bharat petroleum corporation limited...2010/06/16 · major scope of epcm : • development of 3d...

EOI FOR CCU REVAMP -16.06.2010-F.DOC of 21

BHARAT PETROLEUM CORPORATION LIMITED INVITATION FOR EXPRESSION OF INTEREST FOR THE REVAMP OF

CATALYTIC CRACKING UNIT AT MUMBAI REFINERY

1.0 Bharat Petroleum Corporation Limited, India is a Public Sector Undertaking

operating a 12 MMTPA Refinery Complex at Mumbai, India.

2.0 The contract/ order for CCU Revamp is planned to be awarded on a Lump

Sum basis for Licensing, Engineering (Residual/Detailed) , Procurement and

Construction Management (LEPCM) including warehousing on Lump sum

basis based on preliminary Scope of Work (Annexure-I) and Technical

details (Annexure-III). During the revamp the adequacy of the existing

equipments shall be carried out for the new design conditions. Equipments

found adequate along with other equipments of the CCU Complex shall

be subjected to routine turn around jobs involving pre-shutdown

assessment, decommissioning (decontamination, catalyst unloading/

loading, passivation etc.), engineering, procurement, construction

(maintenance including specialized cleaning, decoking) along with

revamp jobs.

3.0 Description of existing Units and Facilities :

REFINERY BLOCK TENTATIVE

CAPACITY

TECHNOLOGY

Catalytic Cracking Unit (CCU) 3500 MT/D SHELL

Gasoline Treater (Design) 1200 T/D UOP

LPG treater (Design) 450 T/D UOP

Catalytic Cracking Unit (CCU) was commissioned in 1955. This unit was designed by M/s Shell with rated fresh feed capacity of 1825 MT/D of ME VGO (Middle East Vacuum Gas Oil). CCU was revamped with know-how from M/s Shell in 1995 to operate at design throughput of 3500 MT/D of Mumbai High (MH) VGO with check case for processing Mumbai High LR (MHLR) to the extent of 40% of total feed. Max. Capacity test run report enclosed as Annexure II.

4.0 While the technical details are covered in Annexure III, Major objectives

envisaged in revamp of the existing CCU are as under:

1. Replacement of CCU Reactor & Stripper. Reactor is being replaced due to inspection recommendation, we would like to take this opportunity to migrate towards a two vessel configuration from the existing three vessel Shell configuration ( Reactor, stripper and Regenerator), since it would be more easier to operate and control

2. Maximize Processing of Resid of ~ 50 wt% on fresh feed along with

Vacuum Gas Oil. The unit has been designed with 3500 MT/D of feed with 40 % LR processing


3. We prefer the revamp to be carried out in single phase restricting

the turn around to 45 days. In case the same is not feasible bidder shall indicate maximum number of days required for the same Or an alternate plan to execute the same.

4. Maximize valuable distillates like LPG (min 15 wt% on fresh feed),

Propylene + Propane (min 10 wt% on fresh feed) & Gasoline (min 60 wt% on fresh feed).

5. CCU revamp design & check case are as under:

Design feed case -1

CCU at 3500 MT/D comprising 50wt% straight run MHVGO and 50wt% MHLR with existing Gas plant capacity

Design feed case -2

CCU at 3500 MT/D comprising 50wt% straight run MHVGO (25wt% straight run MHVGO, 25wt% Low Sulfur High Nitrogenous VGO) and 50wt% MHLR (25wt% MHLR and 25% Low Sulfur High Nitrogenous LR) with augmented Gas plant

Check case-1 CCU at 3500 MT/D comprising 30wt% straight run MH VGO and 70wt% MHLR

5.0 BPCL invites expression of interest from a consortium or Joint venture

partners with sound Licensing know-how, technical / financial capability

coupled with project implementation & management skills.. The interested

parties should support their expressions of interest with documents and

company profiles, in sufficient detail, to allow for initial appraisal of

capability to perform the work outlined. These details shall include, but not

be limited to the following :

i) Experience in executing similar LEPCM jobs either alone or as

consortium Or Joint Venture (at least two in the last ten years) of

similar in size and Complexities.

ii) As a minimum, positive net worth in three preceding years. iii) Financial strength and ability to provide a performance guarantee of at

100% of the contract value. In addition, the party must be willing to

provide completion guarantees as per commercial conditions of the

contract. As the project duration and revamp/turn around time is

the essence of the contract BPCL may consider inclusion of Bonus

clause for completion of job ahead of contract schedule

iv) Capability to make available adequate manpower and resources to

complete a Project of this size as per schedule inclusive of

revamp/turn around duration. Parties should indicate their concurrent

commitments.

v) Information regarding any current litigation in which the parties are

involved.


6.0 Tendering methodology

• Press invitation with major scope of work of CCU revamp for Expression of interest.

• Notice Inviting Tender (NIT) along with Technical, commercial details and Pre-Qualification Criteria to short listed LEPCM bidders.

• Combined quote for License/ BEDP along with EPCM consultancy along with credential for qualification.

• Major element of combined quote would cover (a) Preparation/Supply of Basic Design Engineering Package (BDEP) & (b) Engineering Procurement Construction Management (EPCM) of CCU revamp.

• Evaluation of offers qualified as per Prequalification criteria.

• Selection of LEPCM bids based on NPV considering sales realization, Operating expenditure and Capital expenditure and award for LEPCM job.

7.0 Brief Revamp Project Programme are as under:

The planned milestone dates for this job are as follows:

1. Issue of Bid Document including the

Prequalification criteria : August 2010

2. Award of LEPCM Contract : March 2011

3. Unit outage for Revamp/Turnaround : January 2014

8.0 General

i) The contracts/order will be on a fixed price Lump sum basis and

subcontracting for License/ EPCM is not permitted.

ii) Other things being equal, time for execution of the License/contract

work including the revamp/ turnaround outage of the unit, will be the

essence of the contract.

iii) Parties wishing to pre-quality as a part of a joint venture / consortium

with another company must declare this fact in their letter of Interest,

specifying name(s) of the joint venture / consortium partners, and

their willingness to participate.

iv) Each party must forward its (and its joint venture / consortium

partner’s wherever applicable) audited balance sheet for last three

years.

v) Each party must forward following information as prerequisite. (and

its joint venture / consortium partner’s where applicable) :

• Experience (minimum 2 nos.) for execution of revamp Fluid

Catalytic Cracker units on :

a) Revamp License for FCCU

b) EPCM basis


c) LEPCM basis

(Domestic / International experience shall be mentioned)

• Minimum value of contracts executed for above work (Rs.50

crores and above) indicate scheduled as well as actual

completion and finished contract value.

• Indicate whether any early completion bonus has been awarded

to you for these jobs.

• Specify minimum & maximum value of contract executed.

• Specify the list of orders/contracts presently being under

execution with relevant order/contract value and present state of

completion with schedule thereof.

vi) Interested parties are to note that receipt of “Expression of Interest”

notice does not guarantee any party the right of inclusion to formally

pre-qualify for the project.

vii) BPCL will not be responsible for any costs or expenses whatsoever incurred by interested parties in connection with the preparation and

delivery of their “Expression of Interest”. All costs and expenses

will be the sole responsibility of the interested party.

viii) Telex/fax/E-mail responses are not acceptable.

ix) No correspondence or communication in this regard will be

entertained. Determination of capability to perform the work

described will be assessed solely on the responses received from the

interested parties.

x) Incomplete responses will not be considered.

xi) BPCL will conduct a preliminary screening exercise to determine

those companies who will be asked to pre-qualify for the main bid.

BPCL also reserves the right to reject any or all parties declaring

“Expression of Interest” without assigning any reason or explanation

whatsoever.

xii) Interested parties should send their response in sealed covers to reach the following address latest on or before 19.07.2010 up to 16.00

hours. No extension of this date will be granted.

MR. K. RAVI

DGM (P&CS),

Bharat Petroleum Corporation Limited, (Mumbai Refinery),

Mahul, Chembur,

Mumbai – 400 074. (INDIA)


Annexure I

Revamp of Catalytic Cracking Unit at BPCL (Mumbai Refinery) (SCOPE OF WORK) Major Scope of Bidding entity for CCU Revamp:

1. Proposal shall contain details that would enable BPCL to select licensor along with EPCM. Major details are as under:

• Furnish process details such as preliminary PFD including heat & material balance, process conditions such as pressure, temperature, utilities, chemicals & catalyst requirements.

• Provide plot / equipment layout that are feasible to implement .

• Submit Preliminary equipment specification

• Provide utilities and catalyst consumption

• Estimated shutdown period to be indicated. BPCL prefers to limit CCU revamp period to maximum of 45 days.

• Provide CAPEX with 30% order of magnitude cost.

• Approach for the job indicating the packages and their broad scope.

• Bar chart indicating the project schedule of major activities.

• Deployment schedule for the project.

• Major milestones of the project with committed dates.

• Safety and Quality plan for the project

• Guarantees and their demonstration methodology

2. Selected licensor along with EPCM shall carry out a pre-revamp test run jointly with the client, on feed which may or may not be the same as that defined for the present study proposal. Operating conditions, yields, equipment performance which is obtained from this test run will be used as basis for preparation of the Basic Design & Engineering Package and for CCU revamp. Cost implication for carrying out this test run has to be built in by the licensors at proposal stage.

3. Licensor along with EPCM has to establish feasibility and implementation of CCU revamp within 45 days. LEPCM Contractor is the single point responsibility for all activities of Licensor and EPCM consultancy. Major activities of Licensor / EPCM are as listed below:


Major Scope of License:

• Pre revamp test run jointly with BPCL to establish existing capabilities of the units.

• Preparation of Basic Design & Engineering Package (BDEP) considering design / check feed case to meet aforementioned objective

• BDEP shall consider all sections including Feed section, Heater Reactor / Regeneration section, Main Air Blower, Wet Gas Compressor, Fractionator, Gas Plant, fresh/spent catalyst handling system and facilities handling flue gas ex regeneration upto CO boiler.

• Adequacy check of existing equipments and/or units.

• Development of dismantling P&ID

• HAZOP along with BPCL.

• Provision of data required to complete the detailed engineering by EPCM engaged by licensor.

• Provision of ISBL data required to complete the detailed engineering for offsite / utilities by EPCM engaged by BPCL.

• Review of critical design documents.

• Assist in Performance Guarantee Test Run

Major Scope of EPCM :

• Development of 3D model of existing unit as necessary for ease of implementation of Revamp jobs

• Detail engineering of CCU revamp based on BDEP.

• Dismantling of existing facilities & implementation of CCU revamp.

• Based on licensor input, carry out adequacy check all equipments and facilities including feed section, Fractionator, MAB, WGC, gas plant, LPG and Gasoline treatment along with feasibility of implementation & optimization studies for both design feed case.

• Indicate major limitations of equipment if any for check cases.

• Identify new equipments that can be located within ISBL of CCU.

• Assessment of modifications at site and interaction with licensors / BPCL to convey the specific limitations

• Feasibility of implementing the recommended modification

• Obtain information related to NOx, SOx & particulates and methods to control these emissions to permissible level from the licensors.

• Development of the plot plan / equipment layout based all above inputs.

• Preparation of budget estimates and cost monitoring during the entire period of project

• Complete EPCM work including Planning, Tendering/ Contracting, Procurement, Inspection/ Expediting, Construction supervision and warehousing.

• Assist in pre-commissioning and commissioning activities and test runs.


Annexure-II Operating Parameters of CCU Max test run

Date 28-08-2009

Feed stock origin 30% Azeri+70% Mumbai high

6.0 Operating Conditions Tag No. Unit

Heater/ Reactor Riser/ Prestripper

Cold feed ex storage FC170 MT/D 760

Slurry Recycle FC45 MT/D 230

Atomising steam FC206 MT/D 56

Prestripping steam FC202 MT/D 44.6

Dechoking steam FC201 MT/D 17.7

Catalyst circulation rate CATCIR MT/Min 13.3

Catalyst hold up Calculated MT 21

Cat to oil ratio (Based on fresh feed) Calculated 5.5

Heater outlet temperature TC407 Deg.C 316

Feed to reactor TI14 Deg.C 318

Riser Top TC206 Deg.C 515

Feed Line pressure PR393 Kg/cm2g 6.4

Top pressure before cyclones PC47 Kg/cm2g 2.1

Prestripper bed density KG/M3 712

Prestripper level LC201 % 50

Stripper

Steam to Riser FC169 MT/D 104

Steam to Stripper Bed FIC160 MT/D 10

Total steam per ton of Feed Calculated KG 66.4


Bed temperature TI21 Deg.C 512.1

Top temperature TI22 Deg.C 504.2

Stipper density KG/M3 737.7

Regenerator

Total Air

FC501-FI502-FI503)-FR56 MT/D 2195

Spray water MT/D 0

Steam to Top MT/D Valve kept full open

Torch oil FC53 MT/D 0

Catalyst bed Temperature TR16 Deg.C 689.2

Cyclone inlet Temperature TI5 Deg.C 696

Stack Temperature after cyclones TR26 Deg.C 682.1

Flue gas after COB TI966 Deg.C 257.1


Regenerator Contd…


Regn Inventory PDR14 3.1

Regenerator Bed Density PDR15 4.2

Bed Density Calculated Kg/m3 406.4

Air/(coke+Torch oil) Calculated 17.5

H2 in coke Calculated % 8.4

Catalyst hold up Calculated

Fractionator

Column Top TC34 Deg.C 122

Main reflux drawoff TI240 Deg.C 141.5

LCO Drawoff TI48 Deg.C 208.5

Vapors to LCO zone TI47 Deg.C 205.7

HCO Drawoff TI45 Deg.C 275

Desuperheated vapors to tray1 TI38 Deg.C 261

Grid tray 2 TI272 Deg.C 238.4

Flash zone TI37 Deg.C 333.5

BCR Slurry drawoff TI62 Deg.C 356.1

CLO drawoff TI42 Deg.C 276.7

Bottom slurry TI60 Deg.C 351.9

Column Top pressure PI252 Kg/cm2g 1.6

Column OPA pressure PR21 Kg/cm2g 1.5

Column Pressure drop PDR3 Kg/cm2 0.086

Pumparound flows/Return temperature

Main Reflux FC221 MT/D 2340

Auxillary reflux FC47 MT/D 151

LCO CR FC215 MT/D 2600

HCO CR FC216 MT/D 1362

BCR Circulation FC211+ FC212 MT/D 3825+3247

Main reflux return TI98 Deg.C 65.2

Auxillay reflux return TI253 Deg.C 43.9

Combine reflux temperature TI52 Deg.C 53.9

LCO CR return ex E-341 TI266 Deg.C 135.7

LCO CR return to column TI270 Deg.C 108.3

HCO CR return TI268 Deg.C 200.8

BCR return (TI41/ TI282) Deg.C 217..3/215.8

Stripper Scrubber

SS reflux FC44 MT/D 1050

SS bottom to fractionator FR54 MT/D 95.5

Stripper scrubber Contd…

SS top to fractionator FR55 MT/D 69.4

Vapors ex SS OPA FR49 MT/D 43.3

Total steam to SS

FC169+ FIC160+ FR33 MT/D 117

Clarified oil to SS (Estimate) MT/D

Total HC vapor load to SS (Calculated) MT/D 208

SS bottom temperature TI31 Deg.C 184.7


SS top temperature TI35 Deg.C 155.4

SS OPA temperature TI36 Deg.C 44.2

PC 48 Output PC48 % 1.6

SS OPA pressure PR22 Kg/cm2g 1.1

Absorber

Gas feed FR515 MT/D 290.8

Liquid feed FC58+ FC517 MT/D 1675+177

Lean oil to column FC61 MT/D 312

Rectified Absorber To flow FR518 MT/D 139

Oil to sponge absorber FC60 MT/D 140.4

Rich Oil ex sponge absorber FC62 MT/D 363

1ST Stage liquid to R. Absorber TI65 Deg.C 43

Second stage seperator V-181 I/L TI516 Deg.C 54.4

R. Absorber top temeprature TI76 Deg.C 63.6

Overhead gas (Feed to Sopng) TI517 Deg.C 57.7

Above tray 45 TI73 Deg.C 59.2

Reboiler return to the column TC295 Deg.C 122.4

Lean oil temperature TI83 Deg.C 47.2

Sponge oil temperature TI69 Deg.C 36.6

Sponge gas temperature TI74 Deg.C 35.1

Sponge absorber pressure PC25 Kg/cm2g 14.5

Pressure differential across the column PDR25 Kg/cm2 0.52

Debutanizer-2

Feed to column FC223 MT/D 2364

LPG To Stg FC226 MT/D 555

Gasoline to Merox FI233 MT/D 1552

Reflux to column FC64/ FC224 MT/D 1182

Feed ex E-406/407 TI77 Deg.C 40.8

Debutanizer-2 Contd…

Feed to Bebut ex E-406/407 TI251/ TI243 Deg.C 125.1

Overhead vapors TI80/ TI233 Deg.C 57.9

Tray 32 liquid TC87/ TC224 Deg.C 85

Reboiler return to column TC105/ TC230 Deg.C 161

Reflux temperature TI49/ TI241 Deg.C 46.2

Bottom to E-406/407 TI82/ TI246 Deg.C 148.4

Bottoms ex E-406/407 TI249/ TI245 Deg.C 132

Top pressure PC25/ PC230 Kg/cm2g 9.1

C3/C4

Feed FC101 MT/D 685

Feed Temperature TC102 Deg.C 42.5

Reboiler O/L temperature TC109 Deg.C 112.8

TY-75 temperature TC106 Deg.C 57.5

Column pressure PC103 Kg/cm2g 22.5

Wash Water

To Debutanizer overhead condenser FI228 MT/D 0


To fractionator overhead condenser FR22 MT/D 121.3

To inter stage condenser FR194 MT/D 22.7

To primary absorber FR23 MT/D 21.6

CO Boiler

steam load FR954 MT/D 423.1

CO inlet temperatuure TI960 Deg.C 659

Combustion zone temperature TI956 Deg.C 570.3

Super heater outlet temperature (Bulk steam) TI953 Deg.C 361.1

Economiser outlet temperature TI954 Deg.C 202.1

Stack temperature TI966 Deg.C 257.1

Steam temperature TC952 Deg.C 350

Combustion zone pressure PR957 MM H2O 44

Steam drum pressure PR953 Kg/cm2g 19.6

Attemperator opening %

Blower

Suction flow FC501 MT/D 2195

Steam to turbine FI505 MT/D F

Condensate flow FI515 MT/D 467.5

Discharge temperature TI502 Deg.C 181.5

Discharge pressure PI503 Kg/cm2g 2.3

Condenser vacuum PI513 MM HG 666.5

Steam pressure PI504 Kg/cm2g 16.5

Speed SI501 RPM 480.8

Wet gas compressor

1st Stage suction flow WFC80 MT/D 780

2nd stage suction flow WFC82 MT/D 525

1st Stage antisurge valve opening % 0

WGC Amps CAMPS Amps 225.3

1st stage suction temperature TI88 Deg.C 39.9

2nd stage suction temperature TI90 Deg.C 38.9

1st stage discharge temperature TI89 Deg.C 109

2nd stage discharge temperature TI91 Deg.C 132.5

1st stage suction pressure PC83 Kg/cm2g 0.4

Interstage pressure WPC82 Kg/cm2g 2.7

2nd Stage discharge pressure PR55 Kg/cm2g 15.3

4.0 Whether conditions

Max /Min temperature Deg.C

Barometric pressure mm Hg 760

Relative humidity %


Product Yield

Date 28-08-2009

Feed Type 30% Azeri+70% Mumbai high

Waxy Feed MT/D 3193

Long Residue MT/D 337

Slurry Recycle MT/D 230

LCO Recycle 0

Total Fresh Feed MT/D 3760

Product Ex Reactor

Gas % wt 2.5

LPG % wt 16.2

Gasoline Up to 220 Deg.C % wt

45.3% (up to 180 Deg.C) and 50.5 up to 220 Deg.C

TCO % wt 22.02 (220-370)

CLO (370 Deg.C+) % wt 4.5

Coke % wt 3.6

Conversion up to 220 Deg.C %

72.8 at 220 Deg.C and 65.8 at 180

Deg.C

Operating parameters

Catalyst to oil ratio 5.5

Feed preheat Deg.C 316

Riser temperature Deg.C 515

Regenerator dense phase temperature-TR16 Deg.C 689.2

Regenerator dilute phase temperature-TI5 Deg.C 696

Air flow rate kNm3/Hr 75.9

Wet gas compressor 1st stage flow rate MT/D 780

Wet gas compressor 1st stage flow rate kNm3/Hr 525


Feed/Product Quality

Fresh feed (Combine feed) Unit

Density @ 15 Deg.C Gm/ml 0.8906

Deg.API 27.38

Color ASTM (DIL) L7

Carbon Residue %WT 0.27

Sulphur %WT 0.22

Asphaltenes %WT 0.009

Total N2 %WT 803

Basic N2 %WT NA

Kinematic viscosity @99 Deg.C Cst 5.68

pour point Deg.C 48

Trace metals

Ni PPM WT 0.64

V PPM WT <0.1

Cu PPM WT <0.1

Fe PPM WT 0.24

Na PPM WT 4.2

Metal Index (10 Ni+V) 6.5

Distillation, ASTM D1160

IBP Deg.C 244

5% recovery Deg.C 298











FBP Deg.C 481

Waxy feed (hot)


Deg.API 29.09

Color ASTM (DIL) L3.5


Sulphur %WT 0.2


Total N2 %WT 641

Waxy Feed Contd…

Basic N2 %WT NA


pour point Deg.C 48

Trace metals

Ni PPM WT 0.1

V PPM WT <0.1


Cu PPM WT <0.1

Fe PPM WT 0.34

Na PPM WT 9.15


IBP Deg.C 243











95%/98 % recovery Deg.C 474

FBP 499

Metal Factor

Cold Feed


Deg.API 25.2

Color ASTM (DIL) L3.5


Sulphur %WT 0.24


Total N2 %WT 894

Basic N2 %WT NA


pour point Deg.C 42

Aniline Point Deg.C NA

Trace metals

Ni PPM WT 0.32

V PPM WT <0.1

Cu PPM WT <0.1

Fe PPM WT 0.1

Cold feed contd…

Na PPM WT 11.5


IBP Deg.C 245













FBP 523

Metal Factor 3.3

LR feed


Deg.API 24.5

Color ASTM (DIL) NA


Sulphur %WT 0.29


Total N2 %WT 1530

Basic N2 %WT NA


pour point Deg.C 51

Trace metals

Ni PPM WT 6.74

V PPM WT 0.61

Cu PPM WT 0.1

Fe PPM WT 2.66

Na PPM WT 11.58


IBP Deg.C 289











95% recovery Deg.C NA

Rec at 350/370/520/540/565 10/17/82/86

Tr Gasoline


Tr Gasoline Contd…

Sulphur % WT 0.0162

C4+lighters % WT NA

Total Olefins % V 49

Benzene content % V NA

Total Paraffins content % V NA

Naphthene conetent % V NA

Aromatic content % V 12.67

Unknown % V NA

RVP PSIG NA

ASTM D86 Distillation

IBP Deg.C 41

5%V Recovery Deg.C 53












FBP Deg.C 180

Rec@ 70 Deg.C/100 Deg.C %V 30/58

RON 90.6

MON 80.6

Cu corrosion 1a

Potential gum gm/m3 NA

H2S/RSH ppm negative/<5

UTr Gasoline

RVP psi 7.8

H2S/RSH ppm/ppm negative/24

Sulphur %wt 0.0169

Cu corrosion 1b

Light Cycle oil (LCO)

Density @ 15 Deg.C Gm/cc 0.8992

Sulphur % WT 0.24

Kinematic viscosity @ 38 Deg.C Cst 2.41

Flash point (Abel) Deg.C 66

Pour point Deg.C <0

Light Cycle oil (LCO) Contd…

Aniline point Deg.C 31.8

Catalyst content % Wt NA

Color L2.5

ASTM D86 Distillation

IBP Deg.C 162

5 % Recovery Deg.C 194









90 % Recovery 344


FBP Deg.C

Rec@ 350 Deg.C/370 Deg.C 92/98

Trace metals

Ni PPM WT <0.1

V PPM WT <0.1

Cu PPM WT <0.1


Fe PPM WT <0.1

Na PPM WT 4.63

Heavy Cycle oil (HCO)


Color L4

Sulphur % WT 0.44

Kinematic viscosity @ 50 Deg.C Cst 15.03 @40 Deg.C

Flash point (PMCC) Deg.C 88

Pour point Deg.C 27

Aniline point Deg.C 60

Sediments (unaged) % V

Catalyst content %Wt NA

ASTM D86 Distillation D-1160

IBP Deg.C 192








Heavy Cycle oil (HCO) Contd..




95 % Recovery/98% Deg.C 437

FBP 464

Rec @350/370/520 Deg.C 32/48

Trace metals

Ni PPM WT <0.1

V PPM WT <0.1

Cu PPM WT <0.1

Fe PPM WT <0.1

Na PPM WT 5.87

Clarified oil (CO)


Color D8

Sulphur % WT 0.54

Kinematic viscosity @ 99 Deg.C Cst 25.1 @40 Deg.C

Flash point (PMCC) Deg.C 51

Pour point Deg.C 15

CCR NA


IBP Deg.C 154













FBP Deg.C 500

Rec @350/370/520/540 Deg.C % 37/45

Catalyst content 0.05

Bottom Slurry

Density @ 15 Deg.C Gm/cc NA

Sulphur % WT NA

Catalyst content % WT 0.13

Bottom Slurry Contd…

Pour point Deg.C NA

D-1160 Distillation

IBP 195

5 % Recovery 282

10 % Recovery 325

20 % Recovery 363

30 % Recovery 384

40 % Recovery 401

50 % Recovery 413

60 % Recovery 425

70 % Recovery 441

80 % Recovery 461

90 % Recovery 499

95 % Recovery

FBP

Rec @350/370/520 Deg.C 16/24/92

Stripper scrubber bottom

Catalyst content % WT 0.1

Density @ 15 Deg.C 1.005

Flash point Deg.C 91


IBP Deg.C 186











95% Recovery Deg.C 505

FBP Deg.C 515

Rec @350/370/520 Deg.C % 40/48


Stripper Scrubber Top

Catalyst content % WT NA

Density @ 15 Deg.C 0.8667

Flash point Deg.C <20

Stripper Scrubber Top Contd…


IBP Deg.C 50











95 % Recovery Deg.C

Rec @350/370/520 Deg.C % 90/92

Flue gas analysis

O2 %V 4.4

CO2 %V 13.6

CO %V 0

N2 %V 82

Absorber Top gas

H2S % WT 0.9

CO2 % WT

H2 % WT 0.8

N2+O2 % WT

CO % WT

C1 % WT 22.8

C2 % WT 25.5

C2= % WT 22.3

C3 % WT 3.5

C3= % WT 9.8

TC4 % WT 4.4

IC5+NC5 % WT 0.4

C6+ % WT 9.6

Total % WT 100

Molecular Wt 25.02

RD

H2/CH4 Mole ratio 0.28

WGC 1st stage suction Unit Inert Corre

H2S % WT

CO2 % WT

H2 % WT 0.1


N2+O2 % WT

CO % WT

C1 % WT 3.9

C2 % WT 3.5

C2= % WT 3.5

C3 % WT 5.5

C3= % WT 17.2

IC4 % WT 13.4

NC4 % WT 3.9

Butene-1 % WT 3.5

I-Butene % WT 5.4

T-But-2 % WT 4.9

C-But-2 % WT 3.7

IC5 % WT 8.3

NC5 % WT 0.9

C6+ % WT 22.3

Total 100

Molecular Wt

WGC 2nd stage suction Unit Inert Corr

H2S % WT

CO2 % WT

H2 % WT 0.1

N2+O2 % WT

CO % WT

C1 % WT 5.8

C2 % WT 5.3

C2= % WT 5.3

C3 % WT 6.8

C3= % WT 22.2

IC4 % WT 13.6

NC4 % WT 3.5

Butene-1 % WT 3.6

I- Butene % WT 5.4

T-But-2 % WT 4.7

C-But-2 % WT 3.2

IC5 % WT 6.1

NC5 % WT 0.7

C6+ % WT 13.7

Total % WT 100

Molecular Wt

RD

LPG Merox-2 outlet Unit

H2S % WT Negative

RSH % WT

C2 % WT

C2= % WT

C3 % WT 6.7

C3= % WT 18.9

IC4 % WT 27

NC4 % WT 7.8


Butene-1 % WT 7.4

I-Butene 11.4

T-But-2 % WT 10.5

C-But-2 % WT 7.6

TC4 % WT 71.7

IC5 % WT 1.8

NC5 % WT

TC5 % WT 1.8

C6+ % WT 0.9

Molecular Wt 52.72

C4/(C3+C4) % WT 0.74


.

Annexure-III

Revamp of Catalytic Cracking Unit at BPCL (Mumbai Refinery)

(Technical Details)

• Existing two vessels (Reactor and Stripper) configuration has to be modified to single vessel type configuration. Licensor shall indicate the merits of providing single vessel.

• Licensor can consider new feed nozzles.

• Improved riser design such as cold wall, better residence time etc with state of the art Riser termination device.

• Improved reactor / regenerator cyclone design

• Regenerator will be retained. However regenerator internals may be replaced based on adequacy check of Regenerator & its associated system.

• Standpipes with quick acting slide valves of cold wall or with suitable design.

• Upgraded metallurgy for expansion bellows or use of packed bellows to be considered.

• Cold wall design for orifice chamber.

• Adequacy of reactor overhead line considering proposed reactor effluent.

• New Reactor, Stripper, Main Fractionator and related equipment may be located on existing foundation for which existing load capacity of Reactor & Fractionator foundation to be considered for design. Bidder may also suggest alternates which may add value to the project by way of reduction in execution period.

• Wet Gas Compressor (WGC) adequacy to be checked and suggest suitable option.

• Existing Main Air Blower (MAB) is steam turbine driven with maximum air compression capacity of 2600 MT/D and normal capacity of 2200 MT/D. MAB to be retained however internal modification can be considered. Alternately use of Oxygen may be explored..

• Regenerator operation with complete combustion mode to be considered with existing CO boiler as waste heat boiler. Alternatively licensor may suggest compact waste heat boiler to improve efficiency and reduce plot area.

• Possibility of installing Turbo generator & 3rd stage cyclone separators on flue gas path to be evaluated.

bharat petroleum corporation limited...2010/06/16 · major scope of epcm : • development of 3d...

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