BASIC ENGINEERING DESIGN BASIS (PART —B) DIESEL HYDROTREATER PROJECT FOR NDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY DHT PROJECT JOB NO.: 6261 DOCUMENT NO. : A-6261-000-051-001 — aa 4 vPD sss op 6/01/2609 Revised as marked pp sss J 19/2008 | _ Issued for Engineering sss ASG DP £2199/2008 | For Client's Review & Approval | ggg ASG pp | Issue Date Description Prepared by|Checked by| Approved by 4 TOYO ENGINEERING INDIA LIMITED MUMBAI INDIA< Security Level 2» BASIC ENGINEERING DESIGN BASIS (PART -B) DHT PROJECT i HPCL, Visakh TOYO ENGINEERING INDIA LTD, ISSUED: 17"Feb, 2009 | JOB NO. : 6264 @ | 'DOC.No, A-6261-000-081-001 [Rev.2 Sheet 2 of 114 Section No. 1.0 2.0 24 22 23 3.0 TABLE OF CONTENTS Contents Introduction Project Description Brief Description Project Title List of Facilities, Units and Measurement System Numbering System Equipment numbering System Line Identification Numbers. Instrument numbers. Electrical Numbering Ambient and Meteorological Data Economic Optimization Criteria Unit rates for Feed, Products and Utilities Optimization Criteria Design Plant Life Design Philosophy Water Systems Steam and Condensate System Fuel Systems Flare System Liquid Pumpout and Drain Systems Caustic Storage, Preparation, Distribution ‘Aromatics Handling Fire Proofing Energy Integration \Vacuurn Design Consideration Feed, Intermediate and Product Storage Metallurgy Corrosion Allowance Utility Specifications DM Water Steam Page No. “1 4 13, 15 15BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT PCL, Visakh TOYO ENGHEERING NDIA LTD. | ISSUED: 17" Feb. 2009 JOB NO. : 6261 {s loo. Rev2 Necto” contents 83 Condensate Retuin 35 Ba Service Water 35 85 Potable Water 26 86 Boller Feed Water 38 8.7 Raw Water 37 88 Bearing Cooling Water 38 89 Sea Cooling Water a1 8.10 Fire Water 43 8.11 Plant Air 43 3.12 Instrument Air 43 813 Nitrogen 44 B14 Fuels 44 815 Caustic 49 816 Amine 49 O47 Flare 50 9.0 Equipment Design Philosophy 51 oA Overdesign Philosophy 54 92 Selection of Mechanical Design Conditions 5 93 Heal Exchangers 56 94 Fired Heaters 64 95 Vessels 72 96 Towers 7 9.7 \ Pumps 78 98 Compressors 82 9.9 Steam Turbine Drives 83 9.10 IBR Requirements 84 10.0 Effluent Discharge Criteria 86 14.0 Piping and Insulation 80 12.0 Electrical 101 43.0 Instrumentation 102 14.0 Safety 110 15.0 Process Flow Diagrams (PFDs) and Piping & 112 Instrumentation Diagrams (P&IDs) 16.0 Standards & Codes 114< Security Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART - B) DHT PROJECT es HPOL, Vieakh TOYO ENGINEERING INDIA LTD. | ISSUED : 17" Feb. 2009 JOBNO.: 6261 J [D0C.No. A-6267-000-061-001 |Rev.2 Sheet 4of 114 | 1.0 INTRODUCTION Hindustan Petroleum Corporation Ltd. (HPCL), the Owner operates a refinery located at Vishakapatnam in the state of Andhra Pradesh, India. HPCL now intends to install Diesel Hydrotreatment facilities along with its utilities & offsites for Euro-Iil/IV & Ultra low sulphur diesel production at its Visakh Refinery. HPCL has appointed Toyo Engineering India Limited (TEIL) as Project Management Consultant (PMC) for this Diesel Hydrotreatment (DHT) Project. ‘The design basis presented here interids to provide the Engineering Contractors with the technical information required to complete the engineering design specifications of the pioject units in a uniform and consistent manner. Basic Engineering Design Basis (BEDB) for all facilities, which contains technical information agreed between HPCL and Licensor, and HPCL and PMC, shall be binding on the process design and engineering of units, utility systems and offsite facilites, as applicable to the agreed scope of work. The licensor's design basis for specific units form part of Process Package of the respective units. Guidelines given in BEDB are to be followed during detailed engineering design and construction of the facilities in this project. For ensuring smooth and safe commissioning of the plant including start-up and shutdown/normal operation and emergency handling, EPCC Contractors have to employ and incorporate their best engineering practices and experience.< Security Level 2 > BASIC ENGINEERING DESIGN @G ] BASIS (PART - B) me | DHT PROJECT | POL, Visakh on ___| Too ENGINEERING INDIA LTO. | 2b. 2009 JOB NO. : 6264 a | :6261-000-051-001 JRev.2 Sheet 5 of114_—_| PROJECT DESCRIPTION SRIEF DESCRIPTION The project consists of process units and associated utilities and offsite facilities ‘for Euro-IIINV & Ultra iow sulphur diesel production for existing HPCL Refinery at Vishakapatnem in the State of Andhra Pradesh, India. The project envisages processing of straight-run kerosene / gas oil fractions and cracked gas oil / naphtha streams in order to produce high quality diesel with respect to sulphur content, cetane number, etc. Dedicated utility generation facilities and integrated storage facilities shall be set up to meet utility and storage requirements ot the project. The proposed units will be integrated with the existing refinery system. PROJECT TITLE ——: To be used for all documentation Project Name iesel Hydrotreater Project Customer Name : Hindustan Petroleum Corporation Ltd. (HPCL), Visakh Refinery Plant Location + Vishakapatnam, Andhra Pradesh (India). LIST OF FACILITIES The project essentially consists of following new facilities, ae Facility Mae Capacity | |PRocess uns _ 1 |bieset Hydrotreating Unit (DHT) 90 _ [22 MMTPA of feed 2. [Hydrogen Generation Unit(HGU-) | 91 [36000 TPA of H2 3 [Sulphur recovery Unit (With TailGas | 92 [230 TPD of Sulphur Treatment unit) (GRU + TSTU) : produced a [amine regeneration Unit (ARU) 93 [365th 5. [Hydioprocessing Sour Water Stripping] 94 [65 mam of sour water Unit (SWS-) - _<< Security Level 2> BASIC ENGINEERING DESIGN G @ BASIS (PART - B) ee HCL, Visakh DHT PROJECT TOYO ENGINEERING INDIA LTD. IssuED: 17°Feb, 2009 JOB NO. : 6261 [D0c.No. a6261-000-051.001 [Rev.2 Sheet 6 of 114 Re Facility Nee Capacity UTILITY SYSTEMS 1_ [Raw Water System 172 2 [Bearing Cooling Water System | 173 3. [Recirculating Sea Cooling Water 298 System | 4 |Demineraized Water System | _ 134 ‘Steam, Power and BFW System 142 6 Compressed Air system (Plant & 151 Instrument Ait) 7_ Nitrogen system 95 8_ [Fuel Olland Fuel gas System 260 9 [Caustic System 134 OFFSITE FACILITES 1 [intermediate feed storage tanks and | 120 | _|transfer 2_ |Finished product storage tanks 420 3_ [ows/cRws/storm water system 260 4. [Process interconnecting piping 270 5. |Utity / Offsite interconnecting piping | 260 6 [Flare System 282 INFRASTRUCTURE, ETC. 1. |Contro! Room Building 2_ | Sub station Building & SRR< Security Level 2 > BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT ‘7 Feb. 009 JOB NO. : 6261 TOVO ENGINEERING OIA LTD, \-6261-000-051-001 crear | Unit Number< Secutiy Level 2 > eal BASIC ENGINEERING DESIGN G ] “) BASIS (PART -B) a DHT PROJECT HPCL, Visakh TOYO ENGINEERING INDIA LTD, ISSUED : 17" Feb. 2000 264 3.0 34 32 3.3 a) 2) @ (4) ©) (6) 7) (8) (9) (10) Energy (11) Enthalpy, Latent heat (12 (13) Viscosity (dynamic) (14) Viscosity (kinematic) (15) Density (16) Thermal conductivity [D0c.No. A-6261-000-051-001 |Rev.2 Sheet 8 of 114 UNITS AND MEASUREMENT SYSTEM MKS units shall be followed Only:line sizes and valve sizes shall be identified in inches. The following system of units and measurement shall be adopted (select the applicable box) Temperature Pressure Pressure Drop Area Mass Length Volume Velocity Flow Rate \ Mass Vapor Liquid Steam ) Heat Flow Rate M Deg. C (°C) ® kgicm’g $M kgicm’a C1 mmHg 2M kgiem? 0) bar Bon kg Dtons =m = mm mm Ems kgh Oth Nm Mmm 2 kgf mh Ovm O ms Ml kg/h kgh | Mvh kcal 1 MM kcal keallkg MMkcalh oP cSt kg/m? at flowing condition keal/hm?C< Security Leval 2 > EE BASIC ENGINEERING DESIGN G BASIS (PART -B) DHT PROJECT ‘TOYO ENGINEERING INDIA LTD. =i | Feb, 2009, JOB NO. : 6264 Sheet 9 of'114 Specific Heat WI kcalikg’C Stress IH kglom? Power mkw Omw ) Sound Level Mi dBA ) Electrical conductivity D usicm @ pohm/cm )) Surface tension 1 Dynefem ) Voltage my Ow 4) Concentration W Vol % © wt% I ppm ) Nominal pipe size Inch ) Corrosion @ mm Molecular Weight + fil kg/kerole 28) Plant Capacity mMMIPA 9) Vacuum mm Hg )) Furnace Draft 1 mmwe ') Fouling Factor 2 m’h°Chkcal :2) Heat Transfer coefficient keathhm?°C Nm*/hr at 0 °C and 1.033 kg/cm’a Sm°thr at 15°C mm Wo Standard Vapor a ia i) Standard Liquid . a 35) Storage Tank pressure faterial Balance in Process Flow Diagram (PFD) shall be reported in following units: a) GASES: kg/hr b) LIQUIDS: kg/hr PED shall be flagged with following symbols: iow kg/hr< Security Level 2 > BASIC ENGINEERING DESIGN G | | BASIS (PART - B) DHT PROJECT ves HPCL, Visakh : ___| rovo eNoivEERING mb1A LD. lissuED: 17 Feb. 2008 JOB NO. : 6261 | lboc.No. A-6267-000-051-001 [Rev.2 Sheet 10 of 114 Density kg/m3 @ pressure and temperature Pressure kg/om2(g) Temperature °C Duty MM keal/hr Stream Number — Numeric|issueD: 17" Feb. 2008 HPCL, Visakh BASIC ENGINEERING DESIGN | BASIS (PART -B) DHT PROJECT JOB NO. : 6261 “< Security Level 2 > @ ‘TOYO ENGINEERING INDIA LTD. | [DOC.No, A-6261.000-05 1-001 lRev2 Sheet itofiia | 4.0 NUMBERING SYSTEM 44 Equipment Numbering System: Numbering scheme will be as below: —> Sullix, if required (St ———» Equipment number & tandby, ete.) starting with 01) > Equipment identification Unit number Example: 801-P-01 A/B 4.1.4 Uni Numbers Unit numbers as given in section 2.3 shall be followed for equipment / instrument numbers, line numbers, etc. 4.1.2 Equipment Identification Symbols: The following symbols to be used for various types of eq Identification F >m HPCL, Visakh BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT lisSuED : 17" Feb, 2009, __ JOB NO: : 6261 @ ‘TOYO ENGINEERING INDIA LTD. IDOC.No. A-6261-000-051-001 IRev.2 Sheet 12 of 114 |Compressors, Blowers [Storage Tanks, Pits IEjectors [Miscellaneous Fitters Dryer Fans [Steam Desupetheater [Motor for Pump IMotor for Compressor [Turbine for Pump [Turbine for Compressor [Cooling Tower IMixer Regenerator Inert Gas Generator |Chlorinator Fired Boiler / Utility Boiler Flare Stack Undefined Package Items! IMiscellaneous< Security Level 2 > DHT PROJECT Ph, Visakh ‘eb. 2000 | BASIC ENGINEERING DESIGN G BASIS (PART - B) 1-626 1-000.051-001 |Rev.2 Sheet 13 of 114 TOYO ENGINEERING INDIA LTD, Line Identification Numbers: ine numbering and identification shall be as per following format; 8! CWS-XXX-1001-A1A-H [L Insulation Legend (type) Piping Class ———+ Line sequential Number Unit Number (as per sec, 2.3 above) Fluid identification Code Line Size (in inches) Fluid Identification Codes: Following fluid identification codes shall be used. low down ____Boller feed water high Pressure steam condensate J Medium Pressure steam condensate densate SH____ Very High Pressure Steam SM____ Medium Pressure Steam ‘Pressure Steam | Wes Bearing Cooling water supply WCR Bearing Cooling water return SWS ____ Sea Cooling Water Supply / Sea Fire Water _ SWR Sea Cooling Water Return WOM ____Demineralized water |WDK___ Potable (drinking water WP Process water and Sour water< Security Level 2 > @G ‘TOYO ENGINEERING INDIA LTD. = BASIC ENGINEERING DESIGN @ BASIS (PART - B) HPCL, Visaki alae ISSUED : 17" Feb. 2008 JOB NO. : 6264 lboc.No, a-6267-000.057-001 |Rew.2 Sheet 14 of 114 WR Raw water oon ws Service Water wa Quench Water AL Instrument ai AP. Plant air FG Fuel gas NG Natural Gas, Is Inert Gas. FO Fuel Oil c Chemicals, Additives P Process Fluid FL Flare sv Safety valve outlet (other than flare routing) v Vent to atmosphere ABD Amine Closed Blow-down CBD ___ Hydrocarbon Closed Blow-down cs Chemical Sewer OWS __ Oily Water Sewer ss Storm Water Sewer CRWS Contaminated Rain Water Sewer CA Caustic Soda AC Acid AAG Amine Acid Gas AS Sweep Air SWG SWS Acid Gas CAG __ Acid Gas Condensate HO Hydraulic Oil Ls Liquid Sulphur FLO___Flushing Oil ct Catalyst<< Security Level 2> | = | BASIC ENGINEERING DESIGN G eB BASIS (PART - B) Z DHT PROJECT | treads’ | __| ro nncemne won| Feb. 2000 | _ 6261.000-061-001 |Rev.2_ Sheet 15 of 114 tu the four-digit line sequential number, the digits shall be used as follows; First 2 digits: Same as last 2 digits of P&ID serial number. Last 2 digits: Serial number starting from ‘01’. instrument Numbers: Instrument numbering shall be as outlined below: XXX - PIC ~ 1201 AIB | —> Suffix, if required ‘——+ Serial number —* Instrument designation > Unit number (not indicated in P&ID tag but used in instrument specification / list) Instrument depiction shall be as per ISA. The relevant table for the alphabetic depiction of instrument type is included in drawing No. (LATER). In the four-digit instrument serial number, the digits shall be used as follows: First 2 digits: Same as last 2 digits of P&ID serial number, where this instrument appears. Last 2 digits: Serial number of instrument starting from '01" for that P & 1D. 44 Electrical Numbering: [sc Switchgear TR Transformer Pc. ~ Power control centre (PCC) {mc =Motor control centre (MCC) | Ui Use _ |8C______- Battery ChargerSecurity Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART -B) DHT PROJECT "em HPCL, Visakh TOYO ENGINEERING INDIA LTD. lisSuUED : 47" Feb. 2008 JOB NO. : 6264 IRev2 Sheet 16 of 114 Example: Lp ighting Panel PP. - Power Panel - Lighting Distribution board - Power Distribution board ‘SG ~ XX- 04 Equipment number 4 (starting with 01) Sub-station number |_____, Switchgear (Equipment Tag as identified above table)< Socutity Level 2 > =] BASIC ENGINEERING DESIGN @G ie BASIS (PART - 8) ) NZ) DHT PROJECT ne HPCL Visakn | TOYO ENGINEERING INDIA LTD. Feb, 2009 JOB NO. : 6261 7 7-626 1.000.051-001 |Rev2 - Sheet 17 of 114 AMBIENT AND METEOROLOGICAL DATA Wind |annual prevailing direction Quarter 1: N& SW, Quarter Il: SW, | Quarter Ill: SW, i Quarter IV:NE |Maximum wind velocity —_ 150 km/h J 'Normal wind velocity a | [Minimum wind velocity 1 earthquake For acceleration coefficients and other related data, refer doc. no. A- 6261-110-007, Design Specifications for Seismic [Seismic zone ee ee Basic Earthquake Coefficient | [estan earthquake factor as per IS {1893 - 2002) Ambient Temperature | Maximum Dry Bulb Temperature inimum Dry Bulb Temperature Design Dry Bulb Temperature Average Normal Temperature | Average Minimum Temperature [Design Wet Bulb Temperature Design Air Temperature For HVAC system 45°C @ 95% RH | For Air Compressor/ Blower 45°C @ 95 % RH I< Security Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART - B) d DHT PROJECT ar HPCL, Visakh _ ‘TOYO ENGINEERING INDIA LTO. ISSUED : 17"Feb, 2008 JOB NO. : 6261, ee [boc.No. a.0261.000.061-001 |Rev2 Shoot 18 of 114 c. | For Air Coolers 42°C ther followed by or not followed by water cooling | d 42°C 5.4 Relative Humidity of air Maximum Humidity 195% @ 45°C Minimum Humidity. 260% @ 15°C Normal Humidity 80% @ 36°C Design Humid 195% @ 45°C 5.5 Rainfall Normal Rainfall in 4 Hr 80 mm Maximum Rainfall in 24 Hrs. Maximum Rainfall in 4 Hr 400 mm. 5.6 Barometric Pressure Maximum __ : 760 mm Ha Normal 750 mm Hg Minimum 735 mm Ho 5.7 _ [Altitude above mean sea level 5.56 m _ & Site Information 5.8.1 Site Location State Andhra Pradesh Nearest Important Town & Distance: Vishakapatnam, km Nearest Railway Station & Distance: Vishakapatnam, km Nearest Port & Distance Vishakapatnam, km Nearest Airport & Distance Vishakapatnam, kmHPCL, Vi ISSUED : 17" Feb. 2009 « Secutity Level 2 > aa BASIC ENGINEERING DESIGN | | io BASIS (PART - B) @ DHT PROJECT a ‘TOYO ENGINEERING INDIA LTD. JOB NO. : 6261 [DOC.No. A-6261-000-051-001 |Rev.2 - sheetiort | 5.8.2 5.8.3 5.8.4 Source of water Fresh Water Bearing Cooling Water Recirculating Cooling Water Rainy season Environmental conditions Visakhapatnam Municipal Corporation Fresh Water ‘Sea Water from Bay of Bengal : June/July during SW monsoon, Rain also ‘occurs in November / December during NE monsoon. : Tropical and MarineSecurity Level 2 > iE BASIC ENGINEERING DESIGN BASIS (PART -B) DHT PROJECT HPCL, Visakh eee ISSUED : 17" Fev, 2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD. i) [Doc.No, A-6261-000.051.001 |Rev.2 Shoot 20 of 114 6.0 64 62 6.3 6.3.1 ECONOMIC OPTIMISATION CRITERIA Unit Rates for Feed, Products and Utilities Table-6.1: Feed, Intermediate Product and Finished Product unit rates [Sr. No. FEED / PRODUCT RJ MT 1._|Natural Gas 40820 2._|Naphtha 22987 3.__|Suiphur 2450 Table-6.2: Utility unit rates Sr. No. UTILITY Rs, Unit 1._|Power 45 2._|very High Pressure steam Ton 1329 3._ [Medium Pressure steam Ton 1329 4,_|Low Pressure steam Ton 1329 |_5._|Fuel Fired MMkcal 1006 6.__|Recirculating Sea Cooling water| __m* 1.73 7._ [Boiler Feed Water Ton 171.6 8._[Demineralized Water Ton 43 9.__|Fresh Water m 25 10._|Instrument Air Nm® 0.74 Optimization Criteria Designer and engineering contractor shall use a default criterion of a maximum, 3 year straight-line payback for recovering incremental investment, Design Plant Life Designer and engineering contractor shall take a default plant operating life as 15 years with nil salvage value for economic calculations.« Security Level 2 > BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT TOYO ENGINEERING INDIA LTD, | JOB NO. : 6264 —_ IRov2 Sheet 21 of 114 designer and engineering contractor shall take default plant equipment design lip as follows: 30 years for heavy wall reactors and separators ) 20 years for columns, Vessels, heat exchanger shells and similar services. ©) 10 years for piping, furnace tubes, High Alloy exchanger tube bundles. dj. 5 years for Carbon Steel / Low Alloy heat exchanger tube bundles, ) 20 years for all rotating equipment,< Security Level 2> = BASIC ENGINEERING DESIGN @ & BASIS (PART -B) la DHT PROJECT HPOL, Visakh ‘TOYO ENGINEERING INDIA LTD. lissuED: 17" Feb. 2009 JOB NO. : 6264 [DOC.No, A-6261.000-051.001 |Rev.2 Sheet 22 of 114 70 7A TAA TAQ DESIGN PHILOSOPHY Water Systems Along with normal requirement for pump / compressor bearing, gland and seal cooling, bearing cooling water is used as a cooling medium for Lean Amine ‘cooler in ARU and in compressed air and nitrogen system. ‘The sea cooling water shall be used for all users (exchangers, coolers, etc.) except for those mentioned above. All pump / compressor cooling water lines (for bearing cooling, gland cooling, seal cooling) shall be minimum 1” NB schedule 80. Tapping for cooling water to be taken from top of the cooling water supply header. Cooling water return lines from users shall discharge in a drain funnel which shall be connected to separate buried header leading to a covered sump within unit. Sump to be provided with overflow provision to contaminated rainwater sewer. The water from.sump to be pumped to cooling water return header within ISBL. However, if total quantity is less than 1.0 m* per hour, same may be discharged in CRWS. \ ‘The supply and return headers from / to bearing cooling water system to be laid above ground. The system to be designed accordingly. All cooling water consumers connected to cooling water systems are to be provided with backflush arrangement, The recommended cooling water piping and instrumentation arrangement is shown in Fig. 7.1 below. Fig. 7.1 : Typical cooling water piping and instrumentation at heat exchangers.< Security Level 2 > a= Sct | BASIC ENGINEERING DESIGN @ BASIS (PART - B) DHT PROJECT Gos polrazsi Sheot 23 of 114 ‘cw ret tne to ave Globe Vale for Bearing CW an tec te ‘owRETURN oh gama) “Tis connection to be powded only for exchangers leeated at pao (iamoratove) i ea £. Tepito. Sea ewony Backduan! SZ dranvatre Backus dain ese quieseoemeie =, Test thon sy Ine ia, ‘5 ‘whichevor higher Drinking Water Drinking Water to be used for eyewash safety showers, which are located strategically in unit areas (e.g. near handling area for caustic, acid, corrosives. and chemicals ete.). Drinking Water system, comprising of pumps and chemical dosing system, shail be provided as required. Fire Fighting System CONSULTANT shall prepare the new network for new facilities. Refer Document no, A-6261-601 Design Basis for Fire Fighting System, 2 Steam and Condensate System 7.21 The designer and engineering contractor shall adopt this default philosophy towards sizing of equipment generating or consuming steam; Steam turbine drives and ejectors shall be rated based on MINIMUM steam conditions available at unit battery limits. (ISBL pressure and< Security Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART -B) ae HPCL, Visakh alee ‘TOYO ENGINEERING INDIA LTD. lissueD: 17% Feb. 2009 | JOB NO. : 6264 IDOC.No. A-6261.000.051-001 |Rev.2 Sheet 24 of 114 722 723 temperature drop to be considered). b. All other steam consuming equipment including heat exchangers shall be thermally based on NORMAL steam conditions and reviewed for satisfactory operation anywhere between the maximum and minimum steam header conditions. ¢. All steam generating equipment shall be rated based on delivering steam at MAXIMUM steam conditions to a steam header and reviewed for satisfactory operation anywhere between the maximum and minimum steam header conditions. d. NORMAL steam conditions shall be used for operating utility estimates, heat and material balances and battery limit connectivity. €. DESIGN conditions will be considered to establish relief valve set pressures and mechanical design. Condensate recovery will be maximized from process .consumers. All condensate generated. in a facility will be considered as normally uncontaminated and will be directly reused for steam generation. Contamination detection by on-line analyzers sensing conductivity and pH, with an option of automated drainage upon detection, shall be done as per unit designer's advice. \ Uncontaminated condensate will be directly reused for steam generation. Suspect condensate shall be treated in centralized condensate polishing unit before use in refinery, if required. On line conductivity analyser with DCS alarms shall be provided in condensate return header from each unit with in ISBL. Condensate produced in HGU and SRU block shall be used in respective unit's Deaerator or steam generators. Condensate loss can be reduced in a number of ways, within unit battery limits. In order to minimize the liquid effluent generation from the units, all condensate shall be collected and effort shall be made to minimize condensate drain to OWS / storm water sewer. | |_ _ < Security Level 2 > BASIC ENGINEERING DESIGN @ | BASIS (PART -B) x DHT PROJECT _| Tov0 ENGINEERING INDIA LTD. JOB NO. : 6261 : Reva Sheet 25 of114 | vondensate recovery from steam trap discharge, steam tracer discharge is not \o be considered, However condensate ex steam coils in tanks in unit battery init shall be recovered by connecting this consumer to condensate header only ‘f recovery is more then 1 Uhr, Facility for draining of condensate from respective jenesation unit shall also be provided to take care of emergencies. Uncontaminated condensate recovery from consumer of steam shall be done by fiashing the HP and MP condensate to generate LP steam, LP steam may be ed in the ISBL. Excess LP steam to be connected to main LP steam header. Condensate from HP/MP flash vessel along with LP condensate from LP steam users shall be pumped out and cooled in air cooled exchanger and retumed to condensate recovery system for DM water system, Suspect condensate shall be flashed in an atmospheric pressure flash vessel. Suspect condensate to be pumped to central condensate polishing unit. Vent condenser shall be provided on vent from atmospheric flash drum. Fuel Systems Liquid fuel system \ Fuel oil is available as alternate fuel for data is indicated in section 8.14.1 d heaters. Liquid fucl composition Hot liquid fuel temperature shall be assumed to drop by §°C between unit battery limit and burner manifold. The fuel oll system shall be designed for a recirculation rate of 2:1 Fuel gas system Existing fuel gas network shall be extended to cater to the new units. Fuel gas cnerated in unit areas to be routed to existing refinery fuel gas network. Fuel< Securily Level 2 > = BASIC ENGINEERING DESIGN @ gp BASIS (PART - B) a DHT PROJECT HPcL, Visakn ‘TOYO ENGINEERING INDIA LT. ISSUED: 17" Feb, 2009 JOB NO. : 6264 DOC.No, A6261-000-057-001 [Rev.2 Sheet26of 114 733 734 735 74 gas composition for refinery fuel gas and fuel gas from process plants are given in section 8.14.2. Fuel gas liquid knockout drums and tracing for piping shall be: - Separate KOD for each process unit. - Fuel gas lines shall always be steam traced from KOD upto individual furnace burners. Indine strainers on fuel gas, fuel oil and pilot gas are recommended in burner piping for each unit. These shall be located not more than 20 meters upstream of the bummer manifold and shall be 1 on-line + 1 spare strainer with mesh size of 100 for Fuel oil, 200 for Fuel Gas & atomizing steam. All mesh sizes are Tyler standard. Pilot gas line shall be provided with self actuated PCV. Pilot gas line shall be in stainless steel (SS 304) downstream of strainer. Natural gas will be used as back up for refinery fuel gas. Composition data is indicated in section 8.14.2. Flare System 1. There are two flare headers in refinery. Hydrocarbons released are routed to Normal Flare and acid gases released are routed to Acid Flare. 2. Vapor releases of all molecular weights to be connected to flare system. 3, For adherence to OISD STD.106, EPCC contractor shall specify a dedicated horizontal unit flare KOD, sized to separate out liquid droplets down to a size of 400 micron. The unit flare knockout drum shall be adequately sized for liquid relief also. Sizing should be based on liquid relieving safety valve blowing for 5 minutes< Security Level 2> = BASIC ENGINEERING DESIGN @ | & BASIS (PART - B) , HPCL, Vieakh ae TOYO ENGINEERING INDIA LTD. | ISSUED: 17"Fep.2000_ JOB NO. : 6261 | lboc.No.A.6261.000-051.001 [Rev Sheet 27 of 114 75 7.51 782 ‘4. The liquids from flare KODs will be routed to the slop system. 5. Isolation block valve is to be provided in the flare header at individual units. In addition to the normal fuel gas connection for purging, purge gas (Nitrogen) connection shall be provided in all dead ends of flare header. Rotameter shall be provided in fuel gas & Nitrogen connections to monitor the flow. Liquid Pumpout & Drain Systems Hydrocarbons drains = Connect equipment drains to buried closed blowdown (CBD) network, leading to a closed blowdown drum. Design CBD system for 200 °C. CBD discharge shall be routed to wet slops tank in offsite area. - Buried Closed Blowdown drum shall be: HM Standard size of 10m* for all units to cater to only residual drains. Individually sized for each unit for single largest equipment inventory. \ - CBD drum shall be provided with cooling coils as well as heating coils. CBD drum shall be located in RCC pit and sand packed by Vibro compression with lean concrete on top — 100 mm thk. Cathodic protection is not required for the buried drum, Suitable paint fo be provided. - CBD pump shail be sized adequately to pump out the liquid in maximum of ity minutes. = CBD lines are to be underground with suitable flushing connections, if required. = CBD drum shall be floating with flare. ‘Steam generator blowdown drains< Securiy Level 2 > __HPCL, Visakh lissuED: 17" Feb, 2009 nel BASIC ENGINEERING DESIGN @G @ BASIS (PART - B) lanl DHT PROJECT ‘TOYO ENGINEERING INDIA LTD. IDoc.No, A-6261-000-051-001 |Rev.2 Sheet 28 of 114 753 754 a) ») °) - Flash MP and HP blow downs for recovery of LP Steam only if adequate steam generation is possible. - Direct water quench of blow downs and route to BCW sump within ISBL. Caustic drain All spent caustic inventory drains shall leave process unit under own pressure or be pumped out. This spent caustic to be routed to the effluent treatment plant. For residual caustic drains such as unpumpable vessel bottoms, level gauge drains, etc. one of the following shall be adopted; Provide underground caustic CBD system with buried vessel and pumpout, O Collect residual drains by temporary facility like drums and jars. Other Drains ‘Amine Systems Individual units handling amine will be provided with separate buried amine closed blowdown system from where amine stream will be pumped to ‘regeneration unit via rich amine line going out of the unit area. ‘Amine blowdown drum shall have oil separation and disposal facility. Acidic wash water Acidic wash water from sources such as Air Preheater washings shall be routed to oily water sewer. Provision for suitable neutralization is to be explored. Process sour water Process sour waters shall normally be routed to identified sour water stripper Units. Residual drains from instruments or during intermittent situation where unavoidable, may be drained to oily water sewer. The effluent treatment plant designer shall be advised to incorporate provisions to receive the single largest stream of such sour water.< Security Level 2 > BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT PCL, Visakh | ____| Too ENGINEERING INDIA LTD, 17 Feb. 2000 ____JOB NO. : 6264 = | #-6261-000-051-001 |Rev.2 Sheet 29 of 114 | Water drains All process oily water shall be discharged to open funnels connected to oily water sewer (OWS). Al other contaminated water drains including floor washings shall be routed to contaminated rain water sewer (CRWS). Caustic Storage, Preparation, Distribution austic receiot The required quantity of commercial (40-45%) caustic is stored in the storage tank located in DM plant area. ETP will have its own independent unloading system. (b) Fresh caustic prepay 1n and distribution 10-12 w1% Caustic solution is available from central dilution facility in the DM plant area. This caustic is pumped to all consuming units and separate solution making arrangement shall be provided if a unit requires lower strength. Caustic handling equipment shall be of Carbon Steel construction and stress relieved whenever required for the operating temperatures selected. It is recommended that spent caustic generated in unit areas, after contacting with light hydrocarbons, shall degas the stream in an atmospheric vessel floating with flare and then pumped out to waste water treatment plant in offsites area.BASIC ENGINEERING DESIGN BASIS (PART - B) Yon DHT PROJECT HPCL, Visakh TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2009 JOB NO. : 6264 [Doc No. A-6261-000-051-001 |Rev.2. ‘Sheet 30 of 114 7 17A 772 78 79 ‘Special precautions shall be taken while handling process streams containing aromatics. For applying the special precautions, following threshold values are to be used, a) Benzene content greater than _1% _ weight. b) Cs through Ce aromatics greater than _25% _ weight. The design and equipment provisions towards special precautions shall be: a) Closed sampling points as defined in standard legend P&ID. b) Dual mechanical seals for pumps. ©) Connecting the followings to the unit closed blowdown system: ~ Drains from vessels, pumps, level gauges, level instruments and control valve. - Drains of equipment which can be isolated for maintenance. Fire Proofing Fire proofing shall be provided for Columns / Vessels skirts & legs, Pipe rack, Steel structure & steel support, Staircase, ladder and platform as per OISD- STD-164. Energy Integration Improvement in overall energy efficiency shall call for unit-level and total plant- level optimization of energy. Designer of a particular unit shall indicate the following at the outset of design activities: (a) The total energy consumption expressed as equivalent fuel oil (MMkcal/kg/ Btulbbl or FOE%) (b) The preferred temperatures for hot feeds and products from an energy integration standpoint, if these are significantly different from that stipulated in unit BEDB. (©) The following shall be considered while optimizing the energy consumption< Secutily Level 2> =) | BASIC ENGINEERING DESIGN G \ 1 | BASIS (PART - B) DHT PROJECT ae HPOL, Visakh ‘TOYO ENGINEERING INDIA LTD, 17Feb, 2009, 1, 4-626 1-000-051-001 Sheet 31 of 144 ~ Energy shall be preferentially recovered into process streams. Steam generation shall be considered thereafter to recover excess available energy. Steam generation levels shall be chosen to preferably match the corresponding steam level demand within unit - Low-level energy recoverable for external consumption, say, for Boiler Feed Water preheat serving other units. Vacuum Design Consideration Vacuum design conditions shall be stipulated for: (@)_ Equipment operating normally uncer vacuum conditions. (b) Equipment that are subjected to vacuum conditions during startup, shutdown, regencration or evacuation. (©) Liquid full vessels that can be blocked in and cooled down. (d) Distillation columns / towers and associated equipment that can be ‘subjected to vacuum conditions through loss of heat input. (e) Allsteam users consuming steam during normal operation and condensate vessels. () Pressure vessels containing liquids having vapor pressure at minimum ambient temperature less than atmospheric pressure. (g) All equipment, except storage tanks, where steam out conditions are specified. (h) Special consideration to be given (for vacuum design) to the design of vessels normally subjected to internal pressure and connected to compressor suction. Feed, Intermediate and Product Storage The design specifications for tankages outside unit battery limits shall be prepared by offsite designer, as defined in relevant scope of work. Should the designer of a particular process unit have specific requirements towards feed, product or intermediate product storage tanks such as inert gas blanketing and {ae required minimum purity of the inert gas, material of construction, etc., the< Seouriy Level 2 > BASIC ENGINEERING DESIGN @ ] BASIS (PART - B) DHT PROJECT big |__ HPot, visakn —_| TOYO ENGINEERING INDIA LTD. IissUED 17" Feb. 2009 JOB NO. : 6264 [DOC.No. A6261-000-051.001 |Rev.2 | 114 712 TAZA 7122 7.12.3 7.13.4 same shall be conveyed during preparation of process unit BEDB or relevant licenser document. Metallurgy Metallurgy shall be specified by respective unit designer based on process considerations. Piping metallurgy and metallurgy for instrumentation shall follow a unified overall Piping Material Specification (PMS). For cooling mediums for heat exchangers, metallurgy can be selected for either long tube life at a higher initial cost or for shorter tube life at a lower initial cost with up gradations being decided in the course of operating the plant. In specific cases superior metallurgy is dictated by considerations such as sea water cooling, compatibility with NACE MR- 0103 , etc., and shall be as per designer. For sea water services, the tube metallurgy chosen will be based on the criticality of operation, in view of the closed circulating water system envisaged. The minimum metallurgy preferred by Owner is: + Titanium tubes (welded construction of 20 BWG thickness) with Nickel Al \ bronze tubes sheets. + For hydrogen / H2S services where titanium can not be used, Duplex| /\ stainless steel tubes & tube sheet combination is to be used. + The metallurgy for baffles and other cage components shall be suitable for shell side fluid As a default all steam tracers shall be as per PMS. Corrosion Allowance Minimum Corrosion allowances shall be as follows or as specified by Licensor (Whichever is higher)BASIC ENGINEERING DESIGN BASIS (PART - B) DHT PROJECT come [ _____| Foo enoweerine iwo1a uD. JOB NO. : 6264 a | N Sheet 33 of 14 | Sr |Service Z Default ~ ino} = — \_ |Carbon Steel pressure vessels 3.0 min 3.0 mm “Alloy Steel vessels 75mm | | Slainless Steel vessels nil |Gaa Tiined vessels ft ‘Column Trays, ‘Shell Roof Bottom most shell course & Bottom plate 3.0 mm lining thk min, without jcorrosion allowance [3.0 mm 15mm 15mm 3.0 mm Ferrous exchangers cs [1.5mm onboth sides | —— ~ ‘$84708| Nit ‘ss [NIT ~ ~ Monel |Nil Corrosion allowance as per process data sheet specification< Security Level 2 > —— BASIC ENGINEERING DESIGN @ @ BASIS (PART - B) x DHT PROJECT HPCL; Visakh TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2008 JOB NO. : 6264 Ino No A-6267-000-057-001 Rev? Sheet 34 of 114 8.0 UTILITY SPECIFICATIONS Utility Battery Limit (BL) conditions given below are at unit battery limits. All BL pressures are measured at grade. 81 DMWater Attributes Unit DM water Quality | IpH _ = 28.3 [Turbidity INTU (5 min settled) Nil Conductivity @ 20 °C Imicromhofcm 1-2 (Note-1) ‘Total Dissolved Solids as mgt Icacos = {Total Silica as SiO, Imani <0.02 [Ca hardness as CaCOs Imgvit ‘Total hardness as CaCO; __|malit ___Nil {Total Chlorides as Cl mgiit Nil {Total Sulphur as S Imavlit {Total Iron as Fe |g <0.03 [Total Copper as Cu Imai Ni (Organic Matter (KMnO«) Imgilt Value at 100 °C <5 |Calcium as CaCOs Imaulit [Magnesium as CaCOs____|mgiit_ lol & Grease Imadlit ITSs pW _ BOD 7 jpmw cop pw \Sulphates (as SO.) __[ppmw. |Sodium as Na pm Phosphate lppmw_ |Ammoniacle N jpmw Kejaldhal N __fppmw ‘Alkalinity pw _ lal metals -< Security Level 2 > = BASIC ENGINEERING DESIGN | @ QB BASIS (PART - B) 4) DHT PROJECT ven HPCL, __| TOVO ENGINEERING INDIA LTD, 17" Feb, 2008, _JOB NO. : 6264 = [D0c.No. A-6261-000-051-001 |tev.2 —_ Shoot 35 of 114 Battery Limit Conditions: Minimum [Normal] Maximum | Mech. Design Pressure, kyon g - e0 42.0 HOLD) Temperature, °C Ambient 65 Note-1 - DM water coductivity before morpholine dosing is 0.2 micromho/em 82 Steam Battery Limit Conditions: ~~ Pressire, Kglam?g___| Temperature; *G———) [St2am ——[iinimum| Nommal [Maximum] ~ Mech. | Minimum] Normal [Maxinvam] Misch Isystem Design Design fety_High| 35 38 a o | Drexcure’| 33 | 95 | 38 40 | 340 | 260 | 380 | 400 Medium 4 ae 0 | pressure |mOnd| (0a |r 125 | sata. | 260 | 280 im Low 5 reonen | Eee leo 4 [85 | sata | 190 | 170 | 190 8. Condensate Return (Pure / Suspect Battery Limit Conditions: Pressure, Kg/cm* g [ Temperature; °C | e a — =| Min] Norm Ices see | Min | Norm | Max T Mesh. Condensate Retum (Purey | 6° | joo | 100 | 185 Condensate: Return (Suspect) | 3.5 10.0 100 | 185 84 — Senice Water Battery Limit Conditions: Minimum | Normal [Maximum | Mech. Design Pressure, kg/cm? g 25 60 (Temperature,°C 32 5< Security Level 2 > = BASIC ENGINEERING DESIGN G BASIS (PART -B) DHT PROJECT HCL, Visakn | ‘TOYO ENGINEERING INDIA LTD. |ISSUED : 17"Feb, 2008 JOB NO. : 6264 [DOC.No. A-6261-000-051-001 |Rev.2 ‘Sheet 36 of 114 85 Potable (Drinking) Water Battery Limit Conditions: Minimum | Normal | Maximum | Mech. Design IPressure, kg/cm? g 25 6.0 (Temperature,°C En Ca 8.6 —_Boiler Feed Water Quality Parameter Value lpH 8.5~9.5 | |Conductivity @ 25 °C, micromhos/em s [Total Dissolved Solids as CaCOs, mg/it__|: Nil [Total silica as SiO, mgfit | <0.02 [Chloride as Ci, mgiit Iron as Fe, mgfit [ 0.03(max) (Copper, mg/lit Ni ~ [Dissolved Oxygen, molt 0.005 KMinO. value at 100 °C, mgfit 6 Battery Limit Conditions: Pressure, Kglom? g Temperature, °C Min | Norm ] Max | Meech | Min | Norm | Max | ec fery High 47 | 60 | 58 | 71 | 120] 120 | 135 | 155 pressure steam Medium pressure steam 17.5| 20.5 | 21.5} 29 | 120] 120 | 135] 155Security Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART - B) A DHT PROJECT “ Visakh __| TOYO ENGINEERING INDIA LTD, 17" Feb. 2009 JOB NO. : 6261 -6261-000-051-001 |Rev.2 Sheet 37 of 144 Raw Water 1w water (Filtered) will be available at Battery limit with following specifications: Attributes Unit Quality |Appearance . _ lpH 8.0 ‘Turbidity (5 min settled) InTU EEeane [Total Suspended Solids (TSs)__|mgnit 2 | Dissolved Solids Imgait | asa Conductivity @20°C Inicromhovem - [Total Alkalinity as CaCOs_ lppmw _ IP-Alkalinity as CaCOs pmw IMO- Alkalinity Imgfit 140 (Ca hardness as CaCOs Imanit 70 IMg hardness as CaCO lppmw {Total Hardness as CaCO. Imai 192 ‘Total Cation / Aniorias CaCO; |ppmw ‘Total Silica as SiO, Imghtt 1 (Colloidal Silica as SiO2 lpprmw [Calcium as Ca jpmW [Magnesium as Mg jpmw ‘Sodium as Na lppmw [Potassium as K lpmw Chloride as Ch Imghtt 110 [Free Chlorine pmW 'Sulphates as SO. Imgfit 22 \Organophosphates as PO, lpornw (Organic Matter as KMnO« lppmw Nitrates as NOs mM = ‘Dissolved Oxygen on<< Security Level 2 > @ HPCL, Visakh BASIS (PART - B) DHT PROJECT BASIC ENGINEERING DESIGN @G ‘TOYO ENGINEERING INDIA LTD. ISSUED: 17 Feb, 2009 JOB NO. : 6264 {boc.No.a:6261-000.051.001 [Rev.2 Shoot 38 of 114 Attributes Unit Quality [Total Iron as Fe imgflit 0.2 (max) [Total Sulphur as S ae |Manganese as Mn ppm Lead as Pb lppmw _ | Organic carbon (Total) lppmw_ Fluoride as F lppmw_ Bromide as Br ____|ppmw “Aluminium as AL |ppmw Barium as Ba lppmw | BoronasB lppmw \Cadmium as Ga lbomw a (Chromium as Cr lppmw (Cobalt as Co lomw a {Total Copper as Cu_ Imai 0,04 (max) ‘Molybdenum as Mo pomw | a INickel as Ni lppmw Oil & Grease pomw |KMnO, value at 100 °C Imgflit 5~8 (assumed) IPolymeric dispersant _ lppmw [Zinc sulphate ppm __| |HEDP as POs |pprw lAmmoniacle N lppmw _ Kejaldhal N [ppm BOD. lppmw = a IcoD_ _ —|pemw, (SDI (Silt Density Index) Ie 88 Bearing Cooling Water Battery Limit Conditions:< Security Level 2 > = BASIC ENGINEERING DESIGN @ Ke) BASIS (PART - B) ~ DHT PROJECT MCL, Visakh ‘TOYO ENGINEERING INDIA LTD. {2 Feb, 2009 JOB NO. : 6261 9-6281-000-051-001 |feev.2 Sheet 39 of 114 __ - Minimum | Normal Maximum |Mech. Design| Supply Pressure, kgicm’g | 49 | 53 80 |Retum Pressure, kg/em’g 25 35 80 ‘Supply Temp, °C 33 Co urn Temp, °C 44 65 Quality of Bearing cooling water shall be as below; Attributes Unit Quality _ 7 Maximum pH L [Turbidity (6 min settled) NTU 50 [Total Suspended Solids (TSS) __|ppmw {Total Dissolved Solids Imgfit 875-1300 [Total Alkalinity as CaCO; pmw _| [P-Alkalinity as CaCO; pom [MO- Alkalinity Imgytt 100~120* Ica hardness as CaCO; Imgfit 140-210 Ig hardness as CaCO. lppmw c {Total Hardness as CaCO, Imgflt 385~576 - {Total Cation / Anion as CaCOs [paw [Total Silica as SiO Imgfit 20-35 [Colloidal Silica as SiO; pmw (Calcium as Ca spmW Magnesium as Mg __[ppmw | ISodium as Na mw [Potassium as K jpmw = [Chloride as Cl Imgnit 225-335 [Free Chlorine pmw ‘Sulphates as SO, Imgnit 205~466 \Oiganophosphates as PO, Imgltit 8~10 Organic Matter as KMnO« ppmw= Security Level 2 > BASIC ENGINEERING DESIGN @ BASIS (PART - B) DHT PROJECT mee HPCL, Visakh ‘TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 200 JOB NO. : 6261 [D0C.No. A-6261-000-051-001 |Rev.2 Sheet 40 of 114 Attributes Unit Quality Normal_| Maximum Nitrates as NOs )pmW Dissolved Oxygen pm [Total ron as Fe Imgflt 1 (Total Sulphur as S pm [Manganese as Mn lppmw ILead as Pb lppmw. [Organic carbon (Total). lppmw Fluoride as F pm [Bromide as Br pmw [Aluminium as Al pm Barium as Ba lppmw Boron as B pm [Cadmium as Cd - ypmw. [Chromium as Cr pm (Cobalt as Co lpprmw. \Copper as Cu lppmw. [Molybdenum as Mo. lppmw INickel as Ni lppmw_ loi! Content Imgit 410 (max) Ikwin04 value at 100 °C Imonit 30-40 50 [Polymeric dispersant Imgalit 20-30 | IZine sulphate as Zn Imglt 1-2 IHEDP as PO. lpomw lAmmoniacle N lppmw _ |Kejaldhal N ppmw. [BoD Ippmw _ cop _ ppmw [Benzotriazole Imgfit 05 * MO-alkalinity will find it's own level depending upon pH maintained. The reported M- alkalinity value corresponds to value at pH 7.5~8.0« Secutlly Lovel 2 > BASIC ENGINEERING DESIGN G S| BASIS (PART -B) a DHT PROJECT wpct.visakh | ‘TOYO ENGINEERING INDIA LTD. 1 t!Feb. 2009 JOB NO. : 6261 _t «© No, 46261-000.061-001 [Rev.2 Sheet 41 of 114 Sea Cooling Water Sattery Limit Conditions: ~~ ~~ Minimum: Maximum [Mech, Design| ‘Supply Pressure, kglom’g 49 76 IRetum Pressure, kglong 35 76 Supply Temp, °C 33 65 [Retum Temp, °c a 5 Quality of Sea cooling water shall be as below; Attributes Quality ie | Normai [Maximum [ 8-85 al [Turbidity (6 min settled) ru : Total Suspended Solids (TSS) lppmw {Total Dissolved Solids Imgiit 42998 [Total Alkalinity as CacOs ppv |P-Alkalinity as CaCO fpprow_ |MO- Alkalinity Imgait 143 \Ca hardness as CaCO. Img 1100 [Mg hardness as Caco, lppmw [Total Hardness as CaCOy__|maflit 6545 [Total Cation Anion a CaCO, ppmw Total Silica as SIO, Imgnt_ | 16.5 [Colloidal Silica as SiO, ____(ppmw [Calcium as Ca mw [Magnesium as Mg pw [Sodium as Na lpprmw | [Potassium as K lppmw |Chloride as Cl Imgiit 24420 ‘F1ee Chlorine mvs< Security Level 2 > BASIC ENGINEERING DESIGN @ @| BASIS (PART -B) DHT PROJECT eee HPCL, Visakh ‘TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb, 2009 JOB NO. : 6264 lDoc.No. A-6267-000-051-001 [Rev.2 Sheet 42 of 114 Attributes: Unit Quality 7 Normal Maximum [Sulphates as SO Imari 2915 |Organophosphates as POs mgt a lOrganic Matter as KMnOy lpomw INitrates as NOs lbomw Dissolved Oxygen pnw [Total ron as Fe: Imgslit 1 [Total Sulphur as S jpmw [Manganese as Mn lppmw lLead as Pb lpomw lorganic carbon (Total) lpomw [Fluoride as F lpomw [Free Bromine ___|manit 0.2-0.3 [Aluminium as Al lpomw [Barium as Ba lpormw [Boron as B mw |cadmium as Ca mw [chromium as Cr pnw [Cobalt as Co ppm _ [Copper as Cu pm |Molybdenum as Mo mw INickel as Ni mw [oll Content Imgnit 10 Ikwino, Consumption lppmw [Polymeric dispersant Imait 20~30 [Zinc sulphate pmw IHEDP as POs pin |Ammoniacle N pnw IKejaldhal N mw lBop pmw Icon pmw< Securily Level 2 > DHT PROJECT = BASIC ENGINEERING DESIGN G i BASIS {PART - B) ¢ HPCL, Visakh ‘TOYO ENGINEERING INDIA LTD. lisSuED: 17° Feb. 2009 JOB NO. : 6261 [DOC.No. A-6261-000-051-001 [Rev.2_ Sheet 43 of 114 Attributes Unit ~ Quality | Maximum ‘SDI (Silt Density Index) [Benzotriazole [mgnit 8.10 Fire water Battery Limit Conditions: Minimum [” Normal [ Maximum | Mech. Design | bres kgicm’g 7 70 12.5 [Temperature, °C ‘Amb. 65 8.11 Plant Air Oil free for catalyst regeneration, Battery Limit Conditions’ Minimum | "Normal | Maximum | Mech. Design IPressure, kgicm g 3 4 5 g /Temperature, °C ‘Ambient 65 8.12 Instrument Air Dew point (-) 40 °C at atmospheric pressure with no oil content Battery Limit Conditions: Minimum | Normal | Maximum | Mech. Design | ressure, kglcm” g 4 5 6 9 | [Temperature, °C ‘Ambient | Pec« Security Level 2 > ] (a BASIC ENGINEERING DESIGN @ o BASIS (PART - B) a DHT PROJECT HPCL, Visakh ‘TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2009, ___JOB NO. : 6261 DOC.No, A-6261-000-051-001 |Rev.2 Sheet 44 of 114 8.13 Nitrogen Rs, [Parameter Unit Jo. er | 1. |Dew point at atmospheric pressure _ [°C ~100 2, |Oi1 Content ppm NL 3.__| Nitrogen purity (min) Sevol 99.99 4. |Oxygen content ppmy <3 __5._|Carbon dioxide content ppmy <3 6._|Carbon monoxide content ppmy Traces 7._|Other C compounds ppmv <5 &._|Chlorine ppmv ae 9._|H,0 ppmv : 410." [Hydrogen ppmv - 11._|Noble Gases ppmv Balance Battery Limit Conditions: \ “Minimum |” Normal Pressure, kg/cm? g 5 6 Temperature, °C >5 | Ambient 814 Fuels 8.14.1 Fuel Oil Fuel Oil properties are as follows; Parameter Unit _Value PAPI : : 13,5 -18.5 ‘Sulphur content % 0.994 [Nitrogen content ppmw 3000< Security Level 2 > DHT PROJ BASIC ENGINEERING DESIGN BASIS (PART -B) JECT @G ‘TOYO ENGINEERING INDIA LTD, 1/Feb, 2009 JOB NO. .6267-000-051-001 |rew.2 _ Sheet 45 of 114 (varameter unit Value Nickel content —_lppmw 16.2-18.4 Vanadium content lppmw. 60-88 [Sodium content lppmw 2.0-34.2 \Copper content lbpmw lon content lpmw 20.4~24.8 Flash Point ec 208 | [Pour Point tc 24-60 viscosity @ 99 °C lest 114 |viscosity @ 82 °C lest 250.7 [Temperature required for 20 cSt_|*c : Initia boiling point @ 1 atm lec _| \Conradson Carbon Residue ht % lAsh Content pw 0.02~0.1 | Carbon : Hydrogen ratio wt [Net Heating value Ikcabkg | _9480 attery Limit Conditions: Minimum Mech. Design| Supply header Pressure, 7 7 kkglom? g [Return Header Pressure, 25 7 Ikglom? g [Operating Temperature, °c | 100 | 130 | 170 200 Fuel Gas Fuel Gas compositions are as follows;< Security Level 2 > = | BASIC ENGINEERING DESIGN @ ep | BASIS (PART -B) a DHT PROJECT HPCL, Visakh TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2009, JOB NO. : 6261 [Doc.No. 46261.000-051-001 [Rev2 - Sheet 46 of 114 Refinery Fuel | Fuel Gas (without | Fuel Gas (with H, ‘Gas He recovery in| recovery in PSA) a PSA) 7 Composition : Vol% Mol % Mol % | Hydrogen 167 598 4472 Carbon Dioxide 1.28 ont ont Carbon Monoxide 447 0.07 0.07 Nitrogen 13.42 0.00 0.00 Hydrogen Sulphide | 0.0091 0.00 0.00 Water 3.02 062 0.86 Methane 137 187 23.64 [ethane 11.89 10.76 1371 Ethylene 642 os3 0.53 Propane 1504 | a3 5.13_ Propylene 7.62 044 4 | :eutane 3.26 03 n-Butane 5.33 1.54 274 Butenes o2r | ___o07 oat iPentane 0.22 0.40 [ n-Pentane 027 0.00 0.03 | Pontense _ 0.02 0.40 6 (+) __3.94 627 IToTAL g9909 | 9995 100 Molecular weight 28.55 1355 19.2 Heating Value, kealkg | 10129 (LHV) GAIL Natural Gas: ‘ComponentsN < Securiy Laval 2> ==] BASIC ENGINEERING DESIGN @ Q) BASIS (PART - B) DHT PROJECT nial HPOL, Visakh ‘TOYO ENGINEERING INDIA LTD. 12"Feb, 2000 JOB NO. : 6261 4$261-000.051-001.|Rev.2 Sheet 47 of 114 Composition (mol %) 98.77 7 069 9 | Propane 0.03 45 | Butane, o 25 | Pentane o 0.35 Hexane & Heavier o ots | CO, o 5 Nitrogen 7 ost 416 | Total Non HC 58 58 | Total Supthur including $10 ppmw 510 ppmw ao HyS <4 ppmy HS <4 ppmv _| | Molecular weight 16.21 24.51 [LHV, koallkg 11252 10250 RIL Natural Gas: Composition (mol %, max) | Components Methane, > 80 10 Propane 5 Total Butanes 3 | Total Pentanes 2 Nitrogen 4 Hydrogen 1 vol % (Total Supihur including H; 10 ppmw, Max. variation in Wobbe Inde» 25% WIFLHV (Vol basis)(Sp. Gr. w.rt.ai)*0.5 | a) Trace Metals Phezn 0.5 pprow Nawk 0.3 ppmw | Vanadium 0.5 ppmw< Securiy Level 2 > BASIC ENGINEERING DESIGN ovo BASIS (PART - B) DHT PROJECT __-HPCL, Visakh ISSUED : 17" Feb. 2009 JOB NO. : 6264 ENGINEERING INDIA LTD. [DOC.No. A-6261-000-051-001 |Rev.2 Sheet 48 of 114 _ Caleium 2 ppmw Magnesium 2 ppmw ‘Sum of heavy metals (Hg+V Pb+Zn+Nit 1 ppmw Others) b)SolidParticulstes = Total for particle size upto10 micron 20 ppmw For 2 micron < dé 10 mioron 1.5 ppmw For particle size greater than 10 micron 0.3 ppmw Lc) Liquid Content hina ) Moisture 142.kg J millon SCM lHydrogen Content 4 vol % Acetylene 0.1 vol % Higher hydrocarbon for n>=3 _ 10 vol % Molecular weight Net Heating Value (vol basis) > 30556 BTU/SCM Battery Limit Conditions: ~ | FuetGas || | Fuel Gas Refinery | (without Hy [Gail Naturd| RIL Natural] (with Hp Fuel Gas | Recovery in) Gas Gas | Recovery in PSA) PSA) ISupply header [Maximum 35 3.5, 35 35 35 lOperating Pressure|Normal 3 3 3 3 3 orem’ (Minimum 2.5 25 25 25 25 lsupply header [Maximum 60 60 60) eo | 60 |Operating [Normal 40-50 | 40-50 | 40-50 | 40-60 | 40-50 [Temperature, °C [Minimum 30 30 30 30 30 IMechanical Design |Press.kg/em’g| 9 9 9 9 9 [Conditions “TTemp., °C. 100 | _100 100 00 | 100.| ___< Security Level 2 > a BASIC ENGINEERING DESIGN @ s | BASIS (PART - B) bes DHT PROJECT | HCL, Visakh Z TOYO ENGINEERING INDIA LTD, 52 Feb, 2008 JOB NO. : 6264 26 No. 8:6261-000-051-001_ Rev? Shoot 49 of 114 1 Caustic Caustic strength; 10 wt% Pressure, Kgiom? g Temperature, °C Min [Norm [Max | peetan [Min [Norm [Max | Blech. foo 65 | 728 Ambient 65 peas 6.0 . ‘Ambient 65 © be fixed based on the operating conditions in the source unit i Amine (DEA DEA strength : 25 wi% Sattery Limit Conditions: Rich Amine :0.33 mol of H2S / mol of Amine (At DHT B/L) i Minimum | Normal] Maximum | Mech. Design "Pressure, Kolem® g a0 | Temperature, °C a Lean Amine ; 0.03 mol of H2S / mol of Amine (At DHT B/L) Minimum [Normal | Maximum | Mech. Design . 35 = 45<< Security Level 2 > BASIC ENGINEERING DESIGN @ | BASIS (PART - B) oO pct, visakh | _—___— DIT PROECT TOYO ENGINEERING INDIA LTD. ISSUED: 17"Fep. 2009, JOB NO. : 6261 | lboc.No. A-6261-000.051-001 [Rev2 Sheet 50 of 114 817 Flaw Maximum flare backpressure shall be considered for sizing pressure relief devices as given in table below Header Name Normal Flare | Acid Flare Pressure units ~ kgicm?g kkglem?g /Superimposed backpressure of O74 Total back pressure in main relief 17 17 “| header _ i Design Temperature °C 785 185 Design Pressure 35 35 8.17.1 Over pressure (as percentage of set pressure) for sizing of relief valve shall be: Tow pressure <70 | High pressure >70 contingency meres eee [Steam Generation a Equipment _ a a Fire case 20% As per design \ Thermal relief 25% As per design _ _| Operational failures 10% Asperdesign — |< Security Level 2.> BASIC ENGINEERING DESIGN | w s 1 BASIS (PART -B) x (PCL, Visakh _| Tove ENGINEERING INDIA LTD. ssueD | | 47" Feb. 2009, JOB NO. : 6261 ~— 4 [DOC.No, A-s261-000-051-001 |Rev2 ___Shost tof 14 | 9.0 of 9.2 9.24 92.44 EQUIPMENT DESIGN PHILOSOPHY Overdesign Philosophy The overdesign margins on systems and equipments are considered by respective licensors as per their own standard practice. Selection of Mechanical Design Conditions. Equipment and piping systems shall be designed for the most stringent coincident temperature and pressure conditions, accommodating the maximum expected working pressure and temperature without causing a relieving condition. The design shall be such that instrument safeguarding systems or availability of emergency power or steam are not relied upon for overpressure protection. Abnormal conditions shall be evaluated considering a single contingency. A double or multiple contingency shall not be considered, but, if one failure is a result of another failure, both failures are to be considered as one contingency. Guide for “Pressure relief and depressurizing systems", API RP 521 (latest edition) shall be followed for evaluating failures. \ Mechanical design pressure for pressure systems Mechanical design criteria laid down in this section shall be followed as standard. Deviations to these criteria are not permissible for any facility, except for high pressure equipment working above 70 kg/cm?g or for identified critical equipment for which designer of a particular unit has to necessarily follow the designer's company standards that ensure plant safety and operating personnel protection, A pressure system protected by a pressure relief device connected to the flare system shall have a mechanical design pressure, calculated at the location of the relieving device, as the higher of the following: (For operating pressure upto and including 70 kg/cm’g, design pressure< Security Level 2 > = BASIC ENGINEERING DESIGN @G Q) BASIS (PART - B) x DHT PROJECT oe HCL, Visakh TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2008 _JOB NO. : 6261 lbo.No. A-626%.000-051-001_fev2 _ Sheet 62 of 114 shall be highest of the following = Maximum operating pressure (kg/om*g) x 1.1 = Maximum operating pressure + 2.0 kg/cm’g = 3.5 kglom’g (ii) For operating pressures above 70 kg/cm’g, design pressure shall be as per designer and as permissible by applicable code. 9.2.1.2 The design pressure calculated as per 9.2.1.1 is at the location of relieving 9.2.1.3 92.14 9.2.1.6 device such as the top of a vertical vessel. The design pressure at the bottom of the vessel and of associated pieces of equipment shall be determined by adding applicable maximum operating liquid heads and pressure gradients, Vessels operating under vacuum shalll be, in general, designed for an external pressure of 1.033 kg/cm(a) and full internal vacuum, unless otherwise specified. Vacuum design stipulations shalll be as per section.7.10. Vacuum equipments shall be designed additionally for water filling / LP steam flushing Emergency vacuum pressure of 0.4 kg/cm?(a) can be considered by designer based on the process requirements and assessment of transient operations. For a full liquid system at the discharge of a centrifugal pump, the mechanical design pressure shall be as under: Paes. = Prax suction + APmax Where, Praxsucion = Maximum pressure at suction vessel bottom during suction system relieving conditions (as per 9.2.1.1 & 9.2.1.2) APmax = Pump differential pressure at pump shutoff head with maximum operating density. If not known:«Security Level 2 > = BASIC ENGINEERING DESIGN @ BASIS (PART - B) L DHT PROJECT ee POL, Visakh , _| rovo encineerinc woIaL1. i? Feb. 2009 JOB NO. : 6264 /.9261.000.051.001 Reva . Sheel S3.0f114 | AP roa = 1.3 XAHX Pax constant speed pump A Prax. = 1.11.3 X AHX pina variable speed pump. AP max 1.3 X AH X pmax high head multistage pump. A Prax = 1.1 x 1.3 x AH X pmax : variable speed, high head multistage pumpq, © For a full liquid system at the discharge of a positive displacement pump, the mechanical design pressure shall be the higher of: Paes = Prateg discharge + 2.0 kg/cm? Paes = 1.1 Prat discharge For centrifugal compressors, the mechanical design pressure shall be decided a follows; (2) Discharge side mechanical design pressure shall be the higher of; Paes = Pras discharge + 2.0 kglom? Poss = 1.1 xPrie discharge (b) The interstage design pressure shall be the higher of the following in case of relieving device is not installed = Interstage maximum operating pressure, = Pressure of kick back fiow from the downstream stage, = Compressor settling out pressure, (©) The interstage design pressure in case where relieving device is installed, shall be determined analogous to 9.2.1.7 (a) above. (d) The suction side design pressure shall be fixed analogous to 9.2.1.7 (a) above, in case where relieving device is installed. In the absence of pressure relieving device, the design pressure shall be determined in the ‘same manner similar to 9.2.1.7 (b). / 1.8 For positive displacement compressors, mechanical design pressures shall be<< Security Level 2 > —— BASIC ENGINEERING DESIGN @ BASIS (PART -B) DHT PROJECT noe HPCL, Visakh ~ _| TOYO ENGINEERING INDIA LTD. ISSUED: 17" Feb. 2009 JOB NO. : 6261 [DOC.No, A-6261-000-051.001 |Rev.2 Sheet 54 of 114 determined analogous to 9.2.1.6 and 9.2.1.7 (d) for the discharge and suction sides, respectively. 9.2.1.9 For shell-and-tube heat exchangers, the low pressure (LP) side of exchanger, including upstream and downstream systems, shall be preferably specified with a design pressure at least equal to ten-thirteenth (10/13) of high pressure (HP) side design pressure, in order to avoid having to install a pressure relief device on the LP side, The ten-thirteenth criteria shall necessarily be adhered to when: (1) LP fluid is on the tube side, (2) Relief discharge cannot be connected to flare header owing to nature of fluid. (3) Relief discharge is two-phase and cannot be connected conveniently to a low-pressure destination with free-draining piping. (4) Liquid relief cannot be connected to a closed blowdown system (5) The ten-thirteenth criteria calls for an increase by less than a factor of 1.3 of the mechanical design pressure of the LP side as would be calculated from normal estimation procedures. However, based on process considerations and designer's own practice, heat exchanger can be designed without upgrading design pressure by providing tube rupture pressure relief valve after getting consent on case to case basis from owner. For feed / effluent exchanger, the tubesheet and tubes in high pressure service need not be designed for full design pressure of the shell and / or channel provided these components can never experience these conditions. The same should be designed for maximum differential pressure expected. Designer must consider start-up, shut-down and emergency depressurising while deciding maximum differential pressure. In cases where shell side pressure is very low compared to tube side, for ‘subsequent testing of tube bundle, additional facility like spare shell for testing shall be considered.< Security Level 2 > = BASIC ENGINEERING DESIGN @ @ BASIS (PART - B) : be DHT PROJECT oe HPOL,Visakh TOYO ENGINEERING INDIA LTD. 47% Feb. 2009 JOB NO. : 6261 s #-6261-000-061-001_[Rev.2 : Sheet 55 of 114 _ Mechanical design pressure for storage tanks and atmospheric vessels Sesign pressure of storage tanks shall be in accordance with API-620, API-650 and API-2000 (latest editions), as appropriate. Blanketed storage tanks shall have a blanketing pressure of 150 mmwe, unless a higher pressure is deemed necessary from process considerations. The design pressure of blanketed storage tanks shall be determined to allow adequate overpressure for out-breathing and emergency relief devices. The blanketed tanks shall also be designed for 50 mmwe vacuum. hanical design temperature |. For system operating at or above 0 °C, the mechanical design temperature shall te the higher of the following, Tews = 65°C Tews = Trane + 28°C Tees = Treter (excluding fire relief temperatures) Where, Trax = Maximum operating temperature expected considering different Possible operations for the equipment or system, including air drying or gas drying conditions. Teter = Temperature corresponding to pressure relief conditions for an operational failure case (specifically excluding fire relief case). 3.2 For system operating below 0 °C, the mechanical design temperature shall be equal to the lowest anticipated operating temperature. ® For pressure vessels storing refrigerants or liquefied hydrocarbons at ambient mperature, the design temperature (based on depressurization) shall orrespond fo the coincident design pressure when this lowest temperature is< Security Level 2 > BASIC ENGINEERING DESIGN @G BASIS (PART - B) DHT PROJECT TOYO ENGINEERING INDIA LTD. ISSUED : 17" Feb. 2009 JOB NO. : 6264 [D0C.No, A-6261.000-051-001 |Rev2 Sheet 56 of 114 9.2.3.4 9.24 92.5 9.2.6 9.3 9.3.4 9.3.4.1 reached. The coincident design pressure can be different from the maximum design pressure specified for the vessel depending upon the system under consideration. However, if this calls for a change in metallurgy, then other fool proof strategies to avold this situation shall be evaluated. Otherwise select the metallurgy to suit the minimum temperature. For heat exchangers, consideration should be given to possible failure of cooling medium and resultant impact of higher temperature on tubes, tubesheets and floating head (inlet maximum temperature). The design temperature is highest anticipated temperature in such an event. Vessels provided with steam out conditions shall be designed for the following steam out conditions when LP Steam is considered adequate: (a) Pressure 0.5 kglom?g (b) Temperature = Maximum LP Steam temperature = 170 If specific equipment requires steam out with MP steam, steam out temperature shall be specified accordingly. Storage tank bottoms shall be insulated using foam glass or similar material if operating temperature is more than 100 °C and lower than 0°C. Minimum Design Metal Temperature (MDMT) Designer shall specify MDMT. Ambient temperature data are as per Section 5. Heat Exchangers Selection of Shell and Tube heat exchangers Floating Head type exchanger is preferred construction in refinery service. The< Security Level 2 > = BASIC ENGINEERING DESIGN 3) BASIS (PART -B) — DHT PROJECT CL, Vigakh _ - TOYO ENGINEERING INDIA LTD, Feb. 2009 JOB NO. : 6264 7 5 $264-000-051-001 jRev.2 _ t Sheet 57 0f114 | use of fixed tubesheet heat exchangers shall be minimized to the extent possible. These can be used in limited services such as vertical thermosyphon »boilers where steam is on shell side. Steamout conditions shall be specified for «ed lubesheet heat exchangers, considering either shell side or tube-side being ‘ed out at one time. Start-up and upset conditions for fixed tubesheet -xchangers to be specified as well fean Hairpin type (double pipe or multitube) exchangers are not preferred. The exchangers can be stacked considering the size of exchangers, equipment fayout and approach for operation and maintenance. Stack upto 3 shells when shell diameter are less than 1000 mm and individual shell isolation and bypasses are not provided. For other cases, limit stacking to 2 shells. Vertical thermosiphon, horizontal thermosiphon or kettle type reboilers can be specified by unit designers, as found appropriate. Considerations shall be given to: + Process fluid degradation, * Fouling tendency of process fluid, + Process hold-up volumes within exchangers and constraints, if any, ‘+ Film boiling possibilities and temperature difference between hot and cold fluids, + Width of boiling range, + Vaporization rates and variations anticipated, + Equipment cost, ‘+ Equipment space and installation constraints, if any, + Toensure effective natural circulation. Stabbed-in reboilers shall be avoided as far as possible in order to facilitate equipment maintenance. Seneral criteria for selection of TEMA type of exchangers shall be:«Security Level 2 > BASIC ENGINEERING DESIGN G & BASIS (PART - B) x DHT PROJECT see HPGL, Vieakh _ ‘TOYO ENGINEERING INDIA LTD. ISSUED : 17"Feb. 2008 JOB NO. : 6261 E [006.No. A-6261-000.051-001 |Rev2 Sheet 58 of 114 Shell side fouling resistance | Tube side fouling resistance] TEMA type (Hr-m*°Cikcal) (Hrem?*-°Cikcal) (preferred) — >0.0002 _ >0.0002 loating head_ 50.0002 >0.0002 Fixed tube sheet_ 0.0002 0.0002 | U tube bundle Fixed tube sheet / 0.0002 aoe Utube bundle 93.1.5 9.3.1.6 OR as specified by Licensor. All shell and tube heat exchangers in a refinery application shall follow TEMA- R, unless required otherwise. Proferred exchanger type for refinery services shall be horizontal, single pass shell, floating head tube bundle (TEMA type 'S') arranged with two or more tube passes per shell Tube layout shall be square or rotated square for fouling services and triangular pitch for clean services (i.e. fouling factor $0.0002 Hr-m?-*C/kcal). General criteria for specifying U-tube construction shall be: = Services where steam is condensed or generated on tubeside; tube pitch shall be triangular if shell side fluid is clean and square / rotated square if shell side fluid is fouling. TEMA type B stationary head: hydrogen services or when steam or other clean fluid is on tube side, not requiring cleaning. - TEMA type A stationary head when tube side fluid is cooling water or similar process fluids, requiring cleaning - TEMA type B or C stationary heads shall not be used when design pressure is higher than 140 kg/cm*%a). Tubesheet shall not be full diameter extended type when TEMA type B stationary head is used. ~ For U tube bundles, consideration shall be given for hydrotesting of tubes for IBR / normal testing after preventive maintenance. If necessary, dummy shell shall be designed for testing for maintenance purpose.