The Challenge
The FCC Unit is one of the most important and energy-intensive processes within a refinery. The project involved replacing two critical pieces of equipment, a main air blower and a two-stage gas compressor, by integrating new electric drive technology without compromising plant safety, operational availability, or production continuity.
Key challenges included:
- Replacement of steam turbine-driven compressors with high-power electric motors.
- Integration of equipment with up to 19 MW of installed power.
- Adaptation of existing facilities with significant space constraints.
- Upgrade of electrical systems, control systems, transformers, and instrumentation.
- Re-engineering of piping and structural systems within a fully operational unit.
- Compliance with Repsol-Petronor’s demanding technical and safety standards.
The Solution
EIA21 delivered a comprehensive engineering service from the FEED phase through construction supervision, coordinating all disciplines involved in the implementation of the new compression systems.
The scope included:
- FEED engineering development.
- Multidisciplinary Detailed Engineering.
- Mechanical design, piping engineering, and flexibility analysis.
- Structural and foundation modifications.
- Specification, procurement management, and integration of power electrical systems, including transformer, 30 kV switchgear extension, 11 kV switchboard, and capacitor bank.
- Specification, procurement management, and integration of new compressors, electric motors, and variable speed drive systems.
- Upgrade of control and instrumentation systems, including specification and management of DCS modifications.
- 3D modeling and multidisciplinary technical coordination.
- Construction and installation supervision.
EIA21 also coordinated engineering activities with the main equipment manufacturer, carrying out technical follow-up of fabrication, inspection, and testing activities to ensure compliance with project requirements.
The final solution enabled the complete electrification of the FCC compressor drive system, improving performance and controllability.
Results
The FCC modernization project upgraded a strategic refinery asset through the implementation of state-of-the-art compression technologies.
Key results:
- Electrification of critical compressors using high-power electric motors.
- Total installed power of 19 MW.
- Improved energy efficiency of the FCC Unit.
- Enhanced operational control through advanced variable speed regulation systems.
- Reduced operating and maintenance costs.
- Improved equipment reliability and availability.
- Safe integration within an operating refinery.
The project contributed to the refinery’s technological modernization and supported industrial electrification strategies aimed at improving energy efficiency and reducing utility consumption.
