Reactor–Regenerator (RR) Package — FCCU, Kochi Refinery

Scope of Work

EPCC / LSTK execution of the FCCU reactor–regenerator package for the Integrated Refinery Expansion Project — detailed engineering, procurement, shop fabrication at Tarapur, site assembly on the permanent structure, refractory lining, hot insulation and large-diameter flue gas duct piping.

• Residual design and in-house detailed engineering of static equipment
• Procurement of all major bought-outs — EIL inspection (indigenous) and LRQA third-party inspection for U & R stamp activities
• Complete fabrication and testing at Tarapur shop: orifice chamber, external riser, internal mushroom riser, fresh & spent catalyst storage hoppers, fines hopper, CS & SS flue gas duct spools
• Pre-fabrication of Reactor, Regenerator and TSS segments at Tarapur works under LRQA inspection
• Assembly of segments, welding, NDT, PWHT and hydrotest at Kochi site on the permanent structure
• Refractory lining of Reactor, Regenerator, Orifice Chamber and TSS at Kochi site
• CS large-diameter (38"–129") refractory-lined flue gas duct piping — 290 m with 26 mitre bends; SS heavy 124"/86"/72" FGD piping — 90 m
• Technological structure — 3,878 MT; heavy erection lifts with Demag CC-8800-1 (1,600 T) crawler crane
• Certified by BPCL Kochi Refinery for completing 2 million man-hours without any lost-time accident