Upgrading and Modification of Sulphur Coolers and Boiler Feed Water (BFW) Loop System

MECIP was awarded the Detailed Engineering Design (DED) contract for the upgrading and modification of the Sulphur Recovery Unit (SRU) sulphur cooler system and Boiler Feed Water (BFW) loop to enhance plant reliability, operational safety, and environmental performance. The project was initiated following a series of equipment failures that resulted in significant maintenance costs and production downtime, requiring a robust long-term engineering solution.

The engineering scope involved the replacement and redesign of existing sulphur coolers, modification of the BFW circulation system, development of a new thermosyphon-based cooling arrangement, and integration of associated piping, instrumentation, structural supports, and process control systems. MECIP performed comprehensive process simulation, hydraulic analysis, heat exchanger rating assessments, pressure relief evaluations, piping stress analysis, and multidisciplinary engineering design to ensure safe and reliable operation of the upgraded system.

The project included the development of process design basis documents, process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), equipment datasheets, 3D modelling, piping layouts, mechanical calculations, civil and structural designs, instrumentation engineering, technical procurement packages, and technical bid evaluations for the new equipment. Engineering works were executed using industry-standard tools including Aspen HYSYS, Aspen EDR, CAESAR II, SmartPlant 3D, and AutoCAD.

Through this project, MECIP demonstrated its capability in delivering complex brownfield refinery modifications involving process optimisation, equipment reliability improvement, and multidisciplinary engineering integration. The upgraded system is expected to significantly reduce operational risks, improve asset integrity, minimise environmental exposure, and support long-term refinery performance and sustainability objectives.