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9.13 Hydrogen Compression and Distribution System (HCDS)................................................ 17

9.14 Sour Water Stripper Units (SWS) ..................................................................................... 17
9.15 Amine Regeneration Unit (ARU)....................................................................................... 18
9.16 Sulphur Recovery Unit (SRU) and Tail Gas Treating Unit (TGTU) ................................... 18
10. PETROCHEMICAL PROCESS UNITS............................................................................. 19
10.1 Naphtha and Aromatics Complex (NAC) .......................................................................... 19
10.2 Polypropylene Unit (PPU) ................................................................................................. 20
11. OFFSITE SYSTEMS......................................................................................................... 20
11.1 Crude Oil Import, Storage and Pumping System .............................................................. 20
11.2 Inter Unit Storage and Pumping System........................................................................... 21
11.3 Product Component Storage and Pumping System ......................................................... 21
11.4 Product Storage and Pumping System............................................................................. 21
11.5 Slop Storage and Pumping System .................................................................................. 22
11.6 Product Truck Loading System......................................................................................... 22
11.7 Sulphur Forming and Storage Unit ................................................................................... 22
11.8 Flare System..................................................................................................................... 23
11.9 Spent Caustic Unit - Deleted............................................................................................. 23
11.10 Ship Loading System ........................................................................................................ 23
11.11 Wastewater Treatment System......................................................................................... 23
11.12 Fire & Gas Detection and Protection System ................................................................... 24
11.13 Catalyst and Chemicals Storage and Handling ................................................................ 24
12. UTILITY SYSTEMS .......................................................................................................... 25
12.1 Raw Water/Potable Water Systems.................................................................................. 25
12.2 Demineralised Water System ........................................................................................... 25
12.3 Cooling Water System ...................................................................................................... 25
12.4 Steam & Power System .................................................................................................... 26
12.5 Flue Gas Desulphurisation................................................................................................ 26
12.6 Plant Air / Instrument Air System ...................................................................................... 27
12.7 Nitrogen System ............................................................................................................... 27
12.8 Fuel Oil System................................................................................................................. 27
12.9 Fuel Gas System .............................................................................................................. 28
12.10 Flushing Oil System .......................................................................................................... 28
12.11 Chemical Supply System .................................................................................................. 29
12.12 Sea Water System ............................................................................................................ 29
13. ENVIRONMENTAL DESIGN BASIS................................................................................. 29
14. REFINERY SHUTDOWN PHILOSOPHY ......................................................................... 30
15. BASIC ENGINEERING DESIGN DATA............................................................................ 30
16. INSTRUMENTATION SYSTEM........................................................................................ 30
17. ELECTRICAL SYSTEM .................................................................................................... 31

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1. INTRODUCTION

1.1 Objective

This document defines the technical design basis for the refinery including the
specifications for feedstocks and products and the design bases for process, utility
and offsite facilities.

1.2 Use of Document

This document, together with related documents issued separately (refer to

reference section), defines the overall basis of design for the refinery.

2. PROJECT DESCRIPTION

The refinery will process 200,000 BPSD of imported Kuwait Export Crude (KEC)
oil. The fuels section of the refinery includes Residue Hydrodesulphurisation and
Residue Catalytic Cracking as the main upgrading units. The refinery is integrated
with petrochemical production. The Aromatics Complex produces Paraxylene and
Benzene. A key product from the Residue Catalytic Cracker Unit is Propylene
which is used to produce Polypropylene product.

The products produced include the following:

• LPG
• Gasoline – 92/ 95 RON
• Kerosene / Jet A-1
• Diesel – Premium and Regular
• Paraxylene / Benzene
• Polypropylene
• Sulphur (Solid)

The refinery is situated in Nghi Son, Tinh Gia District, Thanh Hoa Province,
Vietnam (approx. 200 km south of Hanoi).

The refinery includes all process units and associated utility, offsite and
infrastructure facilities to support the refinery operation.
• Complete utility facilities designed to meet the refinery’s demands for
cooling water, fuels, power, steam, water, instrument and plant air, inert
gas, etc.
• Offsite facilities including tankage for feedstocks plus intermediate and final
products as well as systems for import and export of feed and products.
• Other offsite facilities including flare, effluent treatment, firewater,
interconnecting piping and pipelines, etc.

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• Marine facilities include an SPM/ Crude import line and product loading
jetties

3. PROCESS LICENSORS AND DESIGNERS

The process units are designed by a number of different technology providers

according to the following list.

UNIT DESIGNER / LICENSOR

Crude Distillation (CDU) Foster Wheeler
LPG Recovery Foster Wheeler
Hydrogen Compression & Distribution
Foster Wheeler
(HCDS)
Sour Water Stripper (SWS) Foster Wheeler
Amine Regeneration (ARU) Foster Wheeler
Saturated LPG Treater UOP
Naphtha & Aromatics Complex (NAC) UOP
Kerosene Hydrodesulphuriser (KHDS) Axens
Gas Oil Hydrodesulphuriser (GOHDS) Axens
Residue Hydrodesulphuriser (RHDS) Chevron
Residue Fluid Catalytic Cracker (RFCC) Axens
RFCC LPG Treater UOP
RFCC Light Gasoline Treater UOP
Propylene Recovery (PRU) Axens
Selective Hydrogenation and Indirect
UOP
Alkylation (SHU/InAlk)
Polypropylene (PPU) Mitsui
Hydrogen Manufacturing Unit (HMU) Foster Wheeler
Sulphur Recovery Unit (SRU) Jacobs
Tail Gas Treating Unit (TGTU) Jacobs

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4. FEEDSTOCKS AND SPECIFICATIONS

The refinery processes imported Kuwait Export Crude (KEC) oil.

NSRP provided assay data. The assay report is contained in Doc. No. 3550-
8110-PD-0003, Crude Oil Feedstock Data, issued separately.

5. PRODUCT SPECIFICATIONS

The specifications for final products are defined in Doc. No. 3550-8110-PD-0004,
Product Specifications, issued separately. These specifications are based on a
combination of applicable international and national standards supplemented,
where appropriate, by specific Employer sales specifications.

Specifications for the following final products are reported.

• Liquefied Petroleum Gas (LPG)
• Gasoline – RON 92 & 95
• Kerosene and Jet Fuel
• Diesel – Premium and Regular
• Fuel Oil
• Benzene
• Paraxylene
• Polypropylene
• Sulphur
The specifications for intermediate products streams are given, where appropriate,
in the design basis documents for individual process units.

6. PRODUCT DEMANDS

The refinery configuration is based on the Employer Feasibility Report. The

product demand profile used to produce the overall refinery material balance is
based on the following Employer requirements.

• 50 / 50 % production of 92 / 95 RON Gasoline

• 60 / 40 % production of Premium / Regular Diesel

• Maximum Paraxylene production

• Polypropylene – production upper limit is based on single train of PP

• Minimise Fuel Oil production – maximum use of CLO in the utility boilers.

The LPG, Kerosene, and Jet Fuel produced are resultant from the configuration.

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Benzene is a resultant by–product from the Aromatics Complex with no production

target. Actual production rates resulting from the chosen refinery configuration are
given in Section 8 below.

7. FEED AND PRODUCT PRICES

7.1 Crude Oil Prices

The following crude oil prices were used in the development of the design basis
for the project as advised by Employer.

Crude Oil Price (US$ / Tonne)

Kuwait Export 283.2

7.2 Product Prices

The following product prices, supplied by Employer, were used for economic
studies.

Products Price (US$ / Tonne)

LPG 331.9
Gasoline 92 RON 437.1
Gasoline 95 RON 450.3
Kerosene 424.9
Jet Fuel 424.9
Diesel – Premium 419.3
Diesel – Regular 396.8
Fuel Oil 256.2
Paraxylene 682.7
Benzene 508.4
Polypropylene 883.9
Sulphur 16

8. REFINERY CONFIGURATION AND MATERIAL BALANCES

8.1 Material Balance

The overall refinery material balance is based on processing of 100% Kuwait

Export Crude (KEC) oil feedstock. The crude composition is based on Assay data
supplied by Employer.

The overall material balance when the RFCC is operating in Max Propylene mode
is presented in Doc No. 3550-8110-21-0001. The material balance is summarised
as follows.

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FEEDS BPSD KTPA

Kuwait Export 200,000 9,660

PRODUCTS BPSD KTPA

LPG - 38
Gasoline 92 RON 29,005 1,151
Gasoline 95 RON 29,005 1,151
Kerosene / Jet Fuel 13,675 592
Diesel – Premium 47,783 2,202
Diesel – Regular 31,081 1,467
Fuel Oil - -
Paraxylene - 684
Benzene - 246
Polypropylene - 372
Sulphur Product - 257

The overall material balance when the RFCC is operating in Max Gasoline mode
is presented in Doc No. 3550-8110-21-0002.

8.2 Nameplate Capacities for Process Units

8.2.1 Introduction

The nameplate capacities for individual process units have been determined
based on:-

• The annual material balances presented above plus consideration of

appropriate on-stream factors – for determination of stream-days
• Design margins – to allow for design uncertainties and operational
flexibility.

8.2.2 Turnaround Frequency and On-stream Factor

The refinery is required to operate continuously for a minimum period of four (4)
years between major turnarounds, albeit that some process units may require
‘interim’ shutdowns for catalyst change-out, etc.

Considering this turnaround frequency and other factors such as industry

experience, an on-stream factor of 0.95 (8,320 hours per year) has been selected
for the project.

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8.2.3 Design Margins for Design Uncertainty and Operating Flexibility

Design Uncertainty

The design of the refinery is based on established technologies whose

performances are both predictable and well-proven in operation, meaning that no
significant variations are expected to be found between predicted performance (as
developed for design purposes) and actual performance in the field. As a result,
the operation of the refinery – and hence the generation of income – is very
unlikely to be constrained by an unexpected bottleneck in a part of the process
scheme. On this basis, it is considered unnecessary to include design margins on
the capacity or performance of the main process units specifically to allow for
design uncertainties.

One exception is the Sour Water Stripper Unit. These are critical units where
even short-term capacity limitations can impact on refinery throughput and where
refineries often encounter intermittent operating problems. They are also low-
investment relative to the main process units. Therefore a +10% margin on
capacity is included for design purposes for SWS1 and +30% margin on SWS2.

Operating Flexibility

Operating flexibility is accounted for in two main ways:

• The specification of alternative operating cases/modes for specific process

units (e.g. gasoline and propylene modes for the RFCC, and ‘start-of-run’
and ‘end-of-run’ cases for other catalytic units)
• The incorporation of design margins in the design of specific items of
equipment or sub-systems (e.g. pump capacity) to provide sufficient
flexibility for regulatory control and/or on-line maintenance.

Examples of situations where ‘flexibility’ margins are included in the design

include:

The design capacity of the Saturated LPG Treater, RFCC LPG Treater, RFCC
Light Gasoline Treater and the Hydrogen Manufacturing Unit which is set to
provide operating flexibility as described under the ‘unit capacities’ section below.

The design of the Sulphur Recovery Unit which is specified as multiple trains to
allow for on-line maintenance of one train (albeit requiring a reduction in refinery
throughput to 80%)

The design of the Amine Regeneration Unit, in which selected equipment is

specified with spare capacity to permit on-line maintenance.

8.2.4 Unit Design Capacities

Unit design capacities are presented in the table below. The bases for the
derivation of these figures are described in the paragraphs beneath the table.

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Values within the table are quoted on an annualised mass flow basis of feedstock
unless noted otherwise, based on 8,320 operating hours/year at design rate.
Corresponding unit ‘nameplate capacities’ which reflect throughput per operating
day considering on-stream factors, etc., are also shown.

‘Nameplate capacity’ is defined on the conventional basis of barrels-per-stream-

day (BPSD) measured at 15 °C which represents actual maximum unit throughput
when the unit is in full operation under design conditions. Note that some
calculated values have been rounded-up to a convenient whole number for design
purposes.

In cases where BPSD are not a convenient unit to report capacity, either m³/hr
(measured at 15 °C) for liquids or Nm³/hr (measured at 0 °C and 1 atm) for gases
or tonnes per day (TPD) are used. Again, these values are calculated and
reported on a stream-day basis corresponding to actual operation.

UNITS CAPACITY REMARKS

Nameplate Annual
(BPSD) (KTA)
Crude Distillation 200,000 9,660
LPG Recovery - 2,404 Total gas + liquid feed
Saturated LPG Treater 6,500 201
Kerosene
20,000 872
Hydrodesulphuriser (KHDS)
GO Hydrodesulphuriser
60,000 2,906
(GOHDS)
Residue Hydrodesulphuriser
105,000 5,695
(RHDS)
Residue Fluid Catalytic
80,000 4,135
Cracker (RFCC)
RFCC LPG Treater 43,000 1,326
RFCC Light Gasoline Treater 24,000 888
Selective Hydrogenation /
- 707 Based on feed
Indirect Alkylation
Naphtha Hydrotreater 54,100 2,130 Incl. raffinate recycle
Isomerisation (Penex) 23,400 843 Incl. DIH recycle
Catalytic Reformer 39,700 1,615 Based on HN feed
Aromatics (Benzene) - 248 Benzene product
Aromatics (Paraxylene) - 794 PX product
Polypropylene 1,154 TPD 400 PP product
Hydrogen Manufacturing Unit 195.8 kNm³/h 145 Hydrogen product

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(Note A)
Lean amine circulation
Amine Regeneration 789 m³/h - (Note B)
Sour water feed
Sour Water Stripper – Train 1 184.4 m³/h - (Note B)
Sour water feed
Sour Water Stripper – Train 2 90.2 m³/h - (Note B)
Sulphur product
Sulphur Recovery Unit 3 x 320 TPD - (Note C)
Tail Gas Treating 2 x 640 TPD - Note D
Notes
A. Expressed as 100% hydrogen. The centralised Hydrogen Compression and
Distribution System (HCDS) distributes hydrogen to consumers.
B. Volumetric flowrate @ 15 °C.
C. SRU has 3 x 40% trains (Σ 120%).
D. TGT is part of the SRU and is configured as 2 x 80% trains.

The following paragraphs describe how the design capacities of the main process
units have been established.

Crude Distillation Unit

The nameplate capacity of the Crude Distillation Unit is 200,000 BPSD which
corresponds to the nameplate capacity of the refinery. No additional design
margin is included to cover, for instance, handling of different feedstocks or re-
running of off-spec products.

LPG Recovery Unit

The LPG Recovery Unit processes feed streams from the CDU and several other
units. The nameplate capacity for the unit (2,404 KTA) is based on a summation
of the various feed streams on the assumption that all units are operating at their
design capacity, and considering differences between start-of-run and end-of-run.

Saturated LPG Treater Unit

The nameplate capacity of this unit (6,500 BPSD) corresponds to the mixed LPG
yield from the LPG Recovery Unit.

Kerosene Hydrodesulphuriser Unit

The nameplate capacity of the KHDS unit (20,000 BPSD) is based on processing
all the straight-run kerosene produced by the CDU.

Gas Oil Hydrodesulphuriser Unit

The nameplate capacity of the GOHDS unit (60,000 BPSD) is based on
processing all the straight-run gas oil produced by the CDU plus all the light cycle
oil (LCO) produced by the RFCC.

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Residue Hydrodesulphuriser Unit

The nameplate capacity of the RHDS unit (105,000 BPSD) is based on processing
the entire atmospheric residue produced in the CDU. However, since the RHDS
unit has an annual catalyst replacement cycle during which atmospheric residue
feed is stored, the selected nameplate capacity includes an adequate margin to
permit drawdown of the stored feed over an extended period for co-processing
with direct feed from the CDU.

Residue Fluid Catalytic Cracker Unit

The nameplate capacity of the RFCC unit (80,000 BPSD) is set equivalent to the
yield of atmospheric residue from the CDU less the conversion loss in the RHDS
based on start-of-run conditions. Note that the nameplate capacity does not quite
match the actual stream-day output of the RHDS because the RHDS nameplate
capacity is marginally increased to account for downtime for catalyst regeneration.

RFCC LPG Treater

The nameplate capacity of the RFCC LPG Treater corresponds to the production
rate of amine treated mixed LPG from the RFCC gas plant when the RFCC is
operating in maximum propylene mode.

RFCC Light Gasoline Treater

The nameplate capacity of the RFCC Light Gasoline Treater corresponds to the
production rate of light gasoline from the gasoline splitter in the RFCC when the
RFCC is operating in maximum gasoline mode.

Polypropylene Unit
The nameplate capacity of the PPU corresponds to the design production rate of
propylene from the propylene recovery section of the RFCC. The resultant
polypropylene product output of 400 KTPA falls within the maximum capacity limit
of a single train PPU.

Naphtha and Aromatics Complex

The design throughput of the NAC is based on the yield of fresh full-range naphtha
from the naphtha stabiliser in the LPG Recovery Unit. This stream comprises
straight-run naphtha from the CDU plus naphtha from the GOHDS and the RHDS
units. This stream is fed to the Naphtha Hydrotreater (NHT) Unit together with a
raffinate stream recycled from the Aromatics Extraction (Sulfolane) Unit. The
resultant nameplate capacity of the NHT is 54,100 BPSD. The nameplate
capacities of the downstream units within the NAC are resultant and are
determined by the process licensor.

Hydrogen Manufacturing Unit

The determining case which establishes the nameplate capacity of the HMU is the
upset scenario when the Catalytic Reformer (and hence the whole of the
Aromatics Complex) is shutdown while the remainder of the refinery, including the
KHDS, GOHDS and RHDS units, is operating at minimum throughput of 50%
under end-of-run conditions. In this case, the HMU is the only source of hydrogen
treat gas for the refinery and the requirement is 195,800 Nm³/hr of hydrogen (on a

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100% purity basis). During normal refinery operation at 100% throughput, the
Catalytic Reformer provides a significant yield of hydrogen which allows the HMU
to operate at approx. 75% of design capacity.

Indirect Alkylation Unit

The nameplate capacity of the InAlk unit is set to match the yield of C4 from the
C3/C4 Splitter in the RFCC unit when the RFCC is operating in maximum
propylene mode.

Amine Regeneration Unit

The common ARU handles the circulating amine solvent demands of all amine
absorbers/extractors within the refinery with the exception of those located in the
RFCC Unit (which are served by a separate RFCC amine system).

The nameplate capacity (design solvent circulation rate) is based on a summation

of solvent demands defined by the designers of each absorber/extractor.

Sour Water Stripper Unit

The SWS is configured as two independent trains. The design feed rate of sour
water to each train is based on a summation of the various sour water feed
component streams plus a +10% capacity margin for SWS-1 and 30% margin for
SWS-2 to allow for design uncertainty and to provide operating flexibility.

Sulphur Recovery Unit

The SRU is configured as three (3) parallel Claus trains. The overall sulphur
production rate is based on a calculation of the sulphur yield from processing
200,000 BPSD of fresh Kuwait Export Crude Oil plus an allowance for the
additional sulphur yield from the RHDS unit due to co-processing of cold residue
feed, less an allowance for sulphur ‘lost’ in products. The estimated theoretical
yield of sulphur is 800 tpd. The SRU is configured as 3 x 40% trains (i.e. 320 tpd
each). The tail gas treating and incinerator section is configured as 2 x 80% trains
(i.e. each train handles tail gas equivalent to 640 tpd of sulphur production).

Note that sulphur feed to the SRU arrives in the form of acid gases from both the
common ARU and the ARU in the RFCC, plus acid gases from the SWS trains.

9. REFINERY PROCESS UNITS

9.1 Crude Distillation Unit (CDU)

The CDU processes 100 % Kuwait Export Crude oil to produce a range of straight-
run distillate products plus atmospheric residue; these are routed to further
processing within the complex.

The Unit produces the following streams:

• A sour overheads gas stream routed to the LPG Recovery Unit.
• A full-range unstabilised naphtha stream routed to the LPG Recovery Unit.

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• A kerosene stream routed to the Kerosene Hydrodesulphuriser Unit

(KHDS) and to product blending.
• A combined gas oil stream routed to Gas Oil Hydrodesulphuriser Unit
(GOHDS) or to GOHDS inter-unit tankage.
• An atmospheric residue stream routed to the Residue Hydrodesulphuriser
Unit (RHDS) or to RHDS inter-unit tankage.
The design basis for the CDU is described in Doc. No. 3550-8110-PD-010-0001,
Crude Distillation Unit Design Basis, issued separately

9.2 LPG Recovery Unit

The LPG Recovery Unit is designed as a common saturated gas plant; it collects
and processes saturated feed streams (off-gas, LPG and naphtha) received from
the Crude Distillation Unit, the Naphtha Hydrotreater, the CCR, the Isomerisation
Unit and the three Hydrodesulphuriser Units (KHDS, GOHDS & RHDS).
The unit produces the following products:
• Produce an off-gas which is sent to the Refinery Fuel Gas System after
hydrogen sulphide removal.
• Produce separate Propane and Butane LPG product streams which are
routed to Inter Unit storage.
• Produce stabilised full-range naphtha which is routed as feedstock to the
Naphtha Hydrotreater Unit.
The design basis for the LPG Recovery Unit is described in Doc. No. 3550-8110-
PD-011-0001, LPG Recovery Unit Design Basis, issued separately.

9.3 Saturated LPG Treater Unit

The Unit is designed to process mixed LPG feedstock from the amine extractor in
the LPG Recovery Unit to produce treated LPG with a maximum total mercaptans
sulphur content of 20 ppm wt. The Unit designs include facilities for spent caustic
treatment and recycle. The treated LPG product returns to the LPG Recovery Unit
for C3/C4 separation.

The design basis for the Saturated LPG Treater is described in Doc. No. 3550-
8110-PD-012-0001, Saturated LPG Treater Unit Design Basis, issued separately.

9.4 Kerosene Hydrodesulphuriser Unit (KHDS)

The Kerosene Hydrodesulphuriser Unit (KHDS) processes the kerosene fraction

from the Crude Distillation Unit (CDU) and produces desulphurised Kerosene /Jet
Fuel with max. 50 ppm wt sulphur content and max. 0.003 wt% mercaptan sulphur
content.

The Unit also produces a number of by-product streams:

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• Unstabilised Naphtha, which is sent to the Crude Distillation Unit

• Sour off-gas sent to the LPG Recovery Unit.
• Sour water sent to the Sour Water Stripping Unit (SWS-1).

The design basis for the KHDS unit is described in Doc. No. 3550-8110-PD-013-
0001, Kerosene Hydrodesulphuriser Unit Design Basis, issued separately.

9.5 Gas Oil Hydrodesulphuriser Unit (GOHDS)

The Gasoil Hydrodesulphuriser Unit (GOHDS) processes atmospheric Gas Oil

from the Crude Distillation Unit (CDU) and Light Cycle Oil from the RFCC. The
unit desulphurises these feeds to produce low sulphur (max 50 ppm wt) diesel
blendstock.

The Unit also produces a number of by-product streams:

• Unstabilised Naphtha sent to the Crude Distillation Unit

• Treated off- gas sent to the LPG Recovery Unit
• Sweet gas to the HCDS for hydrogen recovery in a PSA
• Sour water sent to the Sour Water Stripping Unit (SWS-1)

The design basis for the GOHDS unit is described in Doc. No. 3550-8110-PD-014-
0001, Gas Oil Hydrodesulphuriser Unit Design Basis, issued separately.

9.6 Residue Hydrodesulphuriser Unit (RHDS)

The RHDS is designed to process atmospheric residue from the Crude Distillation
Unit to produce a feedstock suitable for processing in a downstream RFCC.

The unit produces the following product streams:

• Desulphurised atmospheric residue to the RFCC

• Unstabilised Naphtha to the LPG Recovery Unit
• Desulphurised RHDS diesel to the diesel pool.

The Unit also produces the following by-products:

• Off-gas from the product recovery section to the LPG Recovery Unit
• Off-gas from the reactor section to HCDS for hydrogen recovery.

The design basis for the RHDS unit is described in Doc. No. 3550-8110-PD-020-
0001, Residue Hydrodesulphuriser Design Basis, issued separately.

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9.7 Residue Fluid Catalytic Cracker Unit (RFCC)

The RFCC is designed to process the RHDS residue stream received from the
Residue Hydrodesulphuriser (RHDS). The RFCC is designed for two modes of
operation: maximum olefin (propylene) and maximum gasoline.

The Unit produces the following product streams:

• An amine treated LPG stream. This LPG stream will be caustic treated
(RFCC LPG Treater – Unit 024) to remove Mercaptans. The mercaptan
free LPG will be routed back to the RFCC C3/C4 splitter.

• After mercaptan removal, the LPG stream will be split to produce a

propylene stream to the Polypropylene Unit, a mixed butane stream to
Indirect Alkylation Unit, and a propane stream to the LPG pool.

• Light cracked gasoline (LCG) to the gasoline pool via caustic merox
treating.

• Heavy cracked gasoline (HCG) to the gasoline pool.

• Light cycle oil (LCO) product to the Gas Oil Hydrodesulphurisation Unit
and/or fuel oil

• Clarified Oil (CLO) product to refinery fuel oil

The Unit also produces the following by-products:

• Treated off-gas sent to the refinery fuel gas system.

• Sour water sent to Sour Water Stripping Unit (SWS-2).
• Regenerator flue gas which is sent to atmosphere via a stack.

The RFCC unit includes dedicated amine absorber/extractor/regenerator facilities

to serve the RFCC Unit only.

The design basis for the RFCC is described in Doc. No. 3550-8110-PD-022-0001,
Residue Fluid Catalytic Cracker Design Basis, issued separately.

9.8 Propylene Recovery Unit (PRU)

The Propylene Recovery Unit (PRU) is designed to recover high-purity propylene

from the mixed C3 feedstock received from the RFCC.

The propylene product is fed forward to the Polypropylene Unit (PPU). The PRU
also produces a propane by-product stream which is routed to LPG product
blending and storage.

The Propylene Recovery Unit is designed by the licensor of the RFCC unit and
hence the design basis for the Propylene Recovery Unit is described in Doc. No.

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3550-8110-PD-022-0001, Residue Fluid Catalytic Cracker Design Basis, issued

separately.

9.9 RFCC LPG Treater Unit

The Unit is designed to process LPG feedstock from the RFCC unit after amine
scrubbing. The Unit produces treated LPG with a maximum total mercaptans
content of 3 ppm wt. The designs include facilities for spent caustic treatment and
recycle.

The design basis for the RFCC LPG Treater Unit is described in Doc. No. 3550-
8110-PD-024-0001, RFCC LPG Treater Unit Design Basis, issued separately.

9.10 RFCC Light Gasoline Treater Unit

The Unit is designed to process RFCC light gasoline from the RFCC Gasoline
Splitter. The Unit produces treated Light Gasoline with minimum 95% of
mercaptans extraction from feed. The designs include facilities for spent caustic
treatment and recycle.

The design basis for the RFCC Light Gasoline Treater Unit is described in Doc.
No. 3550-8110-PD-025-0001, RFCC Light Gasoline Treater Unit Design Basis,
issued separately.

9.11 Indirect Alkylation Unit (InAlk)

This Unit comprises three separate process units: a Selective Hydrogenation

Process (SHP), a Nitrile Removal Unit (NRU) and an Indirect Alkylation Unit
(InAlk) designed to maximise the production of high octane alkylate suitable for
gasoline blending based on maximising octane-barrels.
The feed to the units is the mixed butane/butene product from the RFCC. This
stream is first processed in the SHP to remove dienes and then into the NRU to
remove nitriles before passing to the InAlk unit where isobutylene is reacted with
light olefins to yield iso-octane rich alkylate product. The hydrogen requirement for
the SHP and InAlk units is taken from the Hydrogen Compression and Distribution
System. The InAlk unit also produces a mixed C4s stream (unreacted butanes)
which is sent to the LPG pool.

The design basis for the SHP, NRU and InAlk units is described in Doc. No. 3550-
8110-PD-028-0001, Indirect Alkylation Unit Design Basis, issued separately.

9.12 Hydrogen Manufacturing Unit (HMU)

The Hydrogen Manufacturing Unit (HMU) utilises steam-methane reforming of

hydrocarbon feedstock (refinery fuel gas and LPG) to produce a hydrogen-rich gas
product which is purified in a Pressure Swing Adsorption (PSA) to yield hydrogen
with a minimum purity of 99.9 vol% hydrogen.

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The hydrogen product is routed to the RHDS unit with the balance of production
distributed throughout the complex via the Hydrogen Compression and
Distribution System (HCDS).

The HMU generates a substantial quantity of high pressure steam from waste heat
and this steam makes a significant contribution to the refinery steam balance.

The design basis for the HMU is described in Doc. No. 3550-8110-PD-070-0001,
Hydrogen Manufacturing Unit Design Basis, issued separately.

9.13 Hydrogen Compression and Distribution System (HCDS)

The Hydrogen Compression and Distribution System (HCDS) receives high-purity

hydrogen from two sources: the Hydrogen Manufacturing Unit (HMU) and the PSA
section within the Catalytic Reformer (CCR) in the Naphtha and Aromatics
Complex. In addition, a PSA unit shall be installed within HCDS which shall
recover pure H2 from the RHDS & GOHDS H2 rich off-gases.

The objective of the HCDS is to compress and distribute high purity hydrogen to
the following units at the required battery limit pressures:

• Kerosene Hydrodesulphuriser
• Gas Oil Hydrodesulphuriser
• Selective Hydrogenation / Indirect Alkylation Units
• Polypropylene Unit
• Isomar
• Tatoray
• SRU/ Tail Gas Treatment Units

Normally the Hydrogen requirement to the Polypropylene (PP) Unit shall be met by
the H2 from the CCR Patforming PSA Unit.

The hydrogen treat-gas requirements within the Naphtha & Aromatics Complex
(i.e. the Naphtha Hydrotreater and Isomerisation units) are fed directly by
hydrogen-rich gas produced in the CCR, hence, these Units are not normally
served by the HCDS.

The design basis for the HCDS is described in Doc. No. 3550-8110-PD-071-0001,
Hydrogen Compression and Distribution Design Basis, issued separately.

9.14 Sour Water Stripper Units (SWS)

The objective of the SWS Unit is to treat refinery sour water streams such that the
quality of stripped water enables it to be reused as wash water within the refinery
and/or discharged to the Effluent Treatment Plant for final clean-up.

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The sour gases (H2S and NH3) stripped from the sour water in the SWS are routed
to the Sulphur Recovery Unit for further treatment.

The SWS is configured as two separate trains in order to segregate the treatment
of sour waters from different sources; the routings of the most significant sour
water streams are indicated here:

• SWS Train 1 : All sour water production except RFCC

• SWS Train 2 : Dedicated RFCC

The design basis for the SWS unit is described in Doc. No. 3550-8110-PD-080-
0001, Sour Water Stripper Unit Design Basis, issued separately.

9.15 Amine Regeneration Unit (ARU)

The objective of the common Amine Regeneration Unit (ARU) is to strip hydrogen
sulphide from the rich amine solvent (MDEA) returned from amine
absorbers/extractors located within the following refinery units:

ƒ The LPG Recovery Unit

ƒ The Hydrodesulphuriser Units (GOHDS & RHDS)

The various gas and LPG streams requiring treatment within the above units are
essentially free of problematic trace components, such as cyanides and phenols,
which might otherwise be a cause of cross-contamination between processes via
the circulating solvent. Such ‘clean’ systems permit use of a common ARU, and
thus a single ARU train is selected to serve these units.

The design basis for the common Amine Regeneration Unit is described in Doc.
No. 3550-8110-PD-084-0007, Amine Regeneration Unit Design Basis, issued
separately.

[NOTE: a separate, dedicated RFCC amine system is included within the Residue
Fluid Catalytic Cracker Unit designed by the RFCC licensor (refer to section 9.7
above). That system treats contaminated cracked gas and LPG streams
produced in the RFCC Unit only and is not interconnected to the common ARU].

9.16 Sulphur Recovery Unit (SRU) and Tail Gas Treating Unit (TGTU)

The Sulphur Recovery Unit (SRU) is designed to recover elemental sulphur from
the acid gas feed streams received from the common Amine Regeneration Unit,
from the amine regenerator within the RFCC Unit and from the Sour Water
Stripper Unit.

Molten sulphur product is sent to the Sulphur Forming and Storage Facility

The SRU is configured as follows:

• 3 x 40% Claus trains (total 120% providing +20% design margin)

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• 2 x 80% TGT trains (ie. each designed to service two Claus trains)
• 2 x 80% incinerators (i.e. each matched to one TGTU)

Associated sulphur degassing and molten sulphur storage facilities are provided.

The design basis for the SRU is described in Doc. No. 3550-8110-PD-086-0001,
Sulphur Recovery Unit Design Basis, issued separately.

10. PETROCHEMICAL PROCESS UNITS

10.1 Naphtha and Aromatics Complex (NAC)

The Naphtha and Aromatics Complex (NAC) is designed to process a full-range

naphtha feedstock to produce Paraxylene and Benzene products at a purity
suitable for sale, plus heavy aromatics (subject to quality) and isomerate streams
suitable for gasoline blending. The design philosophy of the complex is to
maximise economic Paraxylene production.

The Aromatics Complex comprises the following process units:

• Naphtha Hydrotreater (including naphtha splitter)

• CCR Platformer / CCR Regenerator section (incl. reformate splitter)
• Sulfolane (Aromatics Extraction)
• Benzene / Toluene Fractionation
• Isomar (Xylenes Isomerisation)
• Tatoray (Toluene Transalkylation)
• Xylene Fractionation
• Parex (Paraxylene Separation)
• Penex (Isomerisation)

The NAC feedstock is full-range naphtha produced in the LPG Recovery Unit.

Fresh naphtha feedstock (and recycled raffinate from the Sulfolane Unit) is
processed in the Naphtha Hydrotreater. Treated naphtha product is then sent to
the Naphtha Splitter where it is fractionated into two streams: light naphtha as feed
to the Penex Unit and heavy naphtha to the CCR Platformer. The latter is sent to
the CCR Platformer and the resultant reformate is then routed to the Aromatics
units for production of Paraxylene, Benzene and gasoline blending components.

The primary products from the Naphtha and Aromatics Complex are:

• Paraxylene – sent to paraxylene product storage

• Benzene – sent to benzene product storage.
• An isomerate stream – sent to gasoline blending.

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By-products include:

• A raffinate stream from the Sulfolane Unit – which is totally recycled to the
Naphtha Hydrotreater.
• A toluene stream – can be produced, if required, for gasoline blending
• A C9/C10 aromatics stream (Aromatic Gasoline) from the Heavy Aromatic
column overheads – to gasoline blending, if required.
• A heavy aromatics stream (A10+) from the Heavy Aromatic column bottoms
– to refinery fuel oil blending.
• LPG from the CCR Platformer – to the LPG Recovery Unit.
• A hydrogen-rich gas stream from the CCR Platformer PSA Unit – part of
which is consumed internally within the NAC with the remainder routed to
the refinery’s Hydrogen Compression and Distribution System.

The design basis for the NAC is described in Doc. No.3550 -8110-PD-040-0001,
Naphtha and Aromatics Complex Design Basis, issued separately.

10.2 Polypropylene Unit (PPU)

The Polypropylene Unit is designed to produce Polypropylene from propylene

feedstock and hydrogen.

Propylene feed is obtained from the Propylene Recovery Unit within the RFCC
Unit. Hydrogen feed gas is supplied from the Hydrogen Compression and
Distribution System.

The primary product from the PP is polypropylene homopolymer. A minor purge

gas stream is recycled back to the Propylene Recovery Unit.

Polypropylene product is bagged and loaded into containers on-plot for despatch
by road to the dockside where containers are transferred to ships.

The design basis for the Polypropylene Unit is described in Doc. No. 3550-8110-
PD-061-0001, Polypropylene Unit Design Basis, issued separately.

11. OFFSITE SYSTEMS

11.1 Crude Oil Import, Storage and Pumping System

The Crude Oil Import, Storage and Pumping System is designed to handle a
single imported crude oil feedstock; there is no provision for crude blending.

A Single Point Mooring (SPM) capable of handling Very Large Crude Carrier
(VLCC) tankers of maximum capacity 300,000 DWT is included for Crude Oil
import to the refinery.

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The design basis for the complete system is described in Doc. No. 3550-8110-PD-
151-0001, Crude Oil Import Storage and Pumping System Design Basis, issued
separately.

11.2 Inter Unit Storage and Pumping System

Inter-unit tankage is provided to store intermediate products when a downstream

unit is ‘down’, or to supply feedstock when an upstream unit is ‘down’. This
storage caters for scheduled, unscheduled and emergency shutdowns. For
example, the residue crude and desulphurised residue crude tanks provide ullage
during the annual RHDS shutdown for catalyst change, as well as supporting
unscheduled shutdowns.

The storage capacities for the intermediate products are based on an allowance
for unscheduled shutdown duration for the associated units, also considering the
impact of shutdown of these units on the operation of the remainder of the
refinery.

The inter unit storage and pumping system includes the Saturated Propane and
Saturated Butane storage. The C3/C4 streams are routed to HMU feed, GT/HRSG
and LPG vaporisers to supplement the refinery fuel gas. In addition the C3/C4
streams can be routed to Mixed LPG storage for product export.

The design basis for the inter unit storage and pumping system is described in
Doc. No. 3550-8110-PD-152-0001, Inter Unit Storage and Pumping System
Design Basis, issued separately.

11.3 Product Component Storage and Pumping System

Product Component tankage is used to store the product components that are
required for blending to finished gasoline, gas oil and fuel oil product.

The design basis for the product component storage and pumping system is
described in Doc. No. 3550-8110-PD-153-0001, Product Component Storage and
Pumping System Design Basis, issued separately.

11.4 Product Storage and Pumping System

The Product Tankage philosophy is based on storing blended final products prior
to export by means of ship or truck.

The storage basis for gasoline / gas oil component and finished products is
described in Doc. No. 3550-8110-PD-153-0001, Product Component Storage and
Pumping System Design Basis.

For Paraxylene, Benzene and Jet Fuel tanks, sizing is based on the maximum
shipment size for the product plus10 days capacity because these products do not
have corresponding product component tanks.

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The design basis for the product storage and pumping system is described in Doc.
No. 3550-8110-PD-154-0001, Product Storage and Pumping System Design
Basis, issued separately.

11.5 Slop Storage and Pumping System

Slop tanks are provided to receive the off-spec product from Refinery and Offsite
facilities. Separate tanks are provided for straight run products and cracked
products. Straight run product slop liquid is reprocessed in the CDU (Crude
Distillation Unit) and cracked slops are sent to the RFCC Unit (Residue Fluid
Catalytic Cracker Unit) for reprocessing.

The design basis for the slop storage and pumping system is described in Doc.
No. - 3550-8110-PD-156-0001, Slop Storage and Pumping System Design Basis,
issued separately.

11.6 Product Truck Loading System

The Product Truck Loading System is located inside the Refinery. The Truck
Loading facilities are designed to achieve the following:

• Receive finished products (Gasoline RON 92, Gasoline RON 95, Premium
Diesel and Regular Diesel) from tanks within Product Storage area. LPG and
Fuel Oil truck loading in the future has been allowed for in the development
of the truck loading plot layout.
• Load products into trucks, using top loading systems.
Loading operations are based on 12 hours of operation per day for 7 days per
week.

The truck loading is designed for 5% of liquid products.

The design basis for the product truck loading system is described in Doc. No.
3550-8110-PD-160-0001, Product Truck Loading System Design Basis, issued
separately.

11.7 Sulphur Forming and Storage Unit

The Sulphur Forming and Storage Unit (SFSU) receives molten sulphur from the
liquid sulphur storage tanks located in the Sulphur Recovery Unit and produces
solid sulphur ready for export by ship.

The design basis for this system is described in Doc. No. 3550-8110-PD-155-
0001, Sulphur Forming and Storage Design Basis, issued separately.

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11.8 Flare System

The flaring facilities are designed to safely dispose of relief streams received from
the various units in the refinery. The cases considered in sizing the facilities
include those generally expected to occur and include as a minimum:

• Refinery-wide events (e.g. general power or utility failures).

• Unit events (e.g. fire, unit utility failures or depressuring).
• Single events causing relief (e.g. blocked outlet)

The Flare System is designed to handle all potential discharges from the process,
utility and offsite areas. Vapour and liquid discharges are received, separated and
then disposed of separately. Vapours pass to elevated flares; liquids are
accumulated and sent to slops.

The design basis for the Flare system is described in Doc. No. 3550-8110-PD-
180-0001, Flare System Design Basis, issued separately.

11.9 Spent Caustic Unit - Deleted

The processing of spent caustic streams is included in the refinery Effluent

Treatment Plant (ETP).

11.10 Ship Loading System

The majority of refinery products are transported from the refinery by ship. The
jetty logistics modelling assumes 95% of gasoline and diesel products and 100%
of other products are exported by sea.

The design basis for this system is described in Doc. No. 3550-8110-PD-200-
0001, Ship Loading System Design Basis, issued separately.

11.11 Wastewater Treatment System

The wastewater treatment systems are designed to receive and treat wastewater
streams from the following sources:

• the process and utility units in the refinery complex

• the tank farm area
• the operation, maintenance and administration facilities

• ballast water from the marine facility

However, the systems shall not be designed to receive or treat the following:

• clean surface water run-off

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• demineralisation unit brine and other clean water deemed adequate for
direct discharge

Collection systems for wastewaters are segregated according to the nature or

characteristics of the waters. The various categories of wastewaters are then
routed separately for treatment in appropriate sections of the Effluent Treatment
Plant (ETP).

The design basis for the wastewater treatment system is described in Doc. No.
3550-8110-PD-190-0001, Wastewater Treatment Design Basis, issued separately.

11.12 Fire & Gas Detection and Protection System

The Fire and Gas (F&G) Detection System is designed as an integrated collection
of F&G sub-systems which automatically monitor the entire plant and associated
buildings.

Active fire protection systems for the refinery include various fire-fighting facilities
such as firewater supply and distribution, foam systems, mobile equipment, etc.
Methods of passive fire protection include plant layout and fireproofing.

The design of the refinery fire-fighting systems is based on the assumption that no
outside help will be available to the refinery (including storage and jetty areas) and
thus the on-site fire fighting facilities will need to be self reliant.

The design basis for the F&G system is described in Doc. No. 3550-8140-SP-
0001, Fire & Gas Detection and Protection System Specification, issued
separately.

11.13 Catalyst and Chemicals Storage and Handling

Catalysts, absorbents, chemicals and similar materials are used to support

refinery operation, some are consumed continuously while others are subject to
periodic replacement. Appropriate stocks of these materials are held on-site to
enable continuous refinery operation.

Materials handled include:

■ Catalysts & inert support materials ■ Lubricating oil & greases

■ Caustic soda ■ Transformer oil
■ Amine (MDEA) ■ Corrosion inhibitors
■ DMDS ■ Antifoam agents
■ Activated carbon

Appropriate storage and handling facilities are provided including mechanical

handling systems for the receipt, segregation, storage and transfer of materials,
secure warehouse facilities, stock control systems, safety facilities, etc.

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Bulk stocks are held in a central warehouse. Day-to-day consumables are then
distributed to local chemical stores located within the Units

No specific design basis document is provided for catalyst and chemicals systems,
however catalyst and chemical requirements are summarised in catalyst and
chemical schedule prepared for the overall refinery.

12. UTILITY SYSTEMS

12.1 Raw Water/Potable Water Systems

The raw water supply to the site is drinking water quality and is suitable for use as
service water and potable water without further treatment.

Raw water for use as service water is stored in a buffer storage tank before being
distributed to the following consumers within the refinery:

• Service water distribution (process users and utility stations)

• Make-up to the cooling water systems.
• Make-up to the firewater system
• Feed to demineralisation plant (for boiler feed water)

Raw water for supply to the potable water system is taken directly from the raw
water supply line; a small potable water buffer storage tank is provided prior to
distribution. Chlorination facilities are provided to ensure quality.

The design basis for the fresh water system is described in Doc. No. 3550-8110-
PD-101-0001, Raw Water / Potable Water Design Basis, issued separately.

12.2 Demineralised Water System

The demineralisation plant is fed by service water and produces demineralised

water for use within the refinery. The primary consumer is make-up to the boiler
feed water system for steam generation. A Demineralised Water Tank provides
buffer storage.

The design basis for the demineralised water system is described in Doc. No.
3550-8110-PD-102-0001, Demineralised Water System Design Basis, issued
separately.

12.3 Cooling Water System

Cooling water for the refinery is supplied from a closed loop cooling water system
which is indirectly cooled by sea water.

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The design circulation rates and heat loads for these systems each include a 20%
margin on normal flow rates to allow for potential increases in demand resulting
from normal engineering development.

The design basis for the cooling water system is described in Doc. No. 3550-8110-
PD-103-0001, Cooling Water System Design Basis, issued separately.

[NOTE: major machinery items requiring a tempered cooling water supply are
provided with integral tempered cooling water systems]

12.4 Steam & Power System

The purpose of the steam and power generation system is twofold:

• To supply all electric power to meet the demands of the refinery (imported
power is only available as back-up)
• To supply steam to meet the demands of the refinery.

The system comprises the following main elements:

• Primary HHP steam generation in Utility Boilers.

• Primary electric power generation in condensing HHP steam turbines (also
provided with pass-out).
• Supplementary electric power generation in dedicated Gas Turbine
Generators (GTG) which are equipped with Heat Recovery Steam
Generators (HRSG).
• Supplementary steam letdown via desuperheaters to MP and LP levels to
balance demand. (Note: refinery HP/MP/LP steam supplies are augmented
by generation from waste heat in the process units. Additional MP/LP
supplies are obtained by let-down through back-pressure stream turbine
drivers installed in the process and utility units).
• HP, MP and LP steam distribution header systems (Note: the HHP steam
system is contained within the steam & power generation system area).
• Condensate recovery and conditioning systems.
• Power import from external supply for back-up use only.
• Emergency power generation using Diesel Generators.

The design basis for the steam and power system is described in Doc. No. 3550-
8110-PD-110-0001, Steam & Power Generation System Design Basis, issued
separately.

12.5 Flue Gas Desulphurisation

Flue Gas Desulphurisation (FGD) is provided to reduce the NOx and SOx in the
flue gas produced by the utility boilers when firing high-sulphur refinery fuel oil.

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The design basis for the FGD system is described in Doc. No. 3550-8110-PD-111-
0001, Flue Gas Desulphurisation Design Basis, issued separately.

12.6 Plant Air / Instrument Air System

Atmospheric air is compressed and conditioned for supply to dedicated plant air
and instrument air headers which serve the refinery and the jetty.

Both systems are supplied by a set of common air compressors which discharge
into air receivers which provide sufficient reserve capacity to damp pressure
fluctuations in the distribution networks. A portion of this air supply is directed to
the instrument air dryers, which supply the instrument air distribution network.

Dedicated HP air receivers hold a reserve supply of instrument air to facilitate a

safe shutdown of the refinery in case of power failure.

The design basis for the air systems is described in Doc. No. 3550-8110-PD-121-
0001, Plant and Instrument Air System Design Basis, issued separately.

12.7 Nitrogen System

Inert gas (nitrogen) is used for various purposes within the refinery and jetty
including: periodic purging of equipment and systems during start-up, shutdown
and maintenance; purging of machinery seals; blanketing of storage tanks,
purging of flare headers, etc.

A dedicated nitrogen generation and storage facility is provided within the refinery.
This approach is justified by the remote location of the site (far from commercial
supplies) and the relatively high level of demand. A cryogenic Nitrogen
Generation Unit (NGU) is selected to satisfy nitrogen purity requirements; such a
Unit is also able to produce liquid nitrogen which is stored ready for regassing to
meet occasional peak demands.

The design basis for this system is described in Doc. No. 3550-8110-PD-122-
0001, Nitrogen Generation System Design Basis, issued separately.

12.8 Fuel Oil System

The refinery Fuel Oil System prepares and supplies liquid fuels to consumers
within the refinery.

Two separate grades of internal fuel oil are blended for use within the refinery.
Each grade has a specific use and separate on-line blending, storage and
distribution systems are provided.

Refinery fuel oil : Lighter low sulphur fuel oil supply to GTG/HRSG and
supply to refinery heaters
Utility boiler fuel oil : Heavier higher-sulphur fuel supply to auxiliary boilers

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Key fuel oil blending components are lesser value by-products sourced from within
the refinery; including Light Cycle Oil (LCO) and Clarified Oil (CLO) from the
RFCC and heavy aromatics from the Aromatics Complex.

Refinery fuel oil will be blended to a sulphur specification to keep SO2 stack
emissions within the environmental limits. Flue gas desulphurisation is required
for the utility boilers firing utility boiler fuel oil.

The GTG’s will be fired on vaporised LPG or refinery fuel oil depending on the
prevailing economics.

The design basis for the fuel gas system is described in Doc. No. 3550-8110-PD-
123-0001, Fuel Oil System Design Basis, issued separately.

12.9 Fuel Gas System

Waste refinery off-gases produced within the various Process Units are collected
for use as refinery fuel gas. Potentially sour streams are scrubbed to remove H2S
before entering the refinery fuel gas system.

The majority of fuel gas is consumed as fuel in process unit heaters. Other
relatively minor quantities are used for miscellaneous purposes including pilot gas,
purging, and blanketing.

During Refinery start-up, when refinery fuel gas is not yet available, and in normal
operation provision is made to re-vaporise LPG to provide a gaseous fuel supply
to those heaters which are designed to fire fuel gas only.

The design basis for the fuel gas system is described in Doc. No. 3550-8110-PD-
124-0001, Fuel Gas System Design Basis, issued separately.

12.10 Flushing Oil System

The flushing oil system provides a supply of clean flushing oil for use within the
refinery in locations where blockage problems may arise due to set-up of heavy
hydrocarbon liquids or accumulation/settlement of solids. Typical instances
include related instrument seals, pump seals, equipment and piping.

The units requiring a provision of flushing oil are:

• Crude Distillation Unit (CDU)

• Residue Hydrodesulphuriser Unit (RHDS)
• Residue Fluid Catalytic Cracker (RFCC)
• Utilities (including Fuel Oil)

Flushing oil will be atmospheric gas oil (diesel) sourced from the GOHDS feed
tanks.

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The design basis for this system is described in Doc. No. 3550-8110-PD-125-
0001, Flushing Oil Design Basis, issued separately.

12.11 Chemical Storage System

The Chemical Storage System is designed to supply caustic soda solution to

various users within the refinery complex.

Caustic flake / beads are delivered in 25 Kg bags by truck. The caustic is

dissolved in DM water to prepare a concentrated caustic solution. The caustic is
further diluted with DM water, stored and then distributed to refinery users.

Caustic is required in the following refinery units:

• Crude Distillation
• Saturated LPG Treater
• Residue Fluidised Catalytic Cracker
• RFCC LPG Treater
• RFCC Light Gasoline Treater
• Penex
• Sulphur Recovery
• Demineralised Water Unit

• Sewerage and Effluent Treatment

The design basis for the chemical system is described in Doc. No. 3550-8110-PD-
130-0001, Chemical Storage System Design Basis, issued separately.

12.12 Sea Water System

The Unit is designed to intake and supply sea water to the Steam and Power
System (Unit 110), Flue Gas Desulphurisation (Unit111), three surface
condensers in process units (RHDS & RFCC), and the Cooling Water System
(Unit 103). The Unit returns hot water to the sea, where the outfall piping
disperses the thermal load.

The design basis for the sea water system is described in Doc. No. 3550-8110-
PD-104-0001, Sea Water System Design Basis, issued separately.

13. ENVIRONMENTAL DESIGN BASIS

The Environmental Design Basis document defines the environmental

performance criteria required to achieve compliance with national and local
Vietnamese legislation including all applicable international laws, World Bank / IFC
(International Finance Corporation) Guidelines and regulations to which Vietnam is

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a signatory. The plant and associated facilities is designed to high environmental

standards, and aims to minimise emissions to air, water and land.

These requirements are detailed in Doc. No. 3550 -8150-SP-0001, Environmental

Design Basis, issued separately.

14. REFINERY SHUTDOWN PHILOSOPHY

A refinery shutdown philosophy has been prepared to define the manner in which
individual sections of the refinery can be shutdown for maintenance and/or major
turnaround. Operating strategies to be adopted in the case of emergency
shutdown situations are also described.

In summary, the refinery is planned to be shutdown for a major turnaround every

four (4) years, with intermediate, partial shutdowns for catalyst replacement or
regeneration as necessary.

The philosophy for major turnarounds, on a four-year cycle, is that the entire
processing complex will be shutdown at one time for maintenance.

The shutdown philosophy is defined in Doc. No. 3550-8110-PH-0004, Refinery

Shutdown Philosophy, issued separately.

15. BASIC ENGINEERING DESIGN DATA

Fundamental project data on applicable codes and standards, meteorological

data, etc., upon which the design of the refinery complex is based, are defined in
Doc. No. 3550-8820-SP-0001, Basic Engineering Design Data, issued separately.

16. INSTRUMENTATION SYSTEM

Refinery operations are controlled from several locations:

A Distributed Control System (DCS) provides regulatory control for all facilities,
using Foundation Fieldbus for monitoring and for non-critical control loops and
conventional hardwired systems for critical control loops.

An independent Emergency Shutdown (ESD) system manages the emergency

shutdown of plant and equipment.

Other ‘specialised’ instrumented control systems include process compressors

controls, controls for turbine driven generator sets, burner management systems,
machinery monitoring systems and custody transfer metering.

The control and operating philosophy is described in Doc. No. 3550-8120-PH-

0001, Control and Operating Philosophy, issued separately.

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17. ELECTRICAL SYSTEM

The basis for the Electrical Generation and Distribution System is described in
Doc. No. 3550-8532-70-0200, Overall Key Single Line Diagram, issued separately.

The system is to be operated as two separate power islands at all times. A Power
Management System (PMS) monitors, controls and optimises the performance of
the electrical distribution system in order to ensure personnel and operational
safety at all times and to maximise the availability and power quality of the system.

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REFERENCE DOCUMENTS

The following documents and drawings are referenced within this ‘NSRP Refinery
Design Basis’ document. These documents and drawings are issued separately.

General Documents and Drawings Doc No.

Block Flow Diagram: 3550-8110-21-0001
Overall Basis of Design 3550-8110-PD-0005
Crude Oil Feedstock Data 3550-8110-PD-0003
Product Specifications 3550-8110-PD-0004
Refinery Shutdown Philosophy 3550-8110-PH-0004
Drainage Philosophy 3550-8110-PH-0005
Control and Operations Philosophy 3550-8120-PH-0001
Fire & Gas Detection and Protection System 3550-8140-SP-0001
Environmental Design Basis 3550-8150-SP-0001
Electrical – Overall Key Single Line Diagram 3550-8532-70-0200
Basic Engineering Design Data 3550-8820-SP-0001

Design Basis Documents for Refinery Process

Doc No.
Units
Crude Distillation Unit (010) 3550-8110-PD-010-0001
LPG Recovery (011) 3550-8110-PD-011-0001
Saturated LPG Treatment (012) 3550-8110-PD-012-0001
Kerosene Hydrodesulphuriser (013) 3550-8110-PD-013-0001
Gas Oil Hydrodesulphuriser (014) 3550-8110-PD-014-0001
Residue Hydrodesulphuriser (020) 3550-8110-PD-020-0001
Residue Fluid Catalytic Cracker (022) 3550-8110-PD-022-0001
RFCC LPG Treater (024) 3550-8110-PD-024-0001
RFCC Light Gasoline Treater (025) 3550-8110-PD-025-0001
Selective Hydrogenation & Indirect Alkylation (028) 3550-8110-PD-028-0001
Naphtha & Aromatics Complex (040 to 049) 3550-8110-PD-040-0001
Polypropylene (061) 3550-8110-PD-061-0001
Hydrogen Manufacturing (070) 3550-8110-PD-070-0001
Hydrogen Collection and Distribution (071) 3550-8110-PD-071-0001
Sour Water Stripper (080 & 081) 3550-8110-PD-080-0001
Amine Regeneration (083) 3550-8110-PD-084-0007
Sulphur Recovery (086 to 089) 3550-8110-PD-086-0001
Tail Gas Treating (090 & 091) Included in SRU

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Design Basis Documents for Utility Facilities Doc. No.

Service Water / Potable Water (101) 3550-8110-PD-101-0001
Demineralised Water (102) 3550-8110-PD-102-0001
Cooling Water (103) 3550-8110-PD-103-0001
Sea Water System (104) 3550-8110-PD-104-0001
Steam and Power System (110) 3550-8110-PD-110-0001
Flue Gas Desulphurisation (111) 3550-8110-PD-111-0001
Plant Air and Instrument Air (121) 3550-8110-PD-121-0001
Nitrogen (122) 3550-8110-PD-122-0001
Fuel Oil (123) 3550-8110-PD-123-0001
Fuel Gas (124) 3550-8110-PD-124-0001
Flushing Oil (125) 3550-8110-PD-125-0001
Chemical Storage (130) 3550-8110-PD-130-0001

Design Basis Documents for Offsite Facilities Doc. No.

Crude Oil Storage and Pumping (151) 3550-8110-PD-151-0001
Inter Unit Storage and Pumping (152) 3550-8110-PD-152-0001
Product Component Storage and Pumping (153) 3550-8110-PD-153-0001
Product Storage and Pumping (154) 3550-8110-PD-154-0001
Sulphur Forming and Storage (155) 3550-8110-PD-155-0001
Slop Storage and Pumping (156) 3550-8110-PD-156-0001
Product Truck Loading System (160) 3550-8110-PD-160-0001
Flare System (180) 3550-8110-PD-180-0001
Waste Water Treatment (190) 3550-8110-PD-190-0001
Ship Loading System (200) 3550-8110-PD-200-0001

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