Vendor’s Scope of Supply

1. Design, Fabrication and supply of Reactor Internals with all auxiliaries as per
HPCL approved QAP (QAP will be finalized after PO placement), details &
drawings provided in the Tender.
2. Once the QAP is approved, QAP requirements shall be followed without any
deviations.
3. MOC of the cyclones, plenum and Hex mesh & refractory lining to be installed
into cyclones as per Annexure-II- “Details and Drawings for Cyclones
and Other Internals”.
4. The overall weight of new internals shall not exceed the existing ones to avoid
any additional weight on the reactor foundation/civil design.
5. Also There should not be any significant change in height of reactor to avoid
any major piping modifications. Hence, any design modification to be done
accordingly.
6. Following points are also covered under Vendor scope:
i) Supply of all raw materials required for accomplishing supply of the Reactor
Internals is in vendor scope. HPCL will not supply any materials to the
Vendor.
ii) Supply of all Reactor Internals’ support arrangements like support lugs,
rods, gusseting & reinforcement arrangements, support plates, Fasteners,
nuts, washers etc. required to install the Reactor Internals in entirety.
iii) Refractory lining and heat curing for Reactor internals wherever required
with refractory supporting Hex mesh, anchors, anchor bars, corner tabs,
edging bars, termination strips, etc. as per Exxon Refractory Spec B 19-3-2
(Annexure-V).
iv) Following improvements are required to be made in new cyclones
to improve mechanical integrity as per OEM–
a. Fabricator shall carry out welding of all 6 hex while installing hex
mesh inside cyclone components. Agency shall note that this shall
overrule only 2 hex welding as advised in Annexure-V.
b. Upgradation of refractory material (Resco R Max or Equivalent)
c. Increase in refractory thickness at high erosion prone areas.
d. After PO placement, vendor shall prepare new cyclone system
drawing and get it okayed by the OEM and submit to HPCL for
approval/records.
v) For field joints, welding and refractory application will be done by site
contractor engaged by HPCL under the supervision of Vendor
representative, as per Exxon Refractory Spec B 19-3-2 (Annexure-V). (the
vendor shall follow the same document for refractory application while
fabrication of components at their site). For this, Vendor to estimate the
Refractory material, Anchors, Hex-mesh etc. required for site
joints and provide details of the same along with the dispatch of
Reactor Internals.
vi) SPARES: The following shall be supplied by the vendor as spares along with
supply of cyclones:
a. Minimum 5% of installed quantity of the Hex-mesh, anchors,
refractory.
b. Minimum 5% of all installed fasteners, subject to a min. of 50
numbers for each type/size.
vii) Preparation of Item for transporting, loading / unloading and coordination
for transportation to HPCL Vizag refinery.

Page 1 of 1
 Details of Reactor Internals in FCCU-I

1. Cyclone System in Reactor 04D2X.

1.1. Design data:
1.1.1.Design Pressure: 0.28 Kg/cm2.
1.1.2.Design temp: 557DegC
1.2. Metallurgy:
1.2.1.Plate: ASTM A516 Gr70 Normalised
1.2.2.Pipe: Diplegs and Bracings ASTM A106 GrB
1.2.3.Hexmetal & Edge Bars: ASTM A240-410S
1.2.4.Refractory- Resco AA22S
1.2.5.Bolting: ASTM A193 GrB16 Nuts: A194 Gr2H
1.2.6.Hanger Straps- C1/2Mo (A204 GrB)
1.2.7.Trickle Valves- Body and components ASTM A106 & ASTM A516 Gr70 Normalised
1.2.8.Trickle Valves Hing Rings -304H
1.3. Approx Dimensions of Cyclones: (Refer Attached Drawing)
1.3.1.Plate Thickness: 12.7mm.
1.3.2.Primary Cylones Diameters: D1,D2,D3
1.3.3.Secondary Cylones Diameters: D4,D5,D6
1.3.4.Primary Cyclones Length: L1, L2,L3,L4,L5
1.3.5.Secondary Cyclones Length: L6,L7,L8,L9,L10
Approx
Sr.
Dimension Dimensions
No
(mm)
1. D1 1260
2. D2 750
3. D3 500
4. D4 1140
5. D5 680
6. D6 270
7. L1 1170
8. L2 2400
9. L3 2200
10. L4 700
11. L5 5480
12. L6 1070
13. L7 2100
14. L8 1880
15. L9 800
16. L10 7000

Page 1 of 4
 Details of Reactor Internals in FCCU-I
1.4. Details of Refractory in Cyclones:
1.4.1.Hexmesh 25mm in Cyclones with Resco AA22S
1.4.2.Hexmesh 19mm in Dipleg with Resco AA22S

2. Details of AntiCoking Baffle:

2.1. Metallurgy: Anticoking Baffle- ASTM A516 Gr70 Normalised
2.2. Plate Thickness: 25mm, 16mm.
2.3. Dimensional Details:

Approx
Sr.
Dimension Dimensions
No
(mm)
1. D7 5100
2. H1 300
3. R1 630
4. R2 1800
5. R3 1600

Page 2 of 4
 Details of Reactor Internals in FCCU-I
3. Details of Dome:
3.1. Metallurgy: SA516Gr70 Normalised
3.2. Thickness: 49mm
3.3. Dimensions & NDT : As per drawings attached in Annexure-VI

4. Details of Plenum:
4.1. Metallurgy: SA516 Gr70 Normalised.
4.2. Thickness: 25mm.
4.3. Dimensions:

Approx
Sr.
Dimension Dimensions
No
(mm)
1. R4 2600
2. D8 3600
3. D9 5300
4. D10 2900
5. D11 2200

5. Details of Riser:
5.1. Top section :
5.1.1.Metallurgy: - C1/2 Mo (A204 GrB)
5.1.2.Length : Approx. 3Mtr.
5.1.3.Inner Dia: Approx 1170mm
5.1.4.Refractory: 25mm Hexmesh + Resco AA22S
5.2. Bottom Section upto nozzle 1N:
5.2.1.Metallurgy: C1/2 Mo (A204 GrB)
5.2.2.Length: Approx. 18 Mtr.
5.2.3.Inner Dia: Approx 1170mm
5.2.4.Refractory: 25mm Hexmesh + Resco AA22S

6. Refractory Details:

Dome

Page 3 of 4
 Details of Reactor Internals in FCCU-I

Plenum

Bill of
Material

Page 4 of 4
 Process Data Sheet for Reactor Unit : FCCU-I
Cyclones Visakh Refinery

Service Reactor Cylcones

Quantity 3 sets (Primary & Secondary)

Process data Units Normal

Reactor temperature °C 529
2
Reactor pressure kg/cm (g) 1.7
Catalyst circulation rate MT/hr 840
2
Total allowable pressure drop kg/cm (g) 0.176 (Note-8)
Maximum bed level in reactor mm Ref drawing

Mechanical design conditions

Design temperature °C 557
2
Design Differential Pressure kg/cm (g) 0.28

Other details
Number of cyclones in series 2
Number of cyclones in parallel 3
Reactor height (Tan-to-Tan) mm Note-3
Reactor diameter (ID lining) mm Note-3
Catalyst bed elevation in reactor (min/normal/max) mm Note-3

First Stage Cyclone inlet

Gas rate kg/hr 154918
Gas rate m3/hr 50960
Gas molecular weight kg/kg-mol 74.19
3
Gas density at inlet condition (excluding dust) kg/m 3.04
3
Inlet dust loading (Normal / Maximum) kg/m of gas 16.4 / 19.6 (Note-7)

Second Stage Cyclone inlet

Gas rate kg/hr Note-7
Gas molecular weight kg/kg-mol Note-7
3
Gas density at inlet condition kg/m Note-7
3
Inlet dust loading kg/m of gas Note-7

Catalyst data Fresh E-cat

0-20 micron wt% 3.0 1.0
0-40 micron wt% 15.0 5.0
0-80 micron wt% 62.0 30-40
APS,micron micron 80.0 80-85
3
ABD kg/m 0.8-0.85 0.8-0.9
3
Particle density kg/m 1400 1400
Total catalyst loss from cyclone system kg/day <500 (Note-4)

Design Details
st nd
1 Stage 2 Stage
Inlet Height mm Note-3 Note-3
Inlet width mm Note-3 Note-3
Barrel Dia mm Note-3 Note-3
Barrel height mm Note-3 Note-3
Outlet tube dia mm Note-3 Note-3
Outlet tube penetration mm Note-3 Note-3
Main cone Dia mm Note-3 Note-3
Main cone height mm Note-3 Note-3
Cyclone length mm Note-3 Note-3
Dust hopper dia mm Note-3 Note-3
Dust hopper length mm Note-3 Note-3
Dipleg dia mm Note-3 Note-3
Dipleg length mm Note-3 Note-3
Total Cyclone Length mm Note-3 Note-3

st nd
Cyclone Performance Units 1 Stage 2 Stage
Catalyst loss kg/hr Note-7
Cyclone pressure drop (inlet to outlet for each stage 2
kg/cm (g) Note-7
and cumulative total)
 Process Data Sheet for Reactor Unit : FCCU-I
Cyclones Visakh Refinery

Service Reactor Cylcones

Quantity 3 sets (Primary & Secondary)
3
Inlet dust loading kg/m Note-7
Inlet Velocities m/s Note-7
Outlet Velocities m/s Note-7
3
Dipleg density kg/m Note-7
Dipleg length & diameter mm Note-7
2
Dipleg suction kg/cm (g) Note-7
PSD/APS of fines from cyclones Note-7
Dipleg catalyst level Note-7
2
Dipleg mass flux kg/m sec Note-7
L/D ratio of cyclone based on inside lining Note-7
Note-7
Ratio of outlet tube to inlet tube cross sectional area
Termination valve details Note-7
Design life of Cyclone Note-7
Design life of Refractory Note-9
Note:
1 Cyclones should be able to operate for 'Turn down case' (50%) and normal gas rate. Vendor to
indicate the performance of cyclones for all the cases.
2 The cyclones shall be designed, manufactured, inspected and tested in accordance with the
requirements specified in this datasheet. Catalyst losses to be as low as possible. Cyclones shall be
designed for efficiency >99.999%
3 Refer reactor drawing for elevation details
4 Vendor to guarantee estimated catalyst loss is below 500 kg/day. Vendor to provide the particle size
distribution of catalyst from reactor overhead.
5 Cyclone dipleg shall have internal refractory lining. Refractory thickness should be 25mm. The outside

portion of the diplegs shall have lining from termination to 1 m above the maximum bed level.
6 Cyclone dipleg shall have a termination valve (trickle valve or splash plate) as per vendor's
specifications. Valve opening direction should be such that it will not interfere with primary cyclone
dipleg.
7 Vendor to indicate and confirm
8 Vendor to provide elevation plan views of cyclone layout.
9 Vendor to confirm refractory life
Note:

1. PGTR test shall meet the performance parameters given below.

PARAMETERS VALUE
Catalyst loss from reactor, kg/day <500
Maximum allowable operating pressure drop, kg/cm2 0.176
Mechanical design differential pressure, kg/cm2 0.28

2. Following are the major PGTR conditions:

PARAMETERS VALUE
3 165
Unit feed rate, m /hr
Gas rate, kg/hr 50960
Catalyst circulation rate, MT/min 14.0
Cyclone inlet temperature, deg C 529
Cyclone operating pressure, kg/cm2g 1.7
 Annexure-VII: Special Guidelines
1. Vendor to have a registered agreement with M/s Van Tongeren or
M/s CECO Emtroll Buell for carrying out fabrication of Reactor
Internals. Proof of registered agreement shall be provided to HPCL
along with the Bid document (Notarized Copy).
2. After PO placement, Vendor shall submit WPS, PQR (procedure
qualification record) documents, Refractory application procedure
and dry out / curing procedure, test procedure etc. shall be approved
and stamped by OEM for HPCL’s records.
3. NDT& HT requirement for Reactor Internals to be followed as a
minimum mentioned in the tender. However, suggestions from OEM
will be reviewed during QAP approval stage.
4. After PO placement, agency to submit the GA drawings/ Design
Calculations of Reactor Internals approved by respective OEMs
within 1 week. However, all the detailed fabrication drawings shall
be submitted within 30 days from the date of PO for HPCL review
and Final Acceptance.
5. Data / details given in attached existing as built drawings for some
cases / reasons may not be complete. In such cases vendor to
assume accordingly as per relevant standard/practices and
incorporate in the drawing and submit to HPCL after obtaining
approval from OEM (with whom vendor has valid agreement).
These deviations/assumptions; when taken; must be duly informed
to HPCL at the time of drawing submission.