HPCL

HPCL has two refineries, located in Mumbai (West coast) and

Visakhapatnam (East coast), with capacities of 7.5 MMTPA and
8.3 MMTPA, respectively.

It is proposed for expansion of the Mumbai refinery to 9.5 MTPA

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IOC, will invest Rs 1.75 lakh crore over the next seven years on expanding refinery
capacity, building petrochemical plants and laying pipelines.

• The plan includes spending Rs 34,555 crore in the 15 million tons a year Paradip
oil refinery in Odisha.
• raising Panipat refinery capacity to 20.2 million tons from 15 million tons
currently at a cost of Rs 15,000 crore
• raising capacity of its 13.7 million tons a year Koyali refinery in Gujarat by 4.3
million tons by 2020.
• hiking capacity of Mathura refinery in Uttar Pradesh by three million tons to 11
million tons in two stages – first to 9.2 million tons and than to 11 million tons.
• A small capacity addition of 0.5 million tons is also planned at 7.5 million tons
Haldia refinery
• Barauni refinery in Bihar will be expanded from 6 million tons to 7 million tons
in first phase and than to 9 million tons in second

Prior to Paradip, its eight refineries had a cumulative capacity of 54.2 million tons of
crude oil. Paradip helped IOC overtake Reliance Industries, which has twin refineries at
Jamnagar in Gujarat with a capacity of 62 million tons.

Essar Oil is the only other private refiner having a 20 million tons a year unit at Vadinar in
Gujarat.
11/1/16 HPCL VRMP EPCC - ENGG 2
IOC is also setting up a 700,000 tonnes per annum polypropylene (PP) plant at a cost of
Rs 3,150 crore at Paradip.

IOC is also looking at setting up a 5 million tons a year LNG import terminal at Ennore in
Tamil Nadu.
• New pipelines planned include Paradip-Raipur-Ranchi product pipeline,
• debottlenecking of Salaya-Mathura crude oil pipeline,
• augmentation of Paradip-Haldia-Barauni crude oil pipeline,
• Paradip-Hyderabad pipeline and Jaipur-Panipat naphtha pipeline.

11/1/16 HPCL VRMP EPCC - ENGG 3

 HPCL – VIZAG EXISTING UNITS

8.33 MMTPA refinery

Three crude distillation units,

MS Block (NHT/ISOM/CCR),
Diesel Hydro Desulphurization unit (Euro IV HSD),
two Fluid Catalytic Cracking units,
Visbreaker Unit,
Bitumen Blowing unit
Propylene Recovery unit.

11/1/16 HPCL VRMP EPCC - ENGG 4

 HPCL intends to further enhance its refining capacity up to 15 MMTPA under
VRMP (Visakh Refinery Modernization Project) at 18,400 Cr.

EIL was engaged as Consultant

to
carry out a Configuration Study and prepare a Detailed Feasibility Report. The
same was completed and submitted to HPCL on September 2012.

The basic process unit configuration finalized in the DFR under the selected
case ( Case 2A) were
(a) A new Crude Distillation Unit
(b) Full Conversion Hydrocracker as Secondary Processing unit and
(c) Solvent Deasphalting and Slurry Hydrocracker as Bottoms Upgrade units.

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 Therefore post VRMP, Refinery will be operating three CDUs as below

Existing CDUs :

CDU/VDU-II: 3.0 MMTPA

CDU/VDU-III: 3.0 MMTPA

New CDU

CDU/VDU-IV: 9.0 MMTPA

The basic process unit configuration finalized in the DFR under the selected
case ( Case 2A) were
(a) A new Crude Distillation Unit
(b) Full Conversion Hydrocracker as Secondary Processing unit and
(c) Solvent Deasphalting and Slurry Hydrocracker as Bottoms Upgrade units.

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A. Main Processing Unit

CAPACITY
1 CDU / VDU MMTPA 9
2 NAPHTHA ISOMERISATION UNIT KTPA 292
3 FULL CONVERSION HCU MMTPA 3.3
4 SOLVENT DEASPHALTING MMTPA 3.1
5 SLURRY HYDROCRACKER UNIT MMTPA 2.5
6 PROPYLENE RECOVERY UNIT TPD 96

B. Auxiliary Units
1 HYDROGEN GENRATION UNIT KTPA 2 X 113
2 FUEL GAS PSA KTPA 36
3 SULFUR RECOVERY UNIT TPD 2 X 360
4 SWS-I TPH 300
5 SWS-II TPH 185
6 ARU TPH 2 X 540
7 SR LPG TREATER TPA 112000

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C. Existing Units Requiring Revamp
1. NHT (existing capacity= 1.154 MMTPA) 30% Revamp : MMTPA 0.346
2. CCR/CCR PSA (existing capacity = 0.769 MMTPA) 20% Revamp : MMTPA 0.154
3. DHDT (existing capacity = 2.2 MMTPA) 20% Revamp : MMTPA 0.44

D. OFFSITES & UTILITIES

- N2 PLANT
- BOILER
- HRSG ??
- STORAGES AND TRANSFER (CRUDE, NAPHTHA, KERO, LPG, HSD, LDO ETC)

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11/1/16 HPCL VRMP EPCC 9
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 ITEM BHEL
CDU/VDU
DESALTER NO
HEAT EXCHANGERS - SET YES
PRE FLASH DRUM YES
CRUDE FIRED HEATER YES
AIR FIN COOLER YES
VACUUM FIRED HEATER YES
NAPHTHA STABILSER COLUMN YES
DRUMS - SET YES
PUMPS - SET

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 ITEM BHEL
HCU
REACTORS YES
HEAT EXCHANGERS - SET YES
SEPARATOR DRUMS YES
HCU FIRED HEATER YES
AIR FIN COOLER YES
AMINE ABSORBERS SET YES
FRACTIONATORS, STRIPPERS YES
COALESCER NO
PUMPS SET NO
COMPRESSORS NO
DRUMS - SET YES
PUMPS - SET NO

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 ITEM BHEL
SHCU
REACTOR YES
HEAT EXCHANGERS - SET YES
SEPARATOR DRUMS YES
SHCU FIRED HEATERS YES
AIR FIN COOLER YES
STRIPPERS YES
VACUUM DISTILLATION COLUMN YES
AMINE ABSORBER YES
PUMPS SET NO
COMPRESSOR NO
DRUMS - SET YES
PUMPS - SET NO
SLURRY PITCH DISPOSAL ???
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 ITEM BHEL
SOLVENT DEASPHALTING
EXTRACTION TOWERS YES
HEAT EXCHANGERS - SET YES
SEPARATOR DRUMS YES
EVAPORATORS YES
ASPHALT FIRED HEATER YES
STRIPPERS YES
COLUMNS YES
PUMPS SET NO
COMPRESSOR NO
DRUMS - SET YES
PUMPS - SET NO

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 ITEM BHEL
NAPHTHA ISOMERISATION UNIT
REACTORS YES
HEAT EXCHANGERS - SET YES
SEPARATOR DRUMS YES
AIRFIN COOLERS YES
CHARGE FIRED HEATER YES
STRIPPERS YES
STABILIZER COLUMN YES
PUMPS SET NO
COMPRESSOR NO
DRUMS - SET YES
PUMPS - SET NO

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 ITEM BHEL
PROPYLENE RECOVERY UNIT
HEAT EXCHANGERS - SET YES
SEPARATOR DRUMS YES
STRIPPERS YES
COLUMNS SET YES
PUMPS SET NO
DRUMS - SET YES
PUMPS - SET NO

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EPCC1

PROJECT MANAGEMENT, RESIDUAL PROCESS DESIGN, DETAILED ENGINEERING

(INCLUDING HAZOP STUDY), PROCUREMENT, FABRICATION, INSPECTION,
TRANSPORTATION, STORAGE, ASSEMBLY, ERECTION, INSTALLATION,
CONSTRUCTION , TESTING , STATUTORY APPROVALS, MECHANICAL COMPLETION,
PRE-COMMISSIONING, COMMISSIONING, PERFORMANCE GUARANTEE TEST RUN
(PGTR) OF DCU, CGOT, LPG TREATER, CONTROL ROOM, UNIT SUB STATION AND
COKE DISPATCH FACILITY (EPCC1 PACKAGE) ON LUMSUM TURNKEY BASIS FOR
“AISHWARYA” PROJECT AT IOCL HALDIA REFINERY, WEST BENGAL, INDIA
(BIDDING DOCUMENT NO.: RS/A609-000-PM-TN-7201/1002)
EPCC2 1094 CRORES
PROJECT MANAGEMENT, RESIDUAL PROCESS DESIGN, DETAILED ENGINEERING
(INCLUDING HAZOP STUDY), PROCUREMENT, FABRICATION, INSPECTION,
TRANSPORTATION, STORAGE, ASSEMBLY, ERECTION, INSTALLATION, CONSTRUCTION ,
TESTING , STATUTORY APPROVALS, MECHANICAL COMPLETION, PRE-COMMISSIONING,
COMMISSIONING, PERFORMANCE GUARANTEE TEST RUN (PGTR) OF DCU, CGOT, LPG
TREATER, CONTROL ROOM, UNIT SUB STATION AND COKE DISPATCH FACILITY (EPCC1
PACKAGE) ON LUMSUM TURNKEY BASIS FOR “AISHWARYA” PROJECT AT IOCL HALDIA
REFINERY, WEST BENGAL, INDIA
(BIDDING DOCUMENT NO.: RS/A609-000-PM-TN-7201/1002)
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 PRE-QUALIFICATION DATA BOOKLET
FOR PROVIDING RESIDUAL PROCESS DESIGN, DETAILED ENGINEERING,
PROCUREMENT, SUPPLY, CONSTRUCTION, INSTALLATION, TESTING AND
COMMISSIONING OF COKER BLOCK (EPCC-1) AND SULPHUR BLOCK (EPCC-2) AT
MANALI REFINERY OF CPCL
PREPARED AND ISSUED BY JACOBS ENGINEERING INDIA PRIVATE LIMITED
MUMBAI May 2010
EPCC-1 Coker Block consisting of DCU & LPG CFC Treating Unit.
EPCC-2 Sulphur Block consisting of Sulphur Recovery, Amine Recovery,
Sour Water Striper and Tail Gas Treatment Units.
EPCC Experience
Bidder should possess experience of having successfully executed with a single point
responsibility, at least 1 (one) EPCC (Engineering, Procurement, Construction &
Commissioning) Contract for Process Unit(s) on EPCC Mode in the Hydrocarbon Sector
(Refineries or Petrochemicals or Gas Processing Plant – onshore/offshore or Fertilizer -
gas/naphtha based) during the last 10 (Ten) years, with scope of work comprising of
Engineering, Procurement including Supply, Construction, Pre-commissioning,
Commissioning / Commissioning Assistance, Performance Guarantee Run and total
Project Management.
The above referred unit must have operated successfully for at least 1 (one) year after
commissioning prior to 31.03.2010.
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