaterPumps


16-PA-CF-704A/BDHT KeroseneProduct Pumps

Existing: Flow: 6 m3/hr.Diff. Head: 128 mPost RevampFlow: 9*1.1 m3/hr.Diff. Head: 135 m

Impeller change

16-PA-CF-705A/BDHT FractionatorBottoms Pumps

Existing: Flow: 731.4m3/hr.Diff. Head: 210 mPost Revamp


Impeller change








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 13 of 19



16-PA-CF-813A/B

Sour Water Pumps

Existing: Flow: 40 m3/hr.

Diff. Head: 63.9 mPost RevampFlow: 67.22 m3/hDiff. Head: 54.5 m

Adequate

8. HP Exchangers

The adequacy for the HP Exchangers has been carried out by CLG and their

recommendations are tabulated below:

Addition of a new HP exchanger in the MUG compressor discharge circuit is

proposed post revamp.

HP Exchanger Adequacy Results as per Licensor

16-EE-00-105A-B1st Stage Reactor Feed /Effluent Exchanger

Replacement with new for costpurpose, Mechanical Integrity to bechecked with respect to vibrations

16-EE-00-106Inter Reactor Effluent/Fractionator FeedExchanger

Adequate, Mechanical Integrity to bechecked with respect to vibrations

16-EE-00-1071st Stage Reactor Effluent/DHT ReactorFeed Exchanger

Adequate, Mechanical Integrity to bechecked with respect to vibrations

16-EE-00-1081st Stage Reactor Effluent/FractionatorFeed Exchanger

Adequate, , Mechanical Integrity to bechecked with respect to vibrations

16-EE-00-1091st Stage Reactor Effluent Steam Generator


16-EE-00-2012nd Stage Reactor Feed/Effluent Exchanger


16-EE-00-202A-B2nd Stage Reactor Effluent/FractionatorFeed Exchanger


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


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

16-EE-00-402

1st Stage HHPS Vapor/Feed GasExchanger

New Heat Exchanger considered with

30 % higher weight of existing bundlesfor cost purpose , Mechanical








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 14 of 19


Integrity to be checked with respect tovibrations

EE-00-403Make Up Hydrogen/Cooling Water

New Exchanger With followingSpecifications

Type: AEL,No of Shells: One Area: 81m2

9. LP Exchanger

All the LP exchangers are found adequate with nozzle modifications, tube pass

modification and addition of shell in series /parallel wherever required. Replacement

of exchangers in five cases is considered (mainly reboilers) and two new LP

exchangers are added.

The LP exchangers have been checked based on the data provided by CLG in their

report, adequacy checks done by EIL & various discussions & correspondences’

with CLG. The adequacy report is summarized below:

LP Exchangers Post Revamp Data Adequacy Results

16-EE-00-101Common HCR-DHTCold Feed Heater

Same as existing As existing

16-EE-00-102HCR Feed/Light DieselExchanger

Existing Duty : 4 MMKcal/HrRevamp Duty : 5.5 MMKcal/Hr

Tube side Inlet/Outletnozzle Sizes to beincreased to 10”/10” fromexisting 8”/8”.

16-EE-00-103HCR Feed/HeavyDiesel Exchanger

Existing Duty : 1.7 MMKcal/HrRevamp Duty : 2.3 MMKcal/Hr


EE 104HCR Feed /Frac BottomExchanger -

Duty: 1.7MMKcal/hr New Exchanger Withfollowing SpecificationsType: AES,No of Shells: OneSize: 725*3000mm

Area: 65m216-EE-00-302DHT Feed/ DieselProduct Exchanger


Replaced with new Area: 650 m2/shellSize: 1350mm x 6000mmNo of shells : 1

16-EE-00-405Treated CLPS Vaporcooler


Adequate

16-EE-00-406Lean Amine Heater

Duty: 5.6 MMKcal/Hr Adequate

EE 407

Injection Water Cooler

Duty:0.67MMKcal/hr New Exchanger With

following SpecificationsType: AES,








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 15 of 19


No of Shells: OneSize: 575*6000mm Area: 110m2

16-EE-00-503

Kerosene StripperReboiler

Existing Duty:1.5 MMKcal/Hr

Revamp Duty: 2.2 MMKcal/Hr

Replaced with new

Area: 60 m2Size: 800mm x2500mmNo of shells : 1

16-EE-00-505Kerosene ProductWater Cooler

Existing Duty: 0.2 MMKcal/HrRevamp Duty: 0.26 MMKcal/Hr


16-EE-00-506Light Diesel Stripper

Reboiler

Existing Duty:7.6 MMKcal/HrRevamp Duty: 7.4 MMKcal/Hr

Adequate

16-EE-00-508Light Diesel ProductWater Cooler

Existing Duty: 1.1 MMKcal/HrRevamp Duty: 2.3 MMKcal/Hr


16-EE-00-511Heavy Diesel ProductWater Cooler

Existing Duty : 0.9 MMKcal/HrRevamp Duty: 1.55MMKcal/Hr

Tube pass modificationfor changing 4 pass to 2pass

16-EE-00-512MP Steam Generator

Duty: 5.49MMkcal/hr Adequate as per Licensor

16-EE-00-514A/B

Heavy DieselProduct/BFWExchanger

Existing Duty : 4.20 MMKcal/Hr

Revamp Duty : 4.55 MMKcal/Hr

Adequate

16-EE-00-601A/BDeethanizer OverheadCooler


Adequate

16-EE-00-602Deethanizer Reboiler


Replaced with new Area : 265 m2/shellSize : 1150mm x4000mmNo of shells : 1

16-EE-00-603A/BDebutanizer OverheadCooler

Existing Duty :2 MMKcal/HrRevamp Duty : 2.66 MMKcal/Hr


16-EE-00-604Debutanizer Reboiler


Replaced with new Area : 155 m2Size : 1025mm x3000mmNo of shells : 1

16-EE-00-606 Naphtha

Splitter Reboiler

Existing Duty : 5.5 MMKcal/Hr

Revamp Duty : 7.12 MMKcal/Hr

Replaced with new

Area : 185 m2Size : 1250mm x








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 16 of 19


3000mmNo of shells : 1

16-EE-00-607Light Naphtha Product

Cooler


Adequate

16-EE-00-609AB HeavyNaphtha Product WaterCooler



16-EE-00-610Sponge Oil/NaphthaExchanger


Adequate

16-EE-00-612Sponge Oil Absorber

Overhead Cooler


Additional shell Area : 72

m2/shellNo of shells : 116-EE-00-702DHT FractionatorFeed/Bottoms

Adequate as per Licensor

16-EE-00-704DHT Diesel Product/BFW Exchanger



16-EE-00-706DHT Kerosen Sidecut

Stripper Reboiler


Adequate

16-EE-00- 708DHT Diesel WaterCooler


Tube side Inlet/Outletnozzle Sizes to beincreased to 10”/10” fromexisting 8”/8”. Also tube passmodification for changing4 pass to 2 pass

10. Air Coolers

The reaction effluent air cooler (16-EA-FN-403) in the HP section is found adequate

with replacement of motors of fans from 30 HP to 40 HP.

All other air coolers in the LP section are found adequate with replacement of fan or

addition of bay wherever required.

One additional air cooler has been considered in LT diesel pump around circuit.

The LP air coolers have been checked based on the data provided by Licensor ,

adequacy checks done by EIL & various discussions & correspondences’ with

CLG.The adequacy report is summarized below:








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 17 of 19


Air Coolers Post Revamp Data Adequacy Results

16-EA-FN-110

Backwash Oil AirCooler

Revamp Duty: 7.1 MMKcal/Hr

same as existing

Adequate

16-EA-FN-403Reactor Effluent AirCooler

Duty: 27.8MMKcal/hr Motor replacement of 40HP for air temp of42degC.

16-EA-FN-404HCR HLPS Vapor AirCooler

Existing Duty : 2.8 MMKcal/HrRevamp Duty: 4 MMKcal/Hr

An additional bay(identical to existing bayie 5.0 m*8.5 m) to beconsidered.

16-EA-FN-501Product StripperOverhead Air Cooler

Existing Duty : 9.8MMKcal/HrRevamp Duty: 12.74 MM Kcal/Hr

An additional bay added(identical to existing 2bays each bay of ie 5.4m*8.5 m) to beconsidered.

16-EA-FN-502FractionatorOverhead Air Cooler

Existing Duty : 33.90 MM Kcal/HrRevamp Duty: 32 MM Kcal/Hr

Adequate

16-EA-FN-504Kerosene Product Air

Cooler

Existing Duty : 1.4 MM Kcal/HrRevamp Duty: 1.82 MM Kcal/Hr

Adequate

16-EA-FN-507Light Diesel Product Air Cooler


Adequate

16-EA-FN-510Heavy Diesel Product Air Cooler

Existing Duty:3.94 MM Kcal/HrRevamp Duty: 5.24MMKcal/Hr

Adequate

16-EA-FN-513Fractionator BottomsProduct Air Cooler

Duty : 19.6 MMKcal/hr same asexisting

As existing

16-EA-FN-514Lt Diesel Pump Around Air Cooler

Duty: 3.45MMkcal/hr New Air cooler Withfollowing SpecificationsNo of bays/unit: oneNo of bays/bundle: one Approx Dimension:3.0 mx6.5 m Area: 80 m2

16-EA-FN-605Naphtha SplitterOverhead Cooler


An additional bay added(Identical to existing 2bays each bay of i.e 5.3

m*10.5 m) to beconsidered .








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 18 of 19


Air Coolers Post Revamp Data Adequacy Results

16-EA-FN-608Heavy Naphtha

Product Air Cooler


Adequate

16-EA-FN-701DHT Product StripperOverhead Cooler

Existing Duty : 2.9 MMKcal/HrRevamp Duty: 3.77 MM Kcal/Hr

Motor replacement of 30HP

16-EA-FN-703DHT FractionatorOverhead Air Cooler

Existing Duty : 6.10 MMKcal/HrRevamp Duty: 7.93 MMKcal/Hr

Motor replacement of 50HP

16-EA-FN-707DHT Diesel Product

Air Cooler

Existing Duty:12.45 MMKcal/HrRevamp Duty: 14.32 MMKcal/Hr

Adequate

11. Miscellaneous Systems

The new facilities as per client operational constrain and based on licenser

recommendations are considered as tabulated below:

Miscellaneous Adequacy Results

16-GN-00-1011st Stage HCR FeedFilter

One additional bank similar to existingbanks

16-GN-00-301 DHT Feed Filter One additional bank similar to existingbanks16-VV-VW-405Low Pressure Centrifugal Separator

Replaced by new

16-VV-VW-402High Pressure Centrifugal Separator

Replaced by new

16-VV-VW-104ABackwash Oil Surge Drum

New Backwash Oil Surge Drum similarto existing (16-VV-VW-104)

16-EA-FN-110ABackwash Oil Air Cooler

New Backwash Oil Cooler (16-EA-FN-110) similar to existing

16-PA-CF-102A/B (N)

Backwash Oil Pumps

New Backwash Oil Pumps (16-PA-CF-

102A/B) similar to existing






equipments.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.3 Page 19 of 19


The modifications /new facilities as detailed above were checked and found

feasible from construction and implementation point of view with the following

observations:

The existing structure to be extended to accommodate one additional bay in

Naphtha splitter overhead cooler (16-EA-FN-605). For extension of structure one

exchanger (16-EE-00-610) has to be relocated adjacent to (16-EE-00-601A).

Structural work is envisaged for carrying out the modifications listed above (like

making of new tech structures to accommodate new bays of air coolers,

relocation of staircase etc.).

Piping rerouting/modifications shall be required wherever new

vessels/exchangers/air coolers/pumps are to be accommodated






Process Description

DFR for Debottlenecking ofBharat Oman Refineries Limited

Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 1 of 11


SECTION 7.3.4

MS BLOCK






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 2 of 11


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

considered in detail feasibility report.






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 3 of 11


7.3.4.2 FEASIBILITY STUDY REPORT

The outlines of Feasibility study report of MS block as furnished by UOP are

presented in next section.

1. Naphtha Hydro Treating Unit (NHT)

The UOP Naphtha Hydrotreating unit is a catalytic process that removes organic

sulfur, oxygen and nitrogen from the naphtha streams. Process flow scheme as

furnished by UOP in their report is attached in Annexure 3.

The key features and modification as reported in UOP Revamp feasibility report

which are considered under this project are summarized below:

The unit has been checked to process approximately 1,450,234 MTPA naphtha

feed (@8280 hours per year operation, approximately 145% of original design

feed rate) consisting of 1,081,362MTPA of straight run naphtha, 213,682MTPA of

HCU light naphtha and 155,189 MTPA of HCU heavy naphtha.

The naphtha feed spec considered is same as original naphtha feed composition

except that the sulfur and the N2 of the blended feed to be considered as 500

ppmwt sulfur and 2 ppmwt Nitrogen.

The product specifications considered for NHT revamp are:

i) Naphtha Splitter overhead liquid: 5.63 wt% C7+to maintain 10 wt % C7+ in

Depentaniser bottom.

ii) Naphtha Splitter net bottom liquid: 0.5 vol% max benzene precursor.

iii) Sulfur and N2 less than 0.5 wt ppm.

Reactors (19-RB-00-101) : The existing reactor is suitable for the NHT revamp

conditions without internals modification. The reactor needs new charge of catalyst

(HYT-1119) and new catalyst volume and three layers of top graded beds (Cat

Trap 10, Si Trap 30 and TK-437).

Make up Hydrogen Compressors (19-KA-RP-101A/B): Existing Recycle

Compressor has been evaluated based on the required revamp operating

condition and found to be adequate to handle the increased inlet volumetric

capacity. Based on the preliminary evaluation, the motor appears to be adequate.

The existing motor power rating is 320 kW whereas the revamp brake horse power

is 226 kW.

Stripper Reboiler Heater (19-FF-00-102): It was found inadequate with regards to

burner capacity to provide revamp duty of 8.59MMkcal/h as against original design






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 4 of 11


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.


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


Table 7.3.4.1.: List Of New/Modified EquipmentsSLNO


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

2

19-EE-00-102Stripper Feed-SplitterBottoms Exchanger

Replaced by larger exchanger

Area-52.6 m2No of shells : 1






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 5 of 11


3

19-EE-00-104Naphtha Splitter BottomsCooler

Requires two Identical Shells in parallel Area-356.8 m2Size: 600mm*6000mmNo of shells : 2

AIR COOLERS

119-EA-00-103

Naphtha SplitterCondenser

Post revamp- Two additional bays sameas existing (5.8m*10.5m) are required

PUMPS

119-PA-CF-101A/B Charge Pumps

Impeller of higher dia with new motor of510 KW

219-PA-CF-102A/B

Wash Water InjectionPumps

Replaced by New pump(Flow-7.72m3/hr; head 366.1m; Power-30 KW)

319-PA-CF-104A/B

Naphtha Splitter BottomsPump

Impeller of higher dia with new motor of300 KW

4 19-PA-CF-105A/B Naphtha SplitterOverhead Pump Impeller of higher dia with new motor of110 KW

NEW EQUIPMENTS

1

19-FF-00-103BNaphtha SplitterReboiler AuxilliaryHeater

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






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 6 of 11


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.

Charge Heater, interheaters & debutanizer reboiler (20-FF-00-101/102/103/104) :

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.






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 7 of 11



requirement of new equipments as proposed in UOP revamp feasibility study

report are summarized below in Table 7.3.4.2 and overall equipment list is


Table 7.3.4.2.: List Of New/Modified Equipments

SLNO


FIRED HEATERS 1 20-FF-00-101 Charge Heater Replacement of burners with high

heat release burnerDuty (Absorbed): 12.14 MMKcal/h

2 20-FF-00-102 No 1 Interheater Replacement of burners with high

heat release burnerDuty (Absorbed): 11.89 MMKcal/h

3 20-FF-00-103 No 2 Interheater Replacement of burners with highheat release burnerDuty (Absorbed): 8.37 MMKcal/h

EXCHANGERS 1

20-EE-00-103 Net Gas Cooler

Additional shell in parallel Area-359.2 m2.Size: 775mm*6000mmNo of shells : 1

220-EE-00-104

Recontact CoolerNo 1

Additional shell in parallel required Area-722.4 m2Size: 1050mm*6000mmNo of shells : 1

3

20-EE-00-106DebutanizerBottoms Cooler

Additional shell in parallel required Area-442 m2Size: 800mm*6000mmNo of shells : 1

AIR COOLERS 1

20-EA-00-101 Product CondenserOne additional bay same asexisting (6.2m*10.5m) required

PUMPS 1 20-PA-CF-

101A/BSeparator Pumps

Impeller of higher diameterrequired

2 20-PA-CF-102A/B

DebutanizerReboiler Pumps

Impeller of higher diameterrequired

NEW EQUIPMENTS 1

20-KA-RP-102CNet GasCompressor

One additional new net gascompressor is required.






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 8 of 11


3. Penex Process Unit

UOP performed revamp feasibility study report of Penex considering feed

composition as derived by NHT unit yield estimate and simulation work for the

naphtha splitter.

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

which are considered under this project, shall be confirmed during design stage.

Also UOP will attempt to optimise the scheme to reduce some of equipment

count(if possible) at the time of basic engineering.

The key findings and modifications are as follow:

The unit has been checked meeting the following product specification:

The De-pentanizer column net overhead liquid shall have minimum 97 wt%C5+.

The De-pentanizer column net bottoms liquid shall have maximum 10 wt% C7+.

As a result of the adequacy check of the Penex , the Isomerate Product resultant

(DIH bottom plus DIH overhead) maximum achievable C5+ RONC is 88.5 for SOR

and 87.5 for EOR .

Methanator Reactor:The existing Methanator Reactor was evaluated for the new

revamp conditions with PURASPEC 2020 catalyst and found to be adequate. The

revamp operating conditions are within the limits in terms of reactor design

temperature and pressure. The expected bed life for the revamp flow is around 3

yrs.

Penex Reactors: The existing Penex Reactors were evaluated for the new revamp

conditions with I-82 catalyst. The revamp operating conditions are within the limits

in terms of reactor design temperature and pressure. To meet the revamp

scenario UOP suggested adding more catalyst in existing Reactors. UOPsuggests that each of the Penex Reactors (15-RB-00-202 A/B/C) can

accommodate 1.76 m3 more catalyst with following modifications:

Existing Vapor and liquid distribution tray is not suitable for revamp operating

conditions. UOP recommends two options for VLD tray

- Modified VLD tray by increasing size of all holes (by 2mm) on each VLD tray

riser

- Provide New VLD tray.

VL tray (new or modified) need to be placed 300mm above from current location

on new support structure welded/attached on existing Reactor wall or existingring






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 9 of 11


Makeup Hydrogen Compressors( 15-KA-RP-201A/B): Existing Makeup

Compressors (15-KA-RP-201A/B) have been evaluated based on required revamp

capacity and discharge pressure considering one machine is operating and the

other is on stand-by mode. With spillback of around 5 %, the Makeup Gas

Compressors are adequate for the Makeup gas from CCR Platforming Unit.

However for the Makeup gas from PSA Unit, the Makeup Compressors are not

adequate since the supply pressure of the gas from the PSA unit is lower and

consequently the required volumetric flow rate is high.

Even with the battery limit pressure of the PSA gas increased from 20 Kg/cm2g to

21.5 Kg/cm2g and reduced spill back (5 %), the Makeup Compressors fall short by

around 5.3 % to handle the revamp conditions. In order to make the existing

machines adequate, the battery limit pressure of the PSA gas needs to be

increased to around 22.6 Kg/cm2g.The option of revamping the compressor shallbe explored during detail engineering.


requirement of new equipments as proposed in UOP revamp feasibility study report

are summarized below in Table 7.3.4.3 and overall equipment list is tabulated in

Annexure 2.

Table 7.3.4.3.: List Of New/Modified Equipments

SL

NO TAG NO DESCRIPTION MODIFICATIONCOLUMNS

1 15-CC-00-202 Net Gas Scrubber Gas Distributor to be modified

2 15-CC-00-204 DeisohexanizerExisting 80 Nos. of valve trays to bereplaced with 95 nos. of ECMD trays

VESSELS

1 15-VV-VI-205A/B Feed Driers As Existing, Change in piping forchange in flow direction

2 15-RB-00-202A/B Penex ReactorNew vapour liquid distribution tray atnew location and additional catalyst

EXCHANGERS

1 15-EE-00-201 Methanator Heater Replaced by new larger exchanger Area/shell-9.1 m2

2 15-EE-00-208Cold Combined FeedExchanger

Existing tube bundle needs to bereplaced by new

3 15-EE-00-209Hot Combined FeedExchanger

Replaced by new larger exchanger

4 15-EE-00-211 Stabiliser ReboilerNew Tube Bundle with High Flux Tubes Area -338.8m2No of shells : 2

5 15-EE-00-212 Stabiliser CondenserReplaced by new larger exchanger Area-660 m2

6 15-EE-00-213 Stabiliser Net GasChiller

Replaced by new larger exchanger Area- 215 m2Size: 850mm*5500mm






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 10 of 11


7 15-EE-00-214 LPG Stripper ReboilerReplaced by new larger exchanger Area-17 m2

8 15-EE-00-215 LPG CoolerReplaced by new exchanger Area- 45 m2

9 15-EE-00-216 Deisohexanizer SideDraw Reboiler

Replaced by new with high flux Tubes Area-214.7 m2

10 15-EE-00-217DeisohexanizerReboiler

New tube bundle with high flux Tubes Area-300 m2

11 15-EE-00-218Deisohexanizer BottomCooler

Replaced by new larger exchanger Area-55 m2

12 15-EE-00-219 Isomerate Cooler Tube bundles to be replaced

13 15-EE-00-222DepentanizerOverhead Cooler

Replaced by new Exchanger Area-121 m2

AIR COOLERS

1 15-EA-00-202DeisohexanizerCondenser

Two additional bays same as existing(5.55m*10.5m) is required.

2 15-EA-00-203DepentanizerCondenser

One additional bay same as existing(5.4m*10.5m) is required.

PUMPS

1 15-PA-CF-201A/B Charge PumpImpeller change with motor replacementof 230KW

2 15-PA-CF-206A/BDeisohexaniser SideDraw Pumps

New Impeller of larger diameter isrequired

3 15-PA-CF-208A/BDeisohexaniserOverhead Pumps


4 15-PA-CF-209A/BDepentanizerOverhead Pumps


5 15-PA-CF-226A/B LP Condensate Pumps New Impeller of larger diameter isrequired

6 15-PA-CF-230A/BSour Water DegassingPump


NEW EQUIPMENTS

1 15-EE-00-223Intermediate CombinedFeed Exchanger

New Exchanger Area-228 m2

2 15-XZ-00-205A Refrigeration package Additional refrigeration packagerequired for balance capacity.

3

Two additionalreactors(One lead andlag reactor)

(Note 1)

4CCFE,HCFE& ChargeHeaters

(Note 1)

7

DeisohexaniserColumn and itsassociated equipments

Associated equipments consists ofSeparator, condenser, reboiler, refluxpump, S/D pump, bottom pump (Note 1)

8Stabiliser and itsassociated systems

Associated equipments consists ofreboiler, product condenser, stabilizerreflux pump (Note 1)

Notes

1. Required for 181% capacity increase in PENEX unit.






Process Description


Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.4 Page 11 of 11


UOP will attempt to optimise the scheme to reduce some of equipment count (if

possible) at the time of basic engineering.






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.








Document No.

A439-RP-02-41-0001Rev B



SECTION 7.3.5

HYDROGEN GENERATION UNIT (HGU)








Document No.

A439-RP-02-41-0001Rev B



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.








Document No.

A439-RP-02-41-0001Rev B



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.








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A439-RP-02-41-0001Rev B



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.








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A439-RP-02-41-0001Rev B



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

2 18-FD-00-12 TPR New equipmentNo of tubes 226








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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


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








Document No.

A439-RP-02-41-0001Rev B



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

exchanger.








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A439-RP-02-41-0001Rev B



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.








Document No.

A439-RP-02-41-0001Rev B



SECTION 7.3.6

TREATING UNIT








Document No.

A439-RP-02-41-0001Rev B



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

S.No. TAG NO DESCRIPTION MODIFICATION

VESSELS

1 21-VV-HI-101 Amine Settler Drum New

COLUMNS

1 21-CC-00-101 LPG Amine Absorber Trays (1-10): Replace existing

trays with new configuration trays.








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A439-RP-02-41-0001Rev B



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

S.No. TAG NO DESCRIPTION MODIFICATION

PUMPS

1 21-PA-CF-102 A/B Lean Amine BoosterPumps

Change with larger impellerdiameter.








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A439-RP-02-41-0001Rev B



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.


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


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.








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A439-RP-02-41-0001Rev B



321-CC-00-203 Water Wash Column

New (Dia: 1500 mm and 4500mm)

REACTORS1 21-RB-00-201 Ist Stage CFC

ColumnReplaced with new (shell Dia:680 mm and height: 4500 mm)

2 21-RB-00-202 IInd Stage CFCColumn

Replaced with new (shell Dia:680 mm and height: 5300 mm)

321-RB-00-203

CFC Solvent WashContactor

Replaced with new (shell Dia:550 mm and height: 5300 mm)

VESSELS1 21-VV-HW-201 Ist Stage CFC

SeparatorReplaced with existing 2n Stagevessel 21-VV-HI-202

2 21-VV-HI-202 IInd Stage CFCSeparator


3 21-VV-HI-203 CFC Solvent Wash

Separator

Replaced with new (Dia: 1700

mm and height: 5900 mm)4 21-VV-VI-204 Treated LPG SandFilter Vessel


521-VV-HI-209 Coaleascer Vessel

New (Dia: 1800 mm and 6000mm)

PUMPS1 21-PA-CF-201 A/B Interstage Caustic

Circulation PumpsImpeller need to be changed withhigher diameter

2 21-PA-CF-202 A/B Solvent CirculationPumps

Impeller need to be changed withhigher diameter

3 21-PA-CF-203 A/B Regenerated Caustic

Circulation Pumps

Impeller need to be changed with

higher diameter4 21-PA-CF-207 A/B Water Circulation

Pumps, flowNew Pump (Flow: 6 m3/hr andHead: 110 m)

Equipment wise Adequacy Report

Equipment wise adequacy is as detailed below:

COLUMNS

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.

Prewash Column (21-CC-00-201): The existing column diameter and packing isadequate to handle the revised loadings except the following modifications:

LPG Distributor needs to be changed.Batch time for the prewash column will reduce from 3 days to 2 days.

Regeneration Column (21-CC-00-202): Regeneration Column is checked for post

revamp flow and are found to be inadequate. The new Column of higher diameter is

required.








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A439-RP-02-41-0001Rev B



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:








Document No.

A439-RP-02-41-0001Rev B



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:

Water Wash Column (21-CC-00-203)

Coalescer Vessel (21-VV-HI-209)

Water Circulation pumps(21-PA-CF-207A/B)

PUMPDESCRIPTION

PRE-REVAMP POST-REVAMP

MODIFICATIONS/FINDINGSRATEDFLOW

(m3 /hr)

DIFFHEAD

(M)

RATEDFLOW

(m3 /hr)

DIFFHEAD

(M)Interstage CausticCirculation Pumps(21-PA-CF-201 A/B)

6.42 50.3 9.18 50.3 Impeller need to be changed

Solvent CirculationPumps(21-PA-CF-202 A/B)


RegeneratedCaustic CirculationPumps(21-PA-CF-203 A/B)









Document No.

A439-RP-02-41-0001Rev B



7.3.6.3 FUEL GAS TREATING UNIT (FG ATU)

The existing Fuel Gas Treating Unit (FGATU) is of capacity 12.47 T/hr. Thefollowing is the total feed to FGATU from different units:

UNIT EXISTING FEED (KG/HR) POST REVAMP FEED(KG/HR)

HCU/DHDT 2965 3146NHT 802 1169DCU 8705 14454TOTAL 12472 18769

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.


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).








Document No.

A439-RP-02-41-0001Rev B



ExchangersFindings/

Modifications

Cooing water(m3/hr )

Outlet Temperature(degC)

ExistingPost

revampExisting

Postrevamp

Fuel Gas

Cooler

Higher fuel gas

outlettemperature

12.1 12.1 40 41.5






equipments.The modifications /new facilities as tabulated in Tables 7.3.6.1&7.3.6.2 were

checked and found feasible from construction and implementation point of view.








Document No.

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Ch 7.3.7 Page 1 of 13


SECTION 7.3.7

SULFUR RECOVERY UNIT








Document No.

A439-RP-02-41-0001Rev B

Ch 7.3.7 Page 2 of 13


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.








Document No.

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Ch 7.3.7 Page 3 of 13


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

336 186%








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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.








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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


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)

2 29-RB-00-002C Converter-II

New (Diameter:3450 mm and 4700mm)

HEATER 1 29-FB-00-001C Main Burner New2

29-FF-00-001CMain combustionchamber

New

EXCHANGER 1 29-EE-00-001C Waste Heat Boiler New2 29-EE-00-002C Sulfur Condenser-I New3 29-EE-00-003C Sulfur Condenser-II New4 29-EE-00-004C Reheater-I New5 29-EE-00-005C Sulfur Condenser-III New

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

nitrogen.








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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








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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)

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


(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.


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


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.








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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








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Ch 7.3.7 Page 9 of 13


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

Stripper Reboiler12.58 16.45 126.76 126.76

28-EE-00-204 1s Stage StripperReboiler

2.088 2.8423 166.2 166.2

28-EE-00-206 2nd Stage Stripper

reboiler

8.066 9.5043 126.5 126.5

Air Coolers 28-EA-00-103 Single stage PA air

cooler9.3 12.09 65 65








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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.








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Ch 7.3.7 Page 11 of 13


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.








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Ch 7.3.7 Page 12 of 13


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

power rating 90KW

28-PA-CF-201 A/B(1st StageStripper FeedPumps)

55.7 218.9 72.35 208.5 Adequate

28-PA-CF-202 A/B(1st StageStripper PAPumps)

15.3 48.2 18.3 45.7 Adequate

28-PA-CF-203

A/B(2nd StageStripper BottomsPumps)

61.1 108.7 79.5 123.8 Replaced with new pump of

motor rating 55KW

28-PA-CF-204 A/B(2nd StageStripper PAPumps)

204.3 53.9 243.1 48.78 Adequate








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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






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.

UNIT EXISTING FEED (KG/HR) POST REVAMP FEED

(KG/HR)

FG ATU 105000 113370

LPG ATU 23000 23648

HCU/DHDT 342000 321069

TOTAL 470000 458087






Material BalanceDFR for Debottlenecking of


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Ch 7.4 Page 1 of 5


SECTION 7.4

MATERIAL BALANCE








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Ch 7.4 Page 2 of 5


7.4.1 OVERALL MATERIAL BALANCE

Table 7.4.1: Over all Material Balance of Refinery

KTPA

Crude( 65% Arab Light 35% Arab Heavy

7800

Products

LPG 344Naphtha 189Euro III Regular Gasoline 0Euro IV Regular Gasoline 1242 Aviation Turbine Fuel 722

Kerosene 396Euro IV/V Diesel 3641Coke 523Sulfur 152Fuel & Loss 597

The above material balance corresponds to Arab mix crude slate. In case of

heavy crudes like Kuwait, Basra light etc the petcoke yield and fuel & losses are

comparatively higher which accordingly changes the product pattern.

The overall Material Balance is worked out using LP model (as tabulated above)

and in consideration of followings:

Unit capacities are corresponding to same cut points of distillates as considered

for original design of CDU/VDU except gasoil TBP cut point which has been

changed to 240-370 instead of original design TBP cut point of 250-370. The

unit capacities for above material balance are worked as:

Table 7.4.2: Unit Capacities

Process Unit Revamp Design CapacityMMTPA

Capacity UtilisationMMTPA

CDU/VDU 7.8 7.8NHT 1.45 1.45CCR 0.787 0.77ISOM 0.56 0.56HCU/DHDT 2.625/2.202 2.486/2.224DCU 1.822 1.75HGU 98 KTPA 83 KTPA

The yields of DCU, HCU/DHDT, MS block and H2 units are considered asfurnished by respective licensers for post revamp scenario.








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As per BORL inputs , depentanizer OVHD is considered as 40% of feed and

hydrocracker yields of light naphtha and heavy naphtha are considered as 7.8

and 10.1wt% of HCU feed.The overall Block flow diagram is attached at the end of this chapter.

7.4.2 MAXIMIZATION OF 100% EURO IV MS PRODUCTION

To maximize total Euro IV MS of specification as tabulated below, UOP evaluated

various cases with an aim to upgrade available naphtha to maximum Euro IV

quality MS through (i) Direct Blending into MS Pool (ii) Processing in Units (iii)

Additives (MTBE or Alkylate) to MS Pool.

Table7.4.3: Euro IV MS Specification

For maximization of Euro IV MS Production, following revamp of existing MS block

unit has been considered:NHT capacity: 145% increase of design capacity

Penex Unit: 181% increase of design capacity

CCR Unit: 146% increase of design capacity

Euro IV MS production of 1242 KTPA (refer Table 7.4.3) is estimated following

UOP suggested scheme as shown below

Product QualitiesSpecification of Euro IV

MS

SPECIFIC GRAVITY 0.72-0.775

SULFUR, WT% 0.005 (max)

Vapour Lock Index(7*E70+10*RVP(kpa))

750 (Summer)/950 (winter)

RON 92 (min)

MON81.3 (min)

BENZENE, vol% 1.0 (max)

AROMATICS, Vol% 34.0 (max)

OLEFINS, vol% 18.0 (max)

% Recovery AT 70C -

% Recovery AT 100C -

% Recovery AT 150C -

RVP, PSI 8.41 (58 Kpa)








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Ch 7.4 Page 4 of 5


Penex/DIH

Unit

DeC5

Naptha

Splitter

CCR

Platforming

Euro IV

MS

POOL

SGB

NHT Unit

SGB

C5-90C

Hydrocracker

Light Naptha

C5-150C

SR Naptha

Hydrogen LPG

Reformate

Isomerate

Off Gas

Hydrocracker

Heavy Naptha

LPG

C5s

375

218

1076

487

154

157

264

54

659

394

790

770

20

696

22

29

502

All values are in KTPA

Design Capacity (xxxx)

Operating capacity

(560) 551

(787) 770

(1450) 1450

(1242)

157

1295

0

HDT Heavy Naptha

HCU HY Naptha

1449

157

To Naptha Pool/HGU 234

TO HGU

LOSS

The properties which are considered for blending streams of MS pool are given in

Table 7.4.4 below:

Table 7.4.4: Properties of Bleanding Streams of MS Pool

Product Qualities Reformate IsomerateHCU HyNaphtha

NHT HeavyNaphtha

SPECIFIC GRAVITY 0.806 0.658 0.75 0.733

SULFUR, WT% 0 0 0.0001 0

Vapour Lock Index(7*E70+10*RVP(kpa)) 275 778 138 96.1

RON 98 88 55 65.2MON 87 86.7 55 63.4

BENZENE, vol% 1.1 0 0.6 0

AROMATICS, Vol% 66.0 0 6 9

OLEFINS, vol% 1.3 0 0 0

% Recovery AT 70C 5 84 0 2

% Recovery AT 100C 15 94.5 15 100

% Recovery AT 150C 80 100 100 100

RVP, PSI 3.5 10.88 2.0 1.2

Euro IV MS pool composition based on above scheme and properties of blendedstreams are as follows:








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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.






Utility SystemDFR for Debottlenecking of


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Ch 7.5 Page 1 of 20


SECTION 7.5

UTILITY SYSTEM








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Ch 7.5 Page 2 of 20


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

Utility Block Nm3/hr 630 3140

6 Plant Air Nm3/hr 3160 3530Boiler Feed water

7 MP+LP m3/hr 135.6 184.8HP m3/hr 8 4.6

Steam8 HP TPH -3.6 60.92

MP TPH 76.4 81.25LP TPH 83.4 118








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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)

S.No Unit Estimated Demand

m3 /hr

Normal

EstimatedDemand

m3 /hrmaximum

1. Cooling Tower Makeup (Process) 689 754

2. Cooling Tower Makeup (CPP) 724 790








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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








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units, Utilities (except CPP, Compressed air system, nitrogen system ,CPU/DMand MCR).

Cooling Water Requirement

The cooling water requirement of various process units is given below in theTable-7.5.2.

Table-7.5.2: Cooling water consumption (m3/hr)

UNITSExisting

PostRevamp

CDU/VDU 4750 5937

NHT/NSU 575 543

PENEX 1474 1474

CCR 2710 3037HGU 578 693

HCU/DHDT 6314 7137

DCU 2250 2925

SWSU 523 706

LPG Treating 55 68

ARU 880 861 (Note 1)

S-BLOCK 690 900

SRR & Sub-Stations 330 330

Utilities & Offsite 600 819TOTAL- Refinery CT 21729 25430

TOTAL- Refinery CT(with margin) ~24000 ~28000

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.








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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








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Condensate Return (recovery) Note 1 -128 -194TOTAL- Process & Utility 420.9 477

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








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7.5.5 COMPRESSED AIR SYSTEM

The Compressed air is required in the complex for following usages:

As instrument air As plant air As service air for hose stations and for other requirements of the complex.

Compressed Air Specification

Quality of Plant air and service air is same and these requirements in the complexshall be supplied through common header.

Consumption Requirement

The requirement of instrument air and plant air in the complex are given in Table

7.5.4 and Table 7.5.5 respectively.

Table-7.5.4: Instrument Air (Nm3 /hr)

UNITS

Continuous maximumrequirement (Nm3/hr)

Existing Post Revamp

CDU/VDU 440 350

HCU/DHT 960 1300

DCU 1100 420NHT/NSU/PENEX 325 1300

CCR Plt& Regen 1430 0

HGU 385 180

SWS-I 55 55

SWS-II 55 55

LPG Treating 100 100

ARU 55 55

SRU 440 840

CPP 1025 1025

Subtotal 6370 5680

Utilities and CT 10 Note-1

off-sites RW 20 Note-1

CPU 30 Note-1

RO 50 Note-1

Comp. Air 20 Note-1

N2 50 Note-1

WWTP 120 Note-1

Flare 30 Note-1Tankage 120 Note-1








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CR 30 Note-1

Workshop, Lab. & Misc 50 Note-1

Marketing Terminal 100 Note-1Sub-total 630 3140

TOTAL 7000 8820

Note-1: As per BORL operating data total instrument air consumption for offsites

and utilities (other than CPP) is 3140 Nm3/h.

Table-7.5.5: Plant Air (Nm3 /hr)

UNITS

Continuous maximum requirement (Nm3/hr)


CDU/VDU

HCU/DHT

DCU 300 390NHT/NSU

CCR

PENEX

HGU

SWS-I

SWS-IILPG treating 340 340 ATF Treating

ARU

SRU

WWTP 200 200

Cooling towers

TANKAGES

Workshop, Lab. & Misc.CPP 480 760

Hose station 340 340Total 3160,(Maximum)

(Note-1) 3530 (Note-1)

Note-1: Maximum plant air requirement includes intermittent requirement of 1500Nm3/h of plant air for coke cutting in DCU.

Total Air Requirement

The compressed air requirement of the refinery complex works out to be

Instrument Air : 8820 Nm3/hrPlant air : 3530 Nm3/hr








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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

the nitrogen requirement of the refinery.








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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,

UNITSMaximum continuous (Nm3/hr)


CDU/VDU Nil 0

ATF Merox 20 25

NHT 10 41.4

CCR-Pt. 54 250.0

PENEX 10 41.4

HGU 80 96

DCU 11 395.6HCU/ DHT 56 72.8SRU 200 439 ARU 61 123.8

SWS 27 55

DM plant 100 125

CPU 25 31.3

Offsites 535 860

TOTAL 1169 2557








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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:

Table 7.5.7: HP steam consumption (TPH)

Units Existing Post Revamp

HCU/DHDT 34.3 54.7 (note-1)

DCU 21.8 35.6 (note-1)

PENEX 0.4 0.6

Utilities & Offsite 2 2

HGU -62.1 -31.9 (note-1)

NET TOTAL -3.6 61

With 10% margin -3.6 67.0

-ve sign indicates generation


Table 7.5.8: MP Steam Consumption (TPH)


CDU/VDU 30 44.7

NHT/NSU 2 2.5

PENEX 19.8 24.8

CCR 14.8 2 (note-1)

HGU 0.5 0.5

HCU/DHDT -36.1 -30.9 (note-1)

DCU 24.9 23.7

HOT OIL 1.5 1.5

Utilities & Offsite 10 12.5

NET TOTAL 76.4 81.3With 10% margin 84 89.4










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Table 7.5.9:LP Steam consumption (TPH)


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



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)


CDU/VDU 7522 9402.5NHT/NSU 1700 2125PENEX 3010 3762.5CCR 5164 7229.6HGU 3593 4311.6

HCU/DHDT 30910 40183DCU 5802 7542.6








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SRU 7388 9973.8Utilities & Offsite 24299 30373.8

Total (Normal) 89388 114904

Table 7.5.11: Estimated Steam & Power Summary


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








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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 .


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








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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.

Table 7.5.13: Condensate Balance

UnitsTotal Condensate (TPH)


CDU/VDU Nil 4.0ISO CRACKING &DHDT

53.683.1

DCU 30.5 52.9(Note-1)

HGU +REFORMER Nil NilCCR Platforming 9.9 18Penex unit 19.3 26.1Sulphur Block 40 60Utilities & Offsite Nil NilCPP Nil NilTotal (Normal) 153.3 244.2

Note -1: As per Licensor data.

CPU Capacity

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.








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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.








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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:








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Table-7.5.15: Overall Fuel Balance

UnitTotal fired duty,

MMKcal hr

FGConsumption

KG/HR

FOConsumption

KG/HRCDU 75.03 4421.2 2639.4

VDU 44.53 1113.9 3362.1HCU/DHTReactionHeaters 27.14 2402.1 0HCUFractionatorsHeaters 59.72 1493.6 4349.7

DCU Heater 46.64 1166.4 3397.4

WGC comp dryseal gas 175

NHT 35.09 1666 1650.8

CCR 54 4778.7 0

HGU 50 0

SRU 0 2900

HOT OIL HTR 34.91 872.4 2542.8

Pilot Burner 0 557 0

Flare Purging 0 500 0

Total 22096 17942.3

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.








Document No.

A439-RP-02-41-0001Rev B



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

S.NO UNITLoad Mol. Wt Temp.

Existing Revised Existing Revised Existing Revised

1 CDU/VDU - - - - - -2 DCU 292075 350000 39 57 167.1 2153 MS

BLOCK274250 372291 86.2 89.3 161.2 175.26

4 HCU/DHT 380648 494842.4 45.4 45.4 151.9 151.95 HGU - - - - - -

TOTAL 946973 1217133.4 56.98 62.16 159.3 177.19

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.

Sour Flare Existing Capacity : 30,846 kg/hr ( peak load)Sour flare Post Revamp Capacity : 30,846 kg/hr (peak load)

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.






Offsites DescriptionDFR for Debottlenecking of


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Ch 7.6 Page 1 of 14


SECTION 7.6

OFFSITES DESCRIPTION








Document No.

A439-RP-02-41-0001Rev A

Ch 7.6 Page 2 of 14


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.








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Ch 7.6 Page 3 of 14


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








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A439-RP-02-41-0001Rev A

Ch 7.6 Page 4 of 14


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.








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A439-RP-02-41-0001Rev A

Ch 7.6 Page 5 of 14


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








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A439-RP-02-41-0001Rev A

Ch 7.6 Page 6 of 14


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.

2 52-PA-CF-02A/B/C VGO As Existing

3 52-PA-CF-03A/B HCGOImpeller change withlarger diameter

4 52-PA-SC-04A/B/C VR As Existing

5 52-PA-CF-05A/B DHDT FEED As Existing

6 52-PA-CF-06 NHT FEEDImpeller change withlarger diameter

7 52-PA-CF-07A/B CCR FEED As Existing

8 52-PA-CF-08A/B HGU FEED As Existing

9 52-PA-CF-09A/B DRY SLOP As Existing

10 52-PA-SC-10A/B BLACK SLOP As Existing

1152-PA-CF-11A/B ISOMERATE

Impeller change of largerdiameter and motor

replacement of rating 45KW.

12 52-PA-CF-12A/B REFORMATEImpeller change withlarger diameter

13 52-PA-CF-13A/B CDU IFO As Existing

14 52-PA-CF-14A/B REFINERY IFO As Existing

15 52-PA-CF-15A/B CRUDE WATER As Existing

16 52-PA-CF-16A/B HCU LT NAPHTHA As Existing

17 52-PA-CF-17A/B LCGO As Existing

18 52-PA-CF-18 MTBE As Existing

19 52-PA-CF-19A/B COKER NAPHTHA As Existing20 52-PA-CF-20A/B MTBE As Existing








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Ch 7.6 Page 7 of 14


BLOWDOWN

21 52-PA-CF-21A/B FLUSHING OIL As Existing

22 52-PA-CF-22A/BWHITE OILBLOWDOWN

As Existing

23 52-PA-CF-23A/BBLACK OILBLOWDOWN

As Existing

24 52-PA-CF-24A/BCRUDE SURGESTORAGE

As Existing

25 52-PA-CF-25A/B BCW As Existing

7.6.1.3 Finished Product Storage and Transfer Philosophy

Finished product for the refinery is stored in the BINA dispatch terminal Refersection 7.8 for details.

7.6.2 INTERCONNECTION OF PROCESS LINES BETWEEN PROCESS UNITS

The interconnecting offsite lines between various units are checked for revamped

flow which are corresponding to respective units revamp capacity. Sizes of all

lines are found adequate from hydraulic point of view.

7.6.3 PRODUCT RUN DOWN LINES FROM REFINERY TO MARKETING TERMINAL

Final Products are received to Marketing Terminal from Refinery through

piping.The maximum length of each pipe from Refinery to Bina Dispatch Terminal

is 2.5 Kms. These pipes are above ground lines on Pipe sleepers. The product

wise piping sizes are given in the following table.

Product Receipt Pipeline Size in inch

MS-Euro III/IV 8” ( Common)HSD-Euro III 12”HSD- Euro IV 10”

ATF 8”SKO 8”

Naphtha 6”LPG 6”

LPG ( off spec) 4”

Besides indicated above two more lines are provided from Marketing Terminal to

Refinery.

1. Slop Return line (WO) - 8”

2. LPG reprocessing line - 3”

3. ETP Water to Refinery ETP - 6”








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Ch 7.6 Page 8 of 14


All final products run down lines are checked for product slate based on

revamped material balance ( refer section 7.4) across refinery and blending of

EuroIV MS and diesel.

Existing product headers are found adequate for the post revamp increase in

production. For Euro-IV Gasoline the offsite header sizing is just adequate and

unit B/L pressure for HCU Heavy naphtha, Isomerate and reformate may be

required to increase which shall be established during design stage.

Table 7.6.2: Existing Offsite Tanks

Table 7.6.3 : Existing Offsite Pumps

SERVICE NO. OF PUMPSRATED CAPACITY

OF EACH PUMPM3 /Hr

PRESSURE ATUNIT B/L,Kg/cm2 g

CRUDE 2 + 1 485 3.0VGO 2 + 1 155 12.0

S No. Service

Pumpable Volume

( Vol in between LLLand HLL of Tank)

Type ofTank**

Tank SizeD X H

Current M Meter

1 CRUDE 3 54500 FR 68 X 202 VGO 3 15797 CR 40 X 143 HCGO 2 5220 CR 26 X 114 VR (DCU FEED) 2 12721 CR 40 X 125 DHDT FEED 3 12825 CR 38 X 13.56 NHT FEED 1 25971 FR 52 X 15.37 CCR FEED 1 3857 CR 24 X 11

8 HGU FEED 1 3813 DR 20 X 149 DRY SLOP 1 2116 FR 18 X 1210 BLACK SLOP 1 1830 CR 14 X 13.311 ISOMERATE 2 3813 DR 20 X 1412 REFORMATE 1 8418 FR 30 X 1513 CDU/VDU IFO 2 1293 CR 14 X 1014 REFINERY IFO 2 1615 CR 14 X 1215 CRUDE/WATER 1 1200 CR 14 X 1016 HCU LT NAPHTHA 1 3813 DR 20 X 1417 LCGO 1+1 4565 &

12825CR 24 X 12 &

38 X 13.5

18 MTBE 1 3813 DR 20 X 1419 COKER NAPHTHA 1 3850 CR 24 X 11








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Ch 7.6 Page 9 of 14


HCGO 1 + 1 50 12.0VR 2 + 1 115 4.0DHDT FEED 1 + 1 205 10.0NHT FEED 1 + 0 105 7.0CCR FEED 1 + 1 105 15.5HGU FEED 1 + 1 40 6.0DRY SLOP 1 + 1 50 3.0BLACK SLOP 1 + 1 10 3.0ISOMERATE 1 + 1 55 7.0REFORMATE 1 + 1 85 7.0CDU IFO 1 + 1 20 4.0REFINERY IFO 1 + 1 30 4.0CRUDE WATER 1 + 1 55 2.0HCU LT

NAPHTHA

1 + 1 24 6.0

LCGO 1 + 1 75 10.0MTBE 1 + 0 20 7.0COKERNAPHTHA

1 + 1 30 12.0

FLUSHING OIL 1 + 1 70 7.0

Table 7.6.4: Feed and Intermediate Storage Tanks

TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing

No. of storagedaysPost

Debottlenecking

Remarks

Crude (51-TT-FR-01A/B/C)

54500 60000 6.5 6.5 days will bereduced to 6.3 days

One additionaltank isrequired

VGO(52-TT-

CR-02A/B/C)

15797 17050 i) In case of HCUdown with

CDU/VDUoperating at 60%throughputconsidering tanksare 20% filled,no. of storagedays =12

i) In case of HCUdown with

CDU/VDUoperating at 60%throughputconsidering tanksare 20% filled, no.of storage days=9.5

Oneadditional

tanks

ii) In case ofCDU/VDU down& HCU operatingat 60%

throughputconsidering 20%

ii) In case ofCDU/VDU down &HCU operating at60% throughput

considering 20%filled tanks, no. of








Document No.

A439-RP-02-41-0001Rev A



TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing


Debottlenecking

Remarks

filled tanks, no. ofdaysavailable=3.5

days available=2.3

HCGO(52-TT-

CR-03A/B)

5220 5820 i) In case of HCUdown with DCUoperating at 60%throughputconsidering tanksare 20% filled,no. of storagedays =11

i) In case of HCUdown with DCUoperating at 60%throughputconsidering tanksare 20% filled, no.of storage days=8.7

One additionaltank underconstructionwith oneadditional tankprovidedstorage days= 13.0 in caseof HCU downwith DCUoperating at60%throughput.

ii) In case of DCUdown & HCUoperating at 60%throughput

considering 20%filled tanks, no. ofdaysavailable=3.5

ii) In case of DCUdown & HCUoperating at 60%throughput

considering 20%filled tanks, no. ofdays available=3.1

Consideringone additionaltank beingconstructed,

storage timeincreases to4.7days.

VR(52-TT-

CR-04A/B)

12721 15000 i) In case of DCUdown withCDU/VDUoperating at 60%throughputconsidering tanksare 20% filled,

no. of storagedays =8.2

i) In case of DCUdown withCDU/VDUoperating at 60%throughputconsidering tanksare 20% filled, no.

of storage days=6.6

one additionaltank is underconstruction.With oneadditional tankprovidedstorage

days=9.9

ii) In case ofCDU/VDU down& DCU operatingat 60%throughput with20% filled tanks,no. of daysavailable=2

ii) In case ofCDU/VDU down &DCU operating at60% throughputwith 20% filledtanks, no. of daysavailable=1.6

one additionaltank is underconstruction.With oneadditional tankprovidedstoragedays=2.3








Document No.

A439-RP-02-41-0001Rev A



TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing


Debottlenecking

Remarks

DHDT (52-TT-CR-05A/B/C)

12825 15240 i) In case ofDHDT down withCDU/VDUoperating at 60%throughputconsidering tanksare 20% filled,no. of storagedays =11.8

i) In case of DHDTdown withCDU/VDUoperating at 60%throughputconsidering tanksare 20% filled, no.of storage days=9.4

One additionaltank

ii) In case ofCDU/VDU down& DHDToperating at 60%throughput with20% filled tanks,no. of daysavailable=3

ii) In case ofCDU/VDU down &DHDT operating at60% throughputwith 20% filledtanks, no. of daysavailable=2.3

One additionaltank

NHT (52-TT-FR-06)

25971 28860 i) In case of NHTdown withCDU/VDU

operating at 60%throughputconsidering tankare 50% filled,no. of storagedays =5.9

i) In case of NHTdown withCDU/VDU

operating at 60%throughputconsidering tankare 50% filled, no.of storage days=4.8

One additionaltank

ii) In case ofCDU/VDU down& NHT operatingat 60%throughput with

50% filled tank,no. of daysavailable=5.9

ii) In case ofCDU/VDU down &NHT operating at60% throughputwith 50% filled

tank, no. of daysavailable=4.8

CCR (52-TT-CR-07)

3857 4960 i) In case of NHTdown with CCRoperating at 60%throughputconsidering tankare 50% filled,no. of storagedays =2.5

i) In case of NHTdown with CCRoperating at 60%throughput whentanks are 50%filled, no. ofstorage days =1.1

One additionaltank

HGU (52-TT-DR-08)

3813 4410 i) In case ofISOM down with

i) In case of ISOMdown with HGU

One additionaltank








Document No.

A439-RP-02-41-0001Rev A



TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing


Debottlenecking

Remarks

HGU operating at60% throughputconsidering tankare 50% filled,no. of storagedays =2.5

operating at 60%throughputconsidering tankare 50% filled, no.of storage days=2.2

ISOMERATE (52-TT-DR-11A/B)

3813 4398 i) In case ofISOM down, twotanks withpumpablecapacity of 3813m3 will supply 5.6 days ofproduction ofisomerate for MSblending

i) In case of ISOMdown, two tankswith pumpablecapacity of 3813m3 will supply 4.6

days of productionof isomerate forMS blending

Sufficientstorage timepostdebottlenecking, noadditionaltanks

REFORMATE (52-TT-FR-12)

8418 10603 i) In case of CCRdown, one tankwith pumpablecapacity of 8418

m3 will supply4.8 days ofproduction ofreformate for MSblending

i) In case of CCRdown, one tankwith pumpablecapacity of 8418

m3 will supply 3.2 days of productionof reformate forMS blending

One additionaltank

CDU/VDUIFO (52-TT-CR-13A/B)

1293 1539 3.4 days of IFOconsumption inCDU/VDUconsidering twotanks 50% filled

2.7 days of IFOconsumption inCDU/VDUconsidering twotanks 50% filled

REFINER

Y IFO (52-TT-CR-14A/B)

1615 1847 2.8 days of IFO

consumption inrefinery with twotanks 50% filled

HCU LTNAPHTHA(52-TT-DR-16)

3813 4410 i) In case of NHTdown with HCUoperating at 60%throughputconsidering tanksare 50% filled,no. of storagedays =3.3

i) In case of NHTdown with HCUoperating at 60%throughputconsidering tanksare 50% filled, no.of storage days=2.6

No additionaltank isconsidered

LCGO (52- 4565 5410 i) In case of i) In case of DHDT No additional








Document No.

A439-RP-02-41-0001Rev A



TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing


Debottlenecking

Remarks

TT-CR-17) DHDT down withDCU operating at60% throughputconsideringsmaller tank 20%filled ,and biggertank empty, no. ofstorage days=16.3

down with DCUoperating at 60%throughputconsideringsmaller tank 20%filled, and biggertank empty, no. ofstorage days =12.5

tank required .LCGO (52-TT-CR-17A)

12825 15240

COKERNAPHTHA(52-TT-CR-19)

3850 4960 i) In case of HCUdown with DCUoperating at 60%throughputconsidering 20%filled, tank, no. ofstorage days=8.5

i) In case of HCUdown with DCUoperating at 60%throughputconsidering 20%filled, tank, no. ofstorage days =7.1

Oneadditional tankalready underconstruction. With oneadditional tankno of storagedays =14.2

ii) In case of DCUdown & HCUoperating at 60%throughput with20% filled tank,no. of daysavailable=2.3

ii) In case of DCUdown & HCUoperating at 60%throughput with20% filled tank,no. of daysavailable=1.9

One additionaltank alreadyunderconstruction. With oneadditional tankno of storagedays =3.8

MTBE (52-TT-DR-18)

3813 3813 Tank withpumpable volumeof 3813 m3. Nostorage daysavailable forblending in MS=8.3

Post revampMTBE requirementis 96 MTPA. Noreduction instorage days.

One AdditionalTank

DRYSLOP (52-TT-FR-09)

2116 2116 To Store 8 hoursof off specproduct formCDU @60%throughput duringstart up

Storage timedecreases to 6.4hours.

One AdditionalTank underConstruction








Document No.

A439-RP-02-41-0001Rev A



TankDescriptio

n

Pump-able

volume

(m3)

Vol ofTank(m3)

No of storagedays

Existing


Debottlenecking

Remarks

BLACKSLOP (52-TT-CR-10)

1886 1830 To store 8 hoursoff spec productfor CDU @60%throughput duringstart up

Storage Timedecreases to 6.3hours.

No additionaltank






Crude Oil Terminal/PipelineDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 1 of 7


SECTION 7.7

CRUDE OIL TERMINAL/

PIPELINE








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 2 of 7


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








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 3 of 7


Major Equipments/Lines Requirement

Based on this basis, following major facilities are envisaged for cost consideration

S. noEquipment/

Instrument/LineQuantity Specification

1. Crude Tanks 4

Same as Existing crude tanks

Dia x Ht = 68.0m x 20.0m

Storage Capacity = 60000 M3

2. Receipt Header 1

Size =48”

Length = 300 m (including individual tank

manifold)Line Spec = A9A

3. ROSOV 4 Size-48”, Spec-A9A

4. MOV8 Size-48”, Spec-A9A

8 Size-36”, Spec-A10A








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 4 of 7


7.7.2 PIPELINE

A crude oil pipeline is installed to transport crude oil from COT located at Vadinar

to Bina refinery of BORL through 24” x 931 km pipeline. The pipeline has 3

pumping stations at chainage 0, 358.6 and 556.7 km from Vadinar and isdesigned for throughput of 6 MMTPA.

BORL intends to augment the processing capacity of Bina refinery from present 6

MMTPA to maximum achievable capacity considering low cost expansion.

In line with the expansion of refinery, feasibility study for the Vadinar-Bina pipeline

has been done for 7.8 MMTPA refinery throughput. Suitability of Drag Reducing

Agent injection was also explored to analyze the capacity augmentation without

many modifications in the pipeline.

Salient Features Of The Existing Pipeline

Size : 24”Design Pressure : 70.1 Kg/Cm2gLength : 931 kmNo. of Pumping Stations : 3Configuration : 2 working + 1 Stand by

Chainage 0.0: VadinarChainage 358 km: ThamnaChainage 556 km: Bewari

Intermediate pigging stations : 2 Nos

Chainage 189 km: SidhasarChainage 758 km: Sandavata

Present design capacity : 6 MMTPAMargin available for enhancement : NIL (due to intermediate pumping

station at Thamna operating neardesign pressure)

Pipeline Maximum operatingPressure (MOP) : 63.73 kg/cm2 gPipeline Maximum allowableOperating Pressure (MAOP) : 70.10 kg/cm2 g (MOP x 1.1)Present Pumping capacity : 862 m3/hr

VBPL Simulation With DRA Injection

125% of the existing throughput is considered to check for the capacity

augmentation of the pipeline.

Hence flow rate considered is 862 x 1.25 = 1078 m3/hr.

Presently BORL is using following type of DRA in their pipeline operation.

The basic properties of the used DRA are given below.

1. Type : Vegetable Oil based DRA. Suspension type.2. Density : 7.5 lbs/gal = 0.9 kilos/liter








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 5 of 7


3. Below are the model and correlation

CONOCO DRA type model is used in the simulation which is most applicable for

the type of DRA being introduced presently.

Following are the major results from simulation output:

Sr No

DRA injection rate (ppm) Pump Discharge Pressure(kg/cm2g)

Vadinar Thamna

(IP-1)

Bewari

(IP-2)

Vadinar Thamna

(IP-1)

Bewari

(IP-2)

Case-I 10 36 30 63.6 65.4 59.7

Case-II 10 35 30 63.6 65.6 59.7

Case-III

(SeeNote)

6 (6) 10(10) 6(6) 65.65(59.5) 73.1(56) 74.8(58.5)

6 30 20 65.65 66 63.3

Where,

Case-I: Kuwait Crude with 125% of the normal capacity i.e. 1078 m3/hr

Case-II: Arab-Mix with 125% of the normal capacityCase-III: Kuwait crude with 120% of the normal capacity i.e. 1060 m3/hr

Note: Case-III was used to check/validate the simulation results with the present

DRA injection rate and operating conditions of pipeline. In the first row of the case-

III, the values outside the bracket are present observations at site. Values inside

the bracket are simulation results keeping the same DRA injection rate as present.

In the second row, DRA injection rate is changed to keep the pump discharge

pressure in the acceptable range.

Performance

Coefficients

m 9.000

b 1.250

DR = 1 / ( m / ppm + b )








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 6 of 7


Conclusion

In order to increase throughput to 130% of normal (6MMTPA *1.3) DRA needs to

be injected at pump discharge @ 10 PPM at Vadinar,@36/35 PPM at Thamna

(IPS-1) and @30 PPM at Bewari (IPS-2) for both Arab Mix and Kuwait crudes.

The validation simulation was also carried out for the 120% increase throughput

for Kuwait Crude to compare with actual field data. It was observed that with

present dosing rate at Vadinar of 6PPM simulation predicts that Vadinar pumps

are just adequate, however the pump discharge pressure required is higher than

the field data. However for IPS-1 and IPS-2 the simulation predicts that at IPS-1

the dosing rate should be 30 PPM instead of field data of 10 PPM and at IPS-2 the

dosing rate should be 20 PPM instead of field data of 6 PPM in order to keep

pump discharge pressure within limits of existing pumps.

Pump Adequacy

Based on the simulation with DRA injection at the three stations, the revisedrequirement of head and flow rate for pumps of VBPL calculated as under:

Station Booster pump

@ Vadinar

Main line pump

@Vadinar

IPS-1 IPS-2

Flowrate (M3 /Hr) 539 539 539 539

Differential Head (m) 54 714 669 737

Pump adequacy was checked with respect to the above revised requirements.Following table enlists the results of the pump adequacy.








Document No.

A439-RP-02-41-0001Rev A

Ch 7.7 Page 7 of 7


Sl.No

Item No. Description Existing Pump parameters Proposed pump ratedparameters

Adequacyof pumpsfor PostRevamp

Remarks

1 10-PA-CF-101 A/B/C

BoosterPump

Rated Flow: 474.1 m3/hrDiff. Head: 60 mDriver Rating: 110 kWParallel Operation

(2 Stage, Vertical Barrel Type)

Rated Flow: 539 m3/hrDiff. Head: 54 m

Inadequate

Based on pump vendor's reply, theexisting pumps are Inadequate.Additional booster pump shall beconsidered with the same

parameters as existing. 2 10-PA-CF-

102 A/B/C,(VadinarDispatchTerminal)

MainlinePump

Rated Flow: 474.1 m3/hrDiff. Head: 738 mDriver Rating: 1400 kWParallel Operation(6 Stage)

Rated Flow: 539 m3/hrDiff. Head:714 m Adequate

Based on vendor's reply, theexisting pumps can be consideredadequate for the revised operatingparameters, without anymodification.

3 30-PA-CF-201 A/B/C(IntermediatePumpingStation-I)

MainlinePump

Rated Flow: 474.1 m3/hrDiff. Head: 738 mDriver Rating: 1400 kWParallel Operation(6 Stage)

Rated Flow: 539 m3/hrDiff. Head:737 m

Adequate Based on vendor's reply, Pumpscan be considered as adequate.However, motor and VFD willrequire replacement for the newduty condition.

4 40-PA-CF-301 A/B/C(IPStation- II)

MainlinePump

Rated Flow: 474.1 m3/hrDiff. Head: 738 mDriver Rating: 1400 kWParallel Operation

(6 Stage)

Rated Flow: 539 m3/hrDiff. Head:669m

Adequate Based on vendor's reply, theexisting pump can be consideredadequate for the revised operatingparameters, without any

modification.






Bina Dispatch OilDFR for Debottlenecking of


Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 1 of 10


SECTION 7.8

BINA DISPATCH TERMINAL








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 2 of 10


7.8.1 STORAGES

7.8.1.1 Existing Storage Details

Finished Products received from Refinery are stored in storage tanks. The storage

capacities of each product in existing facilities are decided based on operational

requirement. The number and capacity of tanks can be decided based on

following philosophy.

Receipt

Road Dispatches ( All products )

Rail Dispatches ( HSD, MS, SKO and ATF )

Pipeline dispatch (HSD, MS, SKO and ATF)

Settling time / Quality checks / Certification

Maintenance

The following Table indicates the details of existing product storage facilities for

different products in the Bina Dispatch Terminal.

PRODUCTS NO. OFTANKS

TYPE OF TANK

PUMPABLE

CAPACITYOF EACH

TANK (M3)

Total

storage in

terms of

days for 6

MMTPA

Total

storage in

terms of

days for

7.8 MMTPA

HSD Euro III5 FIXED ROOF 14125

14.5 11.51 FIXED ROOF 14125

HSD Euro IV5 FIXED ROOF 14125

17.8 14.21 FIXED ROOF 6140

MS Euro III 5 FLOATING ROOF 12125 41.6

28.91 FLOATING ROOF 6155

MS Euro IV5 FLOATING ROOF 12125

401 FLOATING ROOF 6155

SKO4 FLOATING ROOF 6155

16.3 11.41 FLOATING ROOF 6155

NAPHTHA3 FLOATING ROOF 6155

22.5 26.01 FLOATING ROOF 6155








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 3 of 10


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.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 4 of 10


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).








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 5 of 10


TLF Gantry Configuration

White oil TLF Gantry bay configuration and loading pattern is given under,

Products HSD

-III

HSD

-IV

MS-III MS

-IV

SKO ATF Naphtha Total

Top loading

points5 - 3 - 3 1 4 16

Bottom loading

points- 1 - 1 - 1 1 4

Total 5 1 3 1 3 2 5 20

Maximum

trucks(Proportionate to

the no of loading

points)

90 18 54 18 54 36 90 360

Maximum

loading per day

according to

maximum no of

trucks, m3/day

1080 216 648 216 648 432 1080 4320

Maximum

loading perannum

according to

maximum no of

trucks, KTPA

320 64 192 64 192 128 320 1282

Details of Road loading pumps

Products Design Pumping Rate

Required

No. of

Pumps

Capacity of each

pump

(M /Hr.) OP. S/B (M /Hr.)

HDS-III 396 2 1 200

HSD-IV 158.4 1 1 160

MS-III 237.6 2 1 200

MS-IV 158.4 1 1 160

SKO 237.6 2 1 200

ATF 237.6 2 1 160

NAPHTHA 475.2 3 1 240








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 6 of 10


2. Design Basis for LPG road gantry

345 days per year shall be considered for loading operation.

LPG road tanker loading is being loaded from bottom only.

Minimum time considered for LPG tanker (18 MT) loading is 45 minutes.

Maximum time considered for connection/disconnection is 15 minutes.

Loading is done in two shifts operation per day.

Working hours per shift shall be 8 hours.


LPG Road loading pump capacity = 150 M3/Hr (2 operating and 1 Stand by)

Based on above basis,

Maximum trucks per day = 4 x 12 = 48Maximum loading per day according to maximum no of trucks, TPD = 864

Maximum loading per day according to maximum no of trucks, KTPA = 298

CONCLUSION

Maximum loading achievable is just below Post revamp LPG production i.e. 287

KTPA. 345 effective days per year and 6 effective hours per shift are considered

for LPG loading operation. If loading time can be increased marginally or over

design margin is reduced, there would not be any additional requirement ofloading facility.

No additional LPG road gantry is envisaged. LPG pumps are adequate enough

to take care of design LPG loading rate of 220 M3/Hr.

7.8.2.2 Rail Loading Facility

Rail loading of products are on volumetric basis for White oils. One full rake siding

is developed for white oils for filling the following products,

Naphtha - 1 Full Rake

HSD (Euro IV) - 1 Full Rake

ATF - 1 Full Rake

SKO - 1/2 (Half) Rake

MS (Euro III) - 1 Full Rake

MS (Euro IV) - 1/2 (Half) Rake

The facility is designed for rail loading of HSD, ATF, SKO and MS from single

spur.








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 7 of 10


Basis For Design

Time available for loading one full rake for Naphtha, HSD Euro IV, ATF, MS and

Half Rake of SKO/MS shall be 5 hours.

Total Time available for a filling = 3.5 hours

Number of BTPN wagons per rake = 50 wagons.

Capacity of each BTPN wagon = 47-55 MT.

Gantry configuration is one gantry for two spurs to accommodate 1full rake in

each spur. One spur is being used in the present scope.

The gantry is being operated in three shifts i.e. 24hrs, 365 days. However, for

design purpose 345 number of working days (10% margin for maintenance and

other contingencies) and 2.5 rakes per day are considered for Rail loading.

Single shift shall be of 8 hours.


The number of wagons considered for pump design (the pumping time shall be

3.5 hours) shall be as follows :-

Product No. of wagons for pump design

Naphtha 50 BTPN

HSD (Euro-IV) 50 BTPN

MS (Euro-III) 50 BTPN

MS (Euro-IV) 25 BTPN ATF 50 BTPN

SKO 25 BTPN

The pump details for existing rail loading are given below:

Products No of Wagons for

pump design

No. of Pumps. Rated capacity of

each Pump (M3/Hr.)OP. SB

Naphtha 50 BTPN 4 1 300

HSD Euro IV 50 BTPN 4 1 300

MS Euro III 50 BTPN 4 1 300

MS Euro IV 25 BTPN 2 1 300

ATF 50 BTPN 4 1 300

SKO 25 BTPN 2 1 300








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 8 of 10


CONCLUSION

There are 1 full rake spurs available in the rail gantry and considering 2.5 rakes

per day with 345 working days about 862.5 full rakes (maximum) filling is

anticipated.

1 BTPN full rake capacity = 55 MT x 50 wagons = 2750 MT

Approximate Total Rail loading achievable per year = 862.5 rakes x 2750 MT

= 2371.87 KTPA

Approximate maximum road loading achievable = 1733 KTPA

Total white oil products to be evacuated in post-revamp shall be about 6275

KTPA. In case of shut down of BKPL total product evacuation cannot be

achieved and which may directly impact the refinery production.

Consider additional spur with full rake loading facility in existing rail gantry.

Facility shall be designed for rail loading of Naphtha, HSD Euro III, HSD Euro IV,

MS Euro III, MS Euro IV, ATF and SKO from both the spurs.

New HSD Euro III rail loading facility shall also be considered with rail loading

transfer pumps, separate header and master meter in the rail gantry. There shall

be common PD meter assembly and loading arms for HSD Euro III and HSD

Euro IV.

Tap off for separate loading arm shall be taken downstream of PD meter

assembly of each product as shown diagrammatically below:

Following are the specifications for additional equipments considered:

1. HSD Euro III rail loading transfer pumps

Total No of Pumps : 5 (4 operating + 1 Stand by)

Rated capacity of each pump : 300 M3/Hr

Differential Head : 90 meter

Design Pressure/ Temperature : 15 kg/cm2 G/ 65 °C

MOC : KCS

NEW SPUR

RAIL

PD METER

LOADING ARMS

RAIL








Document No.

A439-RP-02-41-0001Rev B

Ch 7.8 Page 9 of 10


2. Loading arms for new spur

No of loading arms for HSD Euro III/ Euro IV : 50No of loading arms for Naphtha : 50

No of loading arms for MS Euro III/ Euro IV : 50

No of loading arms for ATF : 50

No of loading arms for SKO : 50

Normal/ Design flow of each loading arm : 65/72 M3/Hr

Design Pressure/ Temperature : 19 kg/cm2 G/ 65 C

MOC : CS

Type : Top Loading

Size : 3”

7.8.2.3 Pipeline Facility

Following is the product slate for marketing through multiproduct pipeline facility.

No modification is envisaged for pipeline transfer facility.

Figures in MTPA (000’TPA)

Route2013-14

MS-4 MS-3 HSD-4 HSD-3 SKO ATF Total

Bina - Kota 363 205 703 915 139 439 2764Kota - Mathura 363 180 703 775 135 439 2595

Mathura - Piyala 315 146 609 538 84 439 2131

Piyala - Bijwasan 292 0 404 0 14 439 1149

Route2019-20

MS-4 MS-3 HSD-4 HSD-3 SKO ATF TotalBina - Kota 459 248 889 1147 139 707 3588

Kota - Mathura 459 216 889 975 135 707 3380Mathura - Piyala 399 176 771 674 84 707 2810

Piyala - Bijwasan 370 0 511 0 14 707 1602

7.8.2.4 MTBE Tank Wagon Unloading Facility

To optimize Euro-IV gasoline blending around 98000 TPA MTBE requirements is

forecasted. To cater the demand Tank wagon unloading facility is required to be

designed at BDT.








Document No.

A439-RP-02-41-0001Rev B



Presently MTBE storage tank is already available at BORL (Tag No. 52-TT-DR-

18) with the storage capacity of 4250 M3. One additional tank is required to

accommodate bulk storage through rail gantry. Consideration of new storage tank

at BDT will not be of much benefit as extra set of pumps shall be required totransfer MTBE from BDT to MS blending station and above that

redundancy/flexibility of tank will not be there. Hence, additional MTBE tank shall

be provided in BORL nearer to the existing tank.

Tank wagon unloading facility and Pipeline from Tank Wagon gantry to the MTBE

tanks at BORL are considered on following basis:

Total Time available for unloading one full rake of MTBE shall be 5 hours.

Time available for a unloading = 3.5 hours

Time for connection/Disconnection = 1.5 hours

Number of BTPN wagons per rake = 50 wagons.

Capacity of each BTPN wagon = 55 MT.

1 full rake from one of the spurs is considered for unloading MTBE. Only one

spur shall be designed for unloading MTBE.

Single shift shall be of 8 hours.


50 number of BTPN wagons are considered for pump design (the pumping time

shall be 3.5 hours)

Total Rake capacity = 50 wagons x 55 MT = 2750 MT i.e. 3682 M3 (MTBE sp.

Gravity = 0.747)

The pump details for MTBE unloading pumps are considered as below:

Pump Rated Capacity : 300 M3/Hr

Pump Head : 100 meter

No of Pumps : 4 working + 1 stand by

Design Pressure/ Temperature : 15 kg/cm2 G/ 65 °C

MOC : KCS

ANNEXURE

Refer to annexure 7.8.1 for Bina Dispatch Terminal layout for post revamp

scenario.






LogisticsDFR for Debottlenecking of


Document No.

A439-RP-0241 -0001Rev B

Ch 7.9 Page 1 of 3


SECTION 7.9

LOGISTICS








Document No.

A439-RP-0241 -0001Rev B

Ch 7.9 Page 2 of 3


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

and partly power.








Document No.

A439-RP-0241 -0001Rev B

Ch 7.9 Page 3 of 3


Raw water : Raw water is made available at the refinery battery limit from river

Betwa. Raw water requirement is around 2000m3/h. Raw water storage and

treatment facility is provided for the refinery. Raw water is the source for Cooling

water, DM water, Drinking water and BFW that are used in the plant.

Power : Total power requirement post revamp will be around 115MW. Post

expansion power available from CPP will be around 47 MW ( CPP designed for

99MW) . The balance power shall be available from Grid power. The fuel for

existing CPP is Coke which is transported to refinery via railway.






Environmental ConsiderationsDFR for Debottlenecking of


Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 1 of 26


SECTION 8

ENVIRONMENTAL CONSIDERATIONS








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 2 of 26


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

its subsequent notifications.








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 3 of 26


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

S.No. Pollutants

TimeWeighted

Average

Concentration in Ambient Air

Industrial,

Residential, Rural

and Other Area

Ecologically

Sensitive

Areas (Notified by

Central

Government)

1 Sulphur Dioxide

(SO2), µg/m

3

Annual

Average*

50 20

24 hours** 80 80

2 Oxides of

Nitrogen as NO2,

µg/m3

Annual

Average*

40 30

24 hours** 80 80

3 Particulate Matter

(size less than 10

µm) or PM10

µg/m3

Annual

Average*

60 60

24 hours** 100 100

4 Particulate Matter(size less than 2.5

Annual Average*

40 40








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S.No. Pollutants

Time

Weighted

Average

Concentration in Ambient Air

Industrial,Residential, Rural

and Other Area

EcologicallySensitive

Areas (Notified by

Central

Government)

µm) or PM2.5

µg/m3

24 hours** 60 60

5 Ozone (O3),

µg/m3

8 hours** 100 100

1 hour** 180 180

6 Lead (Pb), µg/m

3

Annual Average* 0.5 0.5

24 hours** 1 1

7 Carbon Monoxide

(CO) mg/m3

8 hours** 2.0 2.0

1 hour** 4.0 4.0

8 Ammonical (NH3),

µg/m3

Annual

Average*

100 100

24 hours** 400 400

9 Benzene (C6H6),

µg/m3

Annual

Average*

5 5

10 Benzo (α) Pyrene

(BaP), Particulate

Phase Only ng/m3

Annual

Average*

1 1

11 Arsenic (As),

ng/m3

Annual

Average*

6 6

12 Nickel (Ni), ng/m Annual

Average*

20 20

* Annual Arithmetic mean of minimum 104 measurements in a year at a particular

site taken twice a week 24 hourly at uniform intervals.

**24 hourly or 8 hourly or 1 hourly monitored values, as applicable shall be complied

with 98% of the time in a year. 2% of the time, it may exceed the limits but not on

two consecutive days of monitoring.








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8.2.1.2 Emission Standards

The Emission Standards as proposed by CPCB for Petroleum Oil Refineries in thecontext of the proposed project are given below:

Table 8.2: Emission Standards For Furnace / Boilers / Captive Power Plant

S. No. ParameterFuel

Type

Limiting Concentration (mg/Nm3)

Existing

Refineries

New Refinery /

Furnace / Boiler

1NOx (Oxides of

Nitrogen)

Gas

Firing50 50

Liquid

Firing1700 850

2SO2 (Sulphur

Dioxide)

Gas

Firing350 250

Liquid

Firing450 350

3PM (Particulate

Matter)

Gas

Firing10 5

Liquid

Firing 100 50

4CO (Carbon

Monoxide)

Gas

Firing150 100

Liquid

Firing200 150

5Ni + V (Nickel +

Vanadium)

Liquid

Firing5 5

6H2S (Hydrogen

Sulphide) in Fuel gas

Liquid /

Gas150 150

7 Sulphur Content inliquid fuel, wt.%

Liquid /Gas

1.0 0.5

Notes:

1. In case of mixed fuel (gas and liquid) use, the limit shall be computed based on

heat supplied by gas and liquid fuels.

2. All the furnaces/boilers with heat input of 10 million kilo calories/hour or more

shall have continuous systems for monitoring of SO2 and NO2. Manual monitoring








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for all the emission parameters in such furnaces or boilers shall be carried out

once in two months.

3. All the emission parameters in furnaces/boilers having heat input less than 10million kilo calories/hour will be monitored once in three months.

4. In case of continuous monitoring, one hourly average concentration values shall

be complied with 98% of the time in a month. Any concentration value obtained

through manual monitoring, if exceeds the limiting concentration value, shall be

considered as non-compliance.

5. Data on Nickel and Vanadium content in the liquid fuel (in ppm) shall be

reported. Nickel and Vanadium in the liquid fuel shall be monitored at least once in

six months, if liquid fuel source & quality are not changed. In case of changes,measurement is necessary after every change.

Table 8.3: Emission Standards For Sulphur Recovery Unit (SRU)

S.No. ParameterPlant Capacity

(TPD)

Existing

SRU

New SRU or

Refinery

Commissioned

1 Sulphur Recovery, % Above 20 98.7 99.5

2 H2S, mg/Nm3 15 10

3 Sulphur Recovery, % 5-20 96 98

4 Sulphur Recovery, % 1-5 94 96

5Oxides of Nitrogen

(NOx), mg/Nm3 All Capacity 350 250

6Carbon Monoxide

(CO), mg/Nm3 All Capacity 150 100

Notes:

1. Sulphur recovery units having capacity above 20 tonnes per day shall have

continuous systems for monitoring of SO2. Manual monitoring for all the

emission parameters shall be carried out once in a month.

2. Data on Sulphur Dioxide emissions (mg/Nm3) shall be reported regularly.

3. Sulphur recovery efficiency shall be calculated on monthly basis, using quantity

of sulphur in the feed to SRU and quantity of sulphur recovered.








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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

on-stream repair of both seals shall be examined.








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Storage of Volatile Liquids: Benzene Storage

1. FRT with vapor to incineration with 99.9% of removal efficiency for volatile

organic compounds (VOC) shall be provided.

2. IFRT/EFRT with double seals, emission-reducing roof fitting and fitted with

fixed roof with vapor removal efficiency of at least 99% shall be provided.

Solvents for Lube-Base Oil production (Furfural, NMP, MEK, Toluene and

MIBK)

IFRT with double seals and inert gas blanketing with vapor removal efficiency of at

least 97% shall be provided.

Table 8.4: Emission Control For Road Tank Truck / Rail Tank Wagon

Loading

Loading of Volatile

Products

Gasoline & Naphtha:

(i) VOC reduction % 99.5

(ii) Emission, gm/m3 5

Benzene:


(ii) Emission, gm/m3 20Toluene & Xylene:


(ii) Emission, gm/m3 150

Notes:

(i) It shall be applicable for Gasoline, Naphtha,

Benzene, Toluene and Xylene loading.

(ii) Road tank Truck shall have Bottom loading and Roll

tank wagon shall have Top submerged loading.

(iii) Annual leak testing for vapor collection shall bedone.

8.2.1.4 Standards for Equipment Leaks

1. Approach: Approach for controlling fugitive emissions from equipment leaks

shall have proper selection, installation and maintenance of non-leaking or

leak-tight equipment. Following initial testing after commissioning, the

monitoring for leak detection is to be carried out as a permanent on-going

Leak Detection and Repair (LDAR) programme. Finally detected leaks are tobe repaired within allowable time frame.








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2. Components to be Covered: Components that shall be covered under LDAR

programme include (i) Block valves; (ii) Control valves; (iii) Pump seals; (iv)

Compressor seals; (v) Pressure relief valves; (vi) Flanges – Heat Exchangers;(vii) Flanges – Piping; (viii) Connectors – Piping; (ix) Open ended lines; and (x)

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

Table 8.6:








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Table 8. 6: Monitoring Requirements and Repair Schedule

S.No. Component Frequency ofmonitoring Repair schedule

1 Valves / Flanges Quarterly

(semiannual after

two consecutive

periods with < 2%

leaks and annual

after 5 periods with

< 2% leaks)

Repair will be started

within 5 working days and

shall be completed within

15 working days after

detection of leak for

general hydrocarbons. In

case of benzene, the leak

shall be attended

immediately for repair.

2 Pump seals Quarterly

3 Compressor

seals

Quarterly

4 Pressure relief

devices

Quarterly

5 Pressure relief

devices (after

venting)

Within 24 hours

6 Heat Exchangers Quarterly

7 Process drains Annually8 Components that

are difficult to

monitor

Annually

9 Pump seals with

visible liquid

dripping

Weekly Immediately

10 Any component

with visible leaks

Weekly Immediately

11 Any componentafter repair/

replacement

Within a week -

8. The percentage leaking components should not be more than 2% for any

group of components monitored excluding pumps/compressors. In case of

pumps/compressors it should be less than 10% of the total number of

pumps/compressors or three pumps and compressors, whichever is greater.

9. Emission inventory: Refinery shall prepare on inventory of equipment

components in the plant. After the instrumental measurement of leaks,








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emission from the components will be calculated using stratified emission

factor (USEPA) or any other superior factors. The total fugitive emission will be

established.

10. Monitoring following types of monitoring methods may be judiciously employed

for detection of leaks: (i) instrumental method of measurement of leaks; (ii)

Audio, visual and olfactory (AVO) leak detection; and (iii) Soap bubble method.

11. Data on time of measurement and concentration value for leak detection; time

of repair of leak; and time of measurement & concentration value after repair

of leak should be documented for all the components.

12. Pressure relief and blow down systems should discharge to a vapor collection

and recovery system or to flare.

13. Open-ended lines should be closed by a blind flange or plugged.

14. Totally closed-loop should be used in all routine samples.

15. Low emission packing should be used for valves.

16. High integrity sealing materials should be used for flanges.

8.2.1.5 Standards For Voc From Waste Water Collection And Treatment

1. All contaminated and odorous wastewater streams shall be handled in closed

systems from the source to the primary treatment stages (oil-water separator

and equalization tanks).

2. The collection system shall be covered with water seals (traps) on sewers and

drains and gas tight covers on junction boxes.

3. Oil-water separators and equalization tanks shall be provided with

floating/fixed covers. The off-gas generated shall be treated to remove at least

90% of VOC and eliminate odour. The system design shall ensure safety

(prevention of formation of explosive mixture, possible detonation and reduce

the impact) by dilution with air/inert gas, installing LEL detector including

control devices, seal drums, detonation arrestors etc. The system shall be

designed and operated for safe maintenance of the collection and primary

treatment systems.








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4. Wastewater from aromatics plants (benzene and xylene plants) shall be

treated to remove benzene & total aromatics to a level of 10, 20 ppm

respectively before discharge to effluent treatment system without dilution].

8.2.2 Noise Environment

Ambient Standard for Noise, specified by CPCB is given below in Table-8.7.

Table 8.7: Ambient Air Quality Standards in respect of Noise

S.No. Area Code Category of AreaLimit in dB (a) Leg

Day Time Night Time

1.0 A Industrial area 75 70

2.0 B Commercial area 65 55

3.0 C Residential area 55 45

4.0 D Silence zone 50 40

Notes:

1. Daytime is reckoned in between 6 am and 9 pm

2. Nighttime is reckoned in between 9 pm and 6 am3. Silence zone is defined as areas upto 100 meters around such Premises as

hospitals, educational institutions and courts.The Silence zones are to be

declared by the competent authority.

4. Mixed categories of areas should be as "one of the four above Mentioned

categories" by the competent authority and the Corresponding standard shall

apply.

8.2.3 Water Environment

The treatment scheme envisaged will meet the quantitative and qualitative limits of

parameters stipulated in General Standards for Discharge of Environmental

Pollutants for Petroleum Refineries as given in Table-8.8.

Table 8.8: Standards for discharge of Environmental Pollutants from

Petroleum Refineries

S.No Parameter Concentration not to exceed limitsin mg/l except pH

1 pH 6.0-8.5

2 Oil & Grease 5.0








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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








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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








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Fig.8.1








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Refinery has a full-fledged Effluent Treatment Plant (ETP) for treatment of the

following waste water generated from the refinery.

Oily effluent flow : 198 m3/hr (avg.)/ 375 m3/hr (design)

Sanitary flow : 25 m3

/hrSpent caustic flow : 7 m3/hr

CRWS : 25 m3/hr in dry weather and 1400 m3/hr in wet weather

Schematic Diagram of Existing ETP System is attached in Annexure-3

Design capacity of existing ETP at the refinery is 375 m3/h. As per operating data

furnished by BORL the average monthly effluent is 200 m3/h.

Post debottlenecking the maximum additional effluent generation shall be around

50m3/h. Hence existing ETP shall be adequate post debottlenecking and no

capacity augmentation is envisaged for existing ETP. One additional CRWS tank

of existing capacity is considered.

8.3.2 Gaseous Emissions

The atmospheric emissions related to the proposed facilities consist of Point or

stack emissions from continuous combustion sources.

The existing Refinery has a limit of SOx emissions of 30 TPD. At presentconfiguration of 6 MMTPA the total SOx emissions are 28.25 TPD. The unit wise

details are listed in Table 8.9 below:

Table 8.9: SOx emissions for Present Refinery Configuration.

Unit FiredDuty

FuelGas,kg/h

FuelOil,kg/h

FG(S content 150

ppm)

FO(S content 0.5 %)

EquivalentSulphur,

kg/h

SOx,kg/h

EquivalentSulphur,

kg/h

SOx,kg/h

CDU 64.45 1612 4867 0.24 0.48 24.34 48.67

VDU 42.5 1063 3210 0.16 0.32 16.05 32.1

HCU 88.1 4033 4465 0.61 1.22 22.33 44.66

DCU 42.7 1243 3110 0.16 0.32 15.55 31.1

NHT 27.05 676 1970 0.1 0.2 9.86 19.7








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CCR 37.9 948 2761 0.14 0.28 13.81 27.61

Hot Oil

Heater23.651 591 1723 0.09 0.18 8.62 17.23

HGU 50 0.01 0.02

SRU 1200 0.18 0.36

Pilot Burner 6.294 557 0.08 0.17

Flare Header

Purge500 0.08 0.15

TOTAL 332.65 12473 22106 1.84 3.69 110.5 221

Power Plant

Per Coke840

SRU 112.5

TOTAL TPD 28.25

The Total SOx emissions from the Refinery with proposed expansion to 7.5

MMTPA processing capacity, are estimated to be 29.33 TPD. The unit wise

details are listed in Table 8.10 below:

Table 8.10: SOx emissions for Post Expansion Refinery Configuration.

Unit Fired

Duty

Fuel

Gas,kg/h

Fuel

Oil,kg/h

FG

(S content 150 ppm)

FO

(S content 0.5 %)

Equivalent

Sulphur,

kg/h

SOx, kg/h Equivalent

Sulphur,

kg/h

SOx,

kg/h

CDU 75.03 4421 2639 0.66 1.32 13.19 26.39

VDU 44.53 1113 3362 0.16 0.33 16.8 33.62

HCU 86.86 3895 4349 0.58 1.17 21.74 43.49

DCU 46.64 1166 3397 0.17 0.35 16.98 33.97

NHT 35.09 1666 1650 0.25 0.5 8.25 16.50

CCR 54 4778 0.71 1.43

Hot Oil Heater 34.91 872 2542 0.13 0.26 12.71 25.42

HGU 50 0.01 0.02

SRU 2900 0.43 0.87

Pilot Burner 6.29 557 0.08 0.16

Flare Header

Purge500 0.08 0.16








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TOTAL 383.35 22096 17942 3.28 6.56 89.64 173.34

Power Plant

Per Coke840

SRU (243 TPDx 2 Trains)

Note 1 202.5

TOTAL TPD 29.33

Note1: SOx considering 99.5% recovery in SRU

(i) Fugitive Emissions from the process and storage units.

The major sources of fugitive emissions (VOCs) are the main processing area,

and storage tanks. These fugitive emissions originate from the pumps, valve

packing and connections/ joints to the atmosphere like relief valves etc.

8.3.3 Solid waste

Following types of solid wastes are generated in complex:

(i) ETP Sludge &Tank bottom sludge

(ii) Spent catalyst

(iii) General Solid Wastes

8.4 POLLUTION CONTROL MEASURES

8.4.1 Air Environment

Point / Stack Emissions:

For the expansion project, the major air pollutants will be SO2, NOx, and HC. In

order to control the pollution right at the source, low sulphur fuel gas is proposed to

be used. While the project is designed to use low sulphur fuel oil as fuels, flexibility

to use low sulphur fuel gas is also incorporated, depending on the availability, to

minimize SO2 emission. It has been proposed that low NOx burners be used to

reduce the NOx level substantially in comparison to conventional burners. During

start up/shut down or any emergency operation, the hydrocarbon emissions arising

due to lifting of relief valves, shall be directed to an elevated flare for complete

combustion. This shall eliminate the possibility of forming an explosive mixture due








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to sudden release of unburnt hydrocarbon to the atmosphere. The existing flare is

adequate to handle the additional load from this project. The hydrocarbons will be

fully burnt and adequate steam will be supplied at the flare tip to minimize smoke.

To ensure complete combustion of released hydrocarbon through flare, a pilotflame shall always be burning with the aid of fuel gas.

The proposed project shall employ state-of-the-art environmental control

technologies to minimize or eliminate toxic releases and emissions.

Fugitive Emissions Control:

In order to minimize the fugitive emissions of VOCs, the following measures shall

be taken during design stage.

(i) Minimum number of flanges, valves etc.(ii) High grade gasket material for packing.

(iii) Usage of "State of the art" low leakage valves preferably with bellow seals.

(iv) Usage of pumps with double mechanical seals for lighter

hydrocarbon/hazardous service.

(v) Provision of seals in the drains and manholes.

(vi) Floating roof tanks with double seals. Dome/Cone roof tanks with N2

blanketing.

(vii) Close blow down system in offsite and process units.

(viii) Bottom loading & vapor recovery system in Dispatch Terminal(ix) Collecting and recycling seal leaks back to the process, or treating in a

separate emission control device.

(x) Capping or blinding of open-ended valves.

(xi) Providing for closed sampling systems.

(xii) Instituting a comprehensive inspection, leak detection, and maintenance

program conforming to the requirements of the government.

(xiii) VOC Collection and Treatment system is already installed in the Effluent

Treatment Plant of the Refinery

8.4.2 Water EnvironmentThe water requirement at present for the refinery operation is met through

construction of a weir on Betwa River. At the design stage, there are several

measures proposed to be incorporated in the process so as to minimize the impact

on water environment during operational phase on the surrounding water bodies.

Some of these measures are described in subsequent sections.

In the design stage, two major mitigation steps are involved.








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(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.


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








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prominently displayed caution boards. The existing noise levels at the boundary

walls are in the range of 35-60 dB(A). Comprehensive measures for noise control,

at the design stage, shall be followed in terms of

(i) Noise levels specification of various Rotating Equipments as per

Occupational Safety and Health Association (OSHA) standards.

(ii) Equipment layout to consider the segregation of high noise generating

sources.

(iii) Erecting suitable enclosures if required to minimize the impact of high noise

generating sources.

(iv) Sizing of flare lines with low Mach number to have lower noise levels.

(v) Silencers are provided on high velocity venting systems

(vi) Acoustic insulations are provided in Compressor area/Ejector area.

8.4.4 Land Environment

The land environment management at design stage encompasses solid waste

disposal plan and development plan for local land use in such a way that treatment

and disposal do not cause any serious impact on the existing land use pattern.

8.4.4.1 Solid Wastes Handling, Treatment and Disposal

The Handling, Treatment and Disposal of the Solid wastes generated shallcomprise of the following :

ETP Sludge & Tank Bottom Sludge

As the proposed plant will generate only a fraction of total waste water generated,

subsequent increase in ETP sludge generation will also be marginal. Hence,

existing solid waste handling, treatment and disposal facilities will be adequate for

this purpose.

General Solid Wastes

The general solid waste generated will include packaging materials, scraps, spent

catalysts etc. Most of the solid wastes like packaging and scrap materials have

commercial value and will be disposed of by sale.








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 22 of 26


Spent Catalysts

Spent catalysts are essentially Co, Mo, Ni and alumina pellets. These catalysts

have a life of about 5 years after which they are either returned to themanufacturers or sold to approve re-processors or disposed off to authorized

TSDF agencies. Other hazardous wastes and solid wastes generated during

refinery operation are disposed as per the applicable guidelines.

8.4.4.2 Green Belt Development

BORL has carried out plantation activities in the 200m wide Greenbelt area around

the refinery and in BORL Township in a phased manner since 2008. The detailed

year wise saplings planted till date is given in table 8.11:

Table 8.11: Year Wise Plantation Details

S. No. Area & Location of Plantation YearApprox.

area

Sapling

planted

I Refinery

1. Phase – I: (North west side of the

Refinery complex adjoining village

Bhakri and South East Side near

gate no. 02).

2008 65 Hec. 1,06,900

2. Phase – II (South west adjoiningvillage Bildhai) .

2009 40 Hec. 62,000

3. Phase – III (South side of refinery

complex, rear side of Admin block &

front of Engg office).

2010 16 Hec. 25,000

4. Phase – IV (Back side of refinery

railway siding area).

2011 36 Hec. 40,000

5. Phase-V (South side of refinery

complex- Old Labour Colony (rear

side of flare and SRU), In front

contractor yard & Fly ash pond area)

2012 32 Hec 35,000

6. Beside Change Room1, Opp to

Workshop

2013 1 hec 300

Total 190hec. 2,69,200

II Township

1. Phase – I (along township internal 2008 12,000








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 23 of 26


roads)

2. Phase – II (along township boundary

wall)

2009 7,800

3. Road Side plantation (Refinery gate totownship gate)

2009 4,200

4. Fruit Bering tree plantation (Beside

villa A2)

2013 300

Total 24,300

It has been planned that during this year another 25000 Saplings shall be planted

inside refinery and 3500 plants in the township apart from the above mentioned

saplings.

The various species of sapling planted in the Greenbelt are given in table 8.12:

Table8.12: Sapling details

S.No. Name of Species S. No. Name of Species

1 Delvergia Sisoo 13 Castar

2 Pongamia Pinetta 14 Holopterlia Belleria

3 Azadiracta Indica 15 Ucaliptus Hybrid

4 Casia Samia 16 Embilica Officinalis5 Beuhania purpuria 17 Peltaforum Deltadis

6 Habiscus Rozasinensis 18 Sizygium Cumini

7 Casia Biflora 19 Jakrunda Mimiosa

8 Pshethapodia 20 Casia Gluca

9 Dendrocalemus Structus 21 Bouganbelia Spictivillis

10 Delonix Regia 22 Temerendus Indica

11 Anthosephelus Kandamba 23 Annano Squamosa

12 Beuhania Verigeta 24 Psidium Gqaba








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 24 of 26


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

complex.








Document No.

A439-RP-0241-0001

Rev B

Ch 8 Page 25 of 26


At present, a comprehensive water quality monitoring is carried out for physico-

chemical and micro biological parameters (i.e. pH, Oil & Grease, SS, DO, COD,

BOD, Sulphide, Phenol) at the inlet and outlet of both the existing Effluent

Treatment Plants. This monitoring shall be continued in the post project scenarioalso.

8.4.5.5 Soil/Sub Soil Quality Monitoring

Provision shall be kept for periodic monitoring of soil and subsoil characteristics in

and around the plant area. The important physico-chemical and biological

parameters of the soil shall be monitored to evaluate the impact on the land

environment.


As the plant is going to be operational on a 24-hour basis, noise considerations

are very important. All equipments will be specified to meet 85 dB(A) at 1 m

distance. As incorporated during the design stage, the plant areas where noise

levels are high enough to cause operations some adverse impacts, the usage of

ear plugs or ear muffs shall be strictly enforced. The exposure of employees

working in the noisy area shall be monitored regularly to ensure compliance with

the OSHA requirements.

8.4.7 Socio-Economic Environment

The local population is to be helped to take up the opportunities afforded by the

increased economic activities in the area.

Efforts shall be made to promote harmony with the local population and further

consolidate their positive perceptions of industrialization by engaging in socially-

friendly activities such as building hospitals, educational and technical training

institutes, etc. in due course of time, by co-coordinating with the present and future

industries of the area.

8.4.8 Health and Safety

In order to provide safe working environment and safeguard occupational health

and hygiene, the following measures will be undertaken:

Exposure of workers to hazardous/toxic substances will be minimized by

adopting suitable engineering controls.








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A439-RP-0241-0001

Rev B

Ch 8 Page 26 of 26


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.






Project Implementation &Schedule


Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 1 of 8


SECTION 9

PROJECT IMPLEMENTATION AND SCHEDULE








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 2 of 8


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

Uninhibited Tendency to affect mid course changes

Extensive Owners Management set up








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 3 of 8


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

the Contractor.








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 4 of 8


9.0.3. Comparison between Different modes of Implementation

The qualitative comparison between different modes of execution is tabulated

below:

Table 9.1: Comparison between different modes of implementation

PARAMETER EPCM EPC(OBE/LSTK)

Overall Cost Low High Schedule Commitment Low High

Owner’s Risk High Low

Contractor Risk Low High Flexibility to Change High Low

Contractual Issues & Change Orders Low High Owners Management team Resources High Low

Quality of Produce Flexible Not Flexible

9.1 STIPULATIONS – PROPOSAL SCHEDULE FOR LOW COST EXPANSION OF1.8 MMTPA OF BHARAT OMAN REFINERIES LIMITED (BORL)

General & Pre-shutdown related:

1. Zero Date of the Project is considered as award of Contract to EIL/ Go ahead fromBORL.

2. Environmental clearance considered to be available on Zero date.

3. Effective start date of the Project shall be considered as availability of complete

process package (BEDP) from respective licensors for licensed units.4. Final Process package inputs from licensor shall be made available by M/s BORL

within 5 months from agreement with Licensors so that effective start date couldbe maintained as indicated in the schedule

5. Mode of Project execution considered to be on EPCM.

6. Schedule has been Prepared considering capacity enhancement of followingareas based on adequacy check carried out by EIL:

9.1.1 Refinery

Increase in Capacity (Modification including additional Equipment) :

o CDU/VDU- 30%

o Integrated HCU and DHDT- 35%








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 5 of 8


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.








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 6 of 8


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.








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 7 of 8


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

critical equipment datasheet of licensed








Document No.

A439-RP-02-41-0001Rev B

Ch 9 Page 8 of 8


S.No Activity Schedule

unit or 1 month after receipt of critical

equipment datasheet of non-licensed

unit with duration of 25 months.

11 Tendering (incl. S/D related

Contracts)

First tendering to commence in 3 month

after effective start date with overall

duration of 15 months to complete

award of all balance tenders.

12 Construction Construction work/ mobilization of

contractor at site to commence

immediately after award of 1st tender

with duration of 23 months to complete

all construction activities incl.New trainof SRU.

13 Mechanical Completion (Pre-

shutdown Activities)

30 months from effective start date

14 Shutdown & Commissioning 45 Days as per assessment of M/s

Technip KTI from shutdown granted by

owner.

Shutdown duration to start from

permission of hot work by BORL.

15 Refinery MechanicalCompletion

On completion of shutdown activities.






PROPOSAL SCHEDULE - LOW COST EXPANSION OF BINA REFINERY (M/s BORL)

REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1. PROCESS INPUTS FROM LICENSOR

1.1 Environmental Clearance

1.2

Discussion & agreement for modification with Licensors M/s ABB (forDCU), M/s CLG (for HCU/DHDT), M/s UOP (for NHT, CCR & Penex) &M/s KTI for HGU

1.3 Revised Eqpt. Data Sheets for Licensed unit (From Licensor)

1.4 Revised P&ID & Line List (From Licensor)

1.5 Instrumnet data sheets & Process Package (from Licensor)

2. BASIC/ RESIDUAL ENGINEERING

2.1 Revision of Plot Plan identifying area s for New facilities. S/D ACTIVITIES

2.2Revised/ New Equipment Data sheets for CDU & VDU, SRU & OtherNon Licensed units

2.3 Issue of Revised P&ID's

2.4 Issue of Line List

2.5 Issue of Instrumentation Data Sheet

2.6 Updation of P&ID's based on Vendors data & Assistance to Engg.BALANCE VENDOR ENGG.

3. DETAILED ENGINEERING

4. PROCUREMENT

4.1 Wet Gas Compressor for DCU (1 no.) 21 M Supply DELY. - 19 FOB+2 MONTHS

4.2Net Gas Compressor for MS Block (1 no.) & Blow Down Compressor forDCU (1 No.)

18 M DELY. - 18 MONTHS

4.3 Desalter Vessel with Trays for CDU/VDU (1 No.) 12-14 M DELY. - 12 to 14 MONTHS

4.4Modification Eqpt. for Recycle Gas Compressor & Make up GasCompressor for HCU/DHDT (2 Nos.)

Discussion with Vendor 12 M DELY. - 12 MONTHS

4.5Pumps (CDU-12 Nos., VDU- 2 Nos.,DCU- 8 Nos., HCU/DHDT- 13 Nos.MS Block-2 Nos., LPG-4 Nos.,SRU-2, Offsite -3 Nos.=Total 46)

12 -16 MDELY. - 12 to 14 MONTHS

HCU Pump- 16 Months

4.6Heat Exchangers (CDU-2 Nos., DCU-11 Nos., HCU-10 Nos., MS block-16 Nos. HGU-3 Nos, SRU-7 Nos. = Total 49 nos.)

10 -12 M DELY. - 10 to 12 MONTHS

4.7 Air Coolers CDU-1 No., VDU-1 No., DCU-1 No., HCU/DHDT-5 Nos. MSBlock- 6 nos., HGU-1 No.SRU-1 No.= Total 15 Nos.)


4.8 Feed Filter (Addl. Bank) for HCU/ DHDT (2 No.) 10 M DELY. - 10 MONTHS

4.9Column (VDU-1 Columns, LPG CFC -1 No., LPG Amine-1 No, Total-3Nos.)


4.10 Column Trays/ Bed Modi. (27 Columns) 8 -10 M DELY. - 08 to 10 MONTHS

4.11

Vessel/ Separators (DCU-1 No., HCU- 5 Nos., MS Block-1 No., HGU- 1No., LPG-9 Nos., SRU-6 Nos., Total-23 Nos.) 8 -12 M DELY. - 08 to 12 MONTHS

4.12 Auxiliary Heater (MS block - 1 No.) 10 M DELY. - 10 MONTHS

4.13 Piping Material - Pipes/ Fittings/ Flanges (2 MTOs)DELY. - 06 to 10 MONTHS

DELY. - 04 to 06 MONTHS

4.14 Piping Material - Valves (2 MTOs)DELY. - 08 to 12 MONTHS


4.15 Electrical & Instrument items 6 -12 M DELY. - 06 to 12 MONTHS

4.16 DCS (Procurement & Installation) 10 -12 MDCS INSTALLATION


5. TENDERING

5.1 Refinery

5.1.1 Pre shutdown Composite works (Refinery)

5.1.2 Pre shutdown Composite works (Offsite+New SRU Train)

5.1.3 Additional Tankage works (COT- 3 Nos.+ Product-8 Nos.)

5.1.4 Heater Modification works (Including supply)

5.1.5 Shutdown Composite works - Piping+Eqpt Erection

<<< - - - - - - MONTHS - - - - - ->>>S. N. Description

6-10 M

8-12 M

4-6 M

6-8M

--

---

MECH.COMPLNPre S/D

Activities

AWARD OF CONTRACT toEIL (Zero Date)

--

--

--

--

---

EFFECTIVE START DATE(PROCESS PKG. FROM

LICENSORS)

------ --

---

START OFSHUTDOWN

Page 1 of 2






PROPOSAL SCHEDULE - LOW COST EXPANSION OF BINA REFINERY (M/s BORL)

REMARKS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

<<< - - - - - - MONTHS - - - - - ->>>S. N. Description

5.1.6 Shutdown - Electrical + Instrumentation

5.1.7 Shutdown - Insulation + Painting

5.2 Crude Receipt Pipe lines

5.2.1 Crude Pipeline & Booster station Composite works (Inclu. DG supply)

6. CONSTRUCTION

6.1 PRE SHUTDOWN ACTIVITIES

6.1.1 Refinery

Civil work/ Foundations incl. extension/ strengthening Total 20 Months duration

Structural Fabrication & Erection

Structural Modifications

Equipment erection S/D ACTIVITIES

Piping Prefabrication/ Spools (Pre S/D+ S/D Reqmt.)

Piping erection & Field Welding incl. Offsites requirements

Electrical Cable laying (if Required)

Instrument Calibration

Stock of Completed activities and Preparedness for Shut-down

Preparation for S/D related Contract activities

6.1.2 SRU New Train + Offsite

Civil / Foundations & Structural work incl. extension/ strengthening Total 20 Months Duration

Equipment erection

Piping Fab./ Erection & Field Welding incl. Offsites requirements

Electrical & Instrumentation Work

6.1.3 Tankage Work (COT+Product)

Construction of Tankages incl. procurement 16 Months

Tie in / Hook up & Commissioning

6.1.4 Crude Receipt Pipe lines

Construction/ Revamping of Pump Station

Pump/ DG Foundations

Installation of Pumps/ DG & Piping Prefab+ piping erection

Tie-in with Crude line, Hookup & commissioning

6.1.5 Cooling Tower (Addl. 1 No.)

Construction, Supply & Installation 15 Months

Hook up with Existing CT.

6.1.6 DM Plant & CPU (1 Addl. Chain)


Hook up with Existing Plant

6.1.7 N2 Plant & Compressed Air (1 Addl. Chain)


Hook up with Existing Plant

6.2 REFINERY SHUTDOWN

Cool down & HC cleaning by BORL

Shut down activity

Note: This schedule shall be read in ine with stipulations attached as Annexure-1.

Document No.

CLIENT M/s BHARAT OMAN REFINERIES LIMITEDA439-00-2744-P001Issued to Client with DFR

PURPOSE PREP CHKD APVD

PROJECTLOW COST EXPANSION (ADDL. CAPACITY 1.5 MMTPA)

OF BINA REFINERY

C 17-Jan-14 evised for description change & Reissued

PROPOSAL SCHEDULE

B 11-Jan-14

:

:

10-Dec-13

REV DATE

A

Revised & Reissued

START OFSHUTDOWN

DELIVERY AT SITE COMPLETEMILESTONE

MATERIAL REQUISITION

T

TENDER READY AWARD OF WORK ACTIVITY

DELIVERY (PART)ISSUE LOI / FOA

MECH.COMPLNPre S/D

Page 2 of 2






Project Cost Estimate

DFR for Debottlenecking of


Document No.

A439-RP-02-41-0001

Rev A

Ch 10 Page 1 of 8


SECTION 10

PROJECT COST ESTIMATE









Document No.

A439-RP-02-41-0001

Rev A

Ch 10 Page 2 of 8


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









Document No.

A439-RP-02-41-0001

Rev A

Ch 10 Page 3 of 8


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

coolers, Heater Tubes, Vacuum Ejector System.

HCU/ DHDT unit

Column Internals, Vessels, Heat Exchangers, Heater tubes, Pumps, PRTS,

Recycle gas Compressor, Air coolers, Feed Filter, Separators.

DCU unit .

Column Internals, Vessels, Heater tubes, Exchangers, Air coolers, Pumps, WetGas Compressor & Ring Compressor.

MS Block Units

NHT- Column Internals, Vessels, Exchangers, Air coolers, Pumps, New

Auxiliary Heater.

CCR- Exchangers, Air coolers, Net Gas Compressor, Burners

PENEX- Column Internals, Vessels, Exchangers, Air coolers, Pumps, Hot Oil

Heater, Refrigeration Package,Reactors.

HGU

Pre-Reformer, Technip Parallel Reformer (TPR), PSA, Reformer Tubes.









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SRU

One additional sulphur train, O2 enrichment facilities.

ARU & SWS-I & II

Tanks, Vessels, Pumps, Exchangers.

LPGCFC

Column, CFC Contactors & Separators, Pumps.

Utilities & Offsites

Crude & Intermediate Tanks, Offsite Pumps, Raw Water Pump, Cooling Tower

and Cooling Water Pump, additional nitrogen chain, LP Compressor, additional

bank in RO-DM, additional CPU Train, Oil Removal facility, CRWS Tank.

COT & BDT facilities

Additional crude tanks, Pumps and associated bulk items.

Pipelines Additional Booster Pumps & Modification in existing pumps

10.4.2 Catalysts & Chemicals

Cost provision for first fill of catalysts required is based on available information of

quantities and cost.

10.4.3 Indirect Costs, Exchange Rates

The cost estimate is based on following Exchange Rates & Indirect costs:

Exchange Rate 1 US$=Rs 61.0

Ocean Freight 5.0% of FOB cost of imported equipment

Port Handling 2.0% of FOB cost of imported equipment

Inland freight 5% of FOB cost of imported equipment and ex-

works cost of indigenously sourced equipment

Insurance 1% of Plant & machinery cost

Provision for ocean freight is for supplies by marine transportation / ships only. No

provision has been kept for any special transportation means such as Airfreighting or usages of barges.

10.4.4 Statutory Taxes and Duties

Provision for statutory taxes & duties has been made as under:

Custom Duty 25.85% of CIF cost of imported equipment

(7.5% Basic Customs Duty + 12.36% CVD+ 3%

Education Cess and 4% SAD).

Excise Duty 12.36% of ex-works cost of indigenouslysourced equipment.









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Central Sales Tax Applicable rate for CST is 4.1%

VAT on Works Contract 12.5% on Contract

Service Tax on Engineering

and Works Contract

12.36% ( 12% Service Tax + 3% Education

Cess) on Engg; 4.94% on contract

State Entry Tax 1% on Supplies

10.4.5 Land and Site development

Existing land is adequate for expansion project and no cost provision has been

made for land & site development.

10.4.6 Royalty, Know-How, Process Design / Basic Engineering Fees

Cost provision for Royalty, Know-how, Process Design, Licensor’s expatriate and

Basic Engineering has been made based on available information. Cost includesprovision for withholding tax and service tax.

10.4.7 Project Management, Detailed Engineering, Procurement Services &

Construction Supervision

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,









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construction equipment, ware house etc. shall be used and no cost provision has

been made.

10.4.14 Township

Existing township shall meet the requirement of expansion project.

10.4.15 Owners Construction Period Expense




detailed feasibility report - bharat oman refineries ltd

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