Fergana Oil Refinery Modernization

As part of “Modernization of off-site facilities, inter-shop utilities and reconstruction of process units” the following design activities will be performed (in terms of process units) under the project “Fergana Oil Refinery Modernization”:

Reconstruction of 57/1.2 oil compounding unit, “Fergana Oil Refinery” oil compounding unit

Purpose of the detailed documentation development for reconstruction of 57/1.2 type oil compounding unit is to increase energy efficiency of process diagram considering the replacement of obsolete, worn-out equipment and instrumentation, implementation of an automated process control system, including usage of new instruments.

Implementation of a new unit for filling and packaging commercial oils into metal drums and small containers (plastic cans)

Technical parameters of the compounding unit:

The unit capacity after reconstruction, envisaged by the project of compounding unit modernization for 57/1.2 type oils.

Summer case

Base oils — 151 thousand tons/year, including:

• 70N base oil — 28 thousand tons/year;
• 100N base oil — 12 thousand tons/year;
• 300N base oil — 69 thousand tons/year;
• brightstock — 42 thousand tons/year.

Winter case

Base oils — 150 thousand tons/year, including:

• 70N base oil — 27 thousand tons/year;
• 100N base oil — 20 thousand tons/year;
• 300N base oil — 55 thousand tons/year;
• brightstock — 48 thousand tons/year.

The structure includes two units:

• unit 57/1;
• unit 57/2.

The units consist of the following process assemblies:

• Process pumps
• Mixers
• Stirrers
• Tank farms
• Conveyors
• Filling/packing unit

Reconstruction of the existing steam condensate collection and treatment system

Development of detailed documentation (DD) for the project “Replacement of pumps of the local condensate station (LCS-1,2,3)” at Fergana refinery.

Local condensate station is intended for collecting vapor condensate gathered from the plant facilities after consumption and its automated supply by pumps to the central condensate station (CCS).

Local condensate system (LCS) technical parameters:

• Medium — treated vapor condensate
• Vapor condensate pressure at pump discharge, MPa (g) 0.6
• Vapor condensate temperature at pump discharge, °С 105
• Required pump capacity following the replacement, m³/hour 200
• Number of the pumps to be replaced, pcs. 6

Characteristics of treated vapor condensate supplied to LCS-1,2,3 units

The following equipment is included in LCS-1,2,3:

• Condensate collection tank
• Condensate pumps
• Condensate flash tank
• Heat exchange equipment

Reconstruction of HFU compression unit

Reconstruction of the compression unit of gas fractionation plant — selection and replacement of the gas compressor, verification calculation for cooling and condensation system in order to assess operability and select (if necessary) the required equipment considering the planned scopes and composition of HFU processed raw materials following the launch of new capacities.

Objectives of the detailed documentation development for reconstruction of the compression unit of the gas fractionation plant are as follows:

• efficiency assessment of the existing compression circuit, wet hydrocarbon gas condensation considering modernization of Fergana Oil Refinery;
• compression of process hydrocarbon gases with condensate supply to the gas fractionation plant and dry gas supply to Ethane unit;
• replacement of PK-1a type reciprocating compressor.

PK-1a compressor technical parameters:

• Throughput rate of raw materials, nm³/hour
  • Case 1 2727
  • Case 2 2219
• Inlet gas pressure, kgf/cm²
  • Level 1 1.8
  • Level 2 5.91
• Discharge gas pressure,kgf/cm²
  • Level 1 6.12
  • Level 2 14.28
• Inlet gas temperature, ^оC
  • Level 1 38
  • Level 2 40
• Discharge gas temperature, ^оC
  • Level 1 91
  • Level 2 86

New flare system for new units, including flare stacks, flare header and connection to the new units

Designed for collection and recovery (combustion) of hydrocarbon vapors during process operations and emergency situations (including discharges from safety valves) for the needs of new hydrocracking, isomerization, hydrogen and PSA production units.

Consists of new flare headers, knockout drums, flare stacks with flare tips, ignition systems.

Technical re-equipment of existing laboratories

Technical re-equipment of existing laboratories: replacement of laboratory equipment and installation of new laboratory equipment considering the launch of new products and expansion of the range of commercial products.

Technical re-equipment will be carried out in the following Fergana Oil Refinery laboratories:

• Steam condensate laboratory, Shop No.7
• Shop No.10 Fuel laboratory
• Shop No.10 Product laboratory
• Shop No.10 Oil laboratory
• Shop No.17 Scientific research laboratory

Design activities will also be carried out in terms of connecting new and existing facilities:

1. Connection of new 100-400 plants to the existing potable water distribution system
2. Connection of new units 100-400 to the existing steam condensate collection and treatment system
3. Connection of new 100-400 units and a new flare system to the existing plant and instrumentation air distribution system
4. Connection of new 100-400 units and a new flare system to the existing nitrogen distribution system
5. Connection of the existing natural gas distribution system as fuel gas to new 100-400 units and a new flare system
6. Gas pipeline installation from the gas distribution substation (within the enterprise boundaries) to the hydrogen production unit. Receiving and distributing system of natural gas or LHG prior to hydrogen production unit
7. Gas pipeline installation from gas distribution station outside the enterprise territory to gas distribution substation within the enterprise territory — the design scope is in accordance with Technical Assignment and Fergana Oil Refinery specifications
8. Connection of new 100-400 units and a new flare system to the existing fuel gas and/or liquid fuel system (if necessary)
9. Connection of new 100-400 units and a new flare system to the existing steam distribution system
10. Connection of new 100-400 units and a new flare system to the existing water-based fire fighting system
11. Caustic soda solution supply system for new unit 200 — connection to existing caustic soda solution distribution system
12. Connection of new 100-400 units to the existing gathering systems of domestic and process wastewater, contaminated surface water
13. Connection of new 100-400 units to existing tank farms
14. Connection of new 100-400 units and a new flare system to the existing power grid
15. Gas fractionation plant (GFP) — design scope according to Technical Assignment from Fergana Oil Refinery
16. Installation of new control and automation equipment in the existing control rooms/operator rooms considering the retrofitting and reconstruction of existing installations — the design scope is in accordance with Technical Assignment from Fergana Oil Refinery
17. Connection of new installations 100-400 to communication lines (FOCL)
18. Connection of the new flare system to communication lines (FOCL)