Design Basis Process Design Basis FOR UNIT 13,14,15

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DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 1/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

PROCESS DESIGN BASIS

FOR

UNIT 13 - HYDROGEN PLANT UNIT - TRAIN 1


UNIT 14 - HYDROGEN PLANT UNIT - TRAIN 2
UNIT 15 - HYDROGEN PLANT UNIT - COMMON PARTS

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ

EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

3 09 NOV 17 REVISED AS PER MARKED S.J.Kim S. J. Seong K.D.Ko Y.H.Yoon

2 12 OCT 17 REVISED AS PER MARKED S.J.Kim S. J. Seong K.D.Ko Y.H.Yoon

1 07 SEP 17 REVISED AS PER MARKED S.J.Kim S. J. Seong K.D.Ko Y.H.Yoon

0 26 FEB 15 ISSUE FOR CONSTRUCTION J. N. Park S. J. Seong K.D.Ko J.B.Kim

B 01 OCT 14 REVISED AS PER MARKED J. N. Park S. J. Seong K.D.Ko J.B.Kim

A 25 JUL 14 ISSUE FOR APPROVAL J. N. Park S. J. Seong K.D.Ko J.B.Kim

REV. DATE DESCRIPTION PRPD CHKD REVD APPRD CONFD

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering

& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :

a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made

b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 2/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

REVISION HISTORY

Rev Date Description Page


A 25 JUL 14 Refinery fuel gas BL condition is revised. 14
A 25 JUL 14 LPG BL condition is revised. 18
A 25 JUL 14 C4 BL condition is revised. 19
A 25 JUL 14 Environmental requirements for air pollution is 23
revised
A 25 JUL 14 HP BFW BL condition is revised. 24
Demineralized water BL condition is revised.
A 25 JUL 14 Instrument air BL condition is revised. 25
A 25 JUL 14 Nitrogen BL condition is revised. 26
A 25 JUL 14 Exchanger fouling resistance for cooling water is 29
revised.
A 25 JUL 14 As per 2342-AA00-JSD-0000-03_1 PID preparation, 30, 31
medium symbol is revised.
A 25 JUL 14 As per 2342-AA00-JSD-0000-03_1 PID preparation, 31
insulation code is revised.
A 25 JUL 14 The facing and special requirement for piping class 32
to be specified.
B 01 OCT 14 No changes relative to the Rev. A document ALL
0 26 FEB 15 As per Minutes of Management Meeting at Seoul 7
Office, doc.no.: KRP-C-MOM-N-0060-attachment
7_TQ.No.: TQ-PR-E-264, Note 1 is added.
0 26 FEB 15 As per Minutes of Management Meeting at Seoul 10
Office, doc.no.: KRP-C-MOM-N-0060-attachment
7_TQ.No.: TQ-PR-E-056, BR naphtha line from BL is
deleted.
0 26 FEB 15 Natural gas feed minimum temperature is revised as 10
30C as per Process design basis for Unit 45.doc
no.: IONE-4A45-SP-PR-0001_rev.0.
0 26 FEB 15 Boiler Feed Water’s design pressure is changed to 24
131kg/cm2g from 129 kg/cm2g as per pump

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 3/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

hydraulic re-calculation result, 36-P-003A/B HPU


boiler feed water pumps.
0 26 FEB 15 Abbreviations in Section 9.are revised. 30,31,32,33
0 26 FEB 15 Attachment is added in Section 11 as per deletion of 40.41
BR naphtha and Refinery Fuel Gas System future
installation.
1 07 SEP 17 Lay-out of table is revised for easy understanding. ALL
1 07 SEP 17 Source 6 is added according to Letter KRP-EH-CH-128. 12
1 07 SEP 17 Sentence “For refinery fuel gas composition, refer to 14
Basic Design Data para 3.5 (IONE-AA00-SP-PR-
0001)” is added at 3.1.2. And Composition table is
revised to show only design case for clear
understanding.
1 07 SEP 17 B/L Maximum Temperature for Refinery fuel gas 14
feedstock is updated as per CRS [KRP-EH-CH-
2133] no. 1.
1 07 SEP 17 Sentence of 3.1.3. is revised as per CRS [KRP-EH- 15
CH-2133] Additional Comments.
1 07 SEP 17 B/L Maximum Pressure for Light Naphtha feedstock 15
is updated as per CRS [KRP-EH-CH-2133] no. 2.
1 07 SEP 17 B/L Maximum Pressure for Heavy Naphtha feedstock 16
is updated as per CRS [KRP-EH-CH-2133] no.3.
1 07 SEP 17 B/L Pressure & Temperature conditions for LPG 19
feedstock is updated as per CRS [KRP-EH-CH-
2133] no.4.
1 07 SEP 17 B/L Pressure & Temperature conditions for C4 19
feedstock is updated as per CRS [KRP-EH-CH-
2133] no.5.
1 07 SEP 17 The sentence for process gas back-up is deleted as per 20
licenser confirmation. Licenser confirmed that Process
back-up is not required during the HAZOP study.
1 07 SEP 17 B/L Pressure & Temperature conditions for HP BFW 26
is updated as per CRS [KRP-EH-CH-2133] no.6.
1 07 SEP 17 B/L Pressure & Temperature condition for 26

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 4/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Demineralized Water is updated as per CRS [KRP-


EH-CH-2133] no.7. But Supply unit also has limited
information which mentioned on Basic Design Data.
1 07 SEP 17 B/L Pressure & Temperature condition for Instrument 27
Air is updated as per CRS [KRP-EH-CH-2133] no.8.
But Supply unit also has limited information which
mentioned on Basic Design Data.
1 07 SEP 17 B/L Pressure & Temperature condition for Nitrogen is 28
updated as per CRS [KRP-EH-CH-2133] no.9. But
Supply unit also has limited information which
mentioned on Basic Design Data.
1 07 SEP 17 Exchanger fouling resistance for Cooling Water is 32
updated as per Basic Process Design Requirements
and Criteria [IONE-AA00-SP-PR-0002].
2 12 OCT 17 Table is fitted on one page properly as per CRS General
[200063-PMC-JV-11306] no.2, 6 and 10.
2 12 OCT 17 Revision bar is added for revised part as per CRS General
[200063-PMC-JV-11306] no.1.
2 12 OCT 17 Explanation for PS3 is added as per CRS [200063- 13
PMC-JV-11306] no.3.
2 12 OCT 17 Explanation for SOURCE 6 is added as per CRS 13
[200063-PMC-JV-11306] no.4.
2 12 OCT 17 Column of Fuel Gas 1 and Fuel Gas 2 is added on 14, 15
table again for clear understanding as per CRS
[200063-PMC-JV-11306] no.5.
2 12 OCT 17 “paragraph” is revised to “section” as per CRS 20
[200063-PMC-JV-11306] no.7 and 8.
2 12 OCT 17 Typo is correctly revised to “kg/h” as per CRS 30
[200063-PMC-JV-11306] no.9.
3 09 NOV 17 The valve for Iron and KMNO4 is developed as per 26
CRS [20063-PMC-JV-11479 no.1, 2]
3 09 NOV 17 “for cooling water exchanger” is added for clear 39
understanding as per CRS [20063-PMC-JV-11479
no.3]

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 5/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

TABLE OF CONTENTS

1. General information ................................................................................................................................. 8


1.1. Process scheme and plant capacity .......................................................................................... 8
1.2. Interconnections and battery limits ........................................................................................... 9
1.2.1. Incoming lines ....................................................................................................................... 9
1.2.2. Outgoing lines ....................................................................................................................... 9

2. Process products ................................................................................................................................... 10


2.1. Hydrogen product...................................................................................................................... 10
2.2. Export HP Steam ........................................................................................................................ 10

3. Feed and fuel specification .................................................................................................................... 11


3.1. Process feed ............................................................................................................................... 11
3.1.1 Natural gas feed .................................................................................................................. 11
3.1.2 Refinery fuel gas feedstock ................................................................................................ 14
3.1.3 Naphtha feed ...................................................................................................................... 15
3.1.4 LPG feed ............................................................................................................................. 19
3.1.5 C4 feed ............................................................................................................................... 20
3.2. Fuel.............................................................................................................................................. 20
3.2.1 Natural gas fuel ................................................................................................................... 20
3.2.2 Refinery fuel gas ................................................................................................................. 20

4. Climatic conditions ................................................................................................................................ 21


4.1. Temperature ............................................................................................................................... 21
4.2. Relative humidity ....................................................................................................................... 21
4.3. Wind velocity and prevailing wind direction .......................................................................... 21
4.4. Rainfall / snowfall ...................................................................................................................... 21
4.5. Earthquake ................................................................................................................................. 22
4.6. Barometric pressure.................................................................................................................. 22

5. Site information ...................................................................................................................................... 23


5.1. Plant elevation ........................................................................................................................... 23

6. Environmental requirements ................................................................................................................. 24


6.1. Air pollution ................................................................................................................................ 24

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 6/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

6.2. Noise ........................................................................................................................................... 24

7. Utilities ..................................................................................................................................................... 25
7.1. HP steam import ........................................................................................................................ 25
7.2. LP steam import ......................................................................................................................... 25
7.3. Steam Condensate .................................................................................................................... 25
7.4. HP BFW ....................................................................................................................................... 26
7.5. Demineralized water .................................................................................................................. 26
7.6. Cooling water ............................................................................................................................. 27
7.7. Instrument air ............................................................................................................................. 27
7.8. Electrical power ......................................................................................................................... 27
7.9. Nitrogen ...................................................................................................................................... 28
7.10. Hydrogen .................................................................................................................................... 28
7.11. Methanol for start-up ................................................................................................................. 28
7.12. Flare header ............................................................................................................................... 29

8. Units of measurement/codes and standards ...................................................................................... 30


8.1. Units of measurement ............................................................................................................... 30
8.2. Code and standards .................................................................................................................. 31
8.3. Exchanger fouling resistance .................................................................................................. 31

9. Abbreviations.......................................................................................................................................... 33
9.1. Equipment Abbreviation ........................................................................................................... 33
9.2. Fluid symbols ............................................................................................................................. 33
9.3. Insulation codes ........................................................................................................................ 33
9.4. Piping class ................................................................................................................................ 33
9.5. Pipe line numbering .................................................................................................................. 33
9.6. Equipment numbering............................................................................................................... 33
9.7. Instrument numbering............................................................................................................... 33

10. Engineering requirements ............................................................................................................. 34


10.1. General equipment design ....................................................................................................... 34
10.2. Design Pressure ........................................................................................................................ 34
10.3. Design Temperature .................................................................................................................. 34
10.4. Steam out ................................................................................................................................... 34

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 7/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

10.5. Corrosion allowance and material selection .......................................................................... 35


10.6. Nozzles ....................................................................................................................................... 36
10.7. Heat exchanger .......................................................................................................................... 36
10.7.1 Shell diameter ..................................................................................................................... 36
10.7.2 Tube length ......................................................................................................................... 36
10.7.3 Tube pitch ........................................................................................................................... 37
10.7.4 Tube diameter ..................................................................................................................... 37
10.8. Vessels & Columns.................................................................................................................... 38
10.9. Reactors ..................................................................................................................................... 38
10.10. Pumps ......................................................................................................................................... 38
10.11. Compressors & Blowers ........................................................................................................... 39
10.12. Tubular reformer ........................................................................................................................ 39
10.13. Instrumentation .......................................................................................................................... 39
10.13.1 Safety valves ..................................................................................................................... 39
10.13.2 Control valves .................................................................................................................... 39
10.13.3 Control system ................................................................................................................... 40

11. Attachment ...................................................................................................................................... 41

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 8/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

1. General information

1.1. Process scheme and plant capacity

The main process steps are the following:


- Hydrogenation and desulphurization
- Adiabatic pre-reforming
- Tubular steam reforming
- Shift conversion
- Hydrogen product purification by PSA
- Steam production by waste heat recovery

The fuel for the reformer furnace is natural gas/refinery fuel gas and off-gas from the PSA
unit for all feedstock operating cases.
The design capacity is two identical and independent trains of each 36,000 Nm3/h Hydrogen
(as 100% H2).
The design process feedstock are natural gas, refinery fuel gas (Future, See Note 1), C4
feedstock, LPG feedstock, light naphtha feedstock and heavy naphtha feedstock.

Note: 1. The refinery fuel gas was one of six feed sources during FEED stage. However,
according to meeting result (Ref.: KRP-C-MOM-N-0060-Attachment 7, TQ-PR-E-264)
between Employer and Contactor, it has been decided not to install the fuel gas
compressor system due to insufficient availability of refinery fuel gas in the Karbala
Refinery Plant. In this stage of the project, the downstream system will be designed to
cover the refinery fuel gas feed case without installing the refinery fuel gas
compressor system.

The on-stream factor shall be min. 330 days/year (7,920 h/year)


The plant must be designed to operate between 30% and 100% of the design capacity.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 9/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

1.2. Interconnections and battery limits

The interconnections at Topsøe’ BL are as below.


1.2.1. Incoming lines

- Natural gas
- Refinery fuel gas
- C4 feedstock
- LPG feedstock
- Light naphtha feedstock
- Heavy naphtha feedstock
- Boiler Feed water
- Cooling water inlet
- LP steam
- HP steam for start-up
- Nitrogen
- Demineralized water
1.2.2. Outgoing lines

- Hydrogen production
- Export HP steam
- Cooling water return
- Steam condensate

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 10/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

2. Process products

2.1. Hydrogen product

Total flow, Nm3/h (as 100% H2) : 2 x 36,000


Mechanical
BL conditions Units Minimum Normal Maximum
Design
Pressure kg/cm2 g 25 25 - 30
Temperature C - 42 42 80
H2 purity mole % 99.9 - -
Impurities content
CO + CO2 ppm vol. - - 10
CO ppm vol. - - 5
O2 ppm vol. - - 5
HCl ppm vol. - - 0.2
H2S ppm vol. - - 0.2
N2 + CH4 ppm vol. - Balance -

2.2. Export HP Steam

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g - 44 - 52/FV
Temperature C - 405 - 425
Impurities content
Ammonia ppm vol. - - 50 -
Methanol ppm vol. - - 50 -

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 11/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

3. Feed and fuel specification

3.1. Process feed

The plant is designed with either natural gas, refinery fuel gas, C4 feedstock, LPG feedstock,
light naphtha feedstock or heavy naphtha feedstock. The unit will also be capable of
operation with mixtures of the different types of feedstock. The feedstock used for start-up
will be either natural gas or LPG.

3.1.1 Natural gas feed

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 16.5 43.5 43.5 48
Temperature C 30 30 30 80

Below table shows the composition of Natural Gas Feed and its seasonal variation
North Rumialia Gas From Zubair MGL
Composition Units MGL Dry Gas Chilling Plant Dry Gas
Summer Winter Summer Winter Summer Winter
Nitrogen mole % 0.391 0.474 0.6839 0.645 0.51 0.52
Carbon
mole % 0 0 2.111 2.946 2.6 2.6
dioxide
Methane mole % 64.667 65.199 74.011 76.775 72.9 73.5
Ethane mole % 34.133 33.427 15.383 13.949 22.6 22.2
Propane mole % 0.744 0.824 5.545 4.607 1.1 0.96
i-butane mole % 0.025 0.028 0.645 0.533 0.05 0.03
n-butane mole % 0 0 1.162 0.965 0.069 0.03
i-pentane mole % 0 0 0.212 0.201 0 0
n-pentane mole % 0.002 0.003 0 0.004 0.001
Hexane mole % 0 0.001 0.1109 0.135 0.0002 0.00006
Heptane mole % 0 0 0.0222 0.0391 0 0
Octane mole % 0 0 0.0038 0.007 0 0
Nonane mole % 0 0 0.0018 0.0004 0 0
Decane mole % 0 0 0.000077 0.0004 0 0
Total mole % 100 100 100 100 100 100

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 12/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

North Rumialia Gas From Zubair MGL


Composition Units MGL Dry Gas Chilling Plant Dry Gas
Summer Winter Summer Winter Summer Winter
Molecular
kg/kmole 21.13 21.051 21.718 20.9 20.4 20.26
weight
Spec. Grav.
0.729 0.726 0.742 0.721 0.704 0.699
(air=1)
Organic S,
mg/Sm3 15 15 15 15 15 15
max
Total S,
mg/Sm3 15 15 15 15 15 15
average
Water dew point @ 600 psig: -43C

Source 4
Source 4
Composition Units Emergency Source 5 Source 6
Normal case
case
Nitrogen mole % 0 0 0.86 2.5
Carbon dioxide mole % 2.18 2.28 2.39 2.1
Methane mole % 76.38 73.01 76.76 77.01
Ethane mole % 14.01 21.33 17.1 17.67
Propane mole % 6.42 3.04 2.57 1.67
i-butane mole % 0.61 0.11 0.11 0.33
n-butane mole % 1.67 0.21 0.19 0.4
i-pentane mole % 0.45 0 0.01 0
n-pentane mole % 0.31 0 0.01 0
Hexane mole % 0.12 0 Trace 0
Heptane mole % 0.03 0 0 0
Total mole % 100 100 100 100

Molecular weight kg/kmole 21.59 19.92 20.11 20.03


Organic S, max vol ppm 0 0 0 0
Total S, average vol ppm 0 0 1 7.5

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 13/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Natural gas source 4 and 5 are from new pipeline from PS3 (Pipeline Station 3); 24-inch
Gas Pipeline by SOUTH GAS COMPANY.
Natural gas source 6 is from Tie-In Point at 407.28 km of second strategic pipeline.

The hydrogen unit will only be designed for one natural gas composition. Based on the
above data for the different natural gas feedstocks a design composition is determined
which represents the most severe operating conditions.

The composition of Natural Gas used for design will be as specified below.

Composition Units Design

Nitrogen mole % 0.642


Carbon dioxide mole % 2.92
Methane mole % 76.16
Ethane mole % 13.84
Propane mole % 4.57
i-butane mole % 0.530
n-butane mole % 0.960
n-pentane mole % 0.200
Hexane mole % 0.130
Heptane mole % 0.040
Octane mole % 0.007
Nonane mole % 0.0005
Decane mole % 0.0005
Total mole % 100

Molecular weight kg/kmole 21.03


Spec. Grav. (air=1) 0.726
Organic S, max vol ppm 11.2
Total S, average vol ppm 11.2

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 14/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

3.1.2 Refinery fuel gas feedstock

For availability of refinery fuel gas as a feedstock for HPU in this stage of the project, refer to
note 1 in section 1.1 of this document.
For refinery fuel gas composition, refer to Basic Design Data para 3.5 (IONE-AA00-SP-PR-
0001)

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 3.5 4.0 5.0 7.0

Temperature C 45 50 61 80

Composition Units Fuel Gas 1 Fuel Gas 2 Design


Water mole % 1.07 0.90 1.07
Hydrogen mole % 39.55 37.63 39.55
Methane mole % 22.19 13.04 22.19
Ethane mole % 12.13 7.78 12.13
Propene mole % 0.69 1.23 0.69
Propane mole % 6.17 16.11 6.17
i-butane mole % 3.06 10.73 3.06
i-butene mole % 0.06 0.04 0.06
1-butene mole% 0.03 0.30 0.03
n-butane mole % 2.00 8.77 2.00
Trans-2-butene mole % 0.04 0.55 0.04
Cis-2-butene mole % 0.03 0.37 0.03
1-pentene mole % 0.06 0 0.06
i-pentane mole % 0.28 0.26 0.28
n-pentane mole % 0.98 1.31 0.98
Hexane mole % 0.60 0.65 0.60
Heptane mole % 0.27 0.30 0.27
Octane mole % 0.02 0.02 0.02
Nonane mole % 0.01 0.01 0.01
Ethylene mole % 5.05 0 5.05
Nitrogen mole % 5.26 0 5.26

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 15/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Composition Units Fuel Gas 1 Fuel Gas 2 Design


Carbon monoxide mole % 0.21 0 0.21
Carbon dioxide mole % 0.24 0 0.24
Total mole % 100 100 100

Molecular weight kg/kmole 19.07 27.04 19.07


3
LHV kcal/Nm 9393.6 13985.2 9292.4
Hydrogen sulphide vol ppm 50 50 50
Organic S, max vol ppm 0 0 0
Total S, average vol ppm 50 50 50

Above design case is used as design feedstock because of the high content of water,
nitrogen and olefins. The reformer burners will be designed to operate in the entire range of
fuel gas given above.

3.1.3 Naphtha feed

Naphtha feedstocks are all desulphurized straight run naphthas from TANK FARM unit, i.e.
light naphtha, or heavy naphtha. The naphtha is directly fed from an intermediate naphtha
feed storage tank (with blanketing).

3.1.3.1 Light naphtha

Mechanical
BL conditions Units Minimum Normal Maximum
Design
Pressure kg/cm2 g 5.0 18.0 23.6 29
Temperature C 38 38 38 80

Composition Units Basrah Mishrif Design


i-Butane mole % 0.15 0.13 0.15
n-Butane mole % 2.19 2.00 2.19
i-Pentane mole % 17.40 19.09 17.40
n-Pentane mole % 23.85 26.15 23.85
Cyclopentane mole % 5.40 4.95 5.40

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


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PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 16/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Composition Units Basrah Mishrif Design


2,2-Dimethylbutane mole % 0.29 0.26 0.29
2,3-Dimethylbutane mole % 0.68 1.67 0.68
2-Methylpentane mole % 10.54 9.83 10.54
3-Methylpentane mole % 8.62 8.75 8.62
n-Hexane mole % 21.01 18.38 21.01
Methylcyclopentane mole % 4.51 4.00 4.51
Cyclohexane mole % 2.42 2.07 2.42
Benzene mole % 1.49 1.34 1.49
2,2-Dimethylpentane mole % 0.18 0.02 0
2,4-Dimethylpentane mole % 0.35 0.34 0.53
3,3-Dimehtylpentane mole % 0.05 0.02 0
2,3-Dimethylpentane mole % 0.09 0.01 0.14
2-Methylhexane mole % 0.29 0.28 0.42
3-Methylhexane mole % 0.13 0.13 0
n-Heptane mole % 0.01 0.01 0.01
Dimethylcyclopentane mole % 0.35 0.58 0.35
Total mole % 100 100 100

Total sulphur wt. ppm <1 <1 1


Mercaptan sulphur wt. ppm <1 <1 1
H20 wt. ppm Nil Nil Nil
Heavy metals wt. ppm 0.03 0.03 0.03
Chlorine, max wt. ppm 0.5 0.5 0.5
MW kg/kmol 78.8 78.4 78.8

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3.1.3.2 Heavy naphtha

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 5.0 18.0 21.3 28.5
Temperature C 38 38 38 80

Composition Units Basrah Mishrif Design


2-Methylpentane mole % 0.01 0.01 0.01
3-Methylpentane mole % 0.03 0.03 0.03
n-Hexane mole % 0.25 0.23 0.25
Methylcyclopentane mole % 0.13 0.13 0.13
Cyclohexane mole % 0.91 0.84 0.91
Benzene mole % 0.01 0.02 0.01
2,2-Dimethylpentane mole % 0.05 0.01 0
2,4-Dimethylpentane mole % 0.11 0.11 0.16
3,3-Dimehtylpentane mole % 0.14 0.07 0
2,3-Dimethylpentane mole % 1.11 0.08 1.25
2-Methylhexane mole % 3.33 3.48 8.42
3-Methylhexane mole % 4.74 4.97 0
3-Ethylpentane mole % 0.35 0.02 0
n-Heptane mole % 12.37 11.86 12.37
Dimethylcyclopentane mole % 2.54 4.65 2.54
Methylcyclohexane mole % 1.56 4.25 1.56
Ethylcyclopentane mole % 4.07 0.15 4.07
Toluene mole % 3.99 3.50 3.99
i-Octane mole % 11.13 10.49 11.13
n-Octane mole % 8.13 8.71 8.13
Propylcyclopentane mole % 2.18 3.19 0
Ethylcyclohexane mole % 3.63 3.74 5.81
Ethylbenzene mole % 0.92 1.10 0.92
p-Xylene mole % 0.86 1.02 0.86
m-Xylene mole % 2.53 3.02 2.53
o-Xylene mole % 1.09 1.32 1.09

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Composition Units Basrah Mishrif Design


i-Nonane mole % 11.55 8.30 0
n-Nonane mole % 5.49 6.88 17.04
Butylcyclopentane mole % 2.36 4.03 0
Propylcyclohexane mole % 3.07 4.39 5.43
Isopropylbenzene mole % 0.33 0.41 0.66
Propylbenzene mole % 0.33 0.41 0
1-Methyl-3-ethylbenzene mole % 0.28 0.35 0
1-Methyl-4-ethylbenzene mole % 0.60 0.76 0
1,3,5-Trimethylbenzene mole % 0.56 0.71 0
1-Methyl-2-ethylbenzene mole % 0.38 0.48 0
1,2,4-Trimethylbenzene mole % 1.59 2.01 4.04
1,2,3-Trimethylbenzene mole % 0.48 0.60 0
Indane mole % 0.15 0.20 0
C10 paraffins mole % 1.76 1.76 1.76
Butylcyclohexane mole % 1.76 0.92 2.94
Pentylcyclopentane mole % 1.18 0.67 0
C10 aromatics mole % 0.28 0.11 0.28
C11+ paraffins mole % 1.17 0 1.17
C11+ Naphthenes mole % 0.50 0.03 0.5
Total mole % 100 100 100
mole %
Total sulphur wt. ppm <1 <1 1
Mercaptan sulphur wt. ppm <1 <1 1
H2O wt. ppm Nil Nil Nil
Heavy metals wt. ppm 0.12 0.12 0.12
Chlorine, max wt. ppm 0.5 0.5 0.5
MW kg/kmol 113.5 112.5 113.5

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3.1.3.3 Composition of design naphtha feeds

The naphtha compositions for design which are to be used for process simulation are
slightly different from the compositions given in Basrah and Mishrif because not all of the
components can be used with Topsø e simulation software. The composition for design has
been modified so that the physical and chemical properties (molecular weight, C/H-ratio,
distillation curve and PNA composition) are as close as possible to the original data

3.1.4 LPG feed

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 15.8 24 26.6 44
Temperature C 15 38 45 80

Basrah Mishrif
Composition Units Design
Summer Winter Summer Winter
Ethane wt % 0.18 0.29 0.16 0.25 0.29
Propane wt % 30.55 47.77 30.79 48.13 47.77
Propene wt % 2.93 4.63 2.76 4.35 4.63
i-Butane wt % 31.79 22.91 29.07 20.97 22.91
n-Butane wt % 28.25 19.95 31.70 22.39 19.95
i-butene wt % 0.01 0.01 0.01 0.01 0.01
Trans-2-butene wt % 2.29 1.62 2.03 1.43 1.62
Cis-2-butene wt % 1.52 1.07 1.35 0.95 1.07
1-butene wt % 1.24 0.89 1.10 0.79 0.89
C5+ wt % 1.24 0.87 1.04 0.73 0.87
Total wt % 100 100 100 100 100
Diolefins, max wt ppm 100 100 100 100 100
Total S, max. wt ppm 50 50 50 50 50
Water, max. wt ppm 0.1 0.1 0.1 0.1 0.1

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3.1.5 C4 feed

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 15.8 20.5 21.8 44
Temperature C 15 38 45 80

Composition Units Basrah Mishrif Design


Propane wt % 1.11 1.11 1.11
Propene wt % 0.03 0.03 0.03
i-Butane wt % 46.97 42.92 46.97
n-Butane wt % 42.43 47.63 42.43
i-butene wt % 0.02 0.02 0.02
Trans-2-butene wt % 3.44 3.06 3.44
Cis-2-butene wt % 2.28 2.03 2.28
1-butene wt % 1.86 1.65 1.86
C5+ wt % 1.86 1.57 1.86

Total wt % 100 100 100


Diolefins, max wt ppm 150 150 150
Total S, max. wt ppm 50 50 50
Water, max. wt ppm Nil Nil Nil

3.2. Fuel

PSA off-gas is used as fuel for reformer. Complementary fuel for control and duty
requirement is provided by natural gas or refinery fuel gas.
The plant will be started on natural gas or refinery fuel gas and has to be designed for
operation at 100% capacity on natural gas or refinery fuel gas.

3.2.1 Natural gas fuel

As per section 3.1.1.

3.2.2 Refinery fuel gas

As per section 3.1.2.

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4. Climatic conditions

4.1. Temperature

Winter, min. recorded, C -8.5


Summer, max. recorded, C 55
Process calculations, C 25
Air temperature for air cooler design 55
Break point between air and water cooling, °C 65
Minimum metal design temperature for pressure vessels, C -8.5

4.2. Relative humidity

Minimum @ 42.2 °C 9

Maximum @ 5.3 °C 97

For process calculations @ 25 °C 80

For design of fans @ 55 °C 50

For design of air coolers @ 55 °C 50

4.3. Wind velocity and prevailing wind direction

Design wind velocity for structural design, km/h 160

Prevailing wind direction North-west

4.4. Rainfall / snowfall

Maximum recorded rainfall, mm/15 min 19

Maximum recorded rainfall, mm/hour 43

Maximum recorded rainfall, mm/12 hours 67

Maximum recorded rainfall, mm/24 hours 73

Design rainfall, mm/24 hours 73

Design snow load, kN/m2 N/A

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4.5. Earthquake

Code ASCE 7-05

Design spectral acceleration SDS 0.43

Design spectral acceleration SD1 0.118

Site class D

4.6. Barometric pressure

Units Minimum Normal Maximum Design


Pressure mbar 1003 1013 1023 1013

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5. Site information

5.1. Plant elevation

Approximately 59-61 m above the mean sea level.

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6. Environmental requirements

6.1. Air pollution

Burners for the reformer furnace must be of low NOx type. Emissions of the flue gas from
the reformer stack shall be applied as per Environmental Design Criteria (2342-AA00-JSD-
1900-03_3).

6.2. Noise

At 1 m of outdoor machine 85 dB (A)

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7. Utilities

7.1. HP steam import

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 39 40 44 52/FV
Temperature C 395 400 405 425

The HP Steam Import must have the same quality as specified in paragraph 2.2

7.2. LP steam import

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 4 5 6 8/FV
Temperature C 155 210 220 330

7.3. Steam Condensate

HP Steam condensates are utilized in the H2 unit. During start-up and upsets it is sent to
outside BL.

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7.4. HP BFW

Make-up water for the hydrogen plant will be HP BFW as specified below.

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 88.5 88.5 92.3 131
Temperature C 140 142 150 180

Units Topsø e Requirement Provided by Client

Colorless, clear, Free from


non-dissolved matter
pH value at 25°C - 9 - 10 8.5-10
Conductivity at 25°C μS/cm < 2.0 0.3
Oxygen (O2) mg/kg < 0.1 0.007
Iron, total (Fe) mg/kg
< 0.03 ≤0.025

Copper, total (Cu) mg/kg < 0.003 < 0.003


Silicic acid mg/kg < 0.05 0.02
Sodium (Na) mg/kg < 0.01 < 0.01
Chlorine (Cl) mg/kg < 0.1 Nil
mg/kg < 0.2 Nil
Sulphur (as SO42-)

KMnO4 consumpt. mg/kg <3 <3


Mn(VII)→Mn(II),
as KMnO4
Oil, grease mg/kg <1 <1

7.5. Demineralized water

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g N/A 6 N/A 12
Temperature C N/A 35 N/A 80

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7.6. Cooling water

Source : Supplied from BL, Sweet Tower Cooling Water


Mechanical
BL conditions Units CW Supply CW Return
Design
Pressure kg/cm2 g 4 2.5 7
Temperature C 32 43 80

Maximum pressure drop of heat exchangers, kg/cm2 : 0.7


Chloride content, wt ppm, max. : 100

7.7. Instrument air

Mechanical
BL conditions Units Minimum Normal Maximum
Design
2
Pressure kg/cm g 5 7.5 N/A 12
Temperature C N/A N/A 50 80

Dew point @ 7 kg/cm2 g : -40°C


Oil content : Nil
Instrument air pressure used for actuator sizing is 4 kg/cm2 g.

7.8. Electrical power

Service
Rating Range Volts Phase Frequency
From To
Motors >1 MW 11000 3 50(2)
>=100 kW <=1 MW 3300(1) 3 50(2)
>0 kW <100 kW 380(1) 3 50(2)
External national electrical - - 132000 or 3 50(2)
network (Tie-in) 33000
Building Auxiliaries - - 380 3+N 50(2)
Lighting - - 220 1 50(2)
Instrumentation (from UPS) - - 380/110 3+N/DC 50(2)

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Service Volts Phase Frequency


Emergency lighting - - 220 1 50(2)
MCC Control power - - 220 1 50(2)
Switchgear control power - - 110 DC
Notes: (1) Variation + 5% / -5%
(2) Variation + 3% / -3%

7.9. Nitrogen

Mechanical
BL conditions Units Minimum Normal Maximum
Design
Pressure kg/cm2 g 6 7.5 N/A 12
Temperature C 10 N/A N/A 80

N2 content, min. % 99.99


O2 content, max. vol ppm 5
CO content, max. vol ppm 1
CO2 content, max. vol ppm 15
H2O content, max. vol ppm 1
Oil content, max. vol ppm 1

7.10. Hydrogen

Hydrogen for emergency shutdown is supplied from dedicated hydrogen storage.

7.11. Methanol for start-up

Methanol for initial start-up is supplied from dedicated methanol storage.


Flow, normal, kg/h 0
Flow, peak, kg/h 750
(1)
Quantity, kg 1100
Methanol quality shall be in accordance with IMPCA specification:

1
Quantity is equivalent to two start-ups. For presulphiding of hydrogenators a total quantity of approx. 7500 kg is

required.

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Appearance Clear and free of suspended matter


Purity Min. 99.85 dry-wt
Acetone Max. 30 mg/kg
Colour PT-CO Max. 5
Water Max. 0.1 wt%
Distillation range Max. 1.0°C to include
at 760 mmHg 64.6°C ±0.1°C
Specific gravity, 20°/20° 0.791-0.793

Potassium permanganate
Time test at 15°C Min. 60 minutes
Ethanol Max. 50 mg/kg
Chloride as Cl- Max. 0.5 mg/kg
Sulphur Max. 0.5 mg/kg
Hydrocarbons Pass Test

Carbonisable Substances
Ot-Co Scale Max. 30
Acidity as Acetic Acid Max 30 mg/kg
Total Iron Max 0.1 mg/kg
Non volatile matter Max 8 mg/1000 ml

7.12. Flare header

Normal back pressure, kg/cm2 g, max. 1.75


Superimposed back pressure, kg/cm2 g 0.2
2
Mechanical design pressure, kg/cm g 3.5

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8. Units of measurement/codes and standards

8.1. Units of measurement

The SI system of units must be used in all engineering documentation and on drawings with the
exception of the following measurements, which must adopt the stated preferred units.

Area m2
Composition
Products dry mole %, ppm vol.
Impurities ppm vol, ppm wt
Density kg/m3
Energy MMkcal, kcal, cal
Flow
Cooling water kg/h or t/h
Process gas Nm3/h
Steam kg/h or t/h
Gas purity mol %
Heat transfer coefficient kcal/m2hC
Length mm or m
Line, valve and nozzle sizes inch
Nozzle size, vessel inch.
Pipe diameter inch.
Power, duty kcal/h, Gcal/h, kW, MW
Pressure kg/cm2 g or kg/cm2 or mmHg
Sound pressure/power dB(A)
Temperature C
Velocity m/s
Viscosity kg/m/h or cP or cS
Volume
Liquids m3, dm3, cm3
Gas actual m3
Weight kg or t
Wind pressure N/m2

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8.2. Code and standards

The applicable codes and standards for the hydrogen plant are as follows:

Engineering - Topsø e standard


Material specifications - ASTM, ASME
Pressure vessels and boilers - ASME section VIII
ASME section I
Heat exchangers - TEMA R
ASME section VIII
Air Coolers - API 661
Steam reformer - API 530, Topsø e standards
Centrifugal Pumps - API 610
Reciprocating Compressors - API 618
Centrifugal Compressors - API 617
Steam Turbines - API 612
Piping - ASME B31.3
Structural - AISC, API 560
Building - API, IBC
Electrical - IEC
Instrumentation - ISA, IEC, API
Safety Valve - API 520, API 521
Hazardous areas - IEC, API

8.3. Exchanger fouling resistance

The fouling resistance listed below will be used for thermal rating of heat exchangers

Fluid Fouling Resistance


m2hC/kcal
Naphtha 0.0004
Process gas 0.0002
Process gas to process gas boiler 0.0004
Steam 0.0001
Demineralized Water 0.0001
Boiler feed water (BFW) 0.0001

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Boiler Water 0.0001


Cooling water (carbon steel, shell side) 0.0010
Cooling water (carbon steel, tube side) 0.0010
Cooling water (stainless steel, shell side) 0.0010
Cooling water (stainless steel, tube side) 0.0010
Nitrogen 0.0001
Process condensate 0.0001
Boiler blow down 0.0001

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9. Abbreviations

9.1. Equipment Abbreviation

Refer to Project Numbering Procedure.


(Doc. No. : IONE-AA00-PE-PM-0001)

9.2. Fluid symbols

Refer to Piping and Instrument Diagram Standard and Symbols.


(Dwg. No. : IONE-AA00-PID-0021-002)

9.3. Insulation codes

Refer to Piping and Instrument Diagram Standard and Symbols.


(Dwg. No. : IONE-AA00-PID-0021-002)

9.4. Piping class

Refer to Project Specification, General Specification For Piping.


(Doc. No. : IONE-AA00-SP-PI-1000)

9.5. Pipe line numbering

Refer to Piping and Instrument Diagram Standard and Symbols.


(Dwg. No. : IONE-AA00-PID-0021-002)

9.6. Equipment numbering

Refer to Project Numbering Procedure.


(Doc. No. : IONE-AA00-PE-PM-0001)

9.7. Instrument numbering

Refer to Project Numbering Procedure.


(Doc. No. : IONE-AA00-PE-PM-0001)

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10. Engineering requirements

10.1. General equipment design

Equipment will be designed in accordance with Topsø e normal standards unless specific
requirements are given below.

10.2. Design Pressure

The design pressure will be determined according to HTAS practice. In general, the margin
above expected maximum operating pressure will be minimum 10%. Minimum margin shall
be 2.5 kg/cm2.

Minimum design pressure for pressure vessels to be specified is 3.5 kg/cm2g.

Steam equipment will be designed for full vacuum.

10.3. Design Temperature

In general the design temperatures for vessels operating at 0C and above shall be equal to
the maximum operating temperature of the fluid in the vessel plus 28-30C. In specific
services more or less margin may be used as per normal practice and relevant codes.
Design temperature downstream air coolers will be equal to normal inlet temperature.

For boiling service the design temperature shall be the boiling temperature at design
pressure.

Minimum design temperature for equipment shall be 80 °C.

Lower design temperature shall be -8.5 °C unless otherwise dictated by process


requirements.

10.4. Steam out

LP steam will be used for steam out where required. Mechanical design conditions due to
steam out will be:
Pressure, kg/cm2 g -0.5

Temperature, C 120

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10.5. Corrosion allowance and material selection

All Carbon steel material for pressure vessels and heat exchanger in hydrocarbon services
shall be specified as killed carbon steel.

Hydrogen service must be indicated in process datasheets and line list if hydrogen partial
pressure exceeds 7 kg/cm2.

The corrosion allowance for each material shall be determined by its intended service and
shall be added to all parts on all surfaces exposed to the flowing medium.

When service conditions are such that it is not practical to provide corrosion allowance by
adding base metal, a solid corrosion resistant material or cladding with a corrosion resistant
material shall be applied.

Unless otherwise stated, no corrosion allowance is required for external surfaces and for
external appurtenances such as platforms, ladders, support, lugs etc.

Carbon Steel/Alloy Steel Equipment Piping


Non-corrosive environment: Nitrogen, steam 3.0 mm 1.5 mm

Moderately-corrosive environment:
Cooling water, steam condensate, hydrocarbon
3.0 mm 3.0 mm
boiler feed water, Process gas › 10°C above dew point,
fuel gas, PSA off-gas, hydrogen

Stainless Steel Equipment Piping


Corrosive environment:
Process gas ‹10°C above dew point, process 0 mm 0 mm
condensate, demineralised water

Carbon steel with stainless steel lining 0 mm 0 mm

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10.6. Nozzles

Minimum nozzle size (inch) 1½


Default instrument nozzle size (inch) 2
Handhole size (inch) 8
Manhole size (inch)
ID ≥ 1500 mm 24
1000 ≤ ID < 1500 mm 20
800 ≤ ID < 1000 mm 18
ID < 800 mm Full flange

Vent, drain and utility connections for vessels:

Volume of vessel (m3) Vent size Drain size Utility (Steam out)
V ≤ 75 2 inch 2 inch 2 inch
75 < V ≤ 220 3 inch 3 inch 2 inch
220 < V ≤ 420 4 inch 4 inch 3 inch
V > 420 6 inch 4 inch 4 inch
Vent and utility connections are located on the vessel while drain is connected to the bottom
line. Low point drains on piping will be specified by detailed engineering.
Nozzles for level measurement on vessels can be equipped with T-piece to accommodate
two level measurements per nozzle pair.

10.7. Heat exchanger

The heat exchangers are to be designed with a design margin of 10% extra flow and duty
for normal heat exchangers and 20% extra flow and duty for reboilers and condensers.

10.7.1 Shell diameter

The maximum allowed shell diameter is 60”.

10.7.2 Tube length

For heat exchanger design the following standard lengths are to be used:

ft. 10 12 16 20 24 30
mm 3048 3658 4877 6096 7315 9144
The preferred tube length is up to 20 ft.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 37/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

For design of the heat exchangers a length of 10% of the shell diameter will be subtracted
from the standard tube length per tube sheet to calculate the effective tube length.

10.7.3 Tube pitch

The allowed tube pitches are shown below:

Triangular Pitch 23.81 mm 25.4 mm 31.75 mm


Square Pitch - 25.4 mm 31.75 mm

10.7.4 Tube diameter

The allowed bare tube diameters are shown in the table below:

Bare tube diameters and gauges


O.D Copper and Copper Carbon Steel, Aluminium Other Alloys
Inches Alloys and Aluminium Alloys
B.W.G B.W.G B.W.G
5/8 20 18 20
18 16 18
16 14 16
¾ * 20 16 18
18 14 16
16 12 14
1* 18 14 16
16 12 14
14 - 12
1¼ 16 14 14
14 12 12
1½ 16 14 14
14 12 12
2 14 14 14
12 12 12

(*) Preferred diameters

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 38/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Minimum size for cooling water exchanger is 1” B.W.G 12. Material is to be killed carbon
steel unless otherwise required by process conditions.

10.8. Vessels & Columns

Wire mesh demisters will be used for separation.

The following hold-up times will be used for vessel and column design:

Service Normal level High level trip Low level trip


Low – High level High – max. level Min. – low level
General service 2 min 1 min 1 min
K.O. drums 5 min (1) - -
Feed surge drums 15 min 2 min 2 min

(1) Or liquid volume equivalent to 3 m of feed pipe whichever is larger, calculated from BTL
to max. level.

Minimum level is always 500 mm above BTL for vertical vessels.


Minimum level for horizontal vessel is 300 mm or 15% of vessel ID whichever is larger.

10.9. Reactors

No specific requirements

10.10. Pumps

Pumps will be designed with a minimum design margin of 10% additional flow for continuous
service and 0% for intermittent service. Additional margin will be added by Topsø e if
required by their standard engineering practice.
Design pressure of pump discharge pipes is calculated as follows:

K  H R  d max
PDD  PDS 
10

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 39/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

PDD : Design pressure at pump discharge (kg/cm2 g).


PDS : Design pressure at pump suction (kg/cm2 g).
HR : Differential head at rated point (m).
dmax : Maximum specific gravity of pumped fluid.
K : 1.25 for motor driven pump / 1.4 for turbine driven pump.

10.11. Compressors & Blowers

Compressors will be designed with a design margin of 10% additional flow. Flue gas and
combustion air blowers will be designed with a design margin of 20% additional flow and 44%
additional head. Start-up blowers will be designed without additional margin.

Hydrogen recycle compressor will be spared. Other compressors, blowers will not be spared.

10.12. Tubular reformer

Design will be according to Topsø e normal design practice. Coils in the waste heat section
will be designed without additional margin on duty and flow.

10.13. Instrumentation
10.13.1 Safety valves

Safety valves will be spared except for the following cases:


- Fire protection only
- If stand-by equipment with PSV is provided
- If protected equipment can be isolated without impacting process (start-up equipment
etc)
Safety valves will be installed for protection against tube rupture when low pressure side is
liquid filled. Discharge will be to atmosphere for cooling water exchangers.

10.13.2 Control valves

Control valves discharging to atmosphere, flare or similar as well as trip valves will be
specified as tight shut-off (TSO) in control valve datasheet. Leakage class V will be specified
for TSO valves.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 40/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

Maximum and minimum operating conditions will only be indicated if they have influence on
the valve design.
Required Cv of control valves will be 130% of normal calculated Cv or 110% of maximum
calculated Cv, whichever is higher.

10.13.3 Control system

Instrument input to ESD system with 2 out of 3 voting can be repeated to DCS for indication
only. Process control must use independent instrument input.

Signals to DCS will be foundation field bus and signals to ESD will be 4-20 mA.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 41/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

11. Attachment

MOM for Separate FEED Verification Follow-up Meeting


(Doc. No.: KRP-C-MOM-N-0060-Attachment 7) - - - - 2 sheets
(Ref.: KRP-C-MOM-N-0060-Attachment 7, TQ-PR-E-056 & TQ-PR-E-264)

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea


DESIGN BASIS

PROCESS DESIGN BASIS


FOR UNIT 13,14,15
DOC. NO. : IONE-1A13-SP-PR-0001
KARBALA REFINERY PROJECT Rev. 3 Page 42/42
Ref. FEED DOC. No. : S-00781-4336402 WBS

ATTACHMENT

ATTACHMENT:

MOM for Separate FEED Verification Follow-up Meeting

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

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