Supervisory Operating Manual For Unit 190 - Aa

SUPERVISORY OPERATING MANUAL
UNIT NO.: 190

EARLY WORKS
FOR THE
CARTAGENA REFINERY
EXPANSION PROJECT
© CBI Americas Ltd. 2008. All rights reserved. Contains confidential information proprietary to CB&I, or its affiliates, clients or
suppliers and may not to be used, reproduced or disclosed without CB&I's prior written permission.
CB&I CONTRACT NO. 166000
Prepared by: Process - CB&I
Document No: 190-RP-PR35-0001
Information Class: Confidential Business Public

Revision Revision Prepared Checked Approved
Revision Description
Number Date By: By: By:
A 8/18/2010 Issued for information DR AA AA
B 8/18/2010 Issued for information DR AA AA
C 8/23/ 2010 Void DR AA AA
Document No.:
190-RP-PR35-0001
SUPERVISORY OPERATING MANUAL Revision: C
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 3 of 25
TABLE OF CONTENTS
1 GENERAL OVERVIEW........................................................................................................4
1.1 Preface............................................................................................................................................ 4
1.2 Raw Water Pond System................................................................................................................. 5
1.3 Crude Oil Line Relocation................................................................................................................ 5
1.4 Light Fuel Oil Line Relocation......................................................................................................... 6
1.5 Site Dewatering system................................................................................................................... 6
2 RAW WATER POND SYSTEM...........................................................................................6
2.1 Process description.......................................................................................................................... 6
2.2 Process system overview................................................................................................................ 6
2.3 Operating variables and control philosophy.....................................................................................8
2.4 Product specifications and emissions summary..............................................................................9
2.5 Battery Limit conditions.................................................................................................................... 9
2.6 Safety............................................................................................................................................. 10
2.7 Start-up preparation....................................................................................................................... 11
2.8 Start-up procedures...................................................................................................................... 11
2.9 Special procedures........................................................................................................................ 12
2.10 Operating requirements................................................................................................................. 13
2.11 Analytical procedures..................................................................................................................... 14
3 CRUDE OIL LINE RELOCATION......................................................................................14
3.1 Process description........................................................................................................................ 14
3.2 Process system Overview.............................................................................................................. 15
3.3 Operating Variables and control Philosophy..................................................................................15
3.4 Products specifications and emissions summary...........................................................................17
3.5 Battery Limit conditions.................................................................................................................. 17
3.6 Safety............................................................................................................................................. 17
3.8 Start-up procedures....................................................................................................................... 18
4 FUEL OIL LINE RELOCATION..........................................................................................19
4.2 Process system Overview.............................................................................................................. 19
4.6 Safety............................................................................................................................................. 20
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5 SITE DEWATERING SYSTEM..........................................................................................22
5.2 Process system overview.............................................................................................................. 22
5.6 Safety............................................................................................................................................. 23
6 APPENDIX......................................................................................................................... 24
6.1 Utility Summary.............................................................................................................................. 24
6.2 PSV Relieving Summary................................................................................................................ 24
6.3 Process Flow Diagrams................................................................................................................. 24
6.4 Process Piping and instrument diagrams.......................................................................................24
6.5 Heat and Material Balance............................................................................................................. 24
6.6 Alarm Summary(to be provide later)..............................................................................................24
6.7 Preliminary Cause and Effect Diagram(to be provide later)...........................................................24
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1 GENERAL OVERVIEW
1.1 Preface
Supervisory Operating Procedures are intended only as a guide and reference for
personnel connected with the operation and maintenance of the facilities built for unit
190 early works. As such, this manual does not cover each and every step to be taken
in the ordinary operation of the unit. This document provides basic information and
hence is not practical to cover all possible contingencies or emergency situations.
Therefore, some of the procedures and operating conditions stated herein may require
further detailed explanation to meet unusual or emergency conditions.
Additional and detailed operating procedures should be developed as necessary. In

order to be able to operate the plant safely and efficiently, all operating personnel to be
trained to have intimate familiarity with all details of plant operation and function of all
operating equipment.
This Supervisory Operating Manual is the property of CB&I, including all patentable
features and / or confidential information, and its use is conditioned upon the user’s
agreement not to reproduce this information, in whole or in part, nor the material
described therein and not to use the information for any purpose other than for the
operation and maintenance of the unit, without the written permission of CB&I.
The facilities built as early works effort in order to facilitate the construction of the new process
units were:
 Raw Water Pond system
 Crude Oil Line Relocation
 Fuel Oil Line Relocation
 Site Dewatering system
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1.2 Raw Water Pond System

A new raw water pond system consisting of two cells arranged in an “L” shape was built for
Cartagena refinery .The key objectives for the New Pond and associated piping are the
following:
● To Receive, aerate and settle the raw water supplied to Existing plants and new
facilities at Cartagena Refinery.
● To provide storage of 12,800,000 Gallons of Raw water that in conjunction with

new raw water storage tank in unit 131 will maintain a steady supply of raw water
for a minimum of 48 Hours of new and existing refinery needs.
● To supply the existing refinery with 2300 gpm of raw water for the existing water
treatment plant.
● To provide normally 3488 GPM and a maximum of 4500 GPM of Raw water for
new Unit 131 when new water pumps 190-EWO-P-001 A/B will be connected to
this Pond.
Additionally a chlorination system has been provided in order to guarantee adequate

disinfection of raw water supply.
1.3 Crude Oil Line Relocation

CBI relocated approximately 3,200 ft. of the existing Ecopetrol crude pipeline. The
selected route for the relocated pipeline runs along the terrain between the edge of the
existing and new refinery. The Pipeline runs aboveground, except at areas where safety
dictates it be underground and at road crossings, where the line is encased in pipe
sleeves. The new route is 4,400 ft long, with a total of 18 bends (90 and 45 Degree
bends).
The relocated pipeline tie-in to the existing Pipeline at the following plant coordinates:
a) on the South side at S2791, E4326 and b) on the North side at S3012, E3212.
REFICAR has advised that the pipeline currently transport Crude oil and Fuel oil at a
rate of 144,000 BPD and 120,000 BPD respectively. For the new refinery operation this
pipeline is dedicated for crude oil transport only.
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1.4 Light Fuel Oil Line Relocation

CBI relocated approximately 855 ft. of the existing 12” light fuel oil line coming from
Area 1000 crude and light Fuel Oil Pig receiving system. The relocated line route
runs along the Edge of TK-3072 tank dike, underground and intercepts the two 10 “
lines feeding the tank TK -3070 currently in service of light fuel Oil. This system will
not be in use after 2013, since no Fuel oil will be normally produced in Expanded
Cartagena Refinery
1.5 Site Dewatering system

In Order to remove any underground permeated water on the construction site for new
plants, an underground well and a submersible automatically controlled pump was
installed for dewatering operations.
2 RAW WATER POND SYSTEM

(PID 190- DG-PR05-0051 and PID 190- DG-PR05-0052)
2.1 Process description

Raw Water arrives at the refinery battery limit by two Municipal water company
pipelines 40” and 48” and is stored in a two cell “L” shaped pond with a total capacity
of 12.8 Million gallons. Raw water is chlorinated and send to existing refinery through
a 30” gravity line and pumped to the Unit 131 unit using the pumps 190 -EWO-P-
001 A/B. The Raw Water Pumps are subsequently tagged as 131-UWT-P-100 A/B,
since they supply raw water to the new refinery, and would be included within the
scope of Unit 131..
2.2 Process system overview

Raw Water pond is an “L” shaped pond with two independent cells with a total capacity
of 12.8 Million gallons. From each raw water main a 20 “line connection (10” prior to
2013) is connected to the raw water meter through a 24 “ CS header.
A 20” raw water meter is installed with corresponding Self-cleaning filtering system in
order to measure total raw water flow to the Refinery. An underground 24” HDPE
header distributes the raw water to pond cells and finally to the existing Fire water
pond, through a 14 “CS line.
Each pond cell is provided with one 18“ inlet connection (14” prior to 2013) and a 18”
inlet distributor (14” prior to 2013) above the pond walls. There are a 30“ outlet
connection for gravity line a 24“ outlet connections to pump suction, and one overflow
opening located at the pond wall of each cell and in the wall that separates the two
cells.
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The level between the two cells is equalized through the gravity line connection and by
adjusting the flows to each cell.
Effective Storage Capacity
Raw Water supply to existing Refinery is a Gravity flow system, because of this the
normal Water Level inside new pond is set to 53 ft elevation (Ground level in pond
Area is of 36 Ft). The maximum water level is at a 54 ft elevation and the minimum
level to guarantee 2300 gpm, is at 43 ft elevation. Under these conditions the existing
refinery will be guaranteed an effective minimum flow rate of 2300 gpm.
The New unit 131 will receive raw water supplied by pumps 190-EWO-P-001 A/B (131-
UWT-P-100 A/B) located alongside this Pond and will receive raw water at a minimum
elevation of 40 ft.
The effective water storage of the New Raw water Pond for both the existing refinery
and new unit 131 is 12,800,000 gallons.
New Raw water Pond will provide 38.5 hours of raw water supply at a rate of 5520
GPM for existing and new Refinery, approximately 80% of the total raw water storage.
The rest of water storage required to guarantee 48 Hours of operation in new refinery
will be provided by the Filtered water tank located in unit 131.
Gravity Line to Existing refinery supply system.
A 30” gravity line is installed and connected to existing 14”, 18” and 12” inches raw
water supply lines to existing refinery raw water plant. This line will is sized to minimize
head loss and to guarantee 2300 gpm flow to existing Refinery at the minimum water
level of 43 Ft. (Referred to Refinery elevation zero reference point)
Supply to Unit 131.
Connections and valves to the suction of new pumps 190-EWO-P-001 A/B (131-UWT-
P-100 A/B) are provided. Two Horizontal centrifugal pumps (one operating and one
spare) are installed to supply raw water to Unit 131 water Clarifiers. Pumps are
designed for maximum expected flow of 4620 GPM (when condensate recovery is 60
% of normal condensate recovery). And shall have stable operation at the normal raw
water requirements of 3500 GPM
Supply to existing fire water pond
A 14” CS line located at the end of the 24” HDPE pipe supply raw water to the existing
fire water pond. Also a bypass line with a valve is connected from the 14” CS line to
the 30” gravity line that supply water to the existing refinery.
Chlorination systems.
(PID 190- DG-PR05-0056)
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Two independent chlorinator systems are provided for disinfection of the raw water
and oxidation of organic matters. This provides liquid chlorine injection using water
ejectors that inject chlorinated water to the main raw water lines.
Chlorination System for RW to the Existing Refinery:
Chlorination for existing raw water units is provided by Chlorinator 190-EWO-X-002,
this system is conformed by a chlorinator shelter containing the following equipment:
 4 liquid chlorine Ton Cylinder ( 2000 lb each)
 Chlorine Meter and Vacuum controller with a maximum capacity of 500 lb/day
 Chlorine ejector
 Chlorinator booster pumps 190-EWO-P-002 A/B
 Chlorine analyzer.
Water is taken from 30” gravity line by a 3” CS line, at a rate of 25 GPM and
pressurized in pumps 190-EWO-P-002 A/B to a minimum pressure of 55 psig and
passed through the Chlorine ejector. Liquid chlorine is vaporized and measured in
chlorine Vacuum controller and mixed with raw water in the ejector and send to the 30”
gravity line through the injection quill SP-009. The normal amount of chlorine required
is 150 lb/day required to guarantee 5 mg/ L of chlorine in 2300 gpm of raw water after
the mixing quill.
Chlorination System for RW to the New Refinery (Unit 131):
A new Chlorination System (131-UWT-SK-001A) is defined for the RW being received
by Unit 131, which is to be designed, procured and provided on a skid by Siemens,
and constructed by CB&I, under the scope of Unit 131
2.3 Operating variables and control philosophy

Raw water quality
The following is the expected raw water quality received from municipal water mains:
Parameter Units Minimum Average Maximum
pH 6.5 6.9 7.5
Colour CU 18 38 82
Turbidity NTU 1 3.2 10
Chlorides mg/L 28 41 67
Silica mg/L as 6 14 20
SiO2
Sulphates mg/L 2 10 24
Total Hardness mg/L 69 88 104
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CaCO3
Calcium Hardness mg/L 54 62 70
CaCO3
Total Alkalinity mg/L 52 73 95
CaCO3
Organic Matter mg/L 4.1 6.3 30
Ammonium mg/L 0.01 0.12 0.56
Nitrites mg/L 0.02 0.03 0.05
Nitrates mg/L 1.1 2.6 5.3
Fluorides mg/L 0.23 0.23 0.23
Iron mg/L 0.02 0.09 0.31
Manganese mg/L 0.03 0.06 0.12
Sodium mg/L 19 23 32
Potassium mg/L 2.7 3 3.2
Suspended Solids mg/L 25
Total Solids (Dissolved + mg/L 114 215 385
Suspended)
Conductivity μS/cm 244 306 553
Coliformes Totals NMP/100 ml 23 358 1700
E. coli UFC/100 mL 1 14 99
2.4 Product specifications and emissions summary

Raw water properties
Other than chlorine residual and reduced bacteria growth, no special properties are
specified for raw water stored and delivered by the new raw water pond. While some
degree of aeration and settling could be achieved, this will not change raw water
properties significantly.
Parameter Units Minimum Average Maximum

Chlorine Residual mg/L 2.0 5.0 8.0
2.5 Battery Limit conditions

Raw water battery limit conditions are:
Pressure (psig) Temperature (oF)

Stream Normal Max. Min. Normal Max. Min.
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Inlet Raw water supply Industrial 30 157 86 95 73

header
Row water supply to existing 4.3 30 86 95 73
Refinery- Gravity flow at pond (bypass)
outlet
Raw water supply to new 65 86 95 73
Refinery unit 131- Pump flow -
2.6 Safety
Main safety Risks associated with raw water pond are related to:
 Drowning: The possibility of a person falling into the pond and subsequent
drowning should be prevented. No authorized personnel should be allowed to
walk on pond walls. It is responsibility of the owner to assure procedures are
followed for accessing the raw water pond premises. Also during maintenance
of the cells ponds refinery blinding and isolation procedures must be followed.
The 24“ nd 30” inches outlet lines have spacers to install blinds. All inlet valves
should be securely closed. Worker should not be allowed to work by
themselves in pond premises, they should be accompanied.
Adequate safety lines and escape ladders should be used when working inside
the Cells. Cleaning of cells should be done only with inlet and outlet lines
blocked to each cell.
 Falling: Due to the slope of the pond walls and the Polyethylene lining inside
the pond, the possibilities of slipping and falling are high. Caution should be
exercised while walking or working on the Pond walls and piping systems.
 High pressure streams: While the normal pressure of pond inlet line is only 30
Psig, this pressure may rise to 157 psig in case of abnormal conditions in
municipal pipelines. The release of high volume, high pressure water on the
proximity of the external pond walls should be immediately stopped, since it
could damage the pond walls and integrity of the system.
 Sudden flow stops: Because of the use of HDPE underground pipes, the
sudden flow stops should be prevented, since they could produce pipe
breakage and result in big emergency situation due to the possibility of eroding
pond walls and affec the integrity of the system. A minimum of five (5) minutes
should be established during the process of opening or closing inlet or outlet
pond valves.
 Chlorine exposure: chlorine detectors and alarms have been provided in
chlorination areas. Proper safety kit should be located close to chlorinator area
and in case of leakage; evacuation should be done immediately for all
personnel without protection.
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 Electrical shocks: maintenance of electrical system in raw water pond should

be done in accordance to the refinery practices in order to prevent electric
shock. Proper isolation procedures must be following.
2.7 Start-up preparation

Previous activities that need to be completed before initial pond start-up.
- Cleaning and Flushing of 24” and 14” RW supply lines to the pond
- Hydrostatic test of 24” and 14” RW supply lines to the pond
- Cleaning and Flushing of 30“RW supply Line from the pond to the existing Water
Treatment
- Hydrostatic test of 30” RW supply line from the pond to the existing Water Treatment
- Civil engineering to confirm Lining integrity
- Warning: Prior to initial filling of the pond, inside of pond cells should be
thoroughly checked for total cleanness from any debris, or especially from
pieces or leftovers of polyethylene lining. This is because these debris may
promote plugging of existing refinery 12”, 14” and 18 “ pipes as well as the
existing pump filters, with the potential of creating a high cost refinery
emergency.
2.8 Start-up procedures
1. Initial Pond Filling:

a. It is suggested that the initial filling up of the RW pond be done one cell at a time
b. Start filling and circulating the new 30” Line and the existing 12”, 14” and 18” Lines
using the 14” bypass RW supply line in order to eliminate any remaining air in the
system and guarantee siphoning effects.
b. Filling the pond should not be done at a rate greater than 25 % of current water
supply rate (Meter constraints and ACUACAR requirements). This rate need to be
confirmed, but it could be in the order of 750-1000 gpm. Under these circumstances
filling one cell will require 6-7 days. It is not recommended to use water from existing
ponds to fill the first cell initially. The Refinery needs to maintain the Water Reserve in
the existing ponds in case some problem arises during the pond start-up. It is
recommended to feed the existing refinery through the 14“ bypass line and continue
feeding the refinery raw water through the bypass line until the first pond cell is filled.
c. Once the pond cell is filled, Civil engineers will check Pond permeability, stability
and let the system settle down
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d. Continue circulation to the new 30” Line and the existing 12”, 14” and 18” lines
using the bypass line in order to eliminate any remaining air in the system and
guarantee siphoning effects.
e. Remove air from the 30” outlet nozzle by venting and after the pond is ready,
slowly start opening 30” valve on pond outlet and start closing the bypass
f. Confirm that flow is normal by checking existing raw water pumps operation.
g. Check with Refinery Operations to confirm flows and levels are sustainabilie
based on actual operation.
h. Once Cell No 1 is in operation, Cell No 2 could be commissioned. This filling
could be accelerated by pumping (using portable diesel pumps) to empty the existing
ponds. It is not recommended to drain existing ponds to the water treatment Unit,
because the new pond and existing ponds will try to equalize levels. The Use of
portable diesel pumps is recommended (500 GPM)
i. Once Cell No 2 is filled it should be aligned to the 30” line flow.
j. Civil engineers will check Cell No 2 permeability, stability and let the system
settle down.
k. Align cell No 2 by slowly opening outlet valves and adjusting pond inlet flows and
levels.
l. Once stable operation of the new RW system is confirmed, formal approval
should be obtained from Refinery Operation prior to emptying and demolishing of the
old ponds and the related piping system.
2.9 Special procedures

Cleaning. In order to clean pond cell from floating debris and vegetation growth the
flowing steps should be follow:
a. Follow refinery procedures for maintenance work
b. For the cell intended to be cleaned slowly close the inlet water distributor valve,
the 24 “ outlet valve and the 30 “ outlet valves.
c. For the cell that remains in operation open the 14” valve to inlet water distributor
and adjust in order to maintain level.
d. Provide cleaning workers with adequate protection and life vests in order to avoid
drowning. If a special small boat is used this should be approved by refinery
operations.
e. Start cleaning the pond and removing debris. Avoid damaging the pond lining and
avoid walking between the dividing walls between cells.
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f. Follow all Lining manufacturing procedures if lining need to be cleaned or repaired
Chlorination.
Chlorination is adjusted manually, reading the chlorine analyzer data and adjusting the
vacuum controller based on the chlorine meter reader (Rotameter)
Follow the chlorine injection package manufacturer manuals for complete information
about the chlorine operation.
Follow all safety measures recommended by the Chlorine Institute and chlorine
manufactures while operating the chlorinator system.
2.10 Operating requirements
Raw Water Flow: Inlet water system requires 30 psig pressures at municipal raw
water headers of 40” and 48” inches. Under these conditions the following flow are
obtained
 Normal operating flow “ 5800 GPM
 Maximum operating Flow 7300 GPM
 Ultimate operating Flow 11000 GPM
The ultimate capacity is obtained with all inlet valves fully open and meter filters clean,
Two cells operating and two 20 “ lines from municipal raw water main headers in
operation.
The above mentioned flows are distributed to existing refinery and new refinery as
follows:
 Existing Refinery : 2300 GPM normal , 2800 GPM maximum
 Unit 131 : 3500 GPM Normal, 4500 GPM maximum
Pond Levels: In order to guarantee Pond storage capacity the following levels should
be controlled:
Maximum Operating level: 54 Ft Elevation
Normal operating level for 12.8 MM Gallons capacity: 53 FT Elevation
Minimum Operating Level for gravity flow: 43 Ft Elevation
Pond Bottom Elevation 36 Ft Elevation
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Pond levels are indicated in the field and DCS by Level meter and Transmitter LT-
1003 A /B. Level is maintained by manually adjusting valves to inlet pond raw water
distributor nozzles.
For water level Elevations below 43 FT gravity flow rate of 2300 GPM can not be
guaranteed.
Chlorination dosing: for successful elimination of bacteria growth in raw water pipes
and oxidizing organic matters, the following chlorine addition should be used:
Normal Maximum
Chlorine Dosage mg/Litre: 5 8

Chlorine Dosage kg / Hour 2.6 5.2
Raw water Backpressure psig 5 30
Chlorine Injection (PPD Pounds per day) 138 275
Chlorination is adjusted manually, reading the chlorine analyzer data and adjusting the
vacuum controller based on the chlorine meter reader (Rotameter)
Follow the chlorine injection package manufacturer manuals for complete information
about the chlorine operation.
2.11 Analytical procedures

For analytical procedures follow existing refinery water analysis procedures and
chlorinator analyzer manufacturer manuals
3 CRUDE OIL LINE RELOCATION

(PID 190- DG-PR05-0050)

CBI relocated approximately 3,200 ft. of the existing Ecopetrol crude pipeline.
This Pipeline Starts in Covenas 120 Km from Cartagena Refinery and ends at the Pig
station located in Area 1000 of Refinery Tank Farm. The 18” inches pipeline is used to
transport crude and light Fuel Oil in Batches normally separated by pigs.
The relocated pipeline route selected does runs in the terrain between the edge of the
existing and new refinery. The Pipeline runs aboveground, except at areas where
safety dictates it be underground and at road crossings, where the line is encased in
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pipe sleeves. The new route is 4,400 ft long, with a total of 18 bends (90 and 45
Degree bends).
The relocated pipeline tie-in to the existing Pipeline at the following plant coordinates:
a) on the South side at S2791, E4326 and b) on the North side at S3012, E3212.
REFICAR has advised that the pipeline currently transports Crude oil and Fuel oil at a
rate of 144,000 BPD and 120,000 BPD respectively. For the new refinery operation
this pipeline is dedicated for crude oil transport only.
3.2 Process system Overview

The relocated pipeline section built by CB&I have the following characteristics:
Nominal OD (inches): 18”
Nominal Wall Thickness - Basic Pipeline (inches): .375”
Nominal Wall Thickness – Induction Bends (inches): .500”
Nominal Wall Thickness – in front of Delayed Coker Unit (inches): .750”
External Corrosion Allowance (inches): .125”
Length Buried (feet) 1,975’
Length above Ground (feet): 2,250’
External Coating: Polyguard RD-6
Maximum Allowable Operating Pressure (psig):1300 psi
Flow rate: 144,000 Bbls/d – Crude oil
Flow rate: 120,000 Bbls/d – Fuel oil
The pipeline is designed to accommodate pigging operations, including the passage of
instrumented internal inspection devices (intelligent pigs). There are no flanged
connections included in the re-routed portion of the line and Induction bends with a
minimum bend radius of 6D were used.
3.3 Operating Variables and control Philosophy
Product Composition and Operating Flow Rates

Transported products by Covenas – Cartagena Pipeline are Crude Oil and Fuel Oil
with the following conditions and properties:
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Domestic Crude Oil Light Fuel Oil

Normal Flow rate BPSD 144000 108000
Maximum Flow rate BPSD 168,000 120000
API 25.7 7.2
Viscosity Cp @ T 75 98
Flow Temperature 90 90
Density lb/Ft3 @ T 55.2 62.72
Operating Pressures
Operating pressures at Cartagena refinery are relative to the product transported and
flow rates.
Operating pressures measured at Pig receiver are as follows:
Normal operating pressure handling crude oil: 50 psig
Normal Operating Pressures handling fuel oil: 90 psig (Sending product to TNP
Tanks)
Safety Valve GI-2-PSV -100 Located at pig Receiver is set to 175 Psig. VIT is
considering modifying this set pressure in order to manage 168000 BPD crude oil
rates and 120000 BPD fuel oil rates to TNP
Maximum operating pressure is observed when accidentally blocking valves at pig
receiver or downstream at crude or fuel oil tanks inlets. In these cases it is expected
the pipeline will reach a maximum operating pressure consistent with discharge
pressure of the pumps located in Covenas, unless safety relief valve discharge is
properly routed to the Relief tank (Outlet Valve Blocked)
Maximum operating pressure handling Crude Oil: 1350 psig
Maximum Operating Pressures handling Fuel Oil: 1350 psig
Operating Temperatures
Normal Inlet Temperature 90 F
Minimum Inlet Temperature 73 F
Maximum Inlet Temperature 110 F
Pipeline Testing Pressures

Hydro test Pressure 1.25 x MAOP (strength test)
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Control Philosophy
Pipeline is managed by Covenas operations. Refinery Operator controls the Pig
receiving station and the Crude and Fuel Oil allocation to Tankage.
The section installed by CB&I is integral part of the total pipeline and is not
independently controlled
3.4 Products specifications and emissions summary

As mentioned in 3.3 above

Pipeline Handling Crude Oil 50 175 90 110 73
Pipeline Handling Fuel Oil 90 175 90 110 73
3.6 Safety
Main safety Risks associated with Crude and Fuel Oil Pipeline are:
 Overpressure: Pipe line could be over-pressured by downstream blockage,
pig blockage, or sudden flow stop. The PSV for the pipeline protection due to
overpressure is located at the covenas pump discharge. In case of
overpressure, the measured pressured could be in excess of 1000 psig.
 Leakage: Pipeline leaks can be the result of internal or external corrosion as
well as mechanical damage. Corrosion monitoring is required to prevent leaks.
 Fire: In case of pipeline leaks a fire could develop provided an ignition source
is close to the leak. In area were pipeline is crossing close to process units
extra-thickness was considered to prevent leakage. Barriers were also
providing in places near the Refinery roads to prevent mechanical damage...
 Sudden flow stops: Because of the length of the pipeline (in excess of 120
KM) and the high flow rates, sudden flow stops should be prevented, since
such stops could result in dangerous emergency situation due to the possibility
of pipeline breakage, liquid release and subsequent fire. Protection for this risk
is considered part of the pipeline operational protection system installed by the
pipeline operator Ecopetrol. In general operating procedures should be in place
to avoid sudden flow stops
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190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 19 of 25
 Mechanical Damage: Mechanical damage could be the result of vehicle

activity and heavy machinery activity close to pipeline. Refineries procedures to
control vehicle velocity, special permit works for pipeline maintenance or
maintenance in pipeline vicinity are required.
 Third Party Spill and fire: Third party activities could result in leakage and
fires. Refinery procedures to control personnel access and special permits for
work related to pipeline maintenance or other maintenance work in the pipeline
vicinity should be required.

After pipeline relocation works are completed the following activities need to be
completed before pipeline start-up:
- Cleaning and Flushing the 18” Line
- Hydrostatic test
- Water displacement
Pipeline Start-up operation

- Oil Pumping start-up from Covenas
- Pig Removals at Cartagena Refinery Pig station
- Oil segregation to Refinery tanks
- Water settling, disposal and treatment
- Line approval

Normal pipeline start-up, operation and shutdown are not within the scope of this
Manual, since they are considered in Reficar and Ecopetrol operating manuals

Special pipeline procedures are not within the scope of this Manual, since they are
considered in Reficar and Ecopetrol operating manuals

See Ecopetrol pipeline operation Manuals and Reficar Tank farm operation manual for
operating requirements
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 20 of 25

See Ecopetrol pipeline operation Manuals and Reficar Tank farm operation manual for
Analytical procedures
4 FUEL OIL LINE RELOCATION

(PID 190- DG-PR05-0054)

CBI relocated approximately 855 ft. of the existing 12” light fuel oil line coming from
Area 1000 crude and light Fuel Oil Pig receiving station. The selected route for the
relocated line runs along the edge of TK-3072 tank dike underground and intercepts
the two 10 “ lines feeding the tank TK -3070 currently in service of light fuel Oil.
This system will not be in use after 2013 start-up, since no Fuel oil will be normally
produced in the Expanded Cartagena Refinery after project completion.
4.2 Process system Overview

The relocated pipeline section built by CB&I has the following characteristics:
Nominal OD (inches): 12”
Flange Rating: 150 # RF
Flow rate: 120,000 Bbls/d – Fuel oil
The line is connected to two 10 “ lines feeding the tank TK -3070 currently in service
of light fuel Oil.
Product Composition and Operating Flow Rates
Transported Fuel Oil by Covenas – Cartagena Pipeline with the following conditions:
Light Fuel OIL
Normal Flow rate BPSD 108000
Maximum Flow rate BPSD 120000
API 7.2
Viscosity Cp @ T 98
Flow Temperature 90
Density lb/Ft3 @ T 62.72
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 21 of 25
Operating Pressures
Operating pressures for the light Fuel oil lines are:
Normal operating pressure: 90 psig
Maximum Operating Pressures: 175 psig
Safety Valve GI-2-PSV -100 Located at pig Receiver is set to 175 Psig. VIT is
considering modifying this set pressure in order to manage 168000 BPD Crude oil
rates and 120000 BPD fuel Oil rates to TNP
Operating Temperatures
Normal Inlet Temperature 90 F
Minimum Inlet Temperature 73 F
Maximum Inlet Temperature 110 F
Control Philosophy
Fuel oil operation is controlled by Refinery tank farm operations.
The section installed By CB&I is integral part of the fuel oil handling system and
because of this, no separate control philosophy is discussed here.

As mentioned in 4.3 above

Pressure (psig) Temperature (of)
Fuel Oil 90 175 90 110 73
4.6 Safety
Main safety Risks associated with Fuel Oil Pipeline are:
 Overpressure: Pipe line could be over-pressured by downstream blockage, or
sudden flow stop. This pipeline is protected by Safety Valve GI-2-PSV -100,
located at the pig Receiver set at 175 Psig.
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 22 of 25
 Leakage: Pipeline leaks can be the result of internal or external corrosion as

well as mechanical damage. Corrosion monitoring is required to prevent leaks.
 Fire: In case of pipeline leaks a fire could develop provided an ignition source
is close to the leak.
 Sudden flow stops : Because of the length of the pipeline (in excess of 120
KM) and the high flow rates, tsudden flow stops should be prevented, since
such stops could result in dangerous emergency situation due to the possibility
pipeline breakage, liquid release and subsequent fire
 Mechanical Damage: Mechanical damage could be the result of vehicle
activity and heavy machinery activity close to pipeline. Refineries procedures to
control vehicle velocity, special permits for work related to the pipeline
maintenance or other maintenance in the pipeline vicinity should be required.

After pipeline relocation works are completed the following activities need to be
completed before pipeline start-up:
- Cleaning and Flushing of 12” Line
- Hydrostatic test
- Water displacement
Pipeline Start-up operation
- Fuel Oil Pumping start-up from Covenas
- Pig Removals at Cartagena Refinery Pig station
- Fuel Oil receiving in TK-3070
- Water settling, disposal and treatment
- Line approval

Normal fuel oil start-up, operation and shutdown are not within the scope of this
Manual, since they are considered in Reficar tank farm operating manuals.

Special pipeline procedures are not within the scope of this Manual, since they are
considered in Reficar tank farm operating manuals.
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 23 of 25

See Reficar Tank farm operation manual for operating requirements

See Reficar Tank farm operation manual for Analytical procedures
5 SITE DEWATERING SYSTEM

(PID 190-DG-PR05-0053)

In order to remove any underground permeated water on the construction site for new
plants, an underground well and a submersible automatically controlled pump 190-
EWO-P-003 was installed for dewatering operations. The water removed is normally
sent to storm water collection pond in new plant area.
5.2 Process system overview

Water permeated in underground soil is collected in 190-EWO-TK-002 (Sump Tank)
and automatically pumped by submersible pump 190-EWO-P-003 through a 2” PVC
line to the storm water collection pond. The pump has a capacity of 16 GPM and 25
psig discharge head.
190-EWO-TK-002 (Sump Tank) is an underground open bottom tank, 20 ft piped to
collect water permeated at the construction site.

Underground water
Normal Flow rate GPM 16
Maximum Flow rate GPM 21
Viscosity Cp @ T 7.9
Flow Temperature 86
Density lb/Ft3 @ T 61.7
Pump 190-EWO-P-003 is controlled by LSH 1015 that controls the level in the sump
tank. Minimum level is set a 5 ft from tank bottom and high level is controlled at 15 ft
from tank bottom. The level switches start and shutdown the pump in accordance to
sump level.

Water collected is expected to be typical underground water with fine solids.
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 24 of 25

Underground Water 10 29 86 95 73
5.6 Safety
Safety
Main safety Risks associated with Dewatering system are:
• Falling: 190-EWO-TK-002 (Sump Tank) is an underground open bottom tank;
precaution should be taken in working close to tank to avoid falls.
• H2S exposure: When working inside the sump tank precautions and adequate
ventilations is required because of the possibility of H2S or other obnoxious gases
presence, as well as lack of sufficient oxygen.
• Electrical shocks: maintenance of electrical system in raw water pond should
be done in accordance to the refinery practices in order to prevent electric shock.
Proper isolation procedures must be following.

Before starting upthe system, the submersible pump operating instruction must be
follow.

 Set the level switches at the appropriate level height
 Allow the tank to be filled
 Open the 2” valve located on pump discharge pipe ¼ open.
 Energize the system and allow the pump to start automatically
 Adjust valve and tune the level control accordingly.

No especial procedures are required
Document No.:
190-RP-PR35-0001
UNIT NO.: 190
Date: 23-Aug-10
EARLY WORKS
Page: 25 of 25

Follow pump manufacture manual for operating requirements

No special analytical requirements are needed.
6 APPENDIX
6.1 Utility Summary

166000-190-RP-PR13-0001 Rev B
6.2 PSV Relieving Summary
NA
6.3 Process Flow Diagrams
190-DG-PR01-0001 Rev B
190-DG-PR01-0002 Rev B
6.4 Process Piping and instrument diagrams
190-DG-PR05-0050 REV 0
190-DG-PR05-0051 Rev 2
190-DG-PR05-0052 Rev 3
190-DG-PR05-0053 Rev 0
190-DG-PR05-0054 Rev 0
190-DG-PR05-0056 Rev 0
6.5 Heat and Material Balance
166000-190-CL-PR31-0001 Rev B
6.6 Alarm Summary (to be provided later)
6.7 Preliminary Cause and Effect Diagram (to be provided later)

Supervisory Operating Manual For Unit 190 - Aa

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Supervisory Operating Manual For Unit 190 - Aa

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SUPERVISORY OPERATING MANUAL

UNIT NO.: 190

Information Class: Confidential Business Public

B 8/18/2010 Issued for information DR AA AA

C 8/23/ 2010 Void DR AA AA

4.10 Operating requirements................................................................................................................. 21

Additional and detailed operating procedures should be developed as necessary. In

1.2 Raw Water Pond System

● To provide storage of 12,800,000 Gallons of Raw water that in conjunction with

Additionally a chlorination system has been provided in order to guarantee adequate

1.3 Crude Oil Line Relocation

1.4 Light Fuel Oil Line Relocation

1.5 Site Dewatering system

2 RAW WATER POND SYSTEM

2.1 Process description

2.2 Process system overview

2.3 Operating variables and control philosophy

2.4 Product specifications and emissions summary

Parameter Units Minimum Average Maximum

2.5 Battery Limit conditions

Pressure (psig) Temperature (oF)

Inlet Raw water supply Industrial 30 157 86 95 73

 Electrical shocks: maintenance of electrical system in raw water pond should

2.7 Start-up preparation

2.8 Start-up procedures

1. Initial Pond Filling:

2.9 Special procedures

f. Follow all Lining manufacturing procedures if lining need to be cleaned or repaired

2.10 Operating requirements

Chlorine Dosage mg/Litre: 5 8

2.11 Analytical procedures

3 CRUDE OIL LINE RELOCATION

3.1 Process description

3.2 Process system Overview

3.3 Operating Variables and control Philosophy

Product Composition and Operating Flow Rates

Domestic Crude Oil Light Fuel Oil

Pipeline Testing Pressures

3.4 Products specifications and emissions summary

3.5 Battery Limit conditions

Pipeline Handling Crude Oil 50 175 90 110 73

Pipeline Handling Fuel Oil 90 175 90 110 73

 Mechanical Damage: Mechanical damage could be the result of vehicle

3.7 Start-up preparation

Pipeline Start-up operation

3.8 Start-up procedures

3.9 Special procedures

3.10 Operating requirements

3.11 Analytical procedures

4 FUEL OIL LINE RELOCATION

4.1 Process description

4.2 Process system Overview

4.3 Operating Variables and control Philosophy

Product Composition and Operating Flow Rates

4.4 Products specifications and emissions summary

4.5 Battery Limit conditions

Fuel Oil 90 175 90 110 73

 Leakage: Pipeline leaks can be the result of internal or external corrosion as

4.7 Start-up preparation

4.8 Start-up procedures

4.9 Special procedures

4.10 Operating requirements

4.11 Analytical procedures