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HAZard and OPerability Study Of BPCL Kochi Refinery

Bharat Petroleum Corporation Ltd. (BPCL) has an existing facility of the following:

  • SULPHUR RECOVERY UNIT (SRU)
  • DELAYED COKER UNIT-COKE DRUM STRUCTURE PACKAGE (CDSP)
  • FLUIDISED CATALYTIC CRACKING UNIT (FCCU)
  • NAPHTHA SPLITTER UNIT- KEROSINE HYDRO DESULFURIZATION UNIT (NSU-KHDS)

The objective is to conduct HAZOP study of CEMP II units KR to identify shortfalls in design for safe operation of the units and provide recommendations to overcome the risks involved. Addition of new units and revamp of existing units has led to a lot of changes to the refinery configuration. Modern risk analysis methods were adopted for all the new projects taken up recently. HAZOP study is conducted for all the modifications carried out internally in the existing units.

The facilities involved in each unit are as follows:

SRU

  • Combustion/ Thermal oxidation reaction
  • Waste heat recovery
  • Sulphur condensation
  • Reheating
  • Catalytic Conversion

                           Tail Gas Clean-up

  • Extended Claus reaction
  • Residual sulphur condensation
  • Tail gas incineration
  • NH3 Reduction

CDSP

  • Feed Surge Drum and Feed Preheat
  • Primary Fractionation
  • Vapor Recovery Section
  • LPG Amine Treatment Section
  • Coke Drum Steam out/Blow down
  • Decoking
  • Coke Handling

FCCU

  • FCCU MAB
  • FCCU 02
  • Biturox
  • GCU
  • GSU
  • LPG ATU
  • SWSU
  • ATF MEROX

NSU KHDS

  • Naphtha Splitter – I, Naphtha Splitter – I Reflux
  • Naphtha Splitter – II, Naphtha Splitter – II Reflux
  • Naphtha Splitter – II Reboiler
  • Fuel Oil & Fuel Gas Steam
  • Kero feed Reactor Effluent
  • Kero Fractionator feed
  • Kero Fractionator bottom
  • Kerosene stripper
  • Kero Fractionator Reflux
  • KHDS Recycle Gas Compressor
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