DESCRIPTION

PROCESS DESCRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 1/6
Ref. FEED DOC. No. : -

PROCESS DESCRIPTION

FOR

UNIT 44 - REFINERY FUELS UNIT

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ

EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP)

0 06 MAR 15 ISSUE FOR CONSTRUCTION Y.H.Chu S.J.Yoo K.W.Mo J.B.Kim -

th
A 14 August 2014 ISSUE FOR REVIEW Y.H.Chu S.J.Yoo Y.H.Chun J.B.Kim

REV. DATE DESCRIPTION PRPD CHKD REVD APPRD CONFD

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering
& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :
a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 DESCRIPTION
PROCESS DECRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 2/6
Ref. FEED DOC. No. : -

REVISION HISTORY

Rev Date Description Page

th
A 14 August 2014 Initial Issue. -
Description for Refinery Fuel Gas supply is
updated as per no 9. 50mmscfd natural gas of
KRP-C-MOM-N-0006.
0 06 MAR 15 4,6
As a result, relative description is revised
accordingly (Butane Excess Vaporizer (44-E-004)
is deleted)
Description for Refinery Fuel Oil supply is updated
as per no 9. 50mmscfd natural gas of KRP-C-
MOM-N-0006.
0 06 MAR 15 4,5
As a result, relative description is revised
accordingly (Product Diesel is added on Light
Cycle Oil supply line)

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 DESCRIPTION
PROCESS DECRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 3/6
Ref. FEED DOC. No. : -

TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 4

2. PROCESS DESCRIPTION ........................................................................................... 4

2.1 Refinery Fuel Oil ...............................................................................................................4

2.2 Fuel Gas ............................................................................................................................5

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 DESCRIPTION
PROCESS DECRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 4/6
Ref. FEED DOC. No. : -

1. INTRODUCTION
This document defines the process description for the Refinery Fuels Unit in case
Natural Gas is used as back-up for the fuel gas system along with vaporized LPG. The
system provides fuel to utility generation (Boilers), process furnaces, heat recovery
steam generators and gas turbines generators (Refinery fuel oil for gas turbines only).
Fuels burned in the refinery will be refinery fuel gas and two types of refinery fuel oil,
one for gas turbines and one for heaters and utility boilers.

2. PROCESS DESCRIPTION
For and overview of the unit, reference is made to the following Process Flow Diagrams:

 IONE-AA44-PFD-0010-001-01

 IONE-AA44-PFD-0010-002-01

 IONE-AA44-PFD-0010-003-01

 IONE-AA44-PFD-0010-004-01

 IONE-AA44-PFD-0010-005-01

2.1 Refinery Fuel Oil

During normal operation, Refinery Fuel Oil (RFO) system is not operated because all fuel
oil (Clarified Slurry Oil, Light Cycle Oil, and VGO HDT Diesel) shall be blended into Heavy
Fuel Oil (HFO) for Al-khairat power station supply. However, RFO system can be operated
to supply for refinery fuel oil in case of lack of natural gas used as refinery fuel gas.

The refinery fuel oil storage area shall be located in utility area and it is made up of 2 fixed
roof tanks and one blending storage drum.

The two storage tanks are identical but operated at different temperatures since Clarified
Slurry Oil and lighter products (Light Cycle Oil and VGO HDT Diesel) have different flash
point and viscosity.

Gas Turbines Refinery Fuel Oil Pumps (44-P-004 A/B) take suction from tank of lighter
products, while Fuel Oil Transfer Pumps (44-P-001 A/B) take suction from tank of Clarified
Slurry Oil. Both pumps feed Fuel Oil Blending Drum (44-V-001) to obtain refinery fuel oil
for heaters and utility boilers through controlled mix. Gas Turbines Refinery Fuel Oil
Pumps (44-P-004 A/B) shall be also able to feed Liquid Fuel Storage Tank located inside

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 DESCRIPTION
PROCESS DECRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 5/6
Ref. FEED DOC. No. : -

Power Generation Unit with product obtained with a controlled blending of VGO HDT
Diesel and Light Cycle Oil inside lighter products tank. Tank in Power Generation Unit will
serve both Gas Turbines and Heat Recovery Steam Generators.

The Refinery Fuel Oil Distribution Pumps (44-P-002 A/B/C) shall be three in number, two
operating and one stand-by. One of the Refinery Fuel Oil Distribution Pumps will be
turbine driven.

Each pump shall be sized for 50% of the refinery fuel oil for heaters and utility boilers
peak demand plus amount required for fuel oil circulation.

These pumps in normal operating conditions take suction from blending drum. In case of
blending drum and/or one tank out of service, VGO HDT Diesel, Light Cycle Oil and
Clarified Slurry Oil will be sent to one tank only and Refinery Fuel Oil Distribution Pumps
will take suction from tank where VGO HDT Diesel, Light Cycle Oil and Clarified Slurry Oil
will be collected. During this scenario, Power Generation Unit can be fed directly from Unit
52 storage instead of Gas Turbines Refinery Fuel Oil Pumps (44-P-001 A/B).

Downstream of Refinery Fuel Oil Distribution Pumps (44-P-002 A/B/C) two filters (one
operating/one standby) are foreseen in order to protect burner from particulate matter.

Fuel oil is then heated to adjust viscosity in two heat exchangers (one operating/one
standby) installed on distribution pumps discharge.

LPS will be used in tank coil, heat exchanger and piping tracing.

Recirculation line is provided downstream fuel oil furthest user with pressure control loop.

To maintain local circulation of refinery fuel oil for heaters and utility boilers through the
piping a restriction orifice shall be installed on users return header.

Product Diesel will be supplemented from Diesel tank instead of Clarified Slurry Oil and
Light Cycle Oil for FCC unit(Unit 07) failure cases.

2.2 Fuel Gas

Fuel gas produced in process units will be routed to the fuel gas mix drum where
composition of the different stream is homogenized. The mix drum shall be provided with
a demister in order to perform a better separation of liquid particles that may be entrained
in the fuel gas. The liquid phase shall be collected in the bottom of drum and sent to Fuel
System Closed Drain.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea

 DESCRIPTION
PROCESS DECRIPTION
FOR UNIT 44
DOC. NO. : IONE-IH44-SP-PR-0002
KARBALA REFINERY PROJECT Rev. 0 Page 6/6
Ref. FEED DOC. No. : -

Hydrocarbons accumulated in drain drum will be sent to Light Slop Tanks or Heavy Fuel
Oil Tanks.

Pressure in the fuel gas network will be ensured by Natural Gas from Unit 45 and
vaporization of LPG from storage.

The system will control fuel gas network pressure using imported Natural Gas. The LPG
also will be vaporized via LPG vaporizer (44-E-002) in accordance with fuel gas network
pressure.

In case of high pressure, due to upset conditions, the pressure control will release fuel
gas excess to the flare.

LPG from storage area shall be pumped in LPG Vaporizer where it shall be vaporized and
superheated through pressure control valve expansion; therefore LPG shall be sent to
fuel gas mix drum where it is homogenized with Fuel Gas produced streams. Vaporizer
will use LPS as heating medium.

HDGSK JV  Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea