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Objectives, approach, deliverables and benefits for each service area. Open any item for more.

Master Planning & Margin Improvement

Find and capture integrated margin across the whole complex, and plan configuration, crude flexibility and investment in phases.

A1.1A Base Lining Master Planning Studies / Configuration Studies (small revamps, moderate Capex)+

Objective. Evaluate refinery configuration and crude flexibility to maximize Gross Refining Margin (GRM) and ensure long‑term competitiveness.

Scope
  • Review of process units (CDU, FCC, Hydrocracker, Reformers, etc.).
  • Evaluation of energy intensity, yield patterns, and bottlenecks.
  • Crude flexibility analysis for high TAN, high sulphur, and opportunity crudes.
  • LP model reconciliation with actual operating data.
  • Identification of debottlenecking opportunities and phased investment options.
Approach
  • Asset & Crude Basket Review: Assess current refinery assets, process units, and crude slate flexibility.
  • Run Process or Mathematical Models/Tools: Run Linear Programming models of alternate process schemes to identify optimal configurations.
  • Benchmarking vs Peers: Compare performance against regional and global refineries using Benchmarking indices and industry benchmarks.
  • Phased Master Plan: Develop a stepwise roadmap for revamp, debottlenecking, and expansion aligned with investment priorities.
  • Sensitivity Analysis: Test crude price scenarios, product demand shifts, and regulatory changes to ensure resilience.
Key deliverables
  • Configuration Study Report with detailed findings.
  • Investment Roadmap outlining phased options (short, medium, long term).
  • GRM Improvement Scenarios with quantified benefits.
  • Comparative Benchmarking Matrix vs peer refineries.
  • Master Plan Presentation Deck for management and investors.
Direct value
  • GRM uplift 5–10% through optimized crude selection and process schemes.
  • Strategic clarity for long‑term investments and competitive positioning.
  • Enhanced crude flexibility enabling processing of discounted opportunity crudes.
  • Improved energy efficiency and reduced operating costs.
  • Resilience against market volatility and regulatory changes.
A1.1B Investment Master Plan & Configuration Studies (moderate to major Capex)+

Objective. Develop a comprehensive Investment Master Plan and configuration study framework to guide large capital expenditure (Capex) projects under strategic growth options, ensuring sustainable profitability and competitive positioning.

Scope
  • Identification of new process units (e.g., Hydrocracker, Aromatics, Olefins, Resid Upgradation).
  • Integration studies for petrochemical diversification.
  • Infrastructure & logistics planning (storage, jetty, utilities, offsites).
  • Energy efficiency & decarbonisation alignment for ESG compliance.
  • Market demand analysis for fuels, petrochemicals, and specialty products.
Approach
  • Strategic Growth Assessment: Identify long‑term market opportunities, demand centers, and product portfolio expansion.
  • Configuration Studies: Evaluate alternate refinery/petrochemical configurations aligned with growth objectives.
  • LP & Scenario Simulations: Model investment options under varying crude, product, and regulatory scenarios.
  • Capex Prioritization: Rank projects by ROI, payback, and strategic fit.
  • Phased Master Plan: Develop a stepwise roadmap for project execution (short, medium, long term).
Key deliverables
  • Investment Master Plan Report with strategic options.
  • Configuration Study Report detailing process schemes and Capex requirements.
  • Project Portfolio & Roadmap with phased investment sequencing.
  • Financial Models including ROI, IRR, and payback analysis.
  • Risk & Sensitivity Matrix for investment resilience.
Direct value
  • Strategic clarity on growth pathways and investment priorities.
  • Competitive positioning through diversification and scale.
  • GRM uplift (5-20% or $0.50-$2/bbl) depending on Capex deployed includes petrochemical margin expansion.
  • Investor confidence with transparent Capex roadmap.
  • Resilience against crude volatility and regulatory shifts.
A1.2 Margin Improvement Program+

Objective. Identify yield losses, energy inefficiencies, and bottlenecks while optimizing crude basis, process utilization, and blending strategies to maximize Gross Refining Margin (GRM).

Scope
  • LP reconciliation with actual yields and energy consumption.
  • Evaluation of fixed crude basis with optional crude flexibility scenarios.
  • Assessment of intermediate feedstock opportunities.
  • Review of process unit utilization and debottlenecking potential.
  • Optimization of operating parameters for efficiency and reliability.
Approach
  • LP Reconciliation: Align LP model with actual operating data to identify yield and energy gaps.
  • Delta Vector Analysis: Quantify deviations in unit performance and energy consumption.
  • Fixed vs Flexible Crude Basis: Evaluate margin under fixed crude scenarios, with optional crude flexibility analysis.
  • Intermediate Feedstock Potential: Explore opportunities for additional feedstock integration.
  • Process Utilization Review: Assess unit utilization and recommend debottlenecking.
Key deliverables
  • Margin Improvement Plan with prioritized initiatives.
  • Unit‑wise Performance Gap Analysis (yield, energy, PQGA).
  • Debottlenecking & Utilization Recommendations.
  • Blending Optimization Report.
  • Benchmarking Performance Review.
Direct value
  • Margin gain (20-80 cents/bbl) improvement on utilized crude capacity, US$ 14–50 Million per year annualized benefits for a 10 MMTPA integrated Refinery.
  • Energy efficiency improvement +3–5% reducing operating costs.
  • Transparent performance tracking with clear KPIs.
  • Improved process utilization and reliability.
  • Enhanced competitive positioning through benchmarking and optimization.
A1.3 Opportunity Crudes Evaluation – Sul‑TAN Management+

Objective. Opportunity Crudes Evaluation & Sul‑TAN Management Optimizing Feedstock Selection for Margin Enhancement & Asset Integrity

Direct value
  • Margin Improvement: Opportunity crudes can enhance GRM by 0.15-0.5 $/bbl, i.e. US$ 10–30 Million per year for a 10 MMTPA refinery when processed safely.
  • Asset Protection: Controlled TAN and sulphur management reduces corrosion‑related failures by 40–60%.
  • Operational Flexibility: Broader crude basket enables resilience against market volatility.
  • Reduced Maintenance Costs: Optimized inhibitor and neutralizer usage lowers annual maintenance by US$ 2–4 Million per year.
  • Enhanced Planning Accuracy: Integration with LP model ensures realistic yield and constraint forecasting.
A1.4 Benchmarking & Plan of Action (PoA)+

Objective. Benchmark refinery performance against Benchmarking indices to identify operational gaps, inefficiencies, and improvement opportunities, and develop a Plan of Action (PoA) for sustainable competitiveness.

Scope
  • Review of entire asset base including CDU, FCC, Hydrocracker, Reformers, Thermal Conversion units, Utilities, and Offsites.
  • Energy intensity mapping and benchmarking vs global peers.
  • Maintenance and reliability performance review.
  • Process utilization analysis to increase throughput.
  • Operating parameter optimization for yield and energy efficiency.
Approach
  • Data Collection & Validation: Gather operating, energy, maintenance, and utilization data across all process units.
  • Benchmarking vs Benchmarking Indices: Compare refinery performance against peer group benchmarks (Energy Intensity Index, Maintenance Index, Utilization Index, etc.).
  • Performance Gap Analysis: Identify deviations in yield, energy, reliability, and cost efficiency.
  • Constraint & Limit Review: Evaluate process limits, bottlenecks, and capacity restrictions impacting benchmarking scores.
  • Blending & PQGA Review: Assess blending optimization and Product Quality Give Away (PQGA) impact on margins.
Key deliverables
  • Benchmarking Report with comparative performance vs peer refineries.
  • Performance Gap Matrix highlighting yield, energy, reliability, and PQGA gaps.
  • Plan of Action (PoA) with prioritized initiatives (short, medium, long term).
  • Debottlenecking & Utilization Recommendations.
  • Blending Optimization & PQGA Reduction Report.
Direct value
  • Clear roadmap for operational excellence based on global benchmarks.
  • Competitive positioning in Benchmarking rankings.
  • Energy efficiency improvement 3–5% reducing operating costs.
  • Margin uplift GRM by 0.05-0.3 $/bbl, i.e. US$ 3–20 Million per year through PoA
  • Improved reliability and asset utilization.

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Business Planning & LP Model

Make the planning model reflect reality, so crude, throughput and product decisions are made on numbers you can trust.

B1.1 Improving Performance of Business Planning Process+

Objective. Establish a structured Performance Review Framework for refinery and petrochemical business planning. The study ensures accuracy, efficiency, and accountability across annual, rolling, and monthly plans, supported by LP model health checks, KPI tracking, retro analysis, and deviation categorisation.

Scope
  • Annual Business Plan Review
  • Long‑term crude/product strategy, margin targets, investment planning.
  • Benchmark vs industry peers.
  • Incorporates global crude supply outlook, product demand forecasts, and ESG mandates.
  • 12‑Month Business Plan Review
Approach
  • Annual Plan Review – Validate long‑term assumptions vs market reality.
  • 12‑Month Rolling Plan Audit – Quarterly updates aligned with crude/product markets.
  • Monthly Rolling Plan vs Reality – Compare planned vs actual crudes, products, supply‑demand, plant availability, shutdowns.
  • LP Model Health Check – Validate yield structures, constraints, delta vectors.
  • Deviation Categorisation – Assign deviations to buckets (market, operational, model, logistics, commercial).
Key deliverables
  • Annual Business Plan Review Report.
  • 12‑Month Rolling Plan Efficiency Study.
  • Monthly Rolling Plan vs Reality Dashboards.
  • LP Model Health Check Report.
  • Deviation Categorisation Matrix.

Strategic impact. Accuracy: Improved reliability of annual, rolling, and monthly plans. Efficiency: Reduced MVA gaps and improved throughput predictability.

B1.2 Crude Flexibility & Optimization+

Objective. Enable the refinery to expand crude flexibility, safely process opportunity crudes, and optimize crude selection to maximize Gross Refining Margin (GRM) while minimizing risks related to corrosion, TAN, sulphur, and operational reliability. Integrate CIV analysis to rank crudes and blends for economic decision‑making.

Scope
  • Crude Basket Expansion Evaluate high sulphur, high TAN, heavy, and discounted crudes. Develop blending strategies to integrate opportunity crudes.
  • LP Model Integration Simulate crude runs in LP model for yield, margin, and constraint impacts. Generate delta vectors for crude substitution scenarios.
  • Risk Mitigation Corrosion risk simulation for high TAN crudes. Metallurgy adequacy checks and inhibitor strategies.
  • Operational Flexibility CDU/VDU operating window expansion. Debottlenecking downstream units (FCC, Hydrocracker, Reformers).
  • Supply & Trading Optimization Align crude procurement with market discounts. Optimize logistics (SBM, jetty, tankage) for crude receipts.
Approach
  • Crude Assay Characterization
  • Laboratory and simulation analysis of candidate crudes.
  • Identify sulphur, TAN, metals, and yield profiles.
  • LP Model Simulation
  • Run crude assays through LP model.
Key deliverables
  • Crude Flexibility Study Report.
  • LP Model Optimization Scenarios.
  • CIV Ranking Matrix for Crudes & Blends.
  • Risk Mitigation & Reliability Plan.
  • Operational Flexibility Audit Report.

Strategic impact. Profitability: CIV‑based crude ranking ensures best economic choices. Flexibility: Ability to process discounted opportunity crudes.

B1.3 Intermediate Feedstocks Evaluation+

Objective. Evaluate intermediate feedstocks within the refinery system to maximize unit utilization, margin uplift, and product diversification. This study complements Crude Flexibility & Optimization by ensuring that streams generated from crude runs are optimally routed to downstream units, balancing economics, operational constraints, and market opportunities.

Scope
  • Intermediate Stream Characterization
  • Analyze properties of key intermediates (sulphur, aromatics, olefins, metals).
  • Identify potential disposition routes across refinery/petrochemical units.
  • LP Model Integration
  • Simulate routing of intermediates into different units.
Approach
  • Stream Assay Analysis – Characterize intermediates (VGO, SR, Reformate, Naphtha, Hydrowax) as examples.
  • LP Model Simulation – Run disposition scenarios for each stream.
  • CIV Ranking – Calculate CIV for routing options (e.g., VGO → HCU vs FCC).
  • Blend Optimization – Simulate blends of intermediates with base crudes.
  • Operational Audit – Check spare capacity and unit constraints.
Key deliverables
  • Intermediate Feedstock Evaluation Report.
  • LP Model Optimization Scenarios.
  • CIV Ranking Matrix for Intermediate Streams.
  • Blend Optimization Report.
  • Operational Flexibility Audit Report.

Strategic impact. Profitability: CIV‑based ranking ensures optimal routing of intermediates. Flexibility: Spare capacity utilization across hydrocrackers, FCC/RFCC, reformers, aromatics, ECC.

B1.4 Reducing Product Quality Give Away (PQGA)+

Objective. Minimize Product Quality Give Away (PQGA) by improving blending correlations, tightening control on manufacturing specifications, and deploying advanced process control (APC) for online blending. The study ensures margin capture on specifications, benchmarking against peers, and identification of structural bottlenecks.

Scope
  • Blending Correlations Review
  • Validate correlations for key properties (RON, MON, sulphur, density, flash point).
  • Improve regression models and blending rules.
  • Specifications & Margin Capture
  • Review manufacturing specifications vs customer specs.
Approach
  • Compile historical blending records
  • Cross-check with laboratory property data
  • Identify deviations between predicted vs actual properties
  • Validate regression models for RON, MON, sulphur, density
  • Update blending rules with latest assay data
Key deliverables
  • PQGA Data Analysis Report (patterns by product grade).
  • Blending Correlation Validation Report.
  • Benchmarking Study (BM vs Plant).
  • Bottleneck Identification Report.
  • Online Blending APC Implementation Plan.

Strategic impact. Profitability: Capture margins lost to PQGA. Accuracy: Improved blending correlations and property prediction.

B2.1 LP Model Health Check & Improvement+

Objective. Establish a structured LP Model Health Check Framework to validate yield structures, constraints, and delta vectors, ensuring the model accurately reflects plant operations. The study focuses on reducing Model vs Actual (MVA) gaps, improving planning reliability, and enabling better business decisions.

Scope
  • LP Model Validation
  • Verify crude assays, unit yields, and blending correlations.
  • Check constraint definitions and operating limits.
  • Delta Vector Review
  • Validate delta vectors for crude substitutions and unit operations.
Approach
  • Data Collection & Validation – Gather crude assays, unit test runs, blending data, operational constraints.
  • LP Model Audit – Validate yield structures, constraints, and delta vectors.
  • MVA Gap Analysis – Compare LP vs actual GRM, throughput, and yields.
  • Retro Analysis / Back‑Casting – Identify gaps between plan and actual, quantify impact.
  • Deviation Categorisation – Assign deviations to buckets (market, operational, model, logistics, commercial).
Key deliverables
  • LP Model Health Check Report.
  • Delta Vector Validation Report.
  • Model vs Actual Gap Analysis Report.
  • Retro Analysis & Back‑Casting Report.
  • KPI Framework & Governance SOPs.

Strategic impact. Accuracy: Improved reliability of LP model outputs. Efficiency: Reduced MVA gaps and improved throughput predictability.

B2.2 LP Model Base + Delta Vector Generation & Retro Analysis Improvement+

Objective. Strengthen refinery business planning by developing a robust LP base model and systematically updating it with delta vectors to reflect operational realities. This methodology ensures higher fidelity between plan and actual performance, reduces Model vs Actual (MVA) gaps, and enhances margin capture.

Scope
  • LP Base Development
  • Construct a comprehensive LP base covering all process units, blending systems, and utility balances.
  • Validate against historical operating data and licensor design cases.
  • Delta Vector Generation
  • Identify deviations in unit yields, constraints, and operating conditions versus the LP base.
Approach
  • LP Base Construction – Build and validate the LP base against historical and licensor data.
  • Delta Vector Identification – Capture deviations in yields, constraints, and operating conditions.
  • Dynamic Integration – Apply delta vectors to create LP Base + Delta model.
  • Validation & Retro Analysis – Compare LP outputs vs actual performance, reconcile gaps.
  • Continuous Improvement – SOPs for monthly delta updates and quarterly base recalibration.
Key deliverables
  • LP Base Development Report.
  • Delta Vector Generation & Validation Report.
  • LP Base + Delta Model Outputs.
  • Model vs Actual Gap Analysis Report.
  • Continuous Improvement SOPs.
Indirect and collateral benefits
  • Improved Business Plan Accuracy: Reduced gap between LP plan and actual operations, enhancing credibility of forecasts.
  • Retro Analysis / Back‑Casting Improvement: MVA gap minimized from typical 2–3% to < 1%, enabling better decision‑making.
  • Operational Flexibility: Quick incorporation of new crude assays, catalyst changes, and process constraints without full model rebuild.
  • Enhanced Margin Capture: More accurate crude flex and yield predictions translate into higher GRM realization.
  • Decision Support: Provides management with reliable “what‑if” scenarios for crude selection, throughput changes, and debottlenecking.

Strategic impact. Accuracy: LP Base + Delta ensures closer alignment with actual operations. Efficiency: Reduced MVA gaps and improved throughput predictability.

B2.3 Scheduling & Review of Plant Scheduling Tools & Efficiency+

Objective. Strengthen refinery economics and operational reliability by conducting a systematic review of plant scheduling tools and practices, ensuring that crude receipts, product dispatches, unit operations, and maintenance shutdowns are optimally aligned. The study focuses on tool efficiency, scheduling accuracy, and integration with LP models and business plans. Develop a structured Strategic Business Growth Masterplan that identifies core growth drivers, validates project premises, and evaluates project economics. The plan ensures that strategic expansion, diversification, and profitability improvement initiatives are optimized, executable, and financially viable, with clear integration into existing refinery operations.

Scope
  • Scheduling Tools Audit
  • Review current scheduling platforms (e.g., refinery scheduling software, spreadsheets, APC integration).
  • Assess tool capabilities for crude receipts, blending, product dispatch, and unit scheduling.
  • Scheduling Efficiency Review
  • Evaluate scheduling accuracy vs actual execution.
Approach
  • Scheduling Tools Audit – Review current tools and workflows.
  • Efficiency Analysis – Compare scheduled vs actual crude receipts, product dispatches, and unit operations.
  • Integration Review – Align schedules with LP model outputs and business plans.
  • Deviation Categorisation – Identify gaps due to logistics, tankage, blending, or operational constraints.
  • KPI Dashboard Development – Create dashboards for schedule adherence and efficiency.
Key deliverables
  • Scheduling Tools Audit Report.
  • Scheduling Efficiency Review Report.
  • Integration Study with LP & Business Plans.
  • Deviation Categorisation Matrix.
  • KPI Framework & Dashboards.
Indirect and collateral benefits
  • Improved Scheduling Accuracy: Reduced mismatch between planned and actual crude receipts, product dispatches, and unit operations.
  • Enhanced Efficiency: Better tank utilization and blending operations.
  • Reduced Losses: Lower demurrage, evacuation delays, and PQGA from poor scheduling.
  • Integration with Planning: Stronger alignment between LP models, business plans, and execution schedules.
  • Decision Support: Dashboards provide management with real‑time visibility of scheduling efficiency.

Strategic impact. Accuracy: Improved reliability of plant schedules. Efficiency: Reduced losses and improved throughput predictability.

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Troubleshooting & Operations (i-TOP / i-TROM / i-MORE)

Hands-on problem solving for furnaces, fouling, corrosion, hot spots, reactor excursions and catalyst life on CDU/VDU, hydrocracker and FCC units, through our i-TOP, i-TROM and i-MORE assessments.

A2.6A CDU/VDU Operations Optimization & Troubleshooting Support+
Scope
  • Desalter Performance Audit
  • Optimize wash water ratio (3–5 vol%) and demulsifier dosage.
  • Maintain outlet BS&W < 0.1% and salt < 5 ppm.
  • Review mixing valve pressure drop and interface control.
  • Chloride & Overhead Corrosion Control
Direct value
  • CDU/VDU Performance Audit Report
  • Desalter & Overhead Corrosion Control Plan
  • Furnace Hot‑Spot & Skin Temperature Mapping
  • Energy & Yield Optimization Strategy
  • Root‑Cause Analysis & Troubleshooting Matrix
A2.6B Hydrocracker Operations Optimization & Troubleshooting Support+

Objective. Improve reliability, product quality, and energy efficiency of Hydrocracker operations through root cause analysis, data reconciliation, and corrective action planning.

Scope
  • Feed & Catalyst Audit
  • Assess feed contaminants and compatibility.
  • Benchmark catalyst performance (CoMo, NiMo, sandwich systems).
  • Recommend catalyst strategy for yield and quality uplift.
  • Hydrogen Management
Direct value
  • Hydrocracker Performance Audit Report
  • Catalyst Benchmarking & Selection Plan
  • Hydrogen Balance & Optimization Strategy
  • Reactor Hot Spot & Temperature Profile Mapping
  • Energy & Yield Optimization Strategy
A2.6C RFCCU / Petro FCCU Operations Optimization & Troubleshooting Support+

Objective. Enhance reliability, product quality, and energy efficiency of RFCCU/Petro FCCU operations through root cause analysis, data reconciliation, and corrective action planning — with focus on maximizing propylene, gasoline, and aromatics yields while reducing energy intensity and carbon footprint.

Scope
  • Feed & Catalyst Audit
  • Assess feed contaminants and compatibility.
  • Benchmark catalyst performance (ZSM‑5 additives, high‑MAT catalysts).
  • Recommend catalyst strategy for propylene and aromatics uplift.
  • Catalyst Stripping & Residence Time
Direct value
  • RFCCU/Petro FCCU Performance Audit Report
  • Catalyst Stripping & Residence Time Optimization Plan
  • Preheat & Riser Operation Strategy
  • Cyclone Velocity & Entrainment Control Report
  • Regenerator Operation & Hot Spot Mapping
C1 Strategic Trouble Shooting & Operations Management+

Objective. Deliver structured support for troubleshooting and operations management across refinery and petrochemical units, focusing on constraint management, commissioning excellence, and advanced process control (APC) optimization. The aim is to strengthen operational reliability, improve yield selectivity, and enhance flexibility across the full value chain.

Scope
  • Process Constraints & Limits Management
  • Identify and validate process limits across CDU, VDU, FCC, Hydrocracker, Reformers, ECC, DCU/VBU, NHT, DHT, HMU, CPP, Utilities & Offsites, Aromatics Complex, and Polymer Units.
  • Review bottlenecks in throughput, energy, and product quality for better yield selectivity and operational flexibility.
  • Develop SOPs for constraint monitoring, escalation, and debottlenecking strategies.
  • Pre‑Commissioning & Commissioning Support
Approach
  • Constraint Mapping & CAM Expansion – Careful examination and expansion of the Crude Acceptance Matrix (CAM) to validate crude flexibility and operational limits.
  • Commissioning Readiness Review – Identification, recruitment, and training of staff at similar facilities; deployment for structured commissioning activities.
  • APC & Instrumentation Audit – Review blending, energy efficiency, yield optimization, and asset safeguarding strategies.
  • Reliability Safeguarding – Evaluate APC applications for critical equipment and auxiliary systems to manage upset conditions.
  • Troubleshooting Framework – Establish escalation protocols and root cause analysis methods.
Key deliverables
  • Process Constraints & Limits Report (covering all refinery, petrochemical, and utility units).
  • Expanded CAM Crude Acceptance Matrix.
  • Pre‑Commissioning & Commissioning Readiness Checklists.
  • Staff Training & Deployment Plan.
  • APC & Instrumentation Audit Report (including asset integrity and safeguarding).
Indirect and collateral benefits
  • Improved Reliability: Reduced unplanned downtime through proactive constraint management.
  • Enhanced Safety: Structured commissioning protocols and trained staff minimize start‑up risks.
  • Operational Discipline: Clear SOPs for troubleshooting and escalation across all units.
  • Efficiency Gains: APC optimization reduces variability and improves process stability.
  • Asset Integrity: Safeguarding strategies protect plant and process equipment, columns, furnaces, reactors, compressors, and pumps from upset conditions.

Strategic impact. Resilience: Stronger troubleshooting framework reduces operational risks across refinery and petrochemical units. Safety: Commissioning excellence ensures safe start‑ups and smooth integration of new projects.

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Safety, Integrity & Reliability

Protect people, assets and production with structured safety reviews and a reliability programme built on evidence.

C2 Plant Operations & Safety Management+

Objective. Strengthen refinery operations and safety culture by conducting a systematic review of plant operations and safety practices, followed by a performance study that benchmarks process efficiency, operational discipline, and safety management. The goal is to ensure resilient, reliable, and safe operations across all refinery units, even under partial utility failures.

Scope
  • Process Plant Operations & Safety Review
  • Comprehensive audit of operating procedures across CDU, VDU, FCC, Hydrocracker, Reformers, ECC, DCU/VBU, NHT, DHT, HMU, CPP, Utilities & Offsites, Aromatics Complex, and Polymer Units.
  • Review of safety systems: emergency shutdowns, fire & gas detection, relief systems, containment strategies.
  • Validation of compliance with regulatory standards (OSHAS, API, IEC, local statutory requirements).
  • Identification of gaps in SOPs, training, and safety culture.
Approach
  • Operations Audit – Review SOPs, operating envelopes, and compliance with design limits.
  • Safety Systems Review – Audit ESD, fire & gas, relief systems, and containment strategies.
  • Load Shedding Protocols – Develop structured strategies for partial failures of power, steam, CW, hydrogen, and auxiliary systems.
  • Performance Benchmarking – Plant availability, TA planning, catalyst management, utilisation, downtime, RAM models.
  • Data Integration – Align performance outcomes with LP model planning and business objectives.
Key deliverables
  • Operations & Safety Audit Report.
  • Load Shedding Management Protocols for refinery complex utilities.
  • Performance Review Study Report (availability, TA, catalyst, utilisation, downtime, RAM).
  • Benchmarking Dashboard (Operations & Safety KPIs).
  • Continuous Improvement SOPs.
Indirect and collateral benefits
  • Improved Reliability: Stronger operational discipline reduces unplanned downtime.
  • Enhanced Safety Culture: Better preparedness and reduced incident frequency.
  • Operational Discipline: Clearer SOPs and compliance frameworks.
  • Resilience: Structured load shedding ensures continuity under partial utility failures.
  • Decision Support: Dashboards provide management with visibility into operations and safety KPIs.

Strategic impact. Reliability: Improved operational discipline across refinery units. Safety: Enhanced culture and preparedness for emergencies.

C3 Project Operations Readiness & Safety Management+

Objective. Ensure that new and revamped refinery projects achieve safe, reliable, and efficient start‑up readiness by integrating process safety reviews, hazard studies, operating mode analysis, and production promise benchmarking. The goal is to deliver projects that are operationally ready, safety‑compliant, and aligned with business plans.

Scope
  • PSSR Readiness, Process Safety Start‑up & Review
  • Conduct Pre‑Startup Safety Reviews (PSSR) to validate readiness of equipment, procedures, and personnel.
  • Review operating envelopes, interlocks, and emergency shutdown systems.
  • Ensure compliance with OSHA, API, IEC, and local statutory requirements.
  • Validate commissioning checklists and readiness protocols.
Approach
  • PSSR Readiness Review – Validate equipment, procedures, and personnel readiness before startup.
  • SIL/HAZOP Studies – Conduct structured workshops to identify hazards and assign SIL targets.
  • OMAR Analysis – Review operating modes and safeguard transitions between normal and abnormal states.
  • Production Promise Validation – Benchmark availability and UPDT, integrate RAM models, and align with LP planning.
  • Continuous Improvement SOPs – Governance framework for periodic reviews, accountability, and corrective actions.
Key deliverables
  • PSSR Readiness Report.
  • SIL/HAZOP Study Reports (risk matrices, SIL verification sheets).
  • OMAR Operating Modes Analysis Report.
  • Production Promise & Benchmarking Report (availability, UPDT, RAM).
  • Continuous Improvement SOPs.
Indirect and collateral benefits
  • Improved Safety Assurance: Structured PSSR and HAZOP reduce startup risks.
  • Operational Discipline: OMAR ensures smooth transitions across operating modes.
  • Reliability Confidence: Production promise validated with RAM models builds stakeholder trust.
  • Resilience: Benchmarking availability and UPDT strengthens operational readiness.
  • Governance: Clear SOPs embed accountability and compliance.

Strategic impact. Safety: Enhanced assurance of safe startup and operations. Reliability: Stronger confidence in production ramp‑up and availability.

D3 SMMS & Engineering Management+

Objective. Deliver comprehensive Specialist Materials and Maintenance Services (SMMS) and engineering management support across all disciplines to ensure asset integrity, corrosion control, plant reliability, and specification compliance. The aim is to achieve higher availability, reduced downtime, improved safety, and optimized maintenance practices.

Scope
  • Specialist Materials & Maintenance Services – Asset Integrity Study
  • Integrity audits across critical equipment (furnaces, reactors, compressors, charge pumps, pipelines).
  • Review inspection histories, maintenance records, and failure data.
  • Develop integrity management plans aligned with API/ASME standards.
  • Corrosion, Integrity & Reliability Assessment
Approach
  • Asset Integrity Framework – API/ASME based integrity audits.
  • Corrosion Risk Mapping – Identify high‑risk areas, develop control programs.
  • Reliability Modeling – RAM analysis for critical equipment and utilities.
  • Materials Review – PMS validation, metallurgy adequacy, lifecycle cost analysis.
  • Benchmarking – Plant availability and UPDT compared against industry quartiles.
Key deliverables
  • Asset Integrity Study Report.
  • Corrosion & Reliability Assessment Report.
  • Corrosion Control & Materials Review Report.
  • Plant Availability & Reliability Benchmarking Report.
  • PMS Review & Recommendations Document.

Strategic impact. Reliability: Improved plant availability and reduced UPDT. Safety: Enhanced corrosion control and asset integrity.

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Digital Transformation (RWDT²)

A staged route from IT–OT integration to a refinery-wide real-time digital twin, with agentic AI models that monitor, reason and recommend within your guardrails, led by process domain expertise.

What each level delivers

Level 1 Basic and advanced refinery-wide integrated real-time optimisation (RTO)+

Integrates plant data (IT–OT) and delivers basic-to-advanced RTO for the main units, giving a first real-time view of margin and operating targets.

See the nine AI-Modules

Level 2 Complex refinery-wide integrated RTO, including AI-ML+

Extends RTO across the full complex and adds AI-ML to improve prediction, so targets reflect more of the refinery’s interactions.

See the nine AI-Modules

Level 3 IT–OT convergence with MPC/APC; real-time digital twin+

Models the refinery in real time with AI-ML and MPC/APC integration, and delivers an intermediate digital twin with core applications.

See the nine AI-Modules

Level 4 Digital-twin transformation applications+

Refinery-wide applications for margin, operations, crude blend, energy and emissions, asset health and turnaround planning, emissions forecasting, reliability and preventive maintenance.

See the nine AI-Modules

The nine AI-Modules

AI-Module Process Calibration & Real-Time Scenario Simulation+

Keeps simulation and kinetic models calibrated to the plant through data reconciliation, then lets engineers test what-if scenarios on the live model before acting.

Direct value
  • Models that the plant team trusts
  • Safer, better-informed decisions
  • Fast response to feed, severity or shutdown changes
Covers
  • Process Calibration
  • What-If / Real-Time Scenario Simulation
How it works
  • Calibration runs automatically; scenarios run in minutes.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Crude Blend Optimisation & Product Quality Prediction+

Evaluates opportunity crudes and blends with assay-based models, and predicts product properties continuously between laboratory samples so blending and control can run closer to specification.

Direct value
  • Wider, more flexible crude basket
  • Less quality give-away and fewer reblends
  • Faster product release
Covers
  • Crude Blend Optimisation
  • Product Quality Prediction
How it works
  • Soft sensors validated against laboratory results.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Integrated Operations Optimisation, Constraints & Throughput+

Optimises unit set-points inside safe limits, predicts approaching constraints such as flooding, fouling and compressor limits, and identifies the active bottleneck so throughput is lifted without new equipment.

Direct value
  • Higher yield of valuable products
  • Fewer throughput-limiting events
  • Ranked, capital-light debottlenecking options
Covers
  • Operations Optimisation
  • Constraint Prediction & Avoidance
  • Throughput Debottlenecking
How it works
  • Targets flow to advanced process control; operators see early warnings.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Integrated Energy, Furnace & Utilities Optimisation+

Combines energy and emissions optimisation with furnace performance monitoring (efficiency, excess O₂, hot spots, coil temperatures) and utilities performance monitoring (steam, power, hydrogen, fuel gas, flare).

Direct value
  • Lower fuel and utility cost
  • Furnace efficiency held at target
  • Emissions and carbon intensity from live data
Covers
  • Energy & Emissions Optimisation
  • Furnace Performance & Monitoring
  • Utilities Performance & Monitoring
How it works
  • Alerts when a furnace or utility drifts from its efficient operating point.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Catalyst Monitoring & Management of Change (MOC)+

Tracks catalyst activity, selectivity and remaining life against operating history, and links every operating or equipment change to a managed, auditable Management of Change workflow.

Direct value
  • Longer, better-planned catalyst cycles
  • Fewer unreviewed changes
  • Complete audit trail for each change
Covers
  • Catalyst Monitoring
  • Management of Change
How it works
  • Catalyst data and change records held in one place.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Integrated Reliability, Asset Health & Turnaround Planning+

Combines condition monitoring with corrosion and reliability models to score asset health, predict failures, support preventive and predictive maintenance, and plan turnaround scope and timing.

Direct value
  • Fewer unplanned shutdowns
  • Turnaround scope focused on need
  • Maintenance spend targeted
Covers
  • Reliability Management
  • Asset Health
  • Preventive Maintenance
  • Turnaround Planning
How it works
  • Health scores roll up from equipment to unit to plant.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Process Plant Safety & Operating-Envelope Management+

Monitors operating envelopes, interlocks and transient modes such as start-up, shutdown and turndown, and flags safety-critical excursions early, with data to support HAZOP, SIL and OMAR reviews.

Direct value
  • Early warning of safety-critical excursions
  • Safer transitions between operating modes
  • Evidence for safety reviews and audits
Covers
  • Operating-Envelope Management
  • Transient-Mode Monitoring
  • Safety Review Support
How it works
  • Safety KPIs shown alongside production and margin KPIs.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Integrated Margin & Network Optimisation+

Finds the highest-margin operating plan for the whole complex from live data and prices, and balances crude, intermediates, products, tankage and logistics as one network, with inventory and working capital under control.

Direct value
  • Margin gap to the optimum tracked hour by hour
  • Better scheduling, logistics and plan adherence
  • Leaner inventories and less capital tied up
Covers
  • Margin Improvement
  • Network Optimisation
  • Inventory & Working-Capital Management
How it works
  • Plan, schedule and actual brought together in one real-time view.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin
AI-Module Automation of Daily Processes & Decisions+

Automates repetitive daily work: shift reports, data validation, KPI dashboards, laboratory-to-model updates, alerts and routine decisions, so engineers spend time on analysis instead of spreadsheets.

Direct value
  • Hours saved every day, per engineer
  • Consistent decisions across shifts
  • Reports and KPIs available in real time
Covers
  • Daily Reporting Automation
  • Decision Support
  • KPI and Alert Management
How it works
  • Rules and models encode your best practice for every shift.
  • Tied to live plant data and your constraints
  • Designed to work with the other modules as one digital twin

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Project Front-End Development Management (FEDM)

Owner’s-Consultant leadership from feasibility to final investment decision: choose the right project, and develop it rightly.

D1.1 Project Feasibility Studies+

Objective. Conduct feasibility studies to evaluate technical, commercial, and economic viability of proposed projects, ensuring early identification of risks and opportunities. Scope

Approach
  • Technology TRL assessment.
  • Risk matrix development.
  • Commercial viability analysis.
  • Economies of scale evaluation.
Direct value
  • GRM uplift: 0.5–2 $/bbl.
  • CAPEX reduction: 5–10%.
  • OPEX reduction: 5–10%.
  • Schedule savings: ~10-20%.
  • IRR improvement: 2–5 % points.
D1.2 Project Feasibility Review+

Objective. Review completed feasibility studies to validate assumptions, identify gaps, and ensure alignment with strategic objectives. Scope

Approach
  • TRL reassessment.
  • Risk matrix validation.
  • Commercial viability re‑check.
  • Economies of scale optimization.
Direct value
  • Same configuration benefits as above (GRM uplift, CAPEX/OPEX reduction, schedule savings, IRR improvement).
D1.3 Project Concept Development & Selection+

Objective. Develop and select the most viable project concept, balancing technical feasibility, commercial viability, and risk mitigation. Scope

Approach
  • TRL scoring of competing technologies.
  • CAPEX/OPEX trade‑off analysis.
  • IRR sensitivity analysis.
  • Economies of scale evaluation.
Direct value
  • GRM uplift: 0.2–1 $/bbl.
  • CAPEX reduction: 5–10%.
  • OPEX reduction: 5–10%.
  • Schedule savings: ~10%.
  • IRR improvement: 2–5 points.
D1.4 Project Concept Review & Optimization+

Objective. Review and optimize selected project concepts to maximize profitability and minimize risks. Scope

Approach
  • TRL reassessment.
  • Risk matrix optimization.
  • Commercial viability re‑evaluation.
  • Economies of scale optimization.
Direct value
  • Same configuration benefits (GRM uplift, CAPEX/OPEX reduction, schedule savings, IRR improvement).
D1.5 Competitive Scoping & CAPEX Reduction+

Objective. Conduct competitive scoping to identify cost‑efficient project options and achieve CAPEX reduction of 5–10%. Scope

Approach
  • TRL assessment of cost‑efficient technologies.
  • CAPEX/OPEX trade‑off analysis.
  • Economies of scale evaluation.
  • Risk matrix validation.
Direct value
  • CAPEX reduction: 5–10%.
  • OPEX reduction: 5–10%.
  • GRM uplift: 0.2–1 $/bbl.
  • Schedule savings: ~10%.
  • IRR improvement: 2–5 points.
D1.6 Identify / Select Right Project & Do Project Development Rightly+

Objective. Ensure the right project is selected and developed with discipline, maximizing profitability and minimizing risks. Scope

Approach
  • TRL scoring of candidate projects.
  • CAPEX/OPEX trade‑off analysis.
  • IRR sensitivity analysis.
  • Economies of scale evaluation.
Direct value
  • GRM uplift: 0.2–1 $/bbl.
  • CAPEX reduction: 5–10%.
  • OPEX reduction: 5–10%.
  • Schedule savings: ~10%.
  • IRR improvement: 2–5 points.
D2 Project Management Consultancy (PMC) Services+

Objective. Provide end‑to‑end Project Management Consultancy (PMC) support across the full lifecycle — from concept and feasibility through execution and operations. The aim is to ensure value assurance, disciplined project execution, cost efficiency, schedule adherence, and risk mitigation, resulting in better profitability and resilience.

Scope
  • Project Value Assurance Review – Concept validation, Stage Gate 1–5 reviews, FID readiness, execution and operations phase assurance.
  • Design Basis Review – BEDQ – Basic Engineering Design Questionnaire, design margins validation.
  • Process Engineering Review – Review of BDPs/BEDPs for process adequacy and optimization.
  • Design Basis Review – BEDD – Basic Engineering Design Data across all disciplines.
  • Project Cost Estimation Services – CAPEX/OPEX estimation, benchmarking, and value engineering.
Approach
  • Technology TRL Assessment – Evaluate maturity of technologies used in design and execution.
  • De‑Risking Framework – Develop risk matrices across technical, commercial, and operational domains.
  • Commercial Viability Analysis – CAPEX/OPEX trade‑off, IRR/NPV/payback evaluation.
  • Economies of Scale Evaluation – Optimize unit sizing, integration, and infrastructure adequacy.
  • Benchmarking – independent capex benchmarking, peer quartile comparisons.
Key deliverables
  • Value Assurance Review Reports (Stage Gate 1–5, FID readiness).
  • BEDQ/BEDD design basis validation reports.
  • Process Engineering Review Reports (BDPs/BEDPs).
  • CAPEX/OPEX estimation and benchmarking reports.
  • Project schedule and monitoring dashboards.
Indirect and collateral benefits
  • Improved Reliability: Stronger assurance across Stage Gates and execution phases.
  • Enhanced Safety: Design reviews and 3D model validation reduce risks.
  • Operational Discipline: Structured PMC governance ensures accountability.
  • Resilience: Risk & opportunity management strengthens project outcomes.
  • Confidence: Benchmarking and CSRA provide board‑level assurance.

Strategic impact. Value Assurance: Projects deliver on intended outcomes across lifecycle. Efficiency: CAPEX/OPEX reductions and schedule savings improve profitability.

A2.1 Process Concept Selection Review+

Objective. Conduct a comparative evaluation of process schemes and alternatives to recommend the most cost‑effective and sustainable configuration, balancing CAPEX/OPEX trade‑offs, energy efficiency, yield selectivity, flexibility, and carbon intensity reduction.

Scope
  • Evaluation of alternate process schemes (revamp vs new build).
  • Review of technology readiness and licensor track record.
  • CAPEX/OPEX trade‑off analysis for each scheme.
  • Assessment of energy efficiency, yield selectivity, and flexibility.
  • Review of constraints, process limits, and debottlenecking potential.
Approach
  • Comparative Scheme Evaluation: Assess multiple process concepts (revamp, grassroots, hybrid) for technical and economic viability.
  • Technology Readiness & Maturity: Review maturity, reliability, and track record of candidate technologies.
  • CAPEX/OPEX Trade‑off Analysis: Quantify investment vs operating cost implications for each option.
  • Energy Efficiency & Yield Selectivity: Evaluate process schemes for energy intensity, yield distribution, and product flexibility.
  • Carbon Intensity Assessment: Estimate GHG footprint of each scheme, including integration of decarbonisation technologies.
Key deliverables
  • Process Concept Evaluation Report comparing schemes.
  • CAPEX/OPEX Trade‑off Matrix with quantified impacts.
  • Energy & Yield Assessment Report.
  • Carbon Intensity & GHG Reduction Options Report.
  • Recommendation Matrix highlighting best‑fit scheme.
Direct value
  • Optimized investment decisions balancing CAPEX and OPEX.
  • Improved energy efficiency and yield selectivity.
  • Lower GHG footprint through integration of decarbonisation strategies.
  • Enhanced crude and feedstock flexibility.
  • Strategic clarity for long‑term competitiveness.
A2.3 Process Technology Review, Assessment & Selection+

Objective. Assess existing licensed technologies across refinery and petrochemical units, identify upgrade opportunities, and recommend modernization strategies to improve yields, energy efficiency, flexibility, and reduce carbon intensity.

Scope
  • Review of existing licensed technologies across refinery and petrochemical units.
  • Identification of upgrade opportunities (revamp, retrofit, debottlenecking).
  • Evaluation of modernization options (new licensors, advanced catalysts, digitalisation).
  • Energy efficiency and yield selectivity analysis.
  • Carbon intensity benchmarking vs peer refineries.
Approach
  • Technology Assessment: Review current licensed technologies for FCCU, RFCCU, HCU, HDT, Platformer, Aromatics, SGHT, SRU, ECC, and polymer units.
  • Performance Benchmarking: Compare unit performance against licensor guarantees and peer benchmarks.
  • Upgrade Opportunity Identification: Highlight debottlenecking, revamp, and retrofit options.
  • Modernization Review: Evaluate advanced technologies (e.g., high‑selectivity catalysts, energy‑efficient designs, digital twins).
  • CAPEX/OPEX Trade‑off Analysis: Quantify investment vs operating cost implications for modernization options.
Key deliverables
  • Technology Assessment Report for refinery and petrochemical units.
  • Performance Benchmarking Matrix vs licensor guarantees and peers.
  • Upgrade Opportunity Report with quantified benefits.
  • Modernization Recommendations with CAPEX/OPEX trade‑offs.
  • Energy & Yield Optimization Report.
Direct value
  • Optimized technology selection ensuring cost‑effective modernization.
  • Improved energy efficiency and yield selectivity.
  • Lower GHG footprint through advanced technologies.
  • Enhanced product flexibility across fuels, aromatics, and polymers.
  • Strategic clarity for long‑term competitiveness and diversification.
A2.4 Process Technology Selection, Assessment & Review (Including Licensor Selection)+

Objective. Assess existing licensed technologies across refinery and petrochemical units (FCCU, RFCCU, HCU, HDT, Platformer, Aromatics, SGHT, SRU, ECC, Polyolefins, LAOs, polymer derivatives), identify upgrade opportunities, recommend modernization strategies, and support licensor selection to ensure cost‑effective, efficient, and sustainable operations.

Scope
  • Review of existing licensed technologies across refinery and petrochemical units.
  • Identification of upgrade opportunities (revamp, retrofit, debottlenecking).
  • Evaluation of modernization options (new licensors, advanced catalysts, digitalisation).
  • Energy efficiency and yield selectivity analysis.
  • Carbon intensity benchmarking vs peer refineries.
Approach
  • Technology Assessment: Review current licensed technologies for refinery and petrochemical units.
  • Performance Benchmarking: Compare unit performance against licensor guarantees and peer benchmarks.
  • Upgrade Opportunity Identification: Highlight debottlenecking, revamp, and retrofit options.
  • Modernization Review: Evaluate advanced technologies (high‑selectivity catalysts, energy‑efficient designs, digital twins).
  • CAPEX/OPEX Trade‑off Analysis: Quantify investment vs operating cost implications for modernization options.
Key deliverables
  • Technology Assessment Report for refinery and petrochemical units.
  • Performance Benchmarking Matrix vs licensor guarantees and peers.
  • Upgrade Opportunity Report with quantified benefits.
  • Modernization Recommendations with CAPEX/OPEX trade‑offs.
  • Licensor Evaluation Matrix comparing bids.
Direct value
  • Optimized technology selection ensuring cost‑effective modernization.
  • Improved energy efficiency and yield selectivity.
  • Lower GHG footprint through advanced technologies.
  • Enhanced product flexibility across fuels, aromatics, and polymers.
  • Transparent licensor selection process ensuring best GRM & ROI.

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Technical Services Agreements (TSA)

On-call access to senior process specialists under a fixed annual agreement: secure Global Expert advice that solves your reliability or troubleshooting problems at a fraction of the cost of consulting licensors, and can save you millions of dollars in productivity or by averting an outage through higher plant reliability and availability.

TSA Technical Services Agreement (TSA)+

Purpose. Query-based, on-call technical support from senior experts: troubleshooting, unit monitoring and operations guidance under changing feedstocks and operating conditions.

Approach
  • Fixed agreement with a defined window of consulting services
  • Query-based support from experienced process specialists
  • Unit monitoring and trending; operating-envelope guidance
  • Best-practice and recommended-practice documentation
Deliverables
  • Written technical responses and recommendations
  • Root-cause notes for investigations
  • Best-practice documentation
  • Periodic review of issues and learnings
Direct value
  • Global Expert advice at a fraction of the cost of consulting licensors, with potential savings of millions of dollars in productivity or from averting an outage
  • Typical queries answered in 0–5 hours
  • Investigations of 5–40 hours within the agreement
  • Fixed 12-month renewable term with no added headcount

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Energy Efficiency, Offsites & Logistics

Cut fuel, losses and emissions together, from quick operating wins to moderate-capex projects.

A3.1 Utilities & Energy Efficiency Improvement+

Objective. Optimize utility systems and energy consumption across refinery and petrochemical units by benchmarking Energy Intensity Index (EII) against global quartiles, identifying furnace and heat integration opportunities, and implementing pinch analysis strategies to deliver measurable efficiency gains with low to moderate CAPEX investments.

Scope
  • EII benchmarking vs peer refineries and quartile breakpoints.
  • Furnace efficiency improvements (O₂ trim, burner tuning, hot spot control).
  • Heat integration opportunities within CDU, VDU, FCCU, Hydrocracker, and Aromatics units.
  • Pinch analysis for process unit optimization and cross‑unit integration.
  • Utility system optimization (steam balance, condensate recovery, cooling water efficiency).
Approach
  • EII Baseline Assessment: Establish current Energy Intensity Index for the refinery.
  • Benchmarking vs Quartiles: Compare EII against Benchmarking quartile breakpoints (Q1–Q4) to identify performance gaps.
  • Furnace Efficiency Review: Audit furnace firing patterns, excess O₂, and skin temperatures to reduce fuel consumption.
  • Heat Integration Study: Evaluate process‑to‑process heat recovery opportunities within units.
  • Pinch Analysis: Identify pinch points within process units and cross‑pinch opportunities across units.
Key deliverables
  • EII Benchmarking Report with quartile comparison.
  • Furnace Efficiency Audit Report with corrective actions.
  • Heat Integration & Pinch Analysis Report.
  • Utility System Optimization Plan.
  • Energy Efficiency Improvement Roadmap (short, medium, long term).
Direct value
  • Furnace efficiency gains: 2–3% fuel savings via O₂ trim and hot spot control.
  • Heat integration: 3–5% reduction in furnace duty through process‑to‑process recovery.
  • Pinch analysis: Identification of cross‑unit opportunities saving 5-10% of energy.
  • Utility optimization: 5–10% improvement in steam/power balance.
  • Carbon footprint reduction: 5–10% lower CO₂ emissions.
A3.3 Oil Loss Review Study+

Objective. Conduct a comprehensive Oil Loss Review Study to identify, quantify, and mitigate losses across refinery and logistics operations. The study benchmarks against industry best practices, categorizes losses, and develops Standard Operating Procedures (SOPs) to reduce unaccountable losses, improve custody transfer accuracy, and enhance profitability. Categories of Losses

Direct value
  • Oil Loss Review Audit Report (accountable vs unaccountable losses).
  • Evaporation & Flare Loss Control Plan.
  • Fuel & Loss Management Strategy.
  • Ocean Loss & Custody Transfer SOPs.
  • BSW Management & Contract Variance SOPs.
A3.4 Flaring, Fuel & Loss & H₂ Management+

Objective. Develop an integrated Fuel, Loss, Flaring, and Hydrogen Management Plan to minimize hydrocarbon losses, optimize FG/FO utilization, reduce NG imports, improve furnace efficiency, and ensure compliance with SOx/NOx emission limits.

Scope
  • Flaring Loss Audit & Reduction Plan.
  • FG Balance Study (generation vs consumption).
  • FO Balance & Dedicated Burner Management.
  • Furnace Efficiency Audit (HRSG/APH systems).
  • SOx/NOx Compliance Review.
Approach
  • Flaring Loss Management:
  • Benchmark flaring intensity vs best practice (< 0.2% of throughput).
  • Implement flare gas recovery units (FGRUs).
  • Optimize flare tip velocity, pilot flame control, and combustion efficiency.
  • Fuel Gas (FG) Balance:
Key deliverables
  • Flaring Loss Management Report with benchmarks and recovery options.
  • FG/FO Balance & Flexibility Plan.
  • Furnace Efficiency Improvement Strategy (HRSG/APH integration).
  • SOx/NOx Compliance & Monitoring SOPs.
  • Hydrogen Balance Report (consumers vs generators, variability analysis).
Direct value
  • Flaring loss reduction: 20–50% reduction via FGRUs if above BM.
  • Fuel efficiency gains: 3–5% improvement in furnace efficiency.
  • NG import minimization: 10–20% reduction by maximizing FG utilization.
  • FO prioritization: Improved cost control by substituting FO for NG.
  • SOx/NOx compliance: Regulatory adherence and ESG improvement.

Strategic impact. Loss Reduction: Move refinery from Q3/Q4 → Q2/Q1 quartile. Cost Savings: ₹205–335 Crores/year potential gain.

A3.2 Oil Movements & Logistics Master Plan+

Objective. Develop a logistics and blending master plan for crude and product movements, storage, and trading. The plan ensures optimized tank sizing, carrier alignment, freight efficiency, and integration with multimodal transport networks, while enabling trading opportunities through blending of components into finished products.

Scope
  • Audit of tank farm utilization and adequacy.
  • Alignment of 20,000–50,000 m³ tanks with MR/LR1 carriers.
  • Freight cost optimization through carrier selection.
  • Integration with existing transport networks (jetty, rail, truck, pipeline).
  • Trading opportunities via blending surplus streams into marketable products.
Approach
  • Tank Sizing & Storage Economics:
  • Classify tanks by size: 50,000 m³ crude tanks, 20,000–30,000 m³ product tanks, 5,000–10,000 m³ blending tanks.
  • Balance CAPEX vs inventory carrying cost.
  • Carrier Compatibility:
  • Match tank sizes with carrier classes: MR (30–50k DWT), LR1 (55–80k DWT), LR2 (80–160k DWT), VLCC (200–320k DWT).
Key deliverables
  • Tank Sizing & Storage Economics Report (with classifications by m³ and carrier class).
  • Carrier Compatibility & Freight Cost Matrix (MR, LR1, LR2, VLCC).
  • DWT Availability & Evacuation Strategy.
  • Transport Network Integration Plan.
  • Blending & Trading Opportunities Report.
Direct value
  • Optimized tank sizing reducing CAPEX and inventory costs.
  • Lower freight costs through alignment with carrier classes.
  • Improved evacuation reliability via DWT availability planning.
  • Trading opportunities by blending components into finished products.
  • Strategic integration with ocean, rail, truck, and pipeline networks.
A3.5 Infrastructure, Storage & Offsites Management+

Objective. Develop a master plan for infrastructure, storage, and offsites to ensure reliable crude receipt, product evacuation, blending flexibility, and utility supply for refinery and petrochemical operations. The plan integrates logistics, utilities, and energy systems to maximize efficiency and trading opportunities.

Scope
  • Marine & Pipeline Infrastructure
  • Jetty adequacy for MR/LR1/LR2/VLCC carriers.
  • SBM (Single Buoy Mooring) for crude receipt.
  • Pipeline network for crude, products, and utilities.
  • Storage & Blending Facilities
Key deliverables
  • Infrastructure & Offsites Master Plan.
  • Tank Sizing & Blending Flexibility Report.
  • Marine & Pipeline Adequacy Study.
  • Utility Systems Design (water, cooling, power).
  • Flare & OM&S Optimization Report.
Direct value
  • Capex Savings 5-20% reduction
  • Improved crude receipt & evacuation reliability.
  • Trading uplift via blending/export opportunities.
  • Reduced demurrage & freight costs through carrier alignment.
  • Reliable utility supply (water, cooling, power).
A3.6 Wharf & Jetty Adequacy & Utilisation+

Objective. Evaluate and optimize wharf and jetty adequacy and utilisation to ensure reliable crude receipt, product evacuation, and petrochemical export. The plan balances carrier class compatibility, throughput capacity, demurrage minimization, and integration with inland logistics.

Scope
  • Jetty Adequacy Assessment:
  • Structural integrity, draft depth, berth length, fendering, mooring systems.
  • Compatibility with MR (30–50k DWT), LR1 (55–80k DWT), LR2 (80–160k DWT), and VLCC (200–320k DWT).
  • Wharf Utilisation Study:
  • Berth occupancy rates, turnaround times, vessel scheduling.
Key deliverables
  • Jetty Adequacy Report (structural, draft, carrier compatibility).
  • Wharf Utilisation & Scheduling Study.
  • Pipeline & Manifold Integration Plan.
  • Demurrage Reduction Strategy.
  • Export & Trading Flexibility Report.

Strategic impact. Operational Reliability: Adequate jetty depth and berth length for larger carriers. Cost Efficiency: Reduced demurrage and freight costs.

A3.7 Minimizing Pipeline Transfer (PLT) Losses+

Objective. Develop a Pipeline Transfer Loss Management Plan to minimize losses during crude and product transfers, with special focus on contamination in multi‑product pipelines. The plan ensures accurate custody transfer, reduced unaccountable losses, and improved scheduling discipline. Categories of PLT Losses

Strategic impact. Loss Reduction: Move refinery from typical 0.1–0.2% PLT losses → < 0.05%. Cost Savings: ₹ 10–50 Crores/year.

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Bio-Fuels & Low-Carbon Solutions (LCS)

Evaluate how SAF, renewable feedstocks, 2G ethanol, E2J (ethanol-to-jet) technologies, co-processing and carbon management can fit existing refining and petrochemical assets, with a decarbonisation strategy for deep brownfield plants.

A1.5 De‑Carbonisation Studies & Master Plan+

Objective. Develop a phased decarbonisation roadmap for the refinery, identifying technologies and strategies to reduce Greenhouse Gas (GHG) emissions, align with ESG mandates, and ensure long‑term sustainability.

Scope
  • CO₂ baseline assessment across all refinery assets.
  • Evaluation of carbon capture technologies (amine scrubbing, oxy‑fuel combustion, pre‑combustion syngas separation).
  • Fuel substitution studies (natural gas, biomass, renewable electricity).
  • Hydrogen integration roadmap (green hydrogen blending, blue hydrogen from reformers with CCS).
  • Energy efficiency improvements (heat integration, flare minimisation, utility optimisation).
Approach
  • Baseline CO₂ Mapping: Establish current emissions profile across process units, utilities, and offsites.
  • Technology Identification: Evaluate available and emerging technologies for GHG reduction.
  • Post vs Pre‑Combustion Capture: Assess feasibility of carbon capture at flue gas (post‑combustion) vs syngas/hydrogen production stages (pre‑combustion).
  • Fuel Substitution: Explore natural gas, biofuels, and renewable electricity to replace conventional fuels.
  • Hydrogen Utilisation: Assess integration of green/blue hydrogen for process fuel, desulphurisation, and utility systems.
Key deliverables
  • CO₂ Baseline Report with quantified emissions.
  • Technology Evaluation Matrix (capture, substitution, hydrogen).
  • Decarbonisation Master Plan with phased roadmap.
  • Investment & ROI Analysis for each technology option.
  • Risk & Sensitivity Matrix for regulatory and market scenarios.
Direct value
  • 15–30% CO₂ reduction in short‑term through efficiency and fuel substitution.
  • Long‑term net‑zero alignment with hydrogen and CCS integration.
  • ESG compliance improving investor confidence.
  • Operational resilience against carbon pricing and regulatory changes.
  • Competitive positioning as a low‑carbon refinery.

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Note. Benefits are indicative for a 10 MMTPA (210 kbpsd) complex and are not guaranteed. See Legal Disclaimers.

Disclaimer. General information only. Nothing on this website is legal, financial, tax or engineering advice or an offer capable of acceptance. Binding terms arise only under a signed written agreement. See our Legal Disclaimers, NDA & Confidentiality.