RFCC Unit Revamping and Rehabilitation Project
Imam Khomeini Shazand Oil Refinery, Arak, Iran
The RFCC (Residue Fluid Catalytic Cracking) Unit Revamping and Rehabilitation Project was carried out at the Imam Khomeini Shazand Oil Refinery, Arak. The RFCC Unit, with a production capacity of approximately 8 million liters of Euro 4 gasoline per day, together with other valuable products including diesel fuel and LPG, is the only RFCC unit in Iran and one of the largest facilities of its kind worldwide.
The revamping and rehabilitation works were successfully executed by Petrosaz. The project involved the mobilization of more than 250 international specialists from South Korea, Indonesia, and India, together with over 700 highly qualified Iranian professionals. Heavy lifting operations were supported by specialized equipment, including a 1,250-ton crawler crane. The entire shutdown, revamping, inspection, installation, and recommissioning activities were completed within four months.
Scope of Work
- Planning
Comprehensive planning and scheduling of all shutdown activities, ranging from routine maintenance tasks to the most complex engineering and construction operations.
- Engineering
Preparation and implementation of detailed Method Statements covering all major equipment and systems, including:
- Reactor
- Regenerator
- Orifice Chamber
- Slide Valves
- Expansion Joints
- TSS (Third Stage Separator)
- FSS (Fourth Stage Separator)
- Inspection and Quality Control
Execution of comprehensive inspection and quality assurance activities in accordance with the approved QC Plan, including non-destructive examinations (NDE):
- PT (Liquid Penetrant Testing)
- MT (Magnetic Particle Testing)
- VT (Visual Testing)
- UT (Ultrasonic Testing)
- PWHT (Post Weld Heat Treatment Inspection)
- RT (Radiographic Testing)
- Fabrication and Installation
Reactor
Complete replacement and installation of the reactor internals, including:
- Reactor Riser Internals
- Disk-and-Donut Trays
- VSS (Vortex Separation System)
- Chamber
- Cyclones
- Flapper Valves
Regenerator
Major rehabilitation activities included:
- Replacement of Cyclones
- Replacement of Splash Plates
- Replacement of Trickle Valves
- Replacement of Steam Distributor
- Removal of the existing Catalyst Cooler and installation of a new Catalyst Cooler
- Complete replacement of Vent Tubes
- Complete refurbishment of the First-to-Second Stage Separator Head
- Repair and reinforcement of Regenerator shell hot spots
Orifice Chamber
- Fabrication and installation of perforated dished heads
- Modification of Diverter Valves
- Overhaul of Slide Valves
- Replacement and installation of Expansion Joints throughout all connecting lines
Mechanical Completion and Commissioning
Following completion of all mechanical works and successful inspections in accordance with the approved QC Plan, the RFCC Unit was recommissioned and returned to operation using the ICAPS commissioning management system, ensuring safe startup and reliable operational performance.
