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0. INTRODUCTION

This Process Design Questionary lists technical information which is required to

proceed with process design work.

It should be completed at an early date, preferably by the date of the kick-off

meeting, to enable work to proceed rapidly and efficiently, with a minimum of
changes or time delays.

1.0. GENERAL INFORMATION

REFINER’S NAME
_____________________________________________

LOCATION
__________________________________________________

PROCESS UNITS INCLUDED IN THE PROJECT :

Process Code Per Feedstock Service Expected

Units Number Capacity, Factor Run Length
Unit / Year Hours / Year (Year)

LANGUAGE _________________
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UNITS OF MEASURE
This following table indicates the units used in English system or SI. Other
specific units can be used.
Please circle the units to be used for this project for each type of
measurement.

ENGLISH SI OTHERS

Temperature °F °C
Pressure (gauge) psig MPa g, kPa g bar g, kg/cm² g
Pressure (absolute) psia MPa a, kPa a bar a, kg/cm² a
Pressure (vacuum) mmHg kPa a mmHg
Mass lb kg
3
Absolute density ° API kg/m at 15°C
3
Flowing density lb/ft kg/m3
3
Volume (liquid) ft , bbl, US gal m3
Volume (gases) ft3 m3
Flow (mass) lb/hr kg/s kg/h
3 3
Flow (gas) actual ft /s m /h
6
standard 10 SCFD Nm3/h
(760 mmHg, 60°F) (760 mmHg, 0°C)
Flow (liquid) actual USGPM, BPSD m3/s m3/h
standard BPSD (60°F) m3/h (15°C)
Heat Btu kJ kcal
Enthalpy Btu/lb kJ/kg kca/kg
Heat rate 106 Btu/h MW 106 kcal/h
Power HP kW, MW
Heat transfer coefficient Btu/h.ft².°F kcal/h.m².°C W/m².°C
Thermal conductivity Btu/h.ft.°F W/m.°C kcal/h.m.°C
Viscosity cP, lb/ft.s mPa.s cP
Equipment dimensions ft, inch m, mm
Pipe diameter inch mm
Velocity ft/s m/s
Vessel nozzle sizes inch mm

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SCOPE OF FACILITIES

Indicate the utility facilities and offsites to be included in this project :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate the desired specifications, codes and practices to be applied in this

project :
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

UNIT AND EQUIPMENT NUMBERING

One copy of detailed instructions should be provided.

2.0. BASIC DATA

Following data (2.1.1. and 2.1.2.) should be provided in attachments :

CRUDE ANALYSIS
PRODUCT SPECIFICATIONS.

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BATTERY LIMIT REQUIREMENTS

Indicate the following conditions for streams entering or leaving the battery
limits of the facilities defined in the general information section :

INCOMING OUTCOMING SOURCE PRESSURE TEMPERATURE

STREAM STREAM AND
CONTROL Service Design Service Design

INTERMEDIATE STORAGE

Intermediate storage between the units should be provided ?

Indicate for which products should be assigned intermediate storage

INTERCONNECTIONS WITH EXISTING UNITS

INTERCONNECTING UNITS
PRODUCT From To

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UNITS FLEXIBILITY
Indicate the turndown requirements in % of unit design throughput.

3.0. UTILITY INFORMATION

3.1. Steam System

PROCESS AREA HEADER CONDITIONS

Provide the required information for each steam pressure level (high
pressure, medium pressure, low pressure or any other suitable term).
Specify also the conditions for steam producers.

PRESSURE PRESSURE __________ TEMPERATURE________

LEVEL PRICE
min. norm. max. design min. norm. max. desig
IDENTIFICATION $/
n

Provide any appropriate comments on the limiation or availability on each

steam level.
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

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3.2. Condensate Return Systems

TWO PHASE CONDENSATE RETURN SYSTEMS

Destination could be a drum or receiver, if not available indicate the battery
limit pressure.

PRESSURE LEVEL DESTINATION AND GRADE LEVEL GRADE LEVEL

CONDENSATE DISTANCE______ FROM DESTINATION BATTERY LIMIT DESIGN PRICE
IDENTIFICATION BATTERY LIMIT PRESSURE _______ PRESSURE _______ $/

PUMPED CONDENSATE RETURN (ALL LIQUID)

Destination could be the deaerator or receiver, if not available, indicate the
battery limit pressure.

GRADE LEVEL BATTERY

PRESSURE LEVEL DESTINATION AND GRADE LEVEL LIMIT PRICE
CONDENSATE DISTANCE_____ FROM DESTINATION PRESSURE _______ $/
IDENTIFICATION BATTERY LIMIT PRESSURE _______
Normal Design

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3.3. Boiler Feed Water / Demineralized water

Provide the following information for the supply of boiler feed water and / or
demineralized water to the process units.

SYSTEM PRESSURE __________ TEMPERATURE________ PRICE

IDENTIFICATION $/

min. norm. max. desig min. norm. max. desig

n n

Provide any appropriate comments on the limitation or availability of boiler feed

water / demineralized water.

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

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Provide the following information about the internal chemical treatment to be

used in steam generators in process units and corrosion control treatment for
steam and condensate systems.

System Treatment Chemical used

3.4. Cooling Systems

A maximum of air coolers should be installed. Yes No

Moreover to avoid uneconomical addition of extensive air coolers, a water

loop cooled by a cooling tower can be anticipated.

Indicate if other instructions are to be followed :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

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COOLING WATER

The cooling water return to ________________________________

_____________________________________________________

Following information should be provided.

NORMAL OPERATING NORMAL MAX. FOULING

PRESSURE DESIGN OPERATING RETURN DESIGN FACTOR TO BE
AT GRADE LEVEL PRESSURE INLET TEMPERATURE TEMPERATURE USED
TEMPERATURE
Inlet Outlet -------- -------- -------- --------

RAW FEED WATER

DIRECT COOLING DEMINERALIZATIO

N

Source

Quantity available

Feed pressure :
- Normal
- Design

Feed temperature :
- Normal
- Design

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CHEMICAL ANALYSIS OF THE RAW FEED WATER

CHEMICAL UNIT DIRECT RAW WATER FOR

ANALYSIS COOLING DEMINERALIZATION

pH
Total Hardness as Ca CO3
Calcium as Ca CO3 Ca++ mg / l
++
Magnesium as Ca CO3 Mg mg / l
Total Alkalinity as Ca CO3
Sulphates as SO4 -- mg / l
Nitrates as NO3
Chlorides as Cl- mg / l
Silica as SiO2 mg / l
Iron as Fe
Sodium as Na
Potassium as K
Suspended Solids g / m3
Total Dissolved Solids
Turbidity
Conductivity

TEMPERED WATER SYSTEM

If a tempered water system is available, provide following information :

Supplied water temperature _____________

Return water temperature _____________
Supplied water pressure _____________
Design temperature _____________
Design pressure _____________

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ADDITIONAL INFORMATION RELATED TO WATER SYSTEMS

3.5. Fuel Systems

The Fuel Systems will be composed of :

Fuel Gas ________

Natural Gas ________
Fuel Oil ________
Others (specify) ________

(Indicate by crossing out).

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3.5.1. Fuel Gas Data

If fuel gas from existing the facilities is to be used, provide the following
information. Indicate the characteristics of the pilot gas if not supplied from the
refinery fuel gas header :

TYPE OF GAS
CHARACTERISTICS

Pressure Mini
( ) Normal
Maxi
Design

Temperature Mini
( ) Normal
Maxi
Design

Heating value Net

( ) Gross

Molecular weight
Sulphur content wt ppm
H2S content wt ppm
Chloride content wt ppm
Other impurities wt ppm

Price $/
Quantity available

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3.5.2. Liquid Fuel System

Provide the following characteristics (or eventually constraints) :

NORMAL START-UP
OPERATION

Type of fuel oil __________ __________

1
Specific gravity or d 4 __________ __________

Viscosity cSt at __________ __________ __________

__________ __________ __________
__________ __________ __________

Flash point __________ __________ __________

Pour point __________ __________ __________

Sulphur content wt % __________ __________

Nitrogen content wt % __________ __________

Vanadium wt ppm __________ __________

Nickel wt ppm __________ __________
Sodium wt ppm __________ __________
Iron wt ppm __________ __________

Ash wt % __________ __________

Others

Gross heating value __________ __________

Net heating value __________ __________
Price __________ __________

Delivery conditions :

Temperature : Normal __________ __________

Design __________ __________

Pressure : Normal __________ __________

Design __________ __________

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3.6. Air Systems

Provide the following information relating to the existing plant and instrument air
systems :

PLANT INSTRUMENT
AIR AIR

Quantity available _____

Pressure :
- Mini _____
- Normal _____
- Maxi Design _____

Dew point at normal

operating pressure _____

3.7. Nitrogen

In case of availability of nitrogen, provide the following information :

Source flowrate

Available : Normal
Peak (duration)

Pressure at B.L. : Mini

Normal
Maxi (design)

Temperature : Normal
Design

Composition.

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3.8. Electricity

SUPPLY POWER VOLTAGE EARTHING AVAILABILITY

Motor > kW

kW > Motor > kW

kW > Motor

Lighting

3.9. Utilities balances

List of operating cases to be considered for utilities balances.

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4.0. DESIGN CONSIDERATIONS

4.1. Critical Service Rotating Equipment

In the event of general power failure, critical service steam or power driven
equipment must be maintained in service in order to ensure the safe shutdown
of units and the protection of the personnel.

List of concerned equipment :

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

4.2. Heat Recovery

Indicate special requirements

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

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4.3. Heaters

Indicate the following information :

Type of fuel for firing :

Fuel Gas ________________________________________

Fuel Oil ________________________________________
Combined ________________________________________
Others ________________________________________

Desired minimum heater efficiency based on low heating value of fuel :

and ____________% excess air for oil firing

and ____________% excess air for gas firing.

System to be considered for waste heat recovery from flue gas :

Steam generation __________

pressure level __________
requirement __________

Air preheat __________

rotary regenerative __________
stationary tubular __________
circulating fluid __________
other __________

Stacks :

Individual
Combined
Common central stack.

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Minimum turndown based on design case __________________________

___________________________________________________________

Requirements on flue gas emissions ______________________________

___________________________________________________________

Indicate any other process requirements relating to fired heaters

___________________________________________________________

___________________________________________________________

___________________________________________________________

4.4. Shell and Tube Heat Exchangers

Indicate following information :

Desired Metallurgy for Cooling Water Service

__________________________________________________________

__________________________________________________________

Imposed standard tube lengths _________________________________

Imposed maximum bundle diameter _____________________________

Imposed maximum bundle weight _______________________________

Exchangers shall be designed in accordance

with :
TEMA _____
ASME _____
Others _____

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SHELL SIDE OR TUBE SIDE SELECTION

Shell side / tube side selection shall be made to satisfy as many as possible
of the following points by crossing-out :

SERVICE SHELL SIDE TUBE SIDE

Cooling water
Condensing vapours
Lower allowable ∆p
Larger flow with similar properties
on both sides
Clean viscous fluids
Corrosive fluids/alloy construction
High fouling factors
Vaporising fluid

Indicate any additional instructions

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

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4.5. Air Coolers

Air coolers on mixed phase service __________

Definition of distribution type at air cooler inlet __________

Definition of collector type at air cooler outlet __________

Minimum tube diameter should be O.D.

Tubes with or without finned surface are acceptable Yes No

Standard tube lengths are : __________

Type of control to be considered :

Automatic variable pitch __________

Variable speed motors __________

Shutters __________

Air recirculation __________

Type of draft : __________

Forced _______

Induced _______

Indicate any additional instructions

____________________________________________________________
____________________________________________________________
____________________________________________________________

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TYPE
ITEMS
A B C D

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4.6 Trays

Trays to be numbered from :

Top to bottom ____________

Bottom to top ____________

Material of trays :

is carbon steel acceptable for non-corrosion services ____ ________

material required (minimum)___________________________________

Indicate any additional instructions relating to trays

____________________________________________________________
____________________________________________________________
____________________________________________________________

4.7. Pumps and compressors

Provide special instructions relating to selection of drivers and sparing

practice for critical rotating equipment, if any.
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Preferred type of compressor in case of possible options

____________________________________________________________
____________________________________________________________
____________________________________________________________

Sparing philosophy for reciprocating compressors :

Two machines at 100% _______

Three machines at 50% _______
Other _______
Automatic start-up of the spare compressor Yes No

Type of compressor for plant air service :

Oil-free centrifugal compressor _______

Non lubricated reciprocating compressor _______
Others (specify) _______
_________________________________________________________
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Rotating equipment seal systems :

Compressors ____________

Use of seal gas Yes No

Type of seal gas

Compressed gas Yes No

Compressed gas has the required

quality for its use as seal gas Yes No

External gas Yes No

Type of external gas

Use of seal-oil Yes No

Seal oil collector not connected to flare atmosphere

Pumps

Type of seal liquid Pumped liquid

External liquid

Indicate preferred flowrate control method for centrifugal compressor :

Variable speed _____________

Inlet throttling via a butterfly type control _____________
Inlet throttling via inlet guide vane control _____________
(frequently applied on single stage compressors)
Discharge throttling (rarely applied) _____________
If other (specify) _____________

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Indicate preferred reciprocating compressor control :

Step wise or infinitely variable _____________

Start-up only or continuous _____________

Manual or automatic _____________

Integral compressor controls or external process

system controls _____________

If other, specify _______________________________________

______________________________________________________
______________________________________________________

Indicate any additional instructions relating to pumps and compressors :

_________________________________________________________
_________________________________________________________
_________________________________________________________

Services to be equipped with automatic start-up of the spare pump.

4.8. Piping

Piping design shall conform to _____________

standard and specification

Mini pipe size : _____________

- On pipe rack
- On pipe way
- Underground

Mini height of piperack _____________

Special requirements for piping class

_________________________________________________________
_________________________________________________________
_________________________________________________________

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Indicate any other instructions____________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________

4.9. Instrumentation

Provide a general control philosophy joined in attachment like :

Automated control should or not be maximized,

Type of Control (Electronic, Pneumatic, Analog Digital),

Type of Distributed Control System (DCS).

Additional and interdependent System should be installed like Advanced

Control and Advanced Management Systems.

Process parameters attached to unit emergency system :

Number of measure element

Number of transmitters per measure
element voting system Yes No

Specify Special Services where on-line Analysers should be installed :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate any other instructions :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

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4.10. Relief and Flare System

Indicate requirements for sparing pressure relief valves :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

According to the local codes, is it permissible to install pressure relief valves

on the process piping connected to the vessel ? __________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate special instructions relating to the isolation of pressure relief valves :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate local regulations regarding atmospheric releases :

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate requirements for liquid relief :

____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate type of flare network and associated type of flare :

Acid flare network _________

Normal flare _________
Wet flare network _________
Dry and cold flare network _________
Low pressure flare network _________
High pressure flare network _________

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Indicate design conditions (temperature / pressure) of existing flare

networks.

Indicate special consideration relating to stack height and the clear area
around the stack :
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

Indicate any other instructions relating to pressure relief valves and flare
systems :
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

4.11. Offsites Facilities

Provide following general information in attachment :

Process Block Diagrams of the Units or equivalent on each operating case

and each type of crude.

Production planning of the Refinery (Processing program of crude oil,

shutdown program etc...).

Movement program of the products (reception, sales program, type of

transports for the product expedition).

Special rules for the storage, pumps, lines etc...

Required storage volume for crude and products or storage time for crude
and products.

Storage heating systems.

Blending philosophy of products (preferred type of blending, components

etc...).

Indicate any other instructions relating to blending, storage, expedition,

loading etc...

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4.12. Specific electrical requirements

To be defined according to specific requirements.

4.13. Draining facilities

4.1.3.1. Closed systems

a. Underground network

Sour water Yes No

Amine Yes No
Light hydrocarbons (except LPG and lighter) Yes No
Heavy hydrocarbons Yes No
Chemical products Yes No

b. Above ground network

LPG Yes No
BLowdown system Yes No

4.13.2. Opened to atmosphere systems (underground)

Oily water Yes No

Chemical products Yes No
Other (to be defined) Yes No

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4.14. Safety aspects on operating risks

List of units sections to be equipped with a remote depressuring system :

____________________________________________________________
____________________________________________________________
____________________________________________________________

List of units sections to be equipped with a liquid emergency blowdown

system :
____________________________________________________________
____________________________________________________________
____________________________________________________________

List of units concerned by a functional analyse with the Client on operator

actions :
____________________________________________________________
____________________________________________________________
____________________________________________________________

List of units concerned by an emergency shutdown system study :

____________________________________________________________
____________________________________________________________
____________________________________________________________

List of units concerned by a HAZOP review :

____________________________________________________________
____________________________________________________________
____________________________________________________________

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5. UNIT(S) INTEGRATION INTO THE EXISTING COMPLEX

5.1. Normal Operation

Definition of operating integration with existing units (process and utilities).

5.2. Start-up

Definition of process stream and utilities (duration and flowrate) required for unit
start-up.

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