Summary
Owner/Location: HPCL, Visakhapatnam (Andhra Pradesh)
Mode of Execution: Project Management Consultancy Services and Open Book Estimate Basis
Project Management Consultancy Services
Key Features
- Overall Capacity :9 MMTPA
- Major Processing Units: CDU/VDU, FCHCU, RUF, NIU, MS block, DHT, HGU, SRU, CPP, Utilities & Offsites, Crude and Product storage tanks
- Total Project Cost (in USD): 3.2 billion
- Schedule:43 Months
Open Book Estimate Basis
Key Features
Erection of world’s heaviest LC-Max Reactor at VRMP
- Scope under OBE Job includes interface between New Process Units, Revamp Units, Packages, Balance of Plant & Existing Refinery including Units, Tankages, Utilities & Offsite facilities
- Total Project Cost (in USD): 370 Million
- Schedule: 43 Months
Challenges
Process:
- Lowest Energy number among all other CDU/VDUs operating in India with flexibility to operate over extreme wide range of Crudes.
- Production of MS and Diesel complying with BS VI Standards.
- Execution of India’s first Residue Upgradation Facility with 90% Conversion rate.
Procurement:
- Transportation of CDU/VDU columns/FCHCU reactors/ RUF Reactors in single piece from Hazira to Vizag through sea route.
Construction:
- Working in Brown field environment.
- Managed Peak workforce of 20,000 engaged through various contractor.
- Remobilization of Manpower after Mass exodus during Covid 19 Lockdown phase.
- Extensive use of Sheet piling for earth retention/supporting while excavation due to space constraints and extremely poor sub-soil conditions.
- Offsite pipe rack construction after VPT drain diversion and re-routing of existing Pigging station & marketing LPG lines of GAIL.
Achievements
- Erection of World’s Heaviest LC-Max Reactor.
- Execution of Asia’s Largest Hydrogen Generation unit.
- HSE: Achieving 150 Million LTA free safe Manhours.
- Erection of CDU/VDU columns in single piece.
- Erection of India’s Heaviest FCHCU Reactor.
- 42,000 MT of Structural steel (bolted structure) were used for construction of offsite pipe racks – total stretch of approx. 17 KMs.
- Approximately 700 Kms of Piping laid for connecting various facilities.
- 1550 Kms of electrical & 900 Kms instrumentation cabling laid for connecting various facilities
- Approximately 12,600 nos. Piling done in refinery and ATP areas.
- Extensive Tie-ins and hook-ups (approx. 526 nos.) for integration of existing units with New VRMP facilities.