Synopsis:

ZEL engaged ENAR for review of UOP Schedule-A package. EDS package development of Auxiliaries and review of EPC Contractor's Process Design. The Scope of Work performed by ENAR is outlined below"

• Review of UOP Documents
• EDS Package Development

• Pre-HAZOP and Safety Screening and HAZOP
• Review of Contractor's Process Detailed Engineering

Synopsis:

Eastern Refinery Limited (ERL) a subsidiary of Bangladesh Petroleum Corporation (BPC) is operating a petroleum refinery in Bangladesh it is the only petroleum refinery of Bangladesh. The refinery has a design capacity to process 1.50 million metric tons of crude oil per annum. Currently, the refinery is processing Murban Arabian Light Crude Oil and is operating at 1.4 million metric tons per annum. The products from the refinery are meeting 35% of country's petroleum product demand.

Since ERL is the sole refinery of Bangladesh it is firming up plans for expansion of its refining facility to meet maximum petroleum products demand of the country. It is in this connection Bangladesh Petroleum Corporation (BPC) / Eastern Refinery Limited (ERL) has engaged ENAR to prepare Bankable Feasibility Study of ERL BMRE Project.

The objective of ERL's BMRF project is to expand the refinery capacity from 1.5 million MTPA to 4.5 million MTPA and produce 90-95 RON Gasoline, maximize HSD, SKO and enhance bitumen products while minimize FO.

The Feasibility Study being prepared by ENAR is bankable document shall have sufficient information to become part of the tender document for inviting bids for preparation of FEED (Frond End Engineering Design). The main aspects covered in the Study included:

• Petroleum Products Market Analysis
• Comparative Analysis of Alternate Refinery Schemes
• Detailed Description of Proposed Processing Scheme
• Techno-Economic Study of SPM
• Capital and Operating Costs of Proposed Scheme
• Financial & Economic Evaluation
• Environmental Considerations
• Human Resources & Training Needs
• Project Implementation Plan

Synopsis:

Attock Refinery Limited (ARL) is implementing the following projects:

• A 12,400 Barrels per Stream Day (BPSD) Preflash Unit at one of the existing distillation units HBU-I to increase its capacity from 20,000 BPSD to 32,400 BPSD (Designed by CB&I - Howe-Baker Engineers, USA)
• A 7,000 BPSD Isomerization Unit to produce final gasoline pool of 90 RON (Licenses from UOP) and modifications at existing reformer complex.
• A 12,500 BPSD Hydrodesulfurization Unit (HDS) to produce low sulfur High Speed Diesel (Licensed from UOP).

ARL engaged ENAR for providing engineering and consultancy services for the Project. ENAR work areas include:

• Review of UOP and Howe-Baker engineering package.
• FEED for auxiliary units and offsite & utility system based on UOP Schedule A Package and Howe Baker Engineering Package.
• Preparation of Tender Document for EPC Contractor (Including Draft Contract).

Synopsis:

PARCO is in the process of installing a Diesel Hydro Desulphurization (DHDS) Unit of 26,000 BPSD capacity at its Mid Country Refinery (MCR). The Project will enable PARCO to produce HSD wit max sulphur content of 250 wppm under first phase and 10 wppm I second phase.

The project is being implemented on Engineering, Procurement and Construction (EPC) basis UOP is responsible for providing license and preparation of Process Design of DHDS Project.

PARCO engaged ENAR for providing engineering and consultancy services for the Project. ENAR work areas included:

• Review of UOP Document and Design Review
• Development of FEED Document based on UOP Schedule A Package
• HAZOP
• Preparation of Tender Document for EPC Contractor
• Evaluation of Technical Bids
• Project Management/Construction Support

The Tender Document issued by NRL PARCO requires development of EDS package for Amine Unit, sour water stripper and duty spec for sulphur plant. ENAR has got extensive experience in working on Amine Units and in fact is the only company in Pakistan having worked on several fo these projects both in the refinery and gas sector. ENAR's range of service for these units cover process study, design reviews, conceptual design, detailed engineering, revamps, trouble shooting, construction supervision, start-up and commissioning. Amine plants are reactive systems having several operating issues like foaming, carry-over, etc. ENAR having worked with several Amine units is well versed about these issues and will take care that they are minimized during design.

Synopsis:

The project aims to revamp the Lube Refinery with the objective of enhancing the yearly lube base oil production from 96,000 metric tons to 115,000 metric tons. The revamp is being done based process design package provided by Exxon Mobil.

ENAR has been engaged as Engineering Contractor with responsibility of design, procurement services and execution of the project. ENAR's scope include:

• Review of process package & extended process design
• Detailed engineering:
• Mechanical/piping design
• Electrical design
• Instrumentation design
• Civil design
• Procurement & project management services
• Construction, erection, pre-commissioning & commissioning

The project is under execution and construction contractor is expected to mobilize shortly.

Synopsis:

NRL intended to de-bottleneck the Propane Recovery Unit (PRU) installed in 1977. NRL asked ENAR to undertake the required design & related work. The areas of work include:.

• Technical Audit of the unit (including simulation, test runs & equipment check)
• Process design
• Development of new equipment specifications
• Detailed engineering
• Estimation of budgetary capital cost estimate
• Preparation of tender document incorporating specifications, scope of work, BOQs, ITBs, form & conditions of contract

Synopsis:

ENAR was involved in project development as well as execution phases of PARCO's Mid-Country Refinery built at a cost of US$ 1.00 billion. The refinery is capable of processing 4.50 million metric tons of crude oil. During project development stage ENAR was involved in following areas:

• Establishment of design basis of UOP.
• Review of process selection studies prepared by UOP.
• Study of offsites/utilities.
• Review of PFDs and P&IDs prepared by UOP.
• Conceptualization of plot plan.
• Project development support.

During execution stage ENAR provided construction supervision services through a team of engineers, technologists and inspectors. The areas covered by ENAR's team included:

• Construction supervision/installation of vessels spheres, heat exchangers, air coolers, etc.
• Fabrication and construction supervision of fixed and floating roof tanks, checking and witnessing of tanks calibration
• Pre-fabrication, installation of piping works as per isometrics in the process, utilities and off-site areas.
• Supervision and inspection of welding works and other non-destructive testing of various areas throughout the plant. Arrangement and witness of pressure testing of equipment and fabricated piping.
• Health, safety and environment control of the entire refinery facilities during construction period.

Synopsis:

The Revamp-II aimed capacity enhancement and energy efficiency improvement of the following units of the Refinery:

• Naphtha Hydro Treater (UOP Design)
• Platformer (UOP Design)
• Propane De-Asphalting Unit

ENAR engineered and executed this project also on turnkey basis. The work included project management, procurement assistance, construction supervision and commissioning assistance. ENAR carried out complete process and detailed engineering based on UOP Schedule A Package.

For this Revamp also a dedicated team consisting of Coordinator, Engineers (various disciplines), Supervisors and Inspectors was assigned to the site. In this revamp also a running plant was modified. The units revamped operated at a high pressure and work involved addition/modification of complex equipment such as, Texas tower and recycle compressor in a restricted area. The Texas tower is a very tall and heavy vessel erection of which was very critical. Therefore, construction management team had to work very closely with Contractor for carrying out load test of crane and monitor the movement of crane in restricted process area. Welding required special procedures as fabrication of several grades alloys were involved.

Synopsis:

The Project envisaged:

• Addition of two storage tanks
• Enhancement of pumping capacity & fire-fighting system
• Modification of piping network
• Enhancement of electrical/instrumentation system

ENAR responsibilities include:

• Preparation of EDS package for the required additions/ modifications.
• Preparation of EDS package for the required additions/ modifications.
• Tender document for EPC Contractor
• Construction supervision and start-up assistance.

Synopsis:

The revamp aimed to enhance capacity of Crude Distillation Unit (CDU) by 15% and optimize the heat train. ENAR engineered and executed the project on turn-key responsibility basis including project management, procurement assistance, construction supervision and start-up & commissioning assistance.

The project management and construction supervision was carried out by assigning a dedicated team consisting of Coordinator, Engineers (various disciplines), Supervisors and Inspectors at site.

The Revamp-I required preparation of piping spool pieces such as that all tie-ins were carried out within the stipulated time. Several jobs were carried out, while the refinery was on stream. The jobs included civil foundations, steel structures, erection of equipment etc. this required close coordination with refinery operation personnel and contractors to ensure that the jobs were carried satisfactorily and safely. During shutdown all tie-ins were made within the stipulated timeframe and meeting the quality specifications.

Synopsis:

Grass Roots Hydrocracker Project for Upgrading Atmos Bottoms (Capacity 1.65 Million Metric Tons Annum).

ENAR was involved in undertaking the following work:

• Process Studies
• Feasibility Studies
• Preparation of Engineering Design Specification (EDS) Package for complete Offsites and Utilities as Sub-contractor to Procon (GB) Limited.
• Preparation of Job Instruction for revision of EDS packages as Sub-Contractor to UOP.

All the three bidders for execution of Project on EPC basis associated ENAR for substantial portion of engineering and related work.

Synopsis:

Acted as sub-contractor to IEI for complete design of offsite and utility facilities of Lube Expansion Project. The work performed included:

Process Selection:

• Carried out process selection for processing of base stocks for VI and pour point improvement.
• Carried out development of design basis with TEXACO for MEK and FEU units.
• Carried out design review including P&IDs and specification with CE Lummus for VDU, PDA, MEK, FEU.

System Study and Process Design for following offsite facilities:

• Storage Tanks Farm
• Base Oil and Bitumen Loading.
• Flare and Safety Systems.
• Steam and Condensate recovery system.
• Fresh and Potable water system.
• Waste water treatment system.
• Tie-in with existing system.
• Fuel Oil and Fuel Gas System.
• Fire Water System.
• Sewerage System.

Detailed Design for Civil, Mechanical, Electrical and Instrumentation for the following offsite facilities:

• Storages: Red Crude, Base Oil, Bitumen
• Intermediate Storage: P.D. Tar, FEU, MEK
• Utilities: Propane Storage, Fuel Oil, Fuel Gas Storage, Fire Fresh Water Area
• Waste Water Storage, API Separator: Flare stack and related piping, loading gantries for bitumen and base oils, steam and condensate dist. Network, plant and instrument air system distribution network and sewerage network.

Synopsis:

The available processes related to lube oil production viscosity index improvement and de-waxing were evaluated alongwith their licensers. Based on the evaluation carried out the Lube Expansion project configuration was established.

Synopsis:

The project involved blending, dehydration of base lube oil stock to produce transformer and turbine oils.

The facilities constructed for the project included storage tank farm for raw feedstock, blending kettles, dehydration units, re- circulation, feed and filling pumps, filling arrangement for drums and tank lorries, quality control and testing laboratory.

The services provided for the project included process and engineering design, cost estimating, preparation of bid documents, procurement coordination, shop inspection and supervision of construction.

Synopsis:

The project was undertaken in two phases and included storage tanks for raw feedstock, direct fired reactors, air-blowing units, re- circulation and feed pumps, filling kettles, reactor effluent scrubber system and hot oil system.

The services provided for the project include process and engineering design, cost estimating, preparation of bid documents, procurement, coordination, shop inspection and supervision of construction.

Synopsis:

Provided general consultancy to Owner and Project co-ordination- Off- site facilities consisting of steam, water, gas, compressed air system.

The project included site development (power, water, gas, and sewage disposal), steam generation, process water, fire water gas and compressed air systems alongwith raw feed storage facilities.

The services provided included project management, engineering design, preparation of bid documents, bid evaluation, preparation of contract documents and supervision of construction.

Synopsis:

Capacity enhancement of PRL Crude Unit. The assignment included development of :

• Process studies
• Conceptual and detailed process design
• Preliminary material take-offs and cost estimates

Synopsis:

The study was sponsored jointly by PERAC & NIOC and was undertaken by ABB Lummus, Germany in association with ENAR Petrotech Services. The aspects covered in the study included:

• Market analysis.
• Location/site selection analysis and environment impact assessment.
• Plant configuration studies.
• Assessment of processing, utilities, offsite and infrastructure facilities including mooring for receiving crude oil from tankers.
• Estimation of capital and operating costs within + 20% accuracy level.
• Financial analysis.

ENAR was involved in all the earlier aspects. In market analysis ENAR provided the historical petroleum products consumption/supply data alongwith pricing basis and economic data to be used for development of petroleum products demand (supply projection). The demand/supply projections were jointly developed by ENAR and ABB Lummus associated Trichem Limited.

The location/site selection and environmental impact assessment were independently undertaken by ENAR. The process configuration studies, assessment of utilities and infrastructure facilities and their cost estimation was undertaken jointly by ABB Lummus and ENAR. For development of capital cost estimates ENAR carried out preliminary process engineering of non-licensed process units and sizing of all utilities and offsite system. The major material equipment items were identified and sourced from Iran and Pakistan considering their manufacturing and fabrication capability. The remaining material and equipment was considered to be of foreign origin.

ENAR also provided inputs for undertaking the financial and sensitivity analysis of the project.

Synopsis:

The study was sponsored jointly by Pakistan State Oil Company Limited (PSO) and Hyundai Engineering & Construction Co. Ltd., South Korea and was undertaken by Stone & Webster Engineering Corporation, USA in association with Hyundai Engineering Co. Ltd. and ENAR Petrotech Services. The aspects covered in the study included:

• Market analysis.
• Assistance in finalization of refinery processing scheme.
• Location/site selection analysis and environment impact assessment.
• Preliminary design of offsites & utilities.
• Assistance in development of capital & operating cost and financial/economic evaluation.

In market analysis ENAR provided the historical petroleum products consumption/ supply data alongwith pricing basis and economic data to be used for development of petroleum products demand/supply projections. The demand/ supply projections were jointly developed by ENAR and Stone & Webster.

The location/site selection, preliminary design of offsites & utilities and environmental impact assessment were independently undertaken. ENAR gave valuable assistance to Stone & Webster in finalization of refinery processing scheme.

ENAR also assisted Stone & Webster in development of capital/operating costs and financial/economic evaluation.

Synopsis:

The project aims to relocate two old refineries from USA to Pakistan. The evaluation study covered following aspects:

• Technology and equipment evaluation.
• Assessment of offsite & utilities requirements.
• Detailed review of turn-key contractual arrangement.
• Project cost and financial evaluation.
• Environmental impact assessment.

Synopsis:

Under the assignment ENAR carried out following studies:

• Lube Quality Improvement Study
• Crude Processing with/without Visbreaker Unit
• Study of 20,000 BPSD Crude Unt Turn Down & Partial Utilization of Dubbs Unit in Conjunction with 20,000 BPSD Crude Unit

The lube quality improvement study evaluated to main options:

• Solvent Extraction Process
• Blending high VI and Low VI Stocks.

The scope fo study included:

• Development of processing scheme based on furfural/phenol extraction process and appropriate finishing process.
• Assessment of blending storage handling and facilities for blending with High VI lubes.
• Comparative economics of the two options.

Synopsis:

In the study following aspects were covered:

• Pakistani lubricants market size growth pattern
• Blending & marketing of lubricants
• Analysis of lubricants and base oil prices
• Lubricants market and sales forecast
• Future projections of lubricants market of PSO and blending requirements.

Synopsis:

The plants covered to valuation studies included:

• Mide-East Oil & Grease Ltd., Hub Chowki
• Salson Lubricants, Kot Samara, Rahim Yar Khan
• ARMAI, (RMI), Shershah, Multan
• Gizri Lubricants Ltd., Chak Piran
• Auto Oils (Pvt.) Ltd. (AOL), Sihala, Islamabad.

In the Study following aspects were covered:

• Review the past operational and financial performance of the plant(s)
• Assessment of physical condition and operability of plant(s) assets
• Verification of physical existence of the assets
• Indication of probable remaining operational life of the plant(s)
• Estimation of realizable value of plant(s) assets based on replacement value concept.
• Determination of plant(s) value based on future earnings/plant(s) economics.