We would like to thank ORLEN-UNIPETROL for this excellent yet very challenging opportunity for ROEZ in the role of EPC to develop, design, manufacture, install, and commission vacuum distillation technology, a significant part of which was the large distillation column itself, along with heat exchangers, pumps, control and shut-off valves, filters, kilometers of special piping, measurement and regulation systems, and more.
The biggest challenges of the project included the production of the oversized column, which could not be transported via roads, under construction conditions where it was necessary to create manufacturing plant conditions to meet the quality parameters of the product, which is made from carbon steel on the outside and clad with stainless steel on the inside (dimensions – 43 m, largest diameter 5.4 m, weight with insulation: 170,000 kg). It was essential to manage difficult handling, adhere to welding procedures, and comply with very strict requirements regarding the ovality of the vessel due to operation in absolute vacuum. Successfully conducting a pressure test with a volume of 720,000 liters of water was also critical. Furthermore, we developed a special system of handling fixtures and lifting technology to ensure that the original column was lifted and safely stored without affecting the pressure part of the shell due to the presence of residual flammable hydrocarbons.
This was followed by a marathon of shutdown operations in a 24/7 mode, where it was necessary to install the new column and other components of the technology in a short time, assemble numerous pipes, structures, measuring elements, and insulation in the cramped spaces of the original operation, and connect to existing supply boundaries. This was succeeded by a successful commissioning and warranty tests. The work has been accepted and is now part of the key technologies ensuring fuel security in the Czech Republic for the coming decades. We thank our employees, subcontractors, and the customer who participated in this unique project, especially those who made extraordinary personal sacrifices at the expense of their personal time and comfort.
A few interesting facts about the project:
Total weight of the installed system: 441,000 kg
Total number of installed devices: 821
Weight of the column including insulation and platforms: 259,000 kg
Volume of water for the pressure test: 720,000 liters
Number of workers on the project: 412
Project implementation mode: 24 hours / 7 days a week
