Visakh Refinery Modernisation Project


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



  • 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.


  • Transportation of CDU/VDU columns/FCHCU reactors/ RUF Reactors in single piece from Hazira to Vizag through sea route.


  • 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.


  • 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.