Utilities and oil movement-Final.pdf

PARCO-Mid Country Refinery DOC. #: PAR-MCR-PROCESS/
Training Manual-01
PROCESS TRAINING MANUAL Issue # 01 Issue Date:
UTILITIES AND OIL MOVEMENT Page 1 of 28 01-07-2005
SAH/- Utilities and oil movement-Final 7/11/2005
CHANGE RECORD
Prepared by Reviewed by Approved by
Issue
No.
Issue
Date
Change Description
Initial
Sign
Date
Initial
Sign
Date
Initial
Sign
Date
01 01-07-05 Initial release SAH AHQ/AAN AAZ

Training Manual-01
Contents
6.1. INTRODUCTION
6.2. CHEMICALS (U-900)
6.2.1. General Description:
6.2.2. Design Basis:
6.2.3. Material Balance:
6.3. AIR (U-910)
6.4. FLARE (U-915)
6.4.3. Design Flaring Load:
6.5. FUEL GAS (U-920):
6.5.3. Normal operation case
6.5.4. Diesel Max catalytic section down case
6.5.5. Users:
6.6. FUEL OIL (U-920)
6.6.2. Refinery Fuel Oil Sources (Producers):
6.6.3. Destination (Consumers):
6.6.4. Priority of Fuel Oil:
6.7. WATER (U-925)
6.7.4. Effluent Information:
6.7.5. Cooling Tower (925-T1):
6.7.6. Chlorination Systems (925-ME3/ME5):
6.7.7. Raw Water Tanks (925-TK1A/B):
6.7.8. Potable Water Tank (925-TK2):
6.8. FIRE PROTECTION SYSTEM (U-926)

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6.8.1. General System Description:
6.8.2. Fire water pumps and jockey pumps:
6.8.3. System Description:
6.9. EFFLUENT TREATMENT PLANT - ETP (U-930)
6.9.2. Clean water sewer system
6.9.3. Oily water collection system
6.9.4. Slop oil recovery system
6.9.5. Spent caustic neutralization system
6.9.6. Closed aromatics waste system
6.9.7. Waste water treatment Plant ( WTP )
6.9.8. Oily sludge handling system
6.9.9. Bio-sludge handling system
6.9.10. Sanitary waste treatment plant
6.10. STEAM (U-940)
6.10.4. Chemical Requirement:
6.10.5. Boiler Makeup Water Treating System (940-ME1):
6.10.6. Deaerator (940-ME2):
6.10.7. Utility Boilers (940-B1A/B/C):
6.10.8. Demineralized Water Tanks (940-TK1A/B):
6.11. TANKAGE (U-945)
6.11.2. Crude oil storage and process charge:
6.11.3. Intermediate storage:
6.11.4. Component storage:
6.11.5. Finished product storage:
6.11.6. Support facilities:
6.11.7. Blending facilities:
6.11.8. Finished product shipping:
6.11.9. Truck loading and pipeline:
6.11.10. Pipeline:

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6.1. INTRODUCTION
The utilities at MCR consist of the following units.
S. No. Unit No. Unit Name
1 900 CHEMICAL
2 910 AIR
3 915 FLARE
4 920 FUEL GAS
5 920 FUEL OIL
6 925 WATER
7 926 FIRE PROTECTION SYSTEM
8 930 ETP
9 940 STEAM
10 945 TANKAGE
6.2. CHEMICALS (U-900)
Unit 900 is composed of the following systems:
: 25o
Be Caustic Soda Handling System
: 98WT% Sulfuric Acid Handling System
50wt% caustic system and H2SO4 distribution system are designed to meet the
requirements of their various users in the refinery.
50 wt% caustic section consists of, 50 wt% caustic unloading, dilution to 25o
Be,
storage and distribution system. The system is designed to meet the requirement of
25o
Be caustic solution for various users. 50 wt% caustic will be unloaded from
average 10 metric ton trucks to 900-TK1A/B via 50 wt% caustic unloading pump
(900-P1A/B) and diluted to 25o
Be in the tank and transferred to each user by 25o
Be
caustic pump (900-P2A/B).
H2SO4 Distribution Section consists of sulfuric acid unloading, storage and
distribution system. The system is designed to meet the requirement of sulfuric acid
for various users. Sulfuric acid is unloaded from 5 metric ton trucks to 900-V1 via
Sulfuric Acid Transfer Pump (900-P3A/B) and distribute to users by Sulfuric Acid
Process Pump (900-P4A/B) or Sulfuric Acid Injection Pump (925-P53A/B) to Cooling
Tower basin.

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The theoretical material balance for Caustic System and Sulfuric Acid System are
tabulated below:
Caustic System:
The approximate consumption of caustic for different users is tabulated below.
Unit Consumption Strength
Utility 2.1 m3
/day 25o
Be
ETP 0.06 m3
/hr 25o
Be
K-MX 0.2 m3
/hr 10o
Be
LPG-MX 3.14 m3
/week 25 o
Be
CCR 0.34 m3
/day 25o
Be
NHTR 1.6 m3
/hr/10years 10o
Be
AMINE 0.66 m3
/hr/week 10o
Be
D-MAX 984 m3
/172 hrs/year 10o
Be
K-MX(ELEC) 8 m3
/week 10o
Be
TOTAL 1.9 m3
/day average 50wt%
Sulfuric Acid System:
Unit Consumption
Utility
(Boiler Makeup Water System) 640 L/day average
(Cooling Water System) 72 L/day average
Spent Caustic Section 8.5 m3
/hr/<hr/week average
TOTAL 1.9 m3
/day average
6.3. AIR (U-910)
: Air Compressor Package Section
: Air Dryer Package Section
Plant and Instrument Air System is designed to meet the requirements of their
various users in the refinery.
The Plant and Instrument Air System will produce 4168Nm3
/h Instrument Air and
1400 Nm3
/h (3020Nm3
/h in the case of Diesel-Max Regeneration) Plant Air at

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maximum demand rate. Plant and instrument air is supplied by two equal size
centrifugal compressors (910-C1A/B), one operating and one standby. The
compressor capacity is determined in such a way that one compressor can supply
the entire air demand at normal operation. In the case of Diesel-Max Regeneration
operation, both compressors will have to run in parallel. One compressor is motor
driven, and the other one is steam turbine driven.
Plant and Instrument Air System will include adequate facilities to provide required
quantities of instrument air and plant air at users.
The normal flow balance for plant air and instrument air are tabulated below:
Unit Plant Air Consumption
(Nm3/
h)
Instrument Air
Consumption (Nm3/
h)
Utility 470 Note 1 571
Off Site 0 190
CDU 0 200
VDU 0 90
VISB 0 230
N-HTR 0 142
D-MAX 0 {2800 Note 2} 510
PLAT 0 150
CCR 6 620
G-CON 0 70
K-MRX 0 40
L-MRX 16 20
AMN 0 60
SRU 0 258 Note 3
ETP 198 60
FLARE 0 5
TOTAL 690 3216
Note 1; Average of Dryer purge loss.
Note 2; Max. Flow for regeneration operation.
Note 3; Sulfur solidification plant’s consumption is involved.
In normal case total air consumption during regeneration operation will be about
6700 Nm3
/h and the air compressors should be run in parallel. However when
regeneration operation will be done during refinery shut down period, total air
consumption will be about 4600Nm3
/h. At that time one air compressor can cover
the consumption.
The plant and instrument air system has two air receivers that are pressurized
cylindrical vertical vessels. One is main air receiver and the other is instrument air
receiver. The holding capacity is determined in such a way that the combination of

Training Manual-01
the main and instrument air receivers provides approximately five minutes of supply
at the normal instrument air demand rates.
The extracted air from Air Compressor (910-C1A/B) is routed to Air Dryer Package
(910-ME1). The air dryer is heatless regeneration type, and the air is dried to a dew
point of maximum -20°C at 7.0 kg/cm2
G. Then the dried air is distributed to the
whole refinery as instrument air via the instrument air receiver.
6.4. FLARE (U-915)
The Flare System is designed to handle the normal gas release and the emergency
gas and liquid release from the refinery. This system consists of the main flare
system and the acid gas flare system. Capacities of those flare systems are as
follows:
• Main flare system : 950 ton/hr (General power failure case)
• Acid gas flaresystem : 48.6 ton/hr (284 Unit CV failure open case)
The flare system is designed to collect, to knockout liquid, to prevent flashback and
to dispose of relieving vapor. An elevated main flare is provided to combust relief
valve discharges and normal process vents, and acid gas flare is provided for off gas
containing hydrogen sulfide.
Relieving sources:
a. Main flare system
Relieving vapor and liquid from the following units are collected to main flare
system:
• Crude Distillation Unit
• Vacuum Distillation Unit
• Gas Concentration Process Unit
• Visbreaking Process Unit
• Diesel Max Process Unit
• Platforming Process Unit
• Platforming Process Unit CCR Section
• Naphtha Hydrotreating Process Unit
• Kerosene Merox Process Unit
• LPG Merox Process Unit
• Fuel Gas System
• LPG Sphere Tanks
• Boiler Section in Utility Facilities

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b. Acid gas flare system
Relieving vapor and liquid from the following units are collected to acid gas flare
system:
• Diesel Max Process Unit
• Amine Treating Process Unit
• Sulfur Recovery Process Unit
• Effluent Collection, Treatment and Disposal System
6.4.3. Design Flaring Load:
Main flare:
The general power failure case is the design case of main flare system. The relieving
flow rate for each unit in the general power failure case is shown in the following
table:
Unit No. Unit Location Vapor Load
kg/h
100 CDU Crude Column Ovhd 277,672
130 Visbreaker Fractionator Ovhd 6,495
200 Naphtha Hydrotreater Separator 63,567
Stripper Ovhd 125,484
Splitter Ovhd 148,564
284 Diesel Max Separator 6,146
Prod. Fractionator Ovhd 110,442
Flash Fractionator Ovhd 79,878
300 CCR Plat Debutanizer Ovhd 57,597
411 Gas Concentration Stripper Ovhd 203,649
920 Fuel Gas System 20,000
- Future=15%
expansion
164,924
Total 1,264,418
Design vapor flow of the main flare system is calculated as follows based on the
relieving flow rate in the general power failure.
[Total Relieving Rate including 15% margin] x [De-rating Factor : 0.75]
= 1,264,418 x 0.75
= 948,314 -Æ 950,000 [kg/hr]
MW = 79.21
Gas Temperature = 209 [o
C]
Minimum flame emissivity = 0.15

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Acid gases flare system:
The relieving flow rates in the general power failure case and the inadvertent
opening of the level control valve located at Diesel Max Separator are shown in the
following table.
Unit
No.
Unit Location Case Vapor
Load
kg/h
810 Amine Amine Regenerator Ovhd General Power Failure 5,709
284 Diesel
max
Stripper Ovhd Control Valve Fails Open 48,607
Recycle Gas Relieving
Case
13,469
Flaring capacity (kg/hr) : 5,709 * 48,607 ** 13,469 ***
Mol. Wt. : 25.9 98.1 5.17
LHV (kcal/kg) : 3,600 8,300 16,284
Gas temperature (o
C) : 105 169 130
Allowable pressure drop : 0.25 0.25 0.25
(kg/cm2
)
Minimum flame emissivity : 0.15
Composition of acid gas [vol%] :
H2S : 88.6 5.85 1.49
NH3 : 11.4 0.007 0.002
H2 : 0.0 58.4 87.31
H.C. : 0.0 35.743 11.198
* : General power failure case
** : Diesel max control valve fails open case
*** : Diesel max recycle gas relieving case
Flaring gas and/or liquid is routed to the flare knockout drums 915-V1/V2 via flare
headers. These drums remove liquid and any mist from the vapor stream.
The main flare 915-ME1 has four pilot burners and the acid flare 915-ME2 has two
pilot burners with common remote ignition system. Each flare has water seal drum
at the bottom and seal gas arrangement at the top, and the main flare has
smokeless steam injection system.
The main flare knockout drum pump 915-P1A/B transfer any slop oil collected in the
915-V1 to the light slop tank 945-TK47, and sour water knockout drum pump 915-
P2A/B transfer condensate from the 915-V2 to the sour water degassing drum 810-
V10 in the Amine Treating Unit.

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6.5. FUEL GAS (U-920):
The refinery, in which the Fuel Oil and Fuel Gas Systems are installed, is a large
consumer of thermal energy in the form of liquid and gaseous fuel. In the course of
processing the feedstock, the refinery is also the producer of its own fuels. These
fuels are gathered and redistributed by two systems, a fuel oil system and a fuel gas
system.
The Fuel Gas System is designed to collect various fuel gas sources and to distribute
them to the refinery as fuel gas.
The Fuel Gas System is designed to collect process unit off gas, natural gas, and
vaporized LPG, and to distribute them to meet the needs of fired equipment and
miscellaneous users. All sources of gas are routed to a fuel gas knockout drum (920-
V1) which provides liquid knockout and mixing.
One LPG vaporizer (920-E3) is provided to make up fuel gas and to dispose of off-
spec or excess LPG. Off-spec LPG is produced at start-up of Gas Concentration Unit,
LPG Merox Unit and CCR-PLAT. Unit, and sent to the LPG vaporizer.
Design basis for sources and users
There are several operation cases in the Fuel Gas System. The fuel gas sources are
as follows:
(1) Normal operation case
• Purge gas from the catalytic section of the Diesel Max Process Unit
• Treated gas from the Amine Treating Process Unit
(2) Diesel Max catalytic section down case
• Net gas from the Platforming Process Unit
(3) Diesel Max total down case
• Net gas from the Platforming Process Unit
(4) Other sources
• Natural gas from outside of the refinery
• On-spec LPG from LPG spheres.
• Off-spec LPG from several units
The fuel gas system design is based on an average pressure of 5.7 kg/cm2
G. This
pressure is sufficiently high to provide good combustion control and reasonable
piping and knockout drum sizes.

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The priority of fuel gas sources is as follows:
Normal operation : Refinery off gas
Primary makeup : Natural gas
Secondary makeup : On-spec LPG vaporized in LPG vaporizer
The fuel gas header pressure is controlled in two ways. During normal operations, a
fuel availability control system on the boilers varies the ratio of gas/oil firing to
maintain a constant fuel gas system header pressure. If this system can no longer
maintain fuel system pressure, additional actions will commence. On high fuel gas
pressure, excess fuel gas will be dumped to the flare. On low fuel gas pressure,
additional fuel gas will be obtained from the natural gas pipeline. However, based on
the current fuel balance, the need for abnormal import or dumping to flare is very
remote. Natural gas import will be maximum during the plant initial start up since no
refinery off gas is available in that period.
The collected fuel gas is distributed to the following users:
• Crude heater, 100-H1 in the Crude Distillation Unit.
• Vacuum heater, 110-H1 in the Vacuum Distillation Unit.
• Visbreaker heater, 130-H1 in the Visbreaking Process Unit.
• Charge heater, 200-H1 in the Naphtha Hydrotreating Process Unit.
• Reactor charge heater, 284-H1 in the Diesel Max Process Unit.
• Product fractionator feed heater, 284-H2 in the Diesel Max Process Unit.
• Thermal cracker heater, 284-H50A/B/C in the Diesel Max Process Unit.
• Charge heater, 300-H1 in the CCR-Platforming Process Unit.
• No.1 Interheater, 300-H2 in the CCR-Platforming Process Unit.
• No.2 Interheater, 300-H3 in the CCR-Platforming Process Unit.
• Utility boilers, 940-B1 A/B/C in the Steam, Feed water and Condensate
Handling System.
• Purge gas to flare headers.
• Dry seal for flare stacks.
• Incinerator, 820-H3/H4 in the Sulfur Recovery Unit.
• SCOT line heater, 820-H51/H52.
Treated gas from the Amine Treating Process Unit is sent directly to the Sulfur
Recovery Unit in normal operation.
6.5.3. Normal operation case
In normal operation case, about 69% of the purge gas from the Diesel Max Process
Unit and 95 % of the treated gas from the Amine Treating Process Unit are sent
directly to the Fuel Gas System. The remaining 31% of the purge gas is routed to
the Naphtha Hydrotreating Process Unit, and 5% of the treated gas to the Sulfur
Recovery Process Unit as fuel for the incinerator.

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Amine Unit OVHD Gas D-Max Purge Gas MixedFuel Gas
OVHD Gas to SRU to Fuel gas Purge Gas to N-HTR to Fuel gas
Component
(kmol/hr)
N2 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H2O 8.62 0.41 8.20 0.62 0.19 0.43 8.63
H2S 0.01 0.00 0.01 0.43 0.13 0.30 0.31
NH3 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CO2 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H2 101.41 4.88 96.53 501.26 155.82 345.44 441.97
C1 186.28 8.97 177.30 29.23 9.09 20.14 197.45
C2= 1.05 0.05 1.00 0.00 0.00 0.00 1.00
C2 124.57 6.00 118.57 24.88 7.73 17.15 135.72
C3 7.22 0.35 6.87 6.8 2.11 4.69 11.55
C3= 0.44 0.02 0.42 0.00 0.00 0.00 0.42
IC4 0.00 0.00 0.00 0.49 0.15 0.34 0.34
IC4= 0.00 0.00 0.00 0.00 0.00 0.00 0.00
=NIC4 0.00 0.00 0.00 0.00 0.00 0.00 0.00
NC4= 0.01 0.00 0.01 0.00 0.00 0.00 0.01
NC4 0.95 0.05 0.90 0.69 0.21 0.48 1.38
C5= 0.00 0.00 0.00 0.00 0.00 0.00 0.00
IC5 0.00 0.00 0.00 0.15 0.05 0.10 0.10
NC5 0.25 0.01 0.24 0.12 0.04 0.08 0.32
C5OLEFIN 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CP 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C6+ 0.01 0.00 0.01 0.27 0.08 0.19 0.20
Total 430.81 20.75 410.06 564.94 175.62 389.32 799.38
MW 17.49 17.49 17.49 4.71 4.71 4.71 11.27
LHV
(kcal/Nm3) 9201 9201 9201 3758 3758 3758 6550
Flow Rate
(Nm3/h) 9656 465 9191 12663 3936 8726 17917
(kg/h) 7535 363 7172 2661 827 1834 9007

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6.5.4. Diesel Max catalytic section down case
In Diesel Max catalytic section down case, net gas from Platforming Unit is fed to
fuel gas unit instead of purge gas from the Diesel Max Unit. About 89% of the net
gas and 94% of the treated gas from the Amine Unit are sent to the Fuel Gas
System. The remaining 11% of the net gas is routed to the Naphtha Hydrotreating
Unit and 6% of the treated gas to the Sulfur Recovery Unit.
Amine Unit OVHD Gas CCR Platform Net Gas Mixed Fuel
Gas
Component OVHD Gas to SRU to Fuel gas Purge Gas to N-HTR to Fuel gas
(kmol/hr)
N2 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H2O 8.62 0.52 8.09 0.05 0.01 0.04 8.14
H2S 0.01 0.00 0.01 0.00 0.00 0.00 0.01
NH3 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CO2 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H2 59.47 3.61 55.86 1357.28 155.83 1201.45 1257.31
C1 173.38 10.52 162.85 32.86 3.77 29.09 191.94
C2= 1.05 0.06 0.98 0.00 0.00 0.00 0.98
C2 85.30 5.18 80.13 53.31 6.12 47.19 127.31
C3 7.22 0.44 6.78 27.43 3.15 24.28 31.06
C3= 0.44 0.03 0.41 0.00 0.00 0.00 0.41
IC4 0.00 0.00 0.00 2.56 0.29 2.27 2.27
IC4= 0.00 0.00 0.00 0.00 0.00 0.00 0.00
=NIC4 0.00 0.00 0.00 0.00 0.00 0.00 0.00
NC4= 0.01 0.00 0.01 0.00 0.00 0.00 0.01
NC4 0.95 0.06 0.89 2.21 0.25 1.96 2.85
C5= 0.00 0.00 0.00 0.00 0.00 0.00 0.00
IC5 0.00 0.00 0.00 0.54 0.06 0.48 0.48
NC5 0.25 0.02 0.23 0.62 0.07 0.55 0.78
C5OLEFIN 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CP 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C6+ 0.01 0.00 0.01 5.21 0.60 4.61 4.62
0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total 336.70 20.43 316.27 1482.07 170.16 1311.91 1628.17
MW 18.01 18.01 18.01 4.62 4.62 4.62 7.22
LHV
(kcal/Nm3) 7964 7964 7964 3603 3603 3603 4450
Flow Rate
(Nm3/h) 7547 458 7089 33219 3814 29405 36494
(kg/h) 6062 368 5695 6842 786 6056 11751

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6.5.5. Users:
The following table shows the fuel gas consumption for each operation case.
User Flow Rate (Nm3/hr)
Normal operation case D-Max catalytic section
down case
Case 1 Case 2 Case 3 Case 4
100-H1 2607 2691 2747 2803 8847
110-H1 702 724 739 754 2367
130-H1 1052 1085 1107 1129 3511
200-H1 190 190 190 190 280
284-H1 1511 1511 1511 1511 0
284-H2 1005 1039 1062 1084 0
284-H50A/B 1039 1069 1090 1110 3396
300-H1 2217 2217 2217 2217 3263
300-H2 2528 2528 2528 2528 3721
300-H3 1704 1704 1704 1704 2508
940-B1 A/B/C 3221 3018 2882 2746 8460
Flare Purge Gas 141 141 141 141 141
Normal operation case: MW = 17.49, LHV = 6550 kcal/Nm3
D-Max cat down case: MW = 4.71, LHV = 4450 kcal/Nm3
Case 1: All steam user’s maximum case
Case 2: Normal steam user’s maximum case
Case 3: Normal average case
Case 4: Maximum electric power import case
Reactor Charge Heater, 284-H1, Charge Heater, 300-H1, and No.1/2 Interheater,
300-H2/H3 are 100% fuel gas firing heater.
Fuel Gas Knockout Drum (920-V1)
All sources of gas are routed to the fuel gas knockout drum (920-V1). In this drum,
hydrocarbon condensate included in source gases from each unit is separated, and
separated liquid is drained out to flare manually.
Wire mesh is provided in top of drum to prevent entrainment of liquid.
LPG Vaporizer (920-E3)
LPG vaporizer is provided to produce second back-up fuel from on-spec LPG and to
facilitate start-up and dispose of off-spec or excess LPG. Off spec LPG is produced at
the start-up of Gas concentration Unit / CCR-Platforming Unit / LPG Merox Unit. In
case fuel gas pressure is high, excess vaporized LPG can be dumped to flare via 920-
FV-011 manually from DCS.
920-E3 is vertical bayonet type heat exchanger. LP steam flow rate is changed
according to on/off spec LPG flow rate.

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6.6. FUEL OIL (U-920)
The purpose of the refinery fuel oil system is to provide a circulating supply of fuel
oil at the pressure and temperature required for good atomizing and combustion.
Normally, about 58% of the thermal energy consumption is provided by fuel oil.
6.6.2. Refinery Fuel Oil Sources (Producers):
• Diesel Max Residue from Diesel Max Unit (primary fuel oil and blended fuel
oil).
• Visbreaker Residue from Visbreaker Unit (first alternate fuel oil and blended
fuel oil)
• Vacuum Residue from Vacuum Distillation Unit (for blended fuel oil)
• Fuel Oil Product from Fuel Oil Product Tanks (temporary used, such as during
refinery start-up)
• Flushing Oil from Tankage (as cutter stock for heavy oil)
6.6.3. Destination (Consumers):
• Crude heater in Crude Distillation Unit
• Vacuum heater in Vacuum Distillation Unit
• Charge heater in Naphtha Hydrotreating Process Unit (Normally no flow)
• Product fractionator feed heater in Diesel Max Unit
• Thermal cracking heater in Diesel Max Unit
• Visbreaker heater in Visbreaker Unit
• Utility boilers.
6.6.4. Priority of Fuel Oil:
Refinery fuel oil is normally make-up by Diesel Max residue, i.e. primary fuel oil, and
Visbreaker residue is used as first alternate fuel oil.
Fuel oil product will be temporary used, i.e. at refinery start-up operation, and
blended fuel is used as other alternate fuel.
Refinery Fuel Oil Tanks (920-TK1A/B):
Each of two refinery fuel oil tanks is sized 1,600 m3 as nominal capacity.
The tanks are insulated, and equipped with a heating coil (920-E1A/B) and mixer.

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6.7. WATER (U-925)
• Well Pumps Section
• Raw Water and Plant Water Section
• Potable Water Section
• Cooling Water Section
Water System is designed to meet the requirements of their various users in the
refinery.
The scope of design for the Water System will include utility facilities to supply raw
water, cooling water, potable water and plant water to onsite facilities, utility
facilities, offsite facilities and ancillaries at the required temperature and pressure.
Note; Tempered water system is included in Vacuum Distillation Unit (Unit 110 ).
The normal flow balance for water system is tabulated below:
Unit Plant (Raw) Water Consumption
(m3
/hr)
Cooling Water Consumption
(m3
/hr)
Utility 286 (+20.0 Note1) 1029
Off Site 0.0 15.7
CDU 0.3 926
VDU 0.0 1120.3
VISB 3.2 53.7
N-HTR 0.0 1195
D-MAX 2.6 1305.6
PLAT 0.0 2171.6
CCR 0.0 14.5
G-CON 0.0 1266
K-MRX 1.0 0.7
L-MRX 0.6 7.9
AMN 1.5 191.9
SRU 1.0 (+32.0 Note 2) 450.9
ETP 5.7 7.7
FLARE 3.7 -
TOTAL 359 9757
Note 1; Raw water for Potable water make-up.
Note 2; Raw water as cooling medium for Sulfur Solidification Plant. This water is
recovered to cooling water return line.

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Effluents of Water System are “Cooling Water Blow down”, “Side Stream Filter Back
Wash Water” and “Potable Water Filter Back Wash Water”.
6.7.5. Cooling Tower (925-T1):
The circulation capacity of the cooling tower is 10,000 Ton/h. The cooling tower
consists of three operating cells that are used during peak season. A common spare
cell is provided. Two fan motors have emergency diesel generator back up, but only
one motor selected by selector switch to be electrical loaded.
6.7.6. Chlorination Systems (925-ME3/ME5):
Potable water chlorination system (925-ME3) and cooling water chlorination system
(925-ME5) treat toxic chlorine gas. Gas exiting the vacuum regulator shall be
transferred via vacuum tubing through the flow meter and rate valve to the ejector-
diffuser. The ejector shall be equipped with a check valve which will prevent water
from backing up into the chlorinator. The flow of chlorine gas shall automatically
stop when the ejector water supply is off and when the chlorine line vacuum is
broken. A chlorine gas detector (with multi-point sensors) is provided to detect
chlorine gas leakage.
6.7.7. Raw Water Tanks (925-TK1A/B):
Each of two raw water tanks is sized 9,500 m3
as nominal capacity. The raw water
tanks also serve as a secondary of fire water. Each tank has a storage volume of
4542 m3
for fire water back up.
6.7.8. Potable Water Tank (925-TK2):
A potable water tank is sized 640 m3
as nominal capacity.
6.8. FIRE PROTECTION SYSTEM (U-926)
6.8.1. General System Description:
Fire protection system consists of fire water distribution system, foam extinguishing
system, portable nozzles, fire extinguishers, tools and accessories, etc.
The fire protection system intends to prevent fires, as well as to minimize, control, or
extinguish fires already burning.
The fire protection system is designed on basis of the following criteria:
• There will be no outside fire fighting assistance.

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• There will be only one major fire at a time.
Fire Water Capacity:
• Fire water storage tank (926-TK1)
Capacity of tank: 13,626 m3
The capacity is based on requirement of fire water demand at the rate of 2,271 m3
/hr
for six(6) hours continuous fire fighting operation.
• Raw Water Storage(925-TK1A/B)
Additional dedicated fire water capacity of each tank : 4,542 m3
The capacity is based on requirement of fire water demand at the rate of 2,271 m3
/hr
for additional four(4) hours continuous fire fighting operation when the fire water
tank(926-TK1) is empty.
6.8.2. Fire water pumps and jockey pumps:
Item No. Pumps Capacity Total Head Driver
926-P1A Fire water pump 1136.0 m3
/hr 105.5 m Motor
926-P1B Fire water pump 1136.0 m3
/hr 105.5 m Motor
926-P1C Fire water pump 1136.0 m3
/hr 105.5 m Diesel
926-P1D Fire water pump 1136.0 m3
/hr 105.5 m Diesel
926-P2A Jockey pump 24.0 m3
/hr 105.5 m Motor
926-P2B Jockey pump 24.0 m3
/hr 105.5 m Motor
6.8.3. System Description:
Fire protection system consists of the following.
• Fire water storage facility (Fire Water Storage Tank and Raw Water Storage
Tanks).
• Fire water pumps and jockey pumps.
• Fire water main distribution piping with hydrants, fixed monitors, hose reels,
isolating valves, etc.
• Fixed open head water spray.
• Semi fixed foam extinguishing system for outdoor oil storage tanks.

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• Hose houses.
• Portable and wheeled fire extinguishers.
• FM200 system for Buildings
• Fire and gas detection system with fire alarm/control panels.
• Fire training area.
• Fire station, fire truck and its auxiliary equipment.
Water to be used for fire protection system is well water from well water pumps. Well
water will be stored at the Fire Water Storage Tank (926-TK1) and at the Raw Water
Tanks (925-TK1A/B). If the water stored in the fire water storage tank is not enough
for fire protection service, well water at the Raw Water Tanks will be used and
supplied through a 30” back-up fire water piping from the Raw Water Tanks.
6.9. EFFLUENT TREATMENT PLANT - ETP (U-930)
Effluent Collection, Treatment and Disposal System (Unit 930) is to collect and to
treat the expected effluent water from the refinery to be within the stipulated
effluent limits for the treated water, and the system is also to collect aromatics
waste, slop oils to be recovered to the refinery slop oil tank.
The system is composed of the following major systems:
• Clean water sewer system
• Oily water collection system
• Slop oil recovery system
• Spent caustic neutralization system
• Closed aromatics waste system
• Waste water treatment plant( hereinafter referred to as WTP )
• Oily sludge handling system
• Bio-sludge handling system
• Sanitary waste treatment plant
6.9.2. Clean water sewer system
This system collects storm water from the areas where oil contamination is not
present. The clean water sewer is gathered to the spoon basin without any
treatment, via open ditch, without any treatment.
Then, the clean water stored in the spoon basin evaporates to atmosphere by the

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drying of sunshine.
6.9.3. Oily water collection system
This system collects storm water & fire water from areas where oil contamination is
likely to be present and collects process / utility waste water containing oils, BOD5,
CODcr, SS contents, etc.,.
This system receives the waste water to the lift stations by aboveground or
underground piping, from which the oily water is transferred to WTP by lifting
pumps, in order to treat it using a biological process/sand filter process.
The system also includes receiving the treated waste water from WTP and Sanitary
treatment system and then discharge to outside of the refinery.
6.9.4. Slop oil recovery system
This system receives the skimmed oil from the process and/or tankage effluent
skimming sumps and the API skimmed oil sump in WTP to the tank by the lifting
pumps.
The recovered oil is further separated to oil and oily water by adding demulsifying
chemical and heating, before sending the skimmed oil to the light slop tank ( 945-
TK47 ) in the tankage area.
6.9.5. Spent caustic neutralization system
This system collects spent caustic solution from the process units to neutralize prior
to send WTP for further treatment.
6.9.6. Closed aromatics waste system
This system collects the aromatics waste and light hydrocarbons by closed system to
minimize vapor exposure to the operator. The aromatics waste transfers to the light
slop tank ( 945-TK47 ) by the lifting pumps after cool down by an aromatics cooler.
6.9.7. Waste water treatment Plant ( WTP )
This system treats the effluent waste water from the Oily water collection system to
meet the stipulated effluent limits for World Bank Oil Refinery Effluent Guidelines
and sends it to the final lift station sump.
Then, the treated effluent water from WTP is sent to the final lift station basin to
transfer them to the SAIM NALLAH Canal together with the treated sanitary water
from the sanitary waste.
6.9.8. Oily sludge handling system

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The oily sludge system collects the oily sludge from the waste water treatment plant,
crude/slop oil tanks and Heat exchangers cleaning and dewatering the oily sludge to
minimize the sludge volume.
6.9.9. Bio-sludge handling system
The bio-sludge system collects the bio-sludge from WTP and dewatering the oily
sludge to minimize the sludge volume.
6.9.10. Sanitary waste treatment plant
This system receives and treats sanitary water from buildings in the refinery.
Basis of Design:
Oily water collection system
The Oily Water Collection System is designed to have a total capacity of the
process/utility waste water, fire water and contaminated storm water which falls in
the process paved area, based on rainfall intensity of either 25 mm in 1 hour or 60
mm of rain in 24 hours.
The design capacity of the process waste water lift station inlet is 2,620 m3
/hr in
which the part of waste water is transferred to WTP.
The design capacity of the tankage waste water lift station inlet is 460 m3
/hr each.
Total flow rate to the diversion tank is the maximum one lift station plus one low
flow lift pump i.e. 510 m3
/hr.
Most of the amount of waste water is transferred to the diversion tank by the lifting
pumps whenever the flow exceeds 170 m3
/hr normal and 340 m3
/hr maximum.
WTP ( Waste water treatment plant )
The design capacity of WTP is 170 m3
/hr x 2 trains but except Equalization tank.
The effluent water feed and treated effluent properties of waste water to WTP are
as follows:

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Quality of effluent and treated effluent
Expected Effluent water quality at API separator inlet:
Parameter
Temperature 39
pH Value 6 - 9
BOD5 at 20°C 300 mg/l
CODcr 750 mg/l
Suspended Solids (TSS) 50-100 mg/l
Chromium, Hexavalent 0 mg/l
Chromium, Total 0 mg/l
Lead < 0.1 mg/l
Benzo (a) pyrene 0 mg/l
NH3-N 10 mg/l
Benzene < 1 mg/l
Phenol < 6 mg/l
Sulphide < 5 mg/l
Oil and Grease 30 - 2000 mg/l
Alkalinity 200 as CaCO3 mg/l
Treated effluent water quality at the final discharge sump.
Parameter Maximum
pH Value 6 - 9
BOD5 at 20°C 30 (mg/l)
CODcr 150 (mg/l)
Suspended Solids (TSS) 30 (mg/l)
Chromium, Hexavalent 0.1 (mg/l)
Chromium, Total 0.5 (mg/l)
Lead 0.1 (mg/l)
Benzo (a) pyrene 0.05 (mg/l)
TDS 3500 (mg/l)
Benzene 0.05 (mg/l)
Phenol 0.3 (mg/l)
Sulphide 1.0 (mg/l)
Oil and Grease 10 (mg/l)
Total toxic metal ( ) 2 (mg/l)
* Total concentration of toxic metals such as Pb, Cr Cu, Hg, Zn,
− Cd, As, etc. should not exceed 2 mg/l.
− Temperature increase less than or equal to 3 ℃.
Sanitary waste treatment plant
The design capacity of sanitary waste treatment plant is 7.5 m3
/hr total which is
capable of treating an average daily flow rate of 144 m3
.

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The expected sanitary waste water feed and treated water properties are as follows.
Sanitary effluent feed : BOD5 300 mg/l
TSS 300 mg/l
Treated sanitary effluent : BOD5 20 mg/l
TSS 30 mg/l
6.10. STEAM (U-940)
• Boiler Makeup Water Treating Section
• Condensate Recovery Section
• Deaerator Section
• Boiler Section
• Steam letdown Section
Steam, Feed Water and Condensate Handling System is designed to meet the
requirements of their various users in the refinery under the various operation
modes.
The Steam, Feed Water and Condensate Handling System’s main purpose is to
generate and distribute steam to the plant users. The system consists of three
steam levels of HP Steam, MP Steam and LP Steam, and each steam level
condensate is recovered as much as possible.
Boiler Makeup Water Treating System (demineralizer and mixed bed polisher) is also
included in this system.
The scope of design for the Steam, Feed Water and Condensate Handling System
will include all facilities to provide steam at the required temperature and pressure,
except the process steam generators.
The following effluents are generated continuously, intermittently or in emergency
case from Steam, Feed Water and Condensate Handling System.
• Utility Boiler Blow down
• Demineralized Backwash/Regeneration Water
• Oil Contaminated Condensate
• Deaerated Water / Steam Condensate from 940-TK5

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6.10.4. Chemical Requirement:
Injection system for three types of chemicals is provided.
• Oxygen Scavenger is injected to the deaerator to remove the trace of oxygen
dissolved in the Boiler Feed Water.
• Amine is also injected to the deaerator to adjust the pH of the Boiler Feed
Water.
• Phosphate is injected to the steam drums of utility boilers in order to avoid
scaling and maintain pH in the Boiler Water.
Injection quantities are determined by monitoring analyzer and sampling results, and
adjusted by manually setting the stroke of the reciprocating pumps of the chemical
injection packages.
6.10.5. Boiler Makeup Water Treating System (940-ME1):
Boiler makeup water treating system is provided to produce boiler feed water and
makeup water which meets the required water quality for HP steam generator. The
treatment system consisting of Activated Carbon Filters, Cation Exchangers,
Decarbonators, Anion Exchangers and Mixed Bed Polishers are provided. A common
regeneration system of the ion exchangers with Sulfuric Acid Package and Caustic
Soda Package is also provided.
6.10.6. Deaerator (940-ME2):
A single spray-tray type deaerator with a capacity of 250 Ton/hr is provided. The
set pressure / temperature of deaerator are 1.05 kg/cm2g / 121 o
C.
The deaerator is designed so that it will give required performance of refinery
normal operation even at the situation of condensate loss from the plant.
6.10.7. Utility Boilers (940-B1A/B/C):
Normal steam consumption of HP steam in the refinery is about 180 tons/hr, and
about half is supplied by process generated steam. The remaining balance of
approx. 95 Ton/hr is shared by three package boilers with a capacity of 65 Ton/Hr
each. Boiler capacity was defined so that one boiler can be taken out of service for
maintenance, while the remaining boilers meet all the normal and essential
emergency demands.
6.10.8. Demineralized Water Tanks (940-TK1A/B):
Each of two demineralized water tanks is sized 2,200 m3
as nominal capacity.

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6.11. TANKAGE (U-945)
Unit-945 handles 100,000 BPSD of crude oil and refined products from process units,
and is composed of the following systems:
• Crude oil Storage and Process Charge
• Intermediate Semi-product Storage
• Component Storage
• Finished Product Storage
• Support Facilities
• Gasoline/Jet Fuel Blending
• Diesel/Fuel Oil Blending
• Finished Product Transfer (Pipeline/Truck Loading)
Unit 010 and Unit 030, which include Diesel/Fuel Oil Blending system,
interconnecting process piping and utility supply lines in the tankage area, are also
included as part of Unit 945.
6.11.2. Crude oil storage and process charge:
Arabian Light crude, Upper Zakum crude and Murban crude are received from
Karachi via existing pipeline, by time sharing operation, to Crude tanks.
The crude oils are fed to the crude distillation unit (Unit-100) as a mixture or single
crude.
6.11.3. Intermediate storage:
Intermediate tanks and pumps are provided for the following purpose:
- To store feed for start-up of the process unit.
- To absorb excess semi-product rundown over the capacity of downstream unit.
- Low load operation in the downstream process unit.
- Shutdown of upstream or downstream process unit.
Intermediate tanks and their purposes are given below.
Tank Name From To Purpose
Stabilized Naphtha
(945-TK46/52/53)
Gas Concentration
Process Unit
(G-CON; U-411)
Naphtha
Hydrotreating
(N-HTR; U-200)
Shutdown of G-CON
or N-HTR
VGO Intermediate
(945-TK35)
Vacuum Distillation
Unit (VDU; U-110)
Dieselmax
(D-MAX; U-284)
Start-up for VDU
Shutdown of VDU or
D-MAX
Naphtha Naphtha Offsite Blender Blend stock for

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Intermediate
(945-TK33/34)
Hydrotreating
Process Unit (N-
HTR; U-200)
excess heavy
naphtha.
Start-up for N-HTR
Note ; Flushing oil tank is used not only for flushing oil process supply but also for
start up of D-MAX unit.
6.11.4. Component storage:
The following component tanks and their pumps are provided to store blend stock
for gasoline and jet fuel (JP-4):
• Light Naphtha Tanks
• Reformate Tanks
Naphtha Intermediate Tanks (945-TK33/34) are also utilized as component tanks for
gasoline and jet fuel when excess heavy naphtha is produced.
6.11.5. Finished product storage:
For the following finished products, storage tanks are provided for shipping (truck
loading and pipeline).
• LPG
• High Octane Blending Component (HOBC)
• Regular Gasoline
• Jet Fuel (JP-1)
• Jet Fuel (JP-4)
• Kerosene
• High Speed Diesel (HSD)
• Light Diesel Oil (LDO)
• Fuel Oil
Sulfur is produced as a by-product from sulfur recovery unit.
6.11.6. Support facilities:
The following facilities are provided in tankage area to support the refinery
operation:
• Flushing Oil Storage and supply system
• Light Slop Storage and transfer to Crude tank.
• Heavy Slop Storage and transfer to Crude tank and Fuel Oil Blender.
• Leaded Slop Storage and transfer to Regular Gasoline Product tanks and/or
incinerator in SRU.
• Additive Injection Systems.

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6.11.7. Blending facilities:
The following blending facilities are provided to produce final products:
• Gasoline Blending Header (HOBC and Regular Gasoline alternate production).
• Jet Fuel Blending Headers (JP-1 and JP-4).
• HSD (High Speed Diesel) Blender.
• LDO (Light Diesel Oil) Blender.
• Fuel Oil Blender.
Diesel (HSD), LDO and fuel oil blenders are provided in Process common area(Unit
010). Refinery Fuel oil blender is also provided in the common area.
6.11.8. Finished product shipping:
All finished products are shipped from truck loading facilities.
Kerosene, HSD and Fuel oil are also sent outside the refinery by pipeline.
6.11.9. Truck loading and pipeline:
The design capacity of truck loading system is listed below.
Service
Loading
Arm No.
Arm Connect.
Position
Maximum
Capacity
(m3/hr/arm)
Total
Capacity
(m3/hr)
LPG (Liquid) 2 Bottom 60 120
LPG (Vapor) 2 Bottom
HOBC 3 Top 105 315
Regular
Gasoline
6 Top 105 630
JP-1 6 Top 105 630
JP-4 2 Top 105 210
Kerosene 2 Top 105 210
Diesel (HSD) 2 Top 105 210
LDO 2 Top 105 210
Fuel Oil 2 Top 105 210
Note: LPG return vapor flow rate is almost the same as the liquid volume.
The truck loading operations are anticipated to take place on a 6-day per week, 12-
hour per day basis. Number of Lorry bays (equal to loading arms) is determined
based on 22 k liter-capacity of truck lorry and the occupied time (22～27 minutes) of

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a truck loading operation with design loading rates (105 m³/hr; except 60 m³/hr for
LPG loading).
6.11.10. Pipeline:
Kerosene and Diesel (HSD) are transferred to pipelines by the existing pipeline
pumps. Fuel oil pump is newly provided for pipeline and its capacity is:
Max. Design 520 m³/hr batch operation.

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