Design Basis 32062-000-JSD-0000-001-02

Project n° - Unit Material code Serial N° Rev.
Page
32062 000 JSD 0000 001 02 1 / 50
Client : Socar & Turcas Rafineri A.S. (STRAS)

Location : Aegean Refinery, Aliaga, Izmir, Turkey
Plant : Hydrogen Generation Unit (HGU), 160,000 Nm3/h
Engineering Specification
Basis of Design process department
Pages modified under this revision:
02 15.11.2010 RELEASED FOR ENGINEERING CSEP CSEP CJV

01 06.07.2010 REVISED – FOR APPROVAL MSZE CSEP CJV
00 25.06.2010 FOR APPROVAL MSZE CSEP CJV
Date WRITTEN BY CHECKED BY APPROVED BY
Rev STATUS
DD/MM/YY (name & visa) (name & visa)
DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the margin
TECHNIP BENELUX B.V. (TECHNIP)
G:\01-32062.00\D50\ENG\F (Latest Documents)\BOD\Rev 02\32062-000-JSD-0000-001-02.docx.
This document or drawing is the property of TECHNIP BENELUX B.V. and shall not, under any circumstances, be totally or partially, directly or indirectly,
transferred, reproduced, copied, disclosed or used without TECHNIP BENELUX B.V.'s prior written consent.
Project n° - Unit Material code Serial N° Rev. Page
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Engineering Specification Basis of Design process department
TABLE OF CONTENTS
1. General ..........................................................................................................................5
2. A Brief Description of Plant .........................................................................................6
3. Plant Capacity ...............................................................................................................7
4. Over-Design & Turn-Down Factors for Throughput & Equipment ..........................7
5. On-Stream Factors .......................................................................................................8
6. Feed Specifications ......................................................................................................9

6.1 Gaseous Feed Specification ...............................................................................9
6.2 Liquid Feed Specification ..................................................................................10
7. Product Specifications...............................................................................................11
7.1 Gaseous Product Specification .........................................................................11
7.2 By-product specification. ...................................................................................11
8. Effluent Characteristics .............................................................................................12

8.1 Liquid Effluents 2) ...............................................................................................12
8.2 Gaseous Effluents 2) 4) .......................................................................................13
8.3 Solid Effluents 1) ................................................................................................13
9. Utilities Specifications ...............................................................................................14

9.1 Utilities – Water .................................................................................................14
9.2 Utilities – Steam and Condensate .....................................................................15
9.3 Utilities – Fuel Gas ............................................................................................16
9.4 Utilities – Air ......................................................................................................16
9.5 Utilities – Nitrogen .............................................................................................17
9.6 Utilities – Hydrogen ...........................................................................................18
9.7 Catalysts and Adsorbents .................................................................................19
9.8 Chemicals ..........................................................................................................19
10. Environmental Considerations .................................................................................20

10.1 Noise Abatement ...............................................................................................20
10.2 Client/Authority Requirements ...........................................................................20
11. Site / Ambient / Design Conditions ...........................................................................21
12. Units of Measurement ................................................................................................23
13. Basis for Insulation Design .......................................................................................24
14. Computer Programs and other Design Aids ............................................................25

14.1 Process Calculation ...........................................................................................25
14.2 Drawings ...........................................................................................................25
14.3 Medium Identification Codes .............................................................................26
15. Sparing Philosophy & Critical Service Design for Rotating Equipment ...............27
15.1 Sparing Philosophy ...........................................................................................27
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15.2 Automatic Change-over of Spare Equipment ....................................................27

15.3 Non-Electrical Driven Machinery .......................................................................27
16. Piping Design Philosophy .........................................................................................28

16.1 Sizing of Control Valve Manifold .......................................................................28
16.2 Control Valve Sets .............................................................................................30
16.3 Motor Operated Valves .....................................................................................30
16.4 Double Block Valves .........................................................................................30
16.5 Safety Valve Sets ..............................................................................................30
17. Plant Cooling Design Philosophy .............................................................................31

17.1 Categories .........................................................................................................31
17.2 Secondary Cooling ............................................................................................31
18. Heat Recovery Design Philosophy ...........................................................................32

18.1 Heat Exchanger Systems ..................................................................................32
19. Heat Exchanger Design & Fouling Coefficients ......................................................32

19.1 Heat Exchanger Standard for Design and Testing ............................................32
19.2 Preferred Tube Length ......................................................................................32
19.3 Standard Tube Length .......................................................................................32
19.4 Standard Shell Sizes (mm) ................................................................................33
19.5 Standard Tube Size and Thickness ..................................................................33
19.6 Standard Tube Pitch ..........................................................................................33
19.7 Tube Wall Thicknesses .....................................................................................33
19.8 Channel Type Selection ....................................................................................33
19.9 U-Tube Type Construction ................................................................................34
19.10 Other Requirements ..........................................................................................34
19.11 Fouling Coefficients ...........................................................................................34
19.12 Information for convection section coil design ...................................................34
20. Plant Winterization .....................................................................................................35

20.1 General Philosophy ...........................................................................................35
20.2 Minimum Design Metal Temperature (MDMT) ..................................................35
20.3 Initial Start-up and Operation at Subzero Temperatures ...................................35
20.4 Shutdown and Restart at Subzero Temperatures .............................................35
20.5 Heat Tracing of Lines, Instrumentation and Equipment ....................................35
21. Hot Flare System Design ...........................................................................................36

21.1 Design Code ......................................................................................................36
21.2 Flare Header Design .........................................................................................36
21.3 Flare K.O. Drum ................................................................................................36
21.4 HGU Flare Header.............................................................................................36
22. Drains and Slops System Design .............................................................................37

22.1 Hydrocarbon closed Drains System ..................................................................37
22.2 Chemical Drains ................................................................................................37
22.3 Oily-Water Sewer ..............................................................................................37
23. Vessel Design Philosophy .........................................................................................37

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24. Mechanical Design Temperatures & Pressures for Piping and Non-fired
Equipment ...................................................................................................................38
24.1 Mechanical Design Temperature ......................................................................38
24.2 Mechanical Design Pressure .............................................................................38
24.3 Mechanical Design Pressure (Low Pressure Systems).....................................40
25. Mechanical Design Codes .........................................................................................41
26. Tankage .......................................................................................................................41
27. Metallurgy and Corrosion Allowances .....................................................................41
28. Client Side Connections & Conditions at Battery Limit ..........................................42

28.1 Incoming Lines ..................................................................................................42
28.2 Outgoing Lines ..................................................................................................43
29. Design Requirements for Commissioning and Start-Up ........................................44
Attachments
1. Design Basis for Piping inside Battery Limits
2. Fouling Coefficients for Design of Tubular Heat Exchangers
3. Values used for Liquid Hold-Up Times in Vessels and Towers
4. Typical Materials Selection and Corrosion Allowances
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1. General
1) This basis of design shall be completed together with the client, to the fullest extent
possible, prior to contract award.
2) After contract award, all the provisions of this document must be completed with-in
two weeks, by cooperation between TECHNIP and client personnel. Should any
items remain “open” due to lack of data, TECHNIP reserves the right to use any
relevant data at its disposal to complete the design.
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2. A Brief Description of Plant
Refer to 32062-000-JSD-0000-002 “Process description”.

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3. Plant Capacity
Design plant capacity based on Product shall be the following:
Hydrogen Product (100% capacity): 160 000 Nm3/h for Natural Gas as a main feedstock
Hydrogen Product (100% capacity): 160 000 Nm3/h for Light Naphtha from Hydrocracker
Unit (HCU) unit as main liquid back-up feedstock
Capacities are based on hydrogen including impurities.
The Hydrogen Unit will be designed for Refinery Fuel Gas as make-up fuel.
Rate of Capacity Change 0.5 percent/min
4. Over-Design & Turn-Down Factors for Throughput &

Equipment
The following overdesign and turn-down factors, as a percentage of design material
balance flows, will be used.
Percent Percent
Over-design Turn-down
4.1 Plant (Reformer) capacity 2) 0 50
4.2 Trayed columns (hydraulic design) 10 50
4.3 Packed columns (hydraulic design) 10 50
4.4 Heat exchangers/air coolers (surface) 101)4,5) NA
4.5 Process waste heat boilers (surface) 0 NA
4.6 Centrifugal pump capacity (reflux) 15 60
4.7 Centrifugal pump capacity (pump around) 15 60
4.8 Centrifugal pump capacity (general) 10 60
4.9 Compressor capacity (centrifugal) 0 70
4.10 Compressor capacity (reciprocating) 0 50
4.11 Flue gas fan capacity 20 -
4.12 Forced draft fan capacity 10 -
4.13 Burners (heat release) 103) 40
NA = not applicable.
1) Where certain applications, e.g. pump around circuits, demand variations in heating/cooling load,
adequate over-design margins will be added to cover such fluctuations in duty.
2) On steam reformer the overdesign on capacity is 0.
3) Burner heat release 10 % extra for purge gas and make up gas together.
4) EPC contractor to follow 10 % overdesign. For heat exchangers, only duty specification to be specified in
the BDEP. No overdesign to be applied for DEMI water and BFW preheaters.
5) 20 % overdesign for air coolers (surface).
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5. On-Stream Factors
Number of on-stream hours per year: ≥ 8400

Number of on-stream hours per day: 24
Interval between plant maintenance shut-downs: 3 years

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6. Feed Specifications
6.1 Gaseous Feed Specification
PLANT SECTION
Type Natural Gas design
Quality: (..........)
Hydrogen mol %
Methane mol % 92.27
Ethane mol % 5.39
Propane mol % 0.96
n-Butane mol % 0.30
n-Pentane mol % 0.001
Nitrogen mol % 0.94
Oxygen mol % 0.02
Carbon dioxide mol % 0.12
Total sulfur (as S) 3,4) mg/Nm3 50
Water
Molecular mass kg/kmol 17.34
Impurities: (..........)
Total metals ppmv
Sodium ppbv
Copper ppbv
Arsenic ppbv
Iron ppbv
Potassium ppbv
Vanadium ppbv
Aluminum ppbv
Zinc ppbv
Mercury ppbv
Chlorides ppbv
Fluorides ppbv
Carbonyl sulfide ppmv
Asphaltenes ppmv
Styrenes ppbv
Hydrogen sulfide mg / Nm3 6.0
Methyl mercaptan mg / Nm3 (2)
Total sulfur (as S) mg / Nm3 50 2) (Max.)
Dust distribution: (..........)
> 10 µm mg/Nm3
< 10 µm mg/Nm3
Need for water coalescer Yes/No
Min./Nor./Max pressure 1) kg/cm2g 40.0 / 40.0 /
0
Min./Nor./Max. temperature 1) C / 15 / 38
1) Operating conditions. For mechanical design pressure & temperature and operating conditions: see
Section 28.
2) Average Sulphur in natural gas is assumed to be 50 mg / Nm3; min. content is 0. Apart from 6 mg/Nm3 of
H2S, the balance is Methyl-Mercaptan.
3) Total sulphur (as S) in Natural Gas assumed to be equal to 50 mg/Nm3.
2
4) Normal conditions are 0 °C @ 1.033 kg/cm a.
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6.2 Liquid Feed Specification4)
PLANT SECTION
Type Design Light Naphtha
HCU Unit
Quality:
Specific gravity 0.668
ASTM Distillation (D86 at 1 atm)
IBP °C 29
5 vol% over °C 33
10 vol% over °C 35
30 vol% over °C 44
50 vol% over °C 54
70 vol% over °C 68
90 vol% over °C 85
95 vol% over °C 93
FBP °C 100
Loss vol%
Residue on evaporation vol%
Flash point (COC) 2) (..........) °C
PIONA Analysis Method:
n-Paraffins wt% 76.6
Olefins wt%
Naphthenes wt% 20.7
Aromatics wt% 2.7
C/H Ratio (..........) wt/wt
Carbon number mol carbon/
mol liquid feed
Nitrogen wt% 0.5
Total sulfur ppm wt 2 3)
Impurities: -
Total metals ppb wt
Sodium ppb wt
Copper ppb wt
Arsenic ppb wt
Iron ppb wt
Potassium ppb wt
Vanadium ppb wt
Aluminum ppb wt
Zinc ppb wt
Mercury ppb wt
Chlorides ppb wt
Fluorides ppb wt
Carbonyl sulfide ppb wt
Asphaltenes ppb wt
Styrenes ppb wt
Hydrogen sulfide ppm wt
Methyl mercaptan ppm wt
Total sulfur (as S) ppm wt
Min./Nor./Max pressure 1) kg/cm2g 5.1 / /
0
Min./Nor./Max. temperature 1) C / 38 /
Section 28. Liquid pressures are at grade.
2) Cleveland Open Cup method.
3) Minimum sulphur content is 0.
4) Light Naphtha from UOP Unicracking Unit, PONA and MW modified by TECHNIP
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7. Product Specifications
7.1 Gaseous Product Specification
PLANT SECTION
Type Hydrogen product
Quality:
Hydrogen mol % ≥ 99.9
Methane + Nitrogen mol % < 0.1
CO+CO2 ppmv < 10
Dust distribution:
> 10 µm mg/Nm3
< 10 µm mg/Nm3
Min./Nor./Max pressure 1) kg/cm2g / 26.5 /

0
Min./Nor./Max. temperature 1) C / 45 /
Section 28.
7.2 By-product specification

1)
High Pressure Export Steam
PLANT SECTION
Type High Pressure Export Steam
Quality:
Acid conductivity 3) < 0.2
µS/cm
Silica (SiO2) ppb wt < 20
Sodium (Na) ppb wt <5
Iron (Fe), total ppb wt < 20
Copper (Cu) ppb wt <3
Min./Nor./Max pressure 2) kg/cm2g 36.0 / 38.0 / 42.0
0
Min./Nor./Max. temperature 2) C 325 / 365 / 380
1) Parameters according to “Requirements on steam for condensing turbines”, VGB-R 450 Le, Second
Edition 2004, Guidelines for Feed water, Boiler water and Steam Quality for Power Plants / Industrial
Plants.
Section 28.
3) Conductivity of condensate measured downstream of a strongly acidic sampling cation exchanger.
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8. Effluent Characteristics
8.1 Liquid Effluents 2)
Refer to Effluent list (32062-000-NM-0005-001) for details.
Type 3) Boiler Process

3)
Blowdown condensate
Quality: 3)
SiO2 mg/l
Fe mg/l
Cu mg/l
Na mg/l
NH3 mg/l
Ca+Mg mg/l
Phenols mg/l
Conductivity µS/cm < 3000 < 300
Oil mg/l
PH value (25 C0) 9 - 11 4–7
DOC mg/l
VOC mg/l
TDS mg/kg
TOC (Total organic carbon) mg/kg
SS (Suspended solids) mg/kg Traces Traces of
catalyst dust
3)
Frequency Continuous Intermittent
Pressure: 1) kg/cm2g
Minimum
Normal 0 0
Maximum
Temperature: 1) ºC
Minimum
Normal 50 50
Maximum
Section 28. Liquid pressures are at grade.
2) Quality and quantity are estimates and will be confirmed during detailed engineering.
3) Only at start-up with fresh catalyst.
At turndown, a continous purge stream of process condensate to the sewer may be required.
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8.2 Gaseous Effluents 2)
PLANT SECTION
Type: 2) Flue gas Vent Steam Vent Steam
from from
degasifier deaerator
Quality: 2)
Hydrogen mol%
Nitrogen mol%
Oxygen mol%
Argon mol%
Carbon dioxide mol%
Steam or wet steam
Sulfur dioxide mg/Nm3
NOx (dry at 3% O2) mg/Nm3 ≤ 200
SOx (dry at 3% O2) 3) mg/Nm3 ≤ 35
3
Chlorides mg/Nm
Carbon monoxide mg/Nm3
Ammonia mg/Nm3
Hydrocarbons mg/Nm3
Solid Particles mg/Nm3
Molecular weight kg/kmol
Explosion limits
Dew point ºC
Visual appearance
Frequency Continuous Continuous Continuous
Pressure: 1)
2
kg/cm g
Minimum
Normal 0 0 0
Maximum
Temperature: 1) ºC
Minimum
Normal 150 100 100
Maximum
Min./Nor./Max. pressure and temperature 1)
Section 28.
2) Quality and quantity are estimates and will be confirmed during detailed engineering.
3) Uncertain since depending on the refinery fuel gas quality from B.L.
Technip does not guarantee the SOx emission. Any sulfur contained in the fuel will pass through the
combustion system.
8.3 Solid Effluents
There are no continuous solid effluents from Hydrogen Unit.

For catalyst see section 9.10
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9. Utilities Specifications
9.1 Utilities – Water
Type of water Raw Cooling Drinking Demin.

water water
pH @ 25°C 5.5 – 7.2
Turbidity NTU
Conductivity @ 25°C µS/cm < 0.2
Total dissolved solids mg/l
Total silica as SiO2 mg/l < 0.02
Colloidal silica as SiO2 mg/l
Ca hardness as CaCO3 mg/l
Mg hardness as CaCO3 mg/l
Total hardness as CaCO3 mg/l nil
Oxygen O2 mg/l saturated
Carbon dioxide CO2 mg/l
M-Alkalinity mg/l
P-Alkalinity mg/l
Chloride as Cl- mg/l
Sulfate as SO4-- mg/l
Total iron as Fe mg/l < 0.02
Copper as Cu mg/l < 0.0034)
Organic material as KMnO4 mg/l
Oil mg/l nil
Sodium as Na mg/l N/A
Dissolved Organic Carbon mg/l
Phosphate as PO4 mg/l
Free residual Cl2 as Cl2 mg/l
Max. quantity available m3/h
Min./Norm./Max. supply press. 1) -/ 6.0 / 6.0 6.0 / 6.0 / 6.0 / 5.5 / 6.0 /
kg/cm2g /- 7.5
Min./Norm./Max. supply temp. 1) ºC Amb. /30 30 / 30 / Amb. / 30 / 38 / 40
/38 30 Amb. / 38
Min. return pressure 3.5 / 3.5 /
kg/cm2g
Max. return temperature ºC 42
1) Operating conditions. For mechanical design pressure & temperature and operating condtions: see Section
28. Liquid pressures are at grade.
2) Feed water, boiler water and steam quality requirements are according to VGB-R Le, Second Edition 2004,
Guidelines for Feed water, Boiler water and Steam Quality for Power Plants / Industrial Plants.
3) Conductivity measured @ 25°C downstream a strongly acidic sampling cation exchanger.
4) Requirement as per VGB-R Le, Second Edition 2004.
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9.2 Utilities – Steam and Condensate
High Pressure Steam - HPS5)

Low Pressure Steam - LPS
TYPE HPS LPS

PRESSURE LEVEL kg/cm2g 40 - 70 3 - 10
Supply pressure 1) kg/cm2g
Minimum 36.0 3.5
Normal 38.0 4.5
Maximum 42.0 5.8
Supply temperature 1) 0
C
Minimum 325 165
Normal 365 180
Maximum 375 190
Flow kg/h
Conductivity at 25°C µS/cm < 0.2
Total iron (Fe) mg/kg < 0.02
Total copper (Cu) mg/kg < 0.003
Silica (SiO2) mg/kg < 0.02
Sodium (Na) mg/kg < 0.02
Ammonia mg/kg
Methanol & aldehydes mg/kg
TDS (Total Dissolved < 0.5
Solids) mg/kg
Condensate pH
Low Pressure Condensate - LPC6)
TYPE LPC
PRESSURE LEVEL kg/cm2g
Return pressure: 1) kg/cm2g 4.0
Return temperature: 1) °C
Conductivity at 25°C µS/cm
Total iron (Fe) mg/kg
Total copper (Cu) mg/kg
Silica (SiO2) mg/kg
Sodium (Na) mg/kg
TDS (Total Dissolved
Solids) mg/kg
Condensate pH
Section 28.
2) Feed water, boiler water and steam quality requirements according to VGB-R 450 Le, Second Edition
2004, Guidelines for feed Water, Boiler Water and Steam Quality for Power Plants / Industrial Plants
3) Conductivity measured @ 25°C downstream a strongly acidic sampling cation exchanger.
4) Conductivity is a function of BFW quality
5) Steam generating equipment shall designed for a maximum supply temp. of 380ºC.
6) Not Applicable.
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9.3 Utilities – Fuel Gas 1,2)
TYPE OF FUEL GAS Refinery Fuel LPG

Gas for design
Hydrogen mol % 19.18 -
Methane mol % 56.45 -
Ethane mol % 20.33 -
Propane mol % 2.26 19.14
N-Butane mol % 1.36 47.36
I-Butane mol % - 33.50
C5+ mol % 0.42
H2S ppm vol. 100 max. 25 max.
Molecular weight kg/kmol 17.65 55.44
LHV @ 15°C kcal/kg 12000 10943
Wobbe Index (on LHV) kcal/Nm3 12700 20398
Supply pressure,min./norm./max. 3.0 / 3.5 / - 3.0 / 3.5 / -
2
kg/cm g
Supply temperature min./norm./max. Amb. / 42 / 55 Amb. / 42 / 55
°C
1) In case of natural gas loss, the HGU is switched to Light naphtha Feed and refinery will mix LPG in
fuel gas to keep Fuel gas network pressure (the note 1 is added as per Client request but does not
affect Fuel Gas taken for design).
2) Burners shall be designed to burn a mixture of Fuel gas and make-up LPG with a maximum LPG
content of 50 % by weight.
3) Reformer Package Supplier to design burners, fuel gas instrumentation, Fuel Gas K.O drum for the
case when Fuel Gas is mixed with LPG with a max. LPG content of 50 % by weight.
9.4 Utilities – Air
TYPE PLANT AIR 2) INSTRUMENT AIR 2)
Nm3/h 3)
Max. quantity available -
Relative humidity % - -
4)
Dewpoint at normal supply pressure °C -30
Supply pressure: 1) kg/cm2g
Minimum 6.0 6.0
Normal 7.0 7.0
Maximum 8.0 8.0
Supply temperature: 1) °C
Minimum ambient ambient
Normal 42 42
Maximum 42 42
Section 28.
2) Instrument and plant air shall be oil free.
3) A centralized buffer drum will be provided outside TPBV battery limits for 15 minutes of operation.
4) -30ºC is a dew point at normal supply pressure. This value is calculated considering -50ºC at
atmospheric pressure.
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9.5 Utilities – Nitrogen
TYPE PURGE NITROGEN

Composition: vol%
Nitrogen purity, minimum 99.5
Oxygen ppm v < 20
Carbon dioxide ppm v < 20
Other carbon compunds ppm v <5
Carbon monoxide ppm v < 20
Water ppm v <5
Hydrogen ppm v < 20
Chloride 2) ppm v < 0.1
Noble gasses balance
Dewpoint °C
Maximum quantity available Nm3/h
Supply pressure: 1,5)
2
kg/cm g
Minimum 8.5
Normal 8.5
Maximum -
Minimum ambient
Normal 30
Maximum ambient
Section 28.
2) As recommended by pre-reformer catalyst supplier.
3) Nitrogen is produced by Cryogenic unit (the note 3 added as per Client request).
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9.6 Utilities – Hydrogen
TYPE Start-up Hydrogen3 MT Shift reducing hydrogen

2)
Source High Purity Hydorgen Hydrogen bullet
from CCR PSA
Composition: vol%
Hydrogen purity, minimum 99.9 99.9
Methane balance Balance
Ethane -
Propane -
Butane and heaviest -
Pentane -
Carbon monoxide ppm v < 10 -
Carbon dioxide ppm v < 30 (CO + CO2) < 10
Hydrogen sulphide ppm v NIL
Hydrogen chloride ppm v <1 NIL
Nitrogen ppm v < 1000 <1
Other impurities ppm v < 50 ppm H2O Water = NIL
Molecular Weight kg/kmol 2.03
Max. quantity available kg/h
Supply pressure: 1) kg/cm2g
Minimum 24 25
Normal 24
Maximum -
Minimum 45
Normal 45 ambient
Maximum -
Section 29.
2) Pure H2 from portable cylinders / bullets to be available for MT Shift catalyst reduction during initial plant
start-up. Required quantity will be specified later by TPB. Typical Hydrogen Bullets pressure is 150 barg.
3) High Purity Hydorgen from CCR PSA will be connected to recycle hydrogen compressor suction.
130 kg/h of hydrogen during 24 h is the worst case scenario requirement for start-up hydrogen
availability.
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9.7 Catalysts and Adsorbents
Refer to 32062-000-PDS-xxxx-001 to 005
TYPE
Application Hydrogenation Desulphurization Pre-reformer Reformer MT-shift PSA
Form
Size mm
Bulk density kg/m3
Operating life in years
Min. req. life 3 0.5 3 1) 3 3 3
Pretreatment
Regeneration
Activation
Required utilities
Loading method
Unloading method
Reduced state yes/no
Pyrophoric yes/no
Preservation
Mode of delivery
Safety data sheet
provided yes/no
1) This guarantee is only applicable if switchover to naphtha operation is limited to no more than four (4) times per year
with an accumulated operating period not exceeding one month per year.
9.8 Chemicals 1)
TYPE DMDS BFW Chemicals Start-Up chemicals

Application Activating Conditioning For cleaning plant
catalyst of BFW before use
hydrotreating
units
Form
Size (solids)
Density @ 15°C kg/m3
Bulk density (solids) kg/m3
Viscosity mPa.s @ 15°C
Purity
Concentration
Toxicity THL
Dosing basis
Required inventory
Generic or proprietary
Mode of delivery
Handling
Safety data sheet
provided yes/no
1) Details to be provided during DE
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10. Environmental Considerations
10.1 Noise Abatement
Unless otherwise stated in the inquiry, the maximum tolerated SPL (sound Pressure Level)
expressed in dB(A) according IEC 651,calculated from the octave band center frequencies,
according to ISO R266 shall not exceed 80 dB(A)1) at 1 meter distance from the individual
equipment, under normal operating conditions, for single noise sources.
In case of several items of equipment, each producing a noise level and installed in
neighboring position ,such as pump and driver; compressor trains; burners etc., the
specified maximum SPL counts not for the individual equipment but for the unit (including
auxiliaries), c.q. burner wall
The noise from safety/relief valves and depressurizing valves which blow under emergency
conditions only, shall not exceed the absolute limit of 120 dB(A) HOLD in any position not
less than 1 meter from the equipment which is accessible to personnel, or any other
position where an operator may be exposed to noise in the normal course of his duty.
1) TECHNIP specification for noise level is 85 dB(A). Turcas confirms its requirement to be 80 dB(A). Any
deviation with respect to 80 dB(A), also in relation to the associated costs, will be evaluated by STRAS
during EPC phase.
10.2 Client/Authority Requirements
See section 8.2 (Gaseous effluents)

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11. Site / Ambient / Design Conditions
Location:
• Exact location site : Aliaga,Izmir, Turkey.....
• Elevation above sea level : 35 m
Earthquake:
• Earthquake : Yes
• Seismic intensity :
Barometric pressure:
• Highest absolute barometric pressure : N/A kg/cm2a
• Lowest absolute barometric pressure : N/A kg/cm2a
• Annual average barometric pressure (process design) : 1.034 kg/cm2a
Temperature:
• Average maximum temperature (hottest month) : - °C
• Extreme highest temperature : 41.8 °C
• Average minimum temperature (coldest month) : - °C
• Extreme lowest temperature : -6.8 °C
• Average ambient temperature (process design) : 38 °C
• Design air temperature for Air-coolers : 38 °C
• Design air temperature for Stacks : - °C
• Design wet bulb temperature (cooling towers) : N/A °C
• Minimum temperature (process design) : -6 °C
• Air temperature for winterization : -6 °C
• Minimum Design Metal Temperature (MDMT) : -4 °C
Relative humidity:
• Relative humidity in Summer : 67.4 %
• Relative humidity in Winter : 76.3 %
• Design relative humidity : 76.3 %
• Design relative humidity (air fans and compressors) : 69 %
• Average relative humidity : 72.7 %
• minimum humidity : N/A %
Rainfall:
• Maximum hourly rainfall : 40.8 mm
• Maximum daily rainfall : 117 mm
Wind direction:
• Prevailing wind direction whole year : NNE to SSW
• Prevailing wind direction Summer : NNE to SSW
• Prevailing wind direction Winter : NNE to SSW
• Average wind speed..... : 3.6 m/s
Information for Insulation Design:

32062 000 JSD 0000 001 02 22 / 50
See Chapter 13 for summary of basis of design for thermal insulation
Other data
• Airborne material (process/mechanical design) : Salt
• Possibility of sandstorms : No
• Possibility of icing by steam emissions within plant
surroundings : No
• Possibility of icing by water emissions of cooling towers
within plant surroundings : No
• Dusty : No
• Seismologic activity : Yes
• Sulfurous : No
32062 000 JSD 0000 001 02 23 / 50
12. Units of Measurement
Following units or multiples of these units will be used:
process documents
Pressure gauge (operating) kg/cm2g
Pressure gauge (design) kg/cm2g
Pressure kg/cm2g
Differential pressure kg/cm2
Force N
Mass kg
Temperature °C
Vapor/gas flow rate ‘kg/h’ or ‘Nm3/h ’
Steam flow rate kg/h
Liquid flow rate kg/h, m3/h
Flow ratios kg/kg
Heat flow rate or Power kW, Gcal/h
Enthalpy kcal/kg
Specific heat kcal/kg.ºC
Thermal conductivity kcal/hr.m.ºC
Heat transfer coefficient kcal/hr.m2.ºC
Dynamic viscosity cP
Surface tension dynes/cm
Velocity m/s
Density kg/m3
Linear dimensions m, mm
Thickness mm
Area m2
Volume m3
Time h,s
Electrical conductivity µS/cm
Molar quantity kmol
Pipe, valve and nozzle size Inch
Pipe thickness Schedule, inch, mm
Flange rating (ASME) lbs
Velocity m/s
Current (ampere) A, mA
Voltage kV, V, mV
Frequency Hz
Note: Normal molar volume @ 0°C & 1.0332 kg/cm2 = 22.4136 Nm3/kmol.
32062 000 JSD 0000 001 02 24 / 50
13. Basis for Insulation Design
Technip Benelux makes a distinction between insulation for personal protection and
insulation for heat conservation. The parameters that are applicable for determining the
insulation thickness are:
• Process temperature, being the temperature of the medium within the pipe
• Ambient temperature, being the temperature of the bulk air around the plant
• Wind speed
• Insulation material properties
• Maximum allowable sheeting temperature
Personnel protection (for piping).

The main goal of insulation of the personnel protection type is to protect personnel from
injury due to exposure to high temperatures. The insulation design for personal protection
is based upon Technip’s standard isolation tables. The basis for these tables is as follows:
• Maximum sheeting temperature is 60°C.
• Ambient temperature is 25°C.
• Wind speed of 1 m/s.
Heat conservation
Heat conservation prevents the unnecessary loss of heat due to insufficient insulation. The
insulation design for heat conservation is based upon Technip’s standard isolation tables.
These tables are derived from heat loss calculations for actual plant piping take-offs for a
number of reference projects in Technip’s product lines. The basis for these tables is as
follows:
• Comply with personal protection standards (see above)
• The average heat loss for insulated piping is below 3% of the heat loss when no
insulation would be applied, at an ambient temperature of 20°C and a wind speed of
2 m/s.
Guidelines
The ASTM C680-08 guideline is used for calculating insulation thicknesses. The VDI 2055
is another guideline, but is agreement with the above mentioned ASTM standard. Technip
applies a 10% safety factor on the thermal conductivity values as provided by the insulation
vendors to compensate for possible leakages due to installation imperfections.
Insulation materials
Technip applies mineral wool for process operating temperatures till and inclusive 600°C.
Technip applies a 2 layer design for process operating temperatures of 601°C and above.
The inner layer will be a ceramic fiber and the outer layer will be mineral wool.
Sheeting materials
Generally Technip applies aluminum sheeting material, but for high process temperatures
and alloy piping, Technip applies stainless steel sheeting material.
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14. Computer Programs and other Design Aids
14.1 Process Calculation
Please specify any requirements for use of specific software for calculations:
• See Project Procedure Technip Benelux Standard IT Plan
14.2 Drawings
The various engineering sections extensively use Computer-Aided Design (CAD) and
Computer-Aided Engineering (CAE) techniques.
For the production of piping drawings, isometrics, vessel drawings, civil/architectural

drawings, structural steel drawings, electrical and instrumentation schemes, P&IDs and
process flow diagrams, the software to be used is defined in: Project Procedure Technip
Benelux Standard IT Plan.
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14.3 Medium Identification Codes
Technip uses the following standard medium identification codes.

Process
Medium Symbol
Natural Gas NG
Naphtha LNP
Fuel gas FG
Hydrogen H
Start-up Hydrogen gas SH
Process Gas P
Purge Gas PG
Steam
Medium Symbol
High Pressure Steam (export) HS
High Pressure Steam (process) HSP
Medium Pressure Steam MS
Low Pressure Steam LS
Exhaust Steam ES
Water
Medium Symbol
Boiler Feed Water BFW
Demin Water DMW
Process Condensate PW
Low pressure condensate LC
Cooling Water Supply CWS
Cooling Water Return CWR
Potable Water (drinking water) DW
Raw Water RW
Fire Water FW
Miscellaneous
Medium Symbol
Plant Air PA
Instrument Air IA
Combustion Air CBA
Nitrogen (low pressure) LN
High Purity Nitrogen HPN
General Chemicals CH
Flare / Slops / Drains

Medium Symbol
Vent AV
Oily water sewer OWS
Light Hydrocarbon Closed Drain HDL
Blow-down (Boiler Water) BD
Flare VFL
32062 000 JSD 0000 001 02 27 / 50
15. Sparing Philosophy & Critical Service Design for Rotating
Equipment
15.1 Sparing Philosophy
The equipment list specifies the required sparing of equipment, in-line with the manning
philosophy for the plant. Package units which are not detailed in the equipment list, the
sparing of such items as dosing pumps, drain pumps, pumps with intermittent use and
filters must be clearly specified:
1) Centrifugal Pumps
100% installed spare.
The pumps to have automatic change-over (ACO) facility, if cessation of feed due to
pump failure will cause damage to equipment or unacceptable loss of plant capacity.
2) Chemical Dosing Systems

For chemical dosing pumps a 100% installed spare will be provided.
3) Intermittent Services, Blowdown / Slops

No spare unit.
4) Centrifugal Fans.
No spare unit.
5) Centrifugal Compressors
No spare unit.
6) Reciprocating Compressors
100% installed spare (compressor B is a spare for compressor A) No spare for
Nitrogen Circulation Compressor.
15.2 Automatic Change-over of Spare Equipment
The minimum requirement for automatic change over of spared equipment is for safety
only. For plant reliability, or prevention of off-spec material, or production losses,
consideration should be given to the use automatic change over facility.
Technip uses individual pressure switches on the pump discharge, upstream of the check
valve to activate the interlock.
15.3 Non-Electrical Driven Machinery
Not applicable.
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16. Piping Design Philosophy
Process and utility lines are sized in accordance with guidelines given in TECHNIP Process
Manual, see Attachment 1. Pump discharge piping is sized normally in accordance with
the normal flow and not the rated pump capacity. The pump suction piping is sized for the
rated pump capacity (approx. 130%) due to potential NPSH problems.
16.1 Sizing of Control Valve Manifold1)
Table 15.1 shows the recommendations for the sizing of control valves manifold.
It shall be read in conjunction with the following remarks:
1. Indicated size is main line size;

2. Size for by-pass line shall be as the by-pass valve;
3. Block valve shall be selected as per piping class;
4. By-pass valves shall be globe up to 6” and full bore gate for larger diameters;
5. Reference diameter for block valves is the size of the line on which the valve is
located; reference diameter for by-pass valve is the upstream line.
6. Size and characteristics of by-pass valve should correspond with size and
characteristics of control valve
1) Not applicable for BDEP phase.

32062 000 JSD 0000 001 02 29 / 50
RECOMMENDED SIZING OF CONTROL VALVE MANIFOLD1)
TABLE 15.1
Line Valve Control Valve Size

size size ½” ¾” 1” 1,5” 2” 3” 4” 6” 8” 10” 12” 14” 16”
Block ½”
½”
By-pass ½”
Block ¾” ¾”
¾”
By-pass ½” ¾”
Block ¾” 1” 1”
1”
By-pass ½” ¾” 1”
Block 1” 1” 1,5” 1,5”
1,5”
By-pass ½” ¾” 1” 1,5”
Block 1.5” 1.5” 2” 2”
2”
By-pass ¾” 1” 1.5” 2”
Block 2” 2” 3” 3”
3”
By-pass 1” 1.5” 2” 3”
Block 3” 3” 4” 4”
4”
By-pass 1.5” 2” 3” 4”
Block 4” 6” 6”
6”
By-pass 3” 4” 6”
Block 6” 8” 8”
8”
By-pass 4” 6” 6”
Block 6” 8” 10” 10”
10”
By-pass 4” 6” 6” 8”
Block 8” 10” 12” 12”
12”
By-pass 6” 6” 8” 10”
Block 10” 12” 14” 14”
14”
By-pass 6” 8” 10” 12”
Block 12” 14” 16” 16”
16”
By-pass 8” 10” 12” 14”
In case of large difference between sizes of control valve and downstream line
(due to flashing) in a range out of that given in the table, the downstream block
valve shall be equal to or one size smaller than the pipe.
The size of the by-pass valve has to be selected carefully if it has an impact on
a downstream relief valve.
1) Not applicable for BDEP phase.

32062 000 JSD 0000 001 02 30 / 50
16.2 Control Valve Sets
Handwheels or by-pass valves should only be provided when suitable control can
reasonably be achieved without the constant presence of an operator (e.g. purge gas
control valves should not be provided with a by-pass valve or handwheel) and when it is
considered essential for SAFE operation:
• The provision of a by-pass valve is preferred over the provision of a handwheel.
• Temperature control valves applied for heat exchanger control should be provided
with a handwheel.
• On/off or ESD valves should never be provided with a handwheel or a by-pass valve.
• Control valves which are provided with a solenoid valve for interlock or ESD
functions, should not be provided with a handwheel or a by-pass valve.
• By-pass valves should have similar characteristics as the control valve.
For C.V. sets, the block valves shall be the same size as control valve body, unless
pressure drop and/or erosion considerations dictate otherwise.
16.3 Motor Operated Valves
Specify valves which are to be motor operated:
• To be specified later (will be indicated on P&ID).
16.4 Double Block Valves
Double block valves are used for:

• Vents, drains and instrumentation in systems with flange ratings, ANSI 900 pounds
and above.
• Systems containing dangerous or poisonous chemicals.
• Systems subject to freezing risks (for example liquid light hydrocarbon drains)
16.5 Safety Valve Sets
Safety valves will be without spare, without isolation valves

During P&ID’s review, compliance with client requirement shall be checked.
32062 000 JSD 0000 001 02 31 / 50
17. Plant Cooling Design Philosophy
17.1 Categories
For design of coolers and/or condensers, TECHNIP will use the most cost effective system.
If this is not acceptable, please indicate below, the preferred design:
• Maximize air cooling. Preferred process outlet temperature of 55 °C if not followed by
water cooling. Preferred process breakpoint temperature of 60 °C if followed by water
cooling..
17.2 Secondary Cooling
Not applicable.
32062 000 JSD 0000 001 02 32 / 50
18. Heat Recovery Design Philosophy
18.1 Heat Exchanger Systems
TECHNIP practice is normally based on the most cost effective design for heat recovery
from various process streams. Proprietary techniques such as “PINCH” technology are
applied at specific request, in which the desired temperature approach to “PINCH” must
also be specified.
Heat exchanger designs such as plate exchangers or double pipe/multi-tube (finned) may
be viable alternatives in certain applications.
19. Heat Exchanger Design & Fouling Coefficients1)
1) Points applicable for BDEP: 19.1, 19.8, 19.9, 19.10, 19.11
Technip standard engineering practice is to design heat exchangers with the most optimum
dimensions (i.e. shell diameter and tube length). Optimum dimensions are decided on a
case to case basis. Optimum heat exchanger dimensions are a function of thermodynamic
feasibilities, system hydraulics, mechanical feasibility and economics.
Standard design basis for shell and tube heat exchangers is as indicated below with the
“black square”:
19.1 Heat Exchanger Standard for Design and Testing
TEMA R
TEMA R and TEMA C for non-flammable non-hazardous fluids
TEMA B
TEMA C
Other, ....
19.2 Preferred Tube Length
6m
20 ft
Other, .....
19.3 Standard Tube Length
9.0 m, 8 m, 7 m, 6 m, 5 m, 4 m, 3 m, 2.5 m, 2 m, 1.5 m, 1 m

Technip can apply an other tube length if this optimizes the design
30 ft, 24 ft, 20 ft, 16 ft, 12 ft, 10 ft, 8 ft, 6 ft
Other,
32062 000 JSD 0000 001 02 33 / 50
19.4 Standard Shell Sizes (mm)
Inside diameter 200, 250, 300, 350, 400, 450, 500, 550, 600, etc.
Technip can apply an other Shell diameter if this optimizes the design
Inside diameter, 203, 254, 305, 337, 387, 438, 489, 540, 591, 635, etc.
Other, .....
19.5 Standard Tube Size and Thickness
19.5.1 For Carbon Steel and Low Alloys
1” BWG 12 @ 1 ¼” pitch or, ¾” BWG 14 @ 1” pitch, etc.

Technip can apply other tube size if this optimizes design
25 mm x 2.5 mm @ 32 mm pitch or, 20 mm x 2 mm @ 26 mm pitch, etc.
Other, .....
19.5.2 For Stainless Steels
1” BWG 14 @ 1 ¼” pitch or, ¾” BWG 16 @ 1” pitch, etc.

Technip can apply other tube size if this optimizes design
25 mm x 2 mm @ 32 mm pitch or, 20 mm x 1.5 mm @ 26 mm pitch, etc.
Other, .....
19.6 Standard Tube Pitch
Triangular pitch allowable for fouling less than 0.0003 m2 K/W, else square pitch
Square pitch
Triangular pitch
Other, .....
19.7 Tube Wall Thicknesses
Average wall
Minimum wall
Other, .....
19.8 Channel Type Selection
TEMA type B
For cooling water type A
TEMA type B for fouling less than 2866 kcal/h m2 °C. For other service use type A.
Other, .....
32062 000 JSD 0000 001 02 34 / 50
19.9 U-Tube Type Construction
U-tube can be applied for tubeside fouling less than 2866 kcal/h m2 °C
19.10 Other Requirements
• Preferably cooling water will flow through the tubes.

• Preferably ¾” tubes are used for cooling water.
• Preferred maximum bundle weight = 20000 kg, maximum bundle diameter
= 1800 mm.
• If tube cleaning is required without dismantling the piping, use an A-front head.
NOTES:
• Any installed equipment which may come under vacuum, such as condensers, steam
heated reboilers etc. will be designed for vacuum, apart from the normal design
pressure.
• If heat exchangers of special type do not correspond to the TEMA, then the code
should be specified.
• Drains, vents, thermowells and pressure connections will be indicated on the process
data sheet.
19.11 Fouling Coefficients
For fouling coefficients see Attachment 2. For other types of exchangers, the TEMA “shell
and tube” coefficients are modified by the vendor program to suit the type of exchanger
being designed.
19.12 Information for convection section coil design
Maximum allowable finning density (fins per inch): 5

32062 000 JSD 0000 001 02 35 / 50
20. Plant Winterization
20.1 General Philosophy
The air temperature for winterization is specified in Chapter 11.
20.2 Minimum Design Metal Temperature (MDMT)
The Minimum Design Metal Temperature is specified in Chapter 11.
20.3 Initial Start-up and Operation at Subzero Temperatures
TECHNIP assumes that initial plant start-up will take place at above-zero ambient
conditions. Any deviations to this assumption will seriously affect process design.
20.4 Shutdown and Restart at Subzero Temperatures
Shutdown and subsequent start-up could be executed at subzero temperatures by keeping

the utilities in operation. The subzero temperature at which the plant is expected to be
operational at design conditions is -6 °C.
20.5 Heat Tracing of Lines, Instrumentation and Equipment
TECHNIP design will consider steam tracing for winterization and heat loss, unless dictated
by specific process/instrumentation issues. Tracing will be used where holding
temperatures are such to require accurate control, e.g. PSA inlet line. Winterization is used
for process and/or utility equipment and lines where the fluid contained therein could
solidify, congeal or become so viscous due to falling ambient temperatures as to endanger
plant operation or safety.
32062 000 JSD 0000 001 02 36 / 50
21. Hot Flare System Design
21.1 Design Code
The design of safety relief systems is generally in accordance with API recommended
practice and design guidelines 520 and 521.
21.2 Flare Header Design
Flare headers are designed on the basis of maximum velocity not exceeding 0.8 mach,
provided the total built up back pressure does not exceed 10% of the relief valve set
pressure for conventional relief valves.
In principal, for balanced bellow relief valves the total built up back pressure should not
exceed 25% of the relief valve set pressure.
Higher back pressures are possible, but shall be validated through manufacturers feedback
and supported by test reports certified by an independent notified body. In this case the
instrumentation department shall be consulted in an early stage.
21.3 Flare K.O. Drum
The flare header is assumed to be free draining into a flare K.O. drum near the flare,
located outside B.L.
21.4 HGU Flare header.
HGU flare header design criteria:

• Design temperature : 420... °C
• Design pressure of the system : 3.5... kg/cm2g
• Maximum allowable back pressure : 1.05 kg/cm2g
32062 000 JSD 0000 001 02 37 / 50
22. Drains and Slops System Design
22.1 Hydrocarbon closed Drains System
This system is generally designed for hydrocarbon drains from vessels, heat exchanger,
pumps, level instrumentation and control valve sets. The system is normally designed for
gravity flow into a sunken slops drum with pump-out facility.
The operation of the system is at ambient temperature conditions.
22.2 Chemical Drains
Not applicable. Vessels of chemical dosing unit(s) will be drained to oily water sewer.
22.3 Oily-Water Sewer
This system is normally an open sewer system connected to the plant paved area where
leakages from flanges, pump seals etc. are washed away by rain or water hoses. The flow
is by gravity via pipes to battery limits.
23. Vessel Design Philosophy
No transport limitations are envisaged.

Vessels are designed to hold liquid inventory according to the Table given in
Attachment 3.
32062 000 JSD 0000 001 02 38 / 50
24. Mechanical Design Temperatures & Pressures for Piping
and Non-fired Equipment
24.1 Mechanical Design Temperature1)
The design temperature is the maximum and/or minimum temperature value for which
the mechanical calculation of the equipment shall be performed.
The following summarizes the criteria to be followed to set the design temperature:
• Maximum normal operating temperature + 28°C (except for high-temperature fans,
such as induced draft fans and others, shall be mechanically designed for operation
at least 38 °C above maximum specified inlet gas temperature);
• Maximum temperature during start up, shut down, drying, purging, catalyst
regeneration + 28°C;
• When increased operating flexibility is required or future operating conditions are
expected, the above design margin can be higher;
• Maximum temperature during upset conditions (e.g. loss of cooling loss of feed,
etc.);
• Minimum of 80 °C, in the absence of any other specific criteria.
For reaction sections, the loss of feed, water and air cooling and steam (i.e. power
general failure) shall be considered in order to evaluate the temperature profile due to
the generated heat wave. The resulting maximum operating temperatures shall be
selected as design temperatures of the involved equipment, if higher than any other
temperature calculated as per the above criteria.
In case of coolant failure (water or air), the upstream cooler maximum operating inlet
temperature shall be considered as the downstream equipment design temperature,
without taking any credit for the residual natural draft in case of air coolers. In case of
air cooling failure on systems comprising both air and water cooling in series, the air
cooler maximum operating inlet temperature, deducted by the downstream trim cooler
normal delta temperature, shall be considered for design of equipment located
downstream the trim cooler.
Minimum Design Metal Temperature (MDMT) shall be specified. It shall be the lowest
among the following values:
• The minimum ambient temperature selected for this purpose (-4 °C);
• The lowest temperature expected in service (if lower than 0 °C) – 5 °C;
• The minimum temperature, which can be achieved during upset operating
conditions;
• For equipment containing LPG, the minimum temperature which can be achieved
during equipment depressurization at atmospheric pressure.
Calculated design temperature based on all above mentioned criteria shall be rounded
up to the next tenth °C (for instance 132 °C becomes 140 °C while no round-up will be
applied for Minimum Design Metal Temperature.)
24.2 Mechanical Design Pressure2)
The design pressure is the maximum and/or minimum pressure for which the
mechanical calculations shall be performed.
Design pressure does not include the liquid static head. Pressure drop across trays or
32062 000 JSD 0000 001 02 39 / 50
vessel internals should be included if it is significant.

Design pressure shall be set according to the following criteria (whichever is greater):
• 3.5 kg/cm2 g
• Flare design pressure if the vessel is connected to flare.
• Max normal operating pressure + 2.0 kg/cm2 when 0 < max normal operating
pressure <= 18 kg/cm² g
• Max normal operating pressure / 0.90 when 18 < max normal operating pressure <=
70 kg/cm² g
• Special design case when max normal operating pressure > 70 kg/cm² g
• Minimum design pressure for S&T heat exchangers (any side) shall be 5.3 kg/cm2 g.
• Design pressure for atmospheric tanks and drums (normally vented to atmosphere)
shall be 150 mm H2O g) and full of liquid.
• Design pressure for nitrogen blanketed tanks shall be 500 mm H2O g and full of
liquid.
Full vacuum design conditions shall be specified at design temperature for equipment
normally operating under vacuum conditions (i.e. vacuum towers, steam turbine
condensers, etc.).
Full vacuum design conditions shall be specified at minimum ambient temperature for:
• Equipment which handle fluids having a vapour pressure lower than atmospheric
pressure at minimum ambient temperature.
• Equipment normally operated liquid full and that can be blocked in and cooled
down.
Equipment handling steam (e.g. steam drums, condensate flashing drums, etc.) shall be
specified for Full Vacuum at 100 °C.
Equipment subject to evacuation during start up, shutdown, and/or regeneration shall
be specified for Full Vacuum at the corresponding evacuation phase
maximum/minimum temperature.
All vessels not in vacuum service but subject to steam out shall be designed for
half-vacuum at maximum operating LP Steam temperature.
All vessels subject to steam-out shall be designed, as a minimum, for LP Steam
maximum operating conditions of refinery unit steam header.
Equipment in pumped (centrifugal pumps) circuits:

If a control valve or block valve is installed downstream of the equipment, the design
pressure shall be calculated as the greater between:
o Rated pump differential x 1.25 + max pump suction pressure;
o Rated pump discharge pressure x 1.1;
o Normal pump discharge pressure + 2.0 kg/cm2.
Maximum suction pressure is defined as suction vessel design pressure + liquid height
with vessel liquid level at HLL.
Heat exchangers.
Heat exchangers shall be designed by following the “10/13 rule” in accordance with the
latest edition of ASME VIII Div.1. This means to set a design pressure of the lower
pressure side of a heat exchanger not lower than 77% of the design pressure of the
higher pressure side. This design rule allows to protect the equipment against tube
rupture without installing a PRV. The design pressure set following the “10/13 rule” will
be extended also to inlet and outlet piping connected to the lower pressure side of the
heat exchanger including the isolation valves.
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24.3 Mechanical Design Pressure (Low Pressure Systems)
Unless adequately protected by a trip system or safety valve, following design conditions
will be applied for furnaces:
• Maximum forced draft fan shut-off head or
• Maximum induced draft fan shut-off head
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25. Mechanical Design Codes
Any mechanical design codes, such as the “boiler code” which will have to be followed and
having an impact on process design should be specified.
For this project the following mechanical design codes are applicable:
• Vessels (process): ASME VIII div. 1
• Vessels (steam): ASME I
• Piping (process) : ASME 31.3

Piping (steam) : ASME 31.1
• Furnace (steam system) : ASME I

Furnace (process coils) : ASME VIII div. 1
Furnace (process coils) : API 530
26. Tankage
Client requirements with respect to off/on-site tankage for feed, products and utilities to be
specified prior to detailed design work:
• Not applicable.
27. Metallurgy and Corrosion Allowances
Metallurgy specified by TECHNIP will be based upon that required for process
considerations. The requirements are to be found on equipment data sheets and line
designation tables. For corrosion allowances, specify any special requirements. For
TECHNIP standards, see Attachment 4.
32062 JSD 0000 001 01 42 / 50
28. Client Side Connections & Conditions at Battery Limit
28.1 Incoming Lines
1)
Fluid Phase Mech. design Mech. design Corr. allow. Material Location
pressure temperature mm
2
kg/cm g °C
Natural Gas Gas 46.5 80 1.5 CS A.G.
Light Naphtha Liquid HOLD 80 1.5 CS A.G.
Start-up Hydrogen Gas 30 80 1.5 CS A.G.
Fuel gas (Refinery Fuel Gas 7.0 90 1.5 CS A.G.
Gas)
Plant Air Gas 11.0 80 1.5 CS A.G.
Instrument Air Gas 11.0 80 - CS galvanized A.G.
Nitrogen. Low pressure Gas 15 80 1.5 CS A.G.
High Purity Nitrogen Gas 15 80 1.5 CS A.G
Demin water Liquid 15.0 80 0.75 SS A.G.
Raw water Liquid 15 80 1.5 CS A.G.
Drinking water Liquid 15 80 - CS galvanized A.G.
Cooling water supply Liquid 13.5 120 1.5 CS A.G.
Low pressure steam Gas 7.6 235 1.5 CS A.G.
Data to be verified and adjusted by Detailed Engineering Contractor.
NOTE:
1) Above Ground (AG), Underground (UG), Elevation above ground (m), operating pressure of liquid lines are at grade level.
32062 JSD 0000 001 01 43 / 50
28.2 Outgoing Lines
1)
Fluid Phase Mech. design Mech. design Corr. allow. Material Location
pressure temperature mm
kg/cm2g °C
Hydrogen Gas 30 80 1.5 CS A.G.
HP Steam Gas 46.7 418 1.5 CS A.G.
Cooling water return Liquid 13.5 120 1.5 CS A.G.
Flare Gas 3.5 420 3.0 CS N/A
Slops Liquid HOLD HOLD HOLD HOLD A.G.
Data to be verified and adjusted by Detailed Engineering Contractor.
NOTE:
1) Above Ground (AG), Underground (UG), Elevation above ground (m), operating pressure of liquid lines are at grade level.
32062 JSD 0000 001 01 44 / 50
29. Design Requirements for Commissioning and Start-Up
Commissioning and start-up will be as per Technip procedures and practices.

32062 JSD 0000 001 01 45 / 50
Attachment 1
DESIGN BASIS FOR PIPING INSIDE BATTERY LIMITS
Pressure drop considerations:
Line type Average Typical Typical allowable

kg/cm2 / 100 allowable Total ∆ p
2 2
m kg/cm / 100 m kg/cm (approx.)
Pump suction and gravity run-down lines 0.0571 0.0918 -
Pump discharge lines (except high pressure) 0.3467 0.4589 -
High pressure pump discharge lines (50 bar and 0.6934 0.9177 -
above)
Vapor lines (atm. and press. tower overhead lines) 0.0459 0.1173 0.1173-0.2274
Gas lines (within battery limits) 0.0459 0.1173 0.9177-1.1727
Gas lines (tie-in lines) - - 5-10% of available
pressure
Compressor suction lines 0.0235 0.0693 0.1173-0.2274
Compressor discharge lines 0.0459 0.1173 0.9177-1.1727
High pressure steam lines (40-100 bar) 0.5099 1.0197 2.0394
High pressure steam lines (> 100 bar) 1.1727 2.2944 2.2944-4.5887
Exhaust steam lines (short) 0.0459 0.0918 0.2345
Exhaust steam lines (long) 0.0112 0.0235 0.3467-0.4589
Water lines (short) 0.2345 0.3467 0.4589
Water lines (long) 0.0561 0.1173 1.1727
Liquid transfer and tie-in lines - - 5.7104
The specified criteria above are general guidelines and have to be verified against the
pressure profile during the design phase.
32062 JSD 0000 001 01 46 / 50
Liquid velocity considerations:
Line size (inch) Typical allowable velocity

SS & High alloys CS & Low alloys
m/s m/s
1 2.00 1.25
1.5 2.00 1.75
2 2.25 2.00
3 2.50 2.00
4 2.75 2.25
6 3.00 2.50
8 3.00 2.50
10 3.00 2.75
12 and larger 3.00 3.00
Typical vapor / gas velocity considerations:
Air and other vapours 10 –30 m/s

Saturated steam (dry) 15 – 30 m/s
Superheated steam 30 – 50 m/s (and over)
Vacuum lines 10 – 100 m/s
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Attachment 2
THE FOLLOWING FOULING COEFFICIENTS ARE TYPICAL VALUES WHICH CAN BE
APPLIED FOR DESIGN OF TUBULAR HEAT EXCHANGERS.1)
2
Medium Fouling resistance h m °C/kcal
HGU (combined TECHNIP and Client) TEMA (for information)
Light Naphtha 0.0002 0.0004-0.0006
Condensing steam 0.0001 0.0001
Cooling water 0.0004 0.0004
Demin water 0.0001 0.0002
Process water 0.0002 -
Hydrogen 0.0002 -
Process gas 0.0002 -
Flue gas 0.0001 -
Natural gas 0.0002 -
Boiler feed water 0.0001
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Attachment 3
VALUES USED FOR LIQUID HOLD-UP TIMES IN VESSELS AND TOWERS
The following minimum hold-up times are recommended, based on outflow from normal
level, to empty, or low-low trip level:
Liquid from vessel HL to LL LL to LLL

Product to storage 3.0 3
Feed to another tower 3.0 3
Feed to furnaces 3.0 3
Reflux 3.0 5
For closed circulating systems, such as quench oil, quench water, amine scrubbing units,
etc., the following hold-up times in minutes applies, based on full circulation rate. For steam
drums, in both ethylene and reforming plants, the hold-up times are based on BFW cut-off.
From To Steam Deaerator/

Drum Degassifier
1)
HHHL HHL - 1
HHL HL 1 2
HL LL 2 2
LL LLL 2 15
4) 6)
LLL Empty (incl. BTM -
head)
HL Bottom inlet gas - -
nozzle
NOTES:
1) Only applicable if process condensate is sent to deaerator/degassifier.
2) Liquid inventory in packing or on trays, and inlet piping, if applicable.
3) 3 minutes hold-up is from LL to empty (including bottom head).
4) 3 minutes for ethylene plants and 4 minutes for steam reformers.
5) Vessels (such as separators, dry drums) having low liquid knock-off and which are sized for gas flows,
should have gap control applied, with standard minimum instrument ranges (356 mm for displacers and
250 mm for D.P. transmitters).
6) No process requirement; usually 350-500 mm above bottom or TL.
7) For Light Naphtha Feed Surge Drum, the surge time equal 20 minutes shall be provided between low
and high level.
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Attachment 4
TYPICAL MATERIALS SELECTION AND CORROSION ALLOWANCES
Piping Equipment
Name Fluid Code Piping Corrosion Equipment Corrosion Remarks
Material Allowance material Allowance
(C.A.) (C.A.)
mm mm
High pressure steam HS CS/1.25Cr. 1.5 1.5 Material/C.A.
(export) 5Mo dependent on
temperature/
pressure
High pressure steam HPS CS/Low 1.5 1.5 Material/C.A.
(process) Alloy dependent on
temperature/
pressure
MP steam MS CS 1.5 CS 1.5
LP steam LS CS 1.5 CS 1.5
Combustion air CBA CS - CS - Note 1)
(preheated) Cr-Mo (for ducting) Cr-Mo
SS Note 1) SS
Instrument air IA Galvanized - - - SS for small bore
pipe
Plant/service air PA CS 1.5 CS 3.0
Plant nitrogen LN CS 1.5 CS 1.5
Hydrogen H CS/Low 1.5 CS/Low 3.0 Refer to Nelson
Alloy Alloy
Chemicals (all) CH CS/SS 1.5/0.75 CS/SS 3.0/0
Fuel gas (< 10%(v) FG CS 1.5 ** CS 3.0 ** If H2S > 10%(v)
H2S) dry or wet gas with
Temp. < 190°C < 10%(v),
3 mm C.A.
Process condensate PW SS/304L 0.75 SS/304L 0 SS material for
CO2 content
Flare VFL CS 1.5 CS 3.0 Consider
LTCS 3.0 LTCS 3.0 temperature and
SS 0.75 SS 0.0 applicable code
Oily water sewer OWS CS 1.5 - -
Sanitary sewer SS PVC - PVC -
LP condensate LC CS 1.5 CS 3.0
Fire water FW CS 1.5 - -
Cooling water CWS/C CS 1.5 CS 3.0
WR
Demineralized water DMW SS or 0.75 SS or coated 0
coated CS CS
Boiler feed water (all BFW CS 1.5 CS 3.0
pressures)
Raw RW CS 1.5 CS 3.0
Drinking water DW CS 1.5 - -
Natural Gas NG CS 1.5 CS 3.0
Light Naphtha LNP CS 1.5 CS 3.0
NOTE:
1) Material will depend on design temperature and the codes applicable for it.
No corrosion allowance is required for (preheated) combustion air ducting. In case, the combustion air is
piped and falls under a piping class, corrosion allowance may be required.
32062 JSD 0000 001 01 50 / 50
GENERAL PRINCIPLES FOR CORROSION ALLOWANCE:
Vessels
o For carbon steel vessels 3.0 mm minimum
o For low alloy steel (up to 5 Cr) vessels 1.5 mm minimum
o High Alloy Steel and non ferrous vessels – 0,25 mm minimum
S&T heat exchangers
o For carbon steel heat exchangers – 3.0 mm minimum
o For low alloy steel (up to 5 Cr) heat exchangers - 1.5 mm minimum
o High Alloy Steel and non ferrous Heat Exchangers – 0,25 mm minimum
Air coolers
o Carbon Steel Exchangers - 3 mm minimum
o Low Alloy Steel Exchangers - 1.5 mm minimum (up to 5Cr)
o High Alloy Steel and non ferrous Exchangers - 0.25 mm minimum
Piping
o For carbon steel and low chrome alloys - 1.5 mm
o For stainless steels and higher alloys - 0.75 mm
Heaters Coils
o Carbon steel and ferritic alloy steel - 3 mm
o Austenitic alloy steel: 1,5 mm
Cladding and weld overlay
o Cladding minimum thickness: 2 mm
o Weld overlay minimum thickness: 3 mm (1,5 mm min. of undiluted alloy)

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Project n° - Unit Material code Serial N° Rev.

32062 000 JSD 0000 001 02 1 / 50

Client : Socar & Turcas Rafineri A.S. (STRAS)

Pages modified under this revision:

02 15.11.2010 RELEASED FOR ENGINEERING CSEP CSEP CJV

TECHNIP BENELUX B.V. (TECHNIP)

G:\01-32062.00\D50\ENG\F (Latest Documents)\BOD\Rev 02\32062-000-JSD-0000-001-02.docx.

32062 000 JSD 0000 001 02 2 / 50

Engineering Specification Basis of Design process department

2. A Brief Description of Plant .........................................................................................6

3. Plant Capacity ...............................................................................................................7

4. Over-Design & Turn-Down Factors for Throughput & Equipment ..........................7

5. On-Stream Factors .......................................................................................................8

6. Feed Specifications ......................................................................................................9

8. Effluent Characteristics .............................................................................................12

9. Utilities Specifications ...............................................................................................14

10. Environmental Considerations .................................................................................20

11. Site / Ambient / Design Conditions ...........................................................................21

12. Units of Measurement ................................................................................................23

13. Basis for Insulation Design .......................................................................................24

14. Computer Programs and other Design Aids ............................................................25

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Engineering Specification Basis of Design process department

15.2 Automatic Change-over of Spare Equipment ....................................................27

16. Piping Design Philosophy .........................................................................................28

17. Plant Cooling Design Philosophy .............................................................................31

18. Heat Recovery Design Philosophy ...........................................................................32

19. Heat Exchanger Design & Fouling Coefficients ......................................................32

20. Plant Winterization .....................................................................................................35

21. Hot Flare System Design ...........................................................................................36

22. Drains and Slops System Design .............................................................................37

23. Vessel Design Philosophy .........................................................................................37

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Engineering Specification Basis of Design process department

25. Mechanical Design Codes .........................................................................................41

26. Tankage .......................................................................................................................41

27. Metallurgy and Corrosion Allowances .....................................................................41

28. Client Side Connections & Conditions at Battery Limit ..........................................42

29. Design Requirements for Commissioning and Start-Up ........................................44

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Engineering Specification Basis of Design process department

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Engineering Specification Basis of Design process department

2. A Brief Description of Plant

Refer to 32062-000-JSD-0000-002 “Process description”.

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Engineering Specification Basis of Design process department

Design plant capacity based on Product shall be the following:

Capacities are based on hydrogen including impurities.

Rate of Capacity Change 0.5 percent/min

4. Over-Design & Turn-Down Factors for Throughput &

32062 000 JSD 0000 001 02 8 / 50

Engineering Specification Basis of Design process department

Number of on-stream hours per year: ≥ 8400

Interval between plant maintenance shut-downs: 3 years

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Engineering Specification Basis of Design process department

6.1 Gaseous Feed Specification

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