KOCHI: The BPCL-Kochi Refinery is set to transform itself into a ‘state of the art’ industrial complex of global standards with the Integrated Refinery Expansion Project (IREP) of the refinery project entering the commissioning phase. The Rs 16,500 crore-project which began in 2013, envisages setting up major units to enhance the refining capacity of the existing plant by 6 million metric tonnes. The present capacity of the refinery is 9.5 metric tonnes.
“The commissioning of IREP is set to make Kochi Refinery the largest in the country in terms of capacity and complexity and will make the state self-sufficient in petroleum products,’’ said Prasad K Panicker, executive director of BPCL Kochi Refinery. “Besides the advantages for industries, the project will also help Cochin Port earn extra income by handling 7.8 million metric tonne product annually. Propylene production will go up to 0.5 tonnes once the IREP is commissioned.”
Apart from the increased capacity of 15.5 million metric tonnes and planned modernisation, the project will also help the refinery produce eco-friendly petrol and diesel complying with Euro IV and V standards.
‘’Implementing IREP was a Herculean task,” said a refinery officer. “Equipment weighing 41,000 metric tonnes had to be installed, including laying of 1,700 km piping and 700 km cables and transportation of 2,000 equipment. Of these, 220 are over-dimensional consignments which were transported to the project site by road and water.’’
A BPCL-Kochi refinery benchmark
At the peak of construction, more than 17,000 contract labourers were working at the site in a day. A modern palm vein authentication technology was put in place to ensure reliable and rapid entry to the site. A medical unit and ambulances were kept on standby around the the clock.
‘’With the support of trade unions, BPCL could also bring in a new work culture during the implementation of IREP,” said the source.
“This is now known as the BPCL-Kochi Refinery model in the industry. An industrial relations committee was constituted under the assistant labour commissioner to ensure uninterrupted work and enhanced productivity on the IREP. The model was shaped at the early stage of the project by BPCL,
the Union Ministry of Labour and the Kerala Department of Labour through discussions with stakeholders. Disputes were brought up at the committee meeting every month on a fast track basis.’’
Main Control Room isblast-proof
The Main Control Room (MCR) of IREP will be functioning at a specially-built, blast-proof building. The MCR where all the data related to operations control and data are processed, will serve as the IREP cockpit. The 5,500 sq m MCR will also all have full-fledged HVAC system, fire alarm system and clean agent system. The external face of the building is provided with Glass Fibre Reinforced Concrete (GFRC) panels with facade lighting.
Not too hot to handle
In addition to the existing fire fighting facility, a modern fire station has been added with imported fire fighting vehicles. Situated in 1.5 acres, the new fire station has a 2,250 sq m built-up area. Facilities include 12 fire truck bays, main fire control room with modern communication facilities, emergency control centre and training hall for 100 persons.
Top-notch petrochemical complex
The Rs 4,588-crore Propylene Derivatives Petrochemical project is expected to have the biggest benefit on the state’s economy. Propylene produced in the new units after commissioning of the IREP can be used as the feedstock to produce acrylic acid, acrylates, and oxo- alcohols. The state government has plans to set up a petrochemical complex at Ambalamugal which could transform the area into one of the leading petrochemical hubs in the country.
Completed component units
Crude distillation unit
Delayed coker unit
Vacuum gas oil hydro treating unit
Diesel hydro treater