Project Overview

Client: Kaduna Refining and Petrochemical Company (KRPC)
Location: Kaduna, Nigeria
Industry: Oil & Gas, Refining
Services Provided: Control valve rehabilitation, gate valve restoration, site glass replacement, and plant revamp
Project Duration: February – December 2024 (Raw Water Plant), Ongoing (Main Plant)

CCEL Oil & Gas undertook a major refurbishment and revamp project for KRPC, focusing on the Raw Water Plant and the Main Plant. This extensive project involved the rehabilitation of critical control valves, gate valves, and site glasses to enhance the operational efficiency of KRPC’s refining processes.

The Challenge

KRPC faced significant operational challenges due to aging and deteriorated control systems, leading to inefficiencies in plant operations. The primary concerns included:

• Malfunctioning control valves causing process inefficiencies
• Gate valves experiencing severe wear and leakage, leading to safety hazards
• Site glasses becoming non-functional, making it difficult for operators to monitor fluid levels and flow conditions
• Increased maintenance costs and unplanned shutdowns affecting overall productivity
• The scale of the required rehabilitation was enormous, with over 1000 control valves and 500 site glasses needing revamping in the Main Plant alone

KRPC sought a reliable engineering services provider with a proven track record of excellence to maintain safety, efficiency, and compliance with industry regulations. CCEL Oil & Gas was awarded the contract based on its technical expertise, industry experience, and commitment to delivering quality solutions.

The Solution

CCEL deployed a structured and methodical approach to address the challenges:

1. Assessment and Diagnosis:
   • Conducted a detailed inspection of all control valves, gate valves, and site glasses.
   • Identified faulty components and developed a systematic rehabilitation plan.
2. Rehabilitation and Replacement:
   • Revamped all malfunctioning control valves in the Raw Water Plant, ensuring smooth fluid regulation and control.
   • Restored gate valves to optimal working conditions, eliminating leaks and enhancing safety.
   • Replaced and rehabilitated over 500 site glasses, improving real-time process monitoring for operators.
   • Launched an ongoing revamp project for over 1000 control valves in the Main Plant, reinforcing the reliability of critical refinery operations.
3. Technical Expertise & Precision Execution:
   • Utilized high-quality materials and advanced engineering techniques to restore equipment.
   • Ensured that all rehabilitated components met stringent industry standards.
   • Conducted rigorous testing and quality assurance checks before reintegrating components into plant operations.
4. Continuous Support and Expansion:
   • Provided ongoing maintenance and support to sustain long-term efficiency improvements.
   • Engaged with KRPC to identify further areas for improvement, reinforcing CCEL’s commitment to excellence.

The Results

The successful execution of the project delivered significant benefits to KRPC:

• Operational Efficiency: Fully restored control systems improved fluid regulation and process control, reducing unplanned shutdowns.
• Safety Enhancements: Leak-proof gate valves and functional site glasses minimized operational hazards.
• Cost Savings: Reduced maintenance costs and improved system reliability led to lower downtime and enhanced productivity.
• Sustainability: The refurbishment extended the lifespan of existing equipment, reducing the need for costly replacements.

With work still in progress at the Main Plant, CCEL continues to demonstrate its technical expertise, problem-solving skills, and commitment to delivering high-impact engineering solutions. As CCEL Oil & Gas, we remain dedicated to pushing for more projects and driving excellence in the oil and gas industry.

Conclusion

CCEL’s successful execution of the KRPC rehabilitation project underscores our capability as a trusted engineering service provider. By leveraging our expertise in valve refurbishment, mechanical process solutions, and plant maintenance, we help clients achieve improved operational performance, safety, and cost efficiency. Our ongoing commitment to quality and innovation positions us as a leader in the oil and gas industry, ready to take on even more complex challenges.

For inquiries about our engineering solutions and how we can assist your operations, contact CCEL Oil & Gas today.