Contract Date
EPROM is implementing various activities under several contracts and WA with SOPC since 2019.
About
- Location: Suez, Egypt
- Core Business: Refining crude oil into various petroleum products
- Ownership: Fully owned by the Egyptian General Petroleum Corporation (EGPC)
Plant Description
Established in 1921 as Egypt’s first national oil refinery, Suez Oil Processing Company (SOPC) plays a key role in securing the country’s energy needs by refining 3.5 million barrels of crude oil annually. Fully owned by the Egyptian General Petroleum Corporation (EGPC), SOPC produces a wide range of petroleum products, including gasoline, diesel, jet fuel, and industrial lubricants, serving major sectors across the Egyptian market. Its operations contribute significantly to economic growth and job creation, particularly in the Suez region, bolstering national development.
SOPC’s Product Range
Suez Oil Processing Company (SOPC) produces a variety of petroleum products to meet the demands of the Egyptian market. These products include:
- Gasoline: For transportation fuel
- Diesel: For transportation and industrial use
- Jet Fuel: For aviation
- Lubricating Oils: For various industrial applications
- Petroleum Coke: Used in industrial processes
- Other Petroleum Products: Such as asphalt and waxes
New Coker Complex : Overview
Suez Oil Processing Company (SOPC) is undertaking a major project—the new Coker Complex—comprising over 29 units, including licensed and open-art units, designed to maximize the value of low-grade fuel oil (mazut) by converting it into high-value products. The complex includes key production units such as the Delayed Coker Unit (DCU), Distillate Hydrotreating Unit (DHT), Kerosene Hydrotreating Unit (KHT), Vacuum Distillation Unit (VDU), and Sulfur Recovery Unit (SRU). This project will meet local demand for vital petroleum products like diesel, LPG, and jet fuel, reducing Egypt’s dependence on imports, and produce diesel and kerosene that comply with European environmental standards.
EPROM’s Role:
As the Owner’s Representative, EPROM is overseeing all phases of the new Coker Complex project, from FEED to startup, covering detailed engineering, procurement, and construction activities. Since the signing of the contract on February 7, 2021, EPROM has deployed a multidisciplinary team of experts to manage and supervise the project. EPROM ensures smooth coordination with consortium partners Enppi and Petrojet, ensuring the project is delivered on time and meets all technical and operational requirements.
Key Activities:
- Engineering Technical Support
- Construction Supervision (Civil, Mechanical, Electrical, I&C)
- Project Quality Control
- Procurement Supervision
- HSEQ Management
- Project Interface and Phases Management
- Commissioning
- Preservation Management
- Startup
Asphalt Plant (O&M) : Overview
The Asphalt Plant was established to carry out vacuum distillation of atmospheric residue, producing asphalt with a penetration grade of 60/70. With a design capacity of 1,200 tons per day, the plant is designed to meet local market demand, achieve self-sufficiency, and reduce the need for foreign currency. This facility plays a vital role in supporting Egypt’s infrastructure needs by providing high-quality asphalt.
EPROM’s Role:
EPROM successfully executed commissioning activities and ensured a smooth startup, fine-tuning operations to deliver on-spec products. Following this, EPROM was appointed as the primary Operation & Maintenance (O&M) contractor. Over the past two years, EPROM has managed the operation and maintenance of the Asphalt Plant, including routine maintenance. Utilizing top-tier expertise and highly skilled personnel, EPROM has consistently ensured efficient operations, meeting production targets while maintaining the safety and reliability of the unit. The team, comprising approximately 70 specialized technical professionals, continues to uphold the highest standards of operational excellence.
Key Activities:
- Commissioning
- Startup
- Operation
- Maintenance Supervision (Mechanical, Static, Electrical, I&C)
- In-service Inspection Supervision
- Maintenance Planning
- Shutdown Management
- HSEQ Management
3D modelling & Digitalization : Overview
Suez Oil Processing Company (SOPC) launched a project to enhance its digital capabilities by contracting EPROM to perform laser scanning and create a 3D model (Navisworks file) of all units, buildings, and facilities at its site. The project included generating 360˚ images, 2D plot plans, and developing both non-intelligent and intelligent 3D models. Additionally, updated Process Flow Diagrams (PFD) and Piping and Instrumentation Diagrams (P&ID) for all units were created, along with the development of a digital library to archive SOPC’s technical documents.
EPROM’s Role:
EPROM successfully executed all phases of the project, starting with comprehensive laser scanning of SOPC’s facilities. EPROM delivered high-quality 360˚ images, 2D plot plans, and a non-intelligent 3D model. Subsequently, an intelligent 3D model was developed, and isometric drawings were extracted. Alongside this, EPROM updated all PFD and P&ID diagrams and established a digital archive for SOPC’s technical documentation. As part of the project, EPROM also provided professional training to SOPC’s team on Autodesk Plant 3D, ensuring they have the necessary skills to manage and utilize the new digital tools effectively.
Key Activities:
- 3D Model
- Digital Archiving
- Update P&ID
- Update Isometrics
- Update PFD
- Autodesk Plant 3D Training
Refinery Process Safety & Asset Integrity Management : Overview
The Process Safety and Asset Integrity Management (PSAIM) project at Suez Oil Processing Company (SOPC) is aimed at enhancing the safety, reliability, and efficiency of the facility by implementing a comprehensive system based on the guidelines of the U.S. Center for Chemical Process Safety (CCPS). The project focuses on two core areas: Process Safety Management (PSM) and Asset Integrity Management (AIM). PSM is designed to prevent, mitigate, and respond to catastrophic releases of chemicals or energy, structured around CCPS’s Risk-Based Process Safety (RBPS) approach, which prioritizes resources based on risk levels. AIM ensures that all assets, from static equipment to rotating machinery, maintain their functionality throughout their lifecycle while adhering to safety and environmental regulations. The project also includes technical studies like Risk-Based Inspection (RBI) and Reliability-Centered Maintenance (RCM) to ensure optimal asset performance and risk management.
EPROM’s Role:
As part of the PSAIM project, EPROM was responsible for conducting a GAP analysis of SOPC’s operations against CCPS requirements to identify and address areas for improvement. EPROM developed an action plan to close all identified gaps, created essential technical documents such as policies, strategies, procedures, and standard operating procedures (SOPs), and conducted Hazard Identification and Risk Assessment (HIRA) studies across all SOPC units, including HAZID, HAZOP, Bowtie, LOPA, SIL, QRA, and FERA. EPROM also applied an RBI study and integrated RBI software with SAP, as well as conducted RCM/FMECA studies on rotating and electrical equipment. Additionally, EPROM provided capacity-building training for nearly 2,500 SOPC employees, ensuring that the SOPC workforce is fully equipped to manage and maintain the implemented systems.
Key Activities:
- PSM GAP analysis
- PSM CCPS system development
- Asset integrity (AIM)
- Risk Based inspection – RBI study & software
- Reliability center maintenance – FMECA study
- SOP – Standard operation procedure
- HAZID
- HAZOP
- Bowtie
- LOPA
- SIL
- QRA
- FERA
- Capacity building training
