Project ExecutionProject ExecutionExperience of an Indian RefineryExperience of an Indian Refinery

Now CPCL is a group company of IndianOil

Inception

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CPCL owns two Refineries CPCL owns two Refineries in southern part of India with in southern part of India with 220 thousand Barrels Crude 220 thousand Barrels Crude oil processing per Dayoil processing per Day

Company established in Company established in 1965 as a JV of GoI, NIOC 1965 as a JV of GoI, NIOC of Iran & AMOCO, USAof Iran & AMOCO, USA

50 thousand bbl / day grass 50 thousand bbl / day grass root Refinery near Chennai, root Refinery near Chennai, commissioned in 1969 in a commissioned in 1969 in a record time of 27 monthsrecord time of 27 months

YearYear CapacityCapacityMMTPAMMTPA

Major secondary processing Major secondary processing unitsunits

19691969 Initial CapacityInitial Capacity 2.52.5 Lube ,Cat Reforming,Diesel Lube ,Cat Reforming,Diesel Desulphurisation,Vis BreakerDesulphurisation,Vis Breaker

19801980 DebottleneckedDebottlenecked 2.82.8

19841984 Doubled (Refinery-II)Doubled (Refinery-II) 5.65.6 FCC ,WaxFCC ,Wax

1985-881985-88 Value Addition ProjectsValue Addition Projects Propylene,Food Grade HexanePropylene,Food Grade Hexane

19931993 DebotlleneckedDebotllenecked 6.56.5

19931993 CBR RefineryCBR Refinery 7.07.0

20022002 Debottlenecking-CBRDebottlenecking-CBR 7.57.5

20042004 3 MMTPA Expansion 3 MMTPA Expansion at Manali at Manali 10.510.5

Hydro Cracker, Hydro Cracker, Cat.Reforming,Soaker Cat.Reforming,Soaker

Visbreaker Visbreaker

Panorama of GrowthPanorama of Growth

• Refining capacity expanded by revamp of plants and addition of new units

• In 2004 Capacity expanded from 130 to 190,000 Bbls/day by addition of new Crude Distillation, Hydro-Cracker, Cat.Reforming, Soaker Visbreaker Units

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Panorama of GrowthPanorama of Growth

Green Power Generation

Project was completed in 6 months from order

Plant Capacity 17.6 MW

Estimated Power Generation

36 Million KWHrs / Annum

Generator Capacity

800 KW each

No of WEGs 22Project Cost Rs. 89.8 Cr

In 1991, commissioned a 2.5 MGD City Sewage Reclamation plant

In 2001, commissioned RO Rejects Recovery plant

Additional City Sewage Treatment Project

Capacity: 2.5 MGD Project cost : Rs. 46.68 Cr Commissioned : Dec ’06

Sea Water Desalination Project Capacity: 5.8 MGD Project cost : Rs. 231.34 Cr Scheduled completion: Dec

’07Slide 6 of 31

Water Management Projects

Refinery Expansion Cum Refinery Expansion Cum Modernisation Project 2004Modernisation Project 2004

Licensor Selection Implementation Strategies Commissioning

A success story in Project ExecutionA success story in Project Execution

Process Licensor SelectionProcess Licensor Selection

Unit Licensor CapacityCDU / VDU EIL 3.0 MMTPA

Visbreaker Lummus, Netherlands 1.15 MMTPA

Hydrocracker Chevron Global Lummus, USA 1.85 MMTPA

CRU Axens, France 225,000 TPA

Hydrogen Technip Benelux, Netherlands 56,000 TPA

Sulphur Recovery EIL / Delta Hudson, Canada 180 TPD

LPG Merox UOP, USA 42,000 TPA

Kero Merox UOP, USA 600,000 TPA

Associated Utility & Offsite facilities

Facility Utility / Scope Vendor2 x 20 MW Gas Turbine Power BHEL130 tph Boiler Steam BPHVCryogenic Nitrogen Plant Inert Gas BHPVUtility & Offsite facility Design EILSour Water stripper, Amine Treating & Regeneration facilities

Design EIL

Project executed on a combination of Project executed on a combination of Conventional and LSTK basisConventional and LSTK basis

CDU / VDU, OHCU and U&O executed on CDU / VDU, OHCU and U&O executed on conventional basisconventional basis

Hydrogen, NHT / CRU, VBU & SRU executed Hydrogen, NHT / CRU, VBU & SRU executed on LSTK basison LSTK basis

Entire LSTK (200 M US$) bidding process Entire LSTK (200 M US$) bidding process completed in 99 dayscompleted in 99 days

Implementation Strategies

Major Contractors Associated Major Contractors Associated with the Projectwith the Project

EILEIL BHELBHEL BHPVBHPV L&TL&T Punj Lloyd / Punj Lloyd /

PetrofacPetrofac

Bridge & RoofBridge & Roof PetronPetron SpicgelSpicgel NiccoNicco EPILEPIL

Safety Management

Safety features were incorporated right from design basis stage itself and during

• Finalization of P&ID & process package, • Detailed engineering, • 3 D modeling review, • Hazop review etc.

Safety was given top most priority during construction and commissioning.

3D Model & Hazop Review3D Model & Hazop Review 3D Model (Plant Design Software package) was

reviewed by CPCL in two stages.

After the completion of 50 % & 100 % of engineering• Interference checks were carried out • Approach to equipments and valves for operation

and maintenance

After Engineering, Hazop review was carried out After Engineering, Hazop review was carried out extensively in the presence of Licensor, PMC, extensively in the presence of Licensor, PMC, CPCL team comprising of experts from CPCL team comprising of experts from Operations, Process, Engineering and Contractor.Operations, Process, Engineering and Contractor.

Human resourcesHuman resources

Developing the trained manpower Operators with experience in high pressure

units were positioned one year ahead. Blend of experienced operators from with in

the refinery and new recruits. Class room training for two weeks. On the job training for two weeks in similar

units. Simulator training for panel engineers. Interactive sessions for atleast one hour in a

day.

Chemical Cleaning and Pickling Pressure Relief Valve Registration, Tagging,

and verification of Relief Pressure Rotary Equipment & Instrument Checklist Check on Fire protection & Safety system Construction Safety Audit External Safety Audit by OISD team Construction area Turnover

Pre-commissioning

Pre-commissioning

Special Concerns unique to High Pressure Units

Makeup Hydrogen System

RGC & Auxiliary Systems

HP system - Reactor Internals

PEG and RTJ Flanges

Furnaces

HP Loop Leak Test

High Pressure Reactors Pre-commissioningImportant checks doneImportant checks done Reactors expand several feet when heated –

interference from piping and instrumentation Reactor internals marked before removing for easy

reinstallation Levelness and tight fit of internals. Deviation can

cause mal-distribution and poor radial spreads Coat the nuts and bolts with high temperature anti-

seize compound Installation of quench piping Positioning of Temperature instruments inside Catalyst loading

Focus on High Pressure circuitFocus on High Pressure circuit

Protocol established to check all Protocol established to check all flanges in HP circuitflanges in HP circuit

Healthiness of flange faceHealthiness of flange face Right gasket in placeRight gasket in place Torque tension valuesTorque tension values

PSV Setting and validityPSV Setting and validity Spring support releaseSpring support release

CPCL commissioned the entire process units without any setback and in a safe

manner within stipulated time.

Hydro cracker unit was commissioned in 35 days smoothly from pressure test of

HP system in line with the process licensor schedule

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

Chevron Report on Commissioning

Thank YouThank You