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QUESTIONNAIRE
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Table of Contents
1 INTRODUCTION............................................................................4
1.1 OBJECT..................................................................................................................... 4
1.2 PLANT LOCATION....................................................................................................4
1.3 REFERENCE DOCUMENTATION.............................................................................4
1.4 ACRONYMS..............................................................................................................4
2 PROJECT OVERVIEW.....................................................................5
2.1 DOWNSTREAM COMPLEX OVERVIEW..................................................................5
2.2 GENERAL PROCESS SCHEME...............................................................................8
3 REFINERY CAPACITY.....................................................................9
3.1 FACILITY CAPACITY.................................................................................................9
3.2 DESIGN CAPACITY OF PROCESS UNITS.............................................................10
3.3 TURNDOWN............................................................................................................ 10
3.4 ON STREAM FACTOR............................................................................................10
4 FEEDSTOCKS CHARACTERISTICS.................................................11
5 PRODUCTS SPECIFICATION.........................................................15
5.1 CUT POINTS FOR CRUDE DISTILLATION UNIT PRODUCTS..............................15
5.2 END PRODUCT SPECIFICATION...........................................................................15
6 AVAILABILITY OF UTILITIES......................................................20
6.1 RAW WATER CHARACTERISTICS........................................................................20
6.2 NATURAL GAS CHARACTERISTICS.....................................................................21
6.3 MAIN FEATURES OF UTILITY SYSTEMS (TO BE CONFIRMED).........................22
6.4 PROPOSED CHARACTERISTICS OF UTILITY SYSTEMS....................................22
7 BATTERY LIMITS (TO BE CONFIRMED)........................................25
10 SITE CONDITIONS.......................................................................29
10.1 SITE LOCATION......................................................................................................29
10.2 SITE CONDITIONS..................................................................................................29
10.3 SOIL CONDITIONS..................................................................................................29
10.4 REFERENCE ELEVATION......................................................................................30
10.5 CLIMATIC DATA......................................................................................................30
10.6 SPECIAL ENVIRONMENTAL CONDITIONS...........................................................31
11 SYSTEM OF MEASUREMENT UNITS..............................................32
12 ENVIRONMENTAL REQUIREMENTS..............................................33
12.1 ATMOSPHERE........................................................................................................ 33
12.2 WATER EFFLUENT.................................................................................................34
13 PROCESS DESIGN CRITERIA........................................................35
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INTRODUCTION
1.1 OBJECT
The object of this document is to define the Design Basis for the
development of the Basic Engineering and of the Front End Engineering
Design (FEED) for the Petro Bicentenario Refinery Project.
It includes the plant location, design capacity of the facilities, feedstock
characteristics and product specifications, utility characteristics, storage
capacity and battery limit conditions.
Part of the document is dedicated to the Process Design Criteria that
summarize criteria and methodology to be used for specifying major
equipment or systems and piping.
The information needed for this early phase of the project are
indicated as to be provided. Client is requested to provide the
missing information and to confirm the available data.
1.4 ACRONYMS
AGO: Atmospheric Gasoil
BPSD: Barrel per stream day
DCO: Diluted Crude Oil
EHO: Extra Heavy Oil
FEED: Front End Engineering Design
HDC: Full Conversion Hydrotreating Unit
HCGO: Heavy Coker Gasoil
HDT: Naphtha Hydrotreating Unit
HDS: Gasoil Hydrodesulphurization Unit
LCGO: Light Coker Gasoil
LVGO: Light Vacuum Gasoil
MLA: Marine Loading Arm
PDVSA: Petrleos de Venezuela S.A.
SMR: Steam Methane Reforming
SBM: Single Buoy Mooring
VGO: Vacuum Gasoil
VR: Vacuum Residue
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PROJECT OVERVIEW
In 2010 PDVSA has formed two Joint Ventures Companies with Eni
Lasmo for the exploitation of Extra Heavy Oil (EHO) in Orinoco Faja:
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To support the ongoing operation of the various process units, the utility
facilities listed below are required.
Raw Water System
Service Water System
Potable Water System
Demineralization Water System
Oily and Clean Condensate System
Boiler Feed Water System
Cooling Water System
Compressed Air System
Nitrogen System
Natural Gas and Fuel Gas Distribution System
Steam and Power Generation System
Pressure Relief and Disposal System
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Note: the SMR unit figure is referred to hydrogen chemical consumption only
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REFINERY CAPACITY
CAPACITY
FEEDSTOCK SOURCE
(BPSD)
Petro Bicentenario
312,000
Diluted Crude Oil (DCO) (*) Upstream Complex
to be
Atmospheric Residue PetroMonagas Refinery
provided
to be
Middle Distillates PetroMonagas Refinery
provided
to be
Light Coker Gasoil PetroMonagas Refinery
provided
to be
Heavy Coker Gasoil PetroMonagas Refinery
provided
(*) = Diluted Crude Oil is a blend of 240,000 BPSD of EHO and 72,000 BPSD of
Dilution Naphtha.
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The Design Capacities of the process Units are summarized in the Table 3.2.
1.9 TURNDOWN
All the Refinery Units shall be designed for sustained on-spec operation under a
turndown condition of 50% of design flow.
The on stream time specification will be 97% (8500 hours per year) outside
general turnarounds and turnarounds for catalyst replacement.
Due to the peculiar refinery configuration, it has been assumed that
Hydrocracker/Hydrotreaters units will need a turnaround for catalyst
replacement/regeneration every two years (24 months of operations).
According to the experience with similar units these shut down will last 45 days
(production loss). The general turnaround of catalytic units will coincide with
the above said turnarounds and so no additional general turnaround period has
to be considered for these units.
The general turnaround of non-catalytic units will be coincident with one of the
above said turnaround of catalytic units, i.e. in principle a general turnaround
every 4 years, lasting 45 days (production loss).
To be confirmed during FEED and in accordance with Process Licensors.
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FEEDSTOCKS CHARACTERISTICS
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Diluent Naphtha
The main properties of Diluent naphtha indicated in the Table 4.2 are relevant
to a Hydrotreated full range Coker Naphtha from a reference project and shall
be confirmed during the FEED.
Value
Property Unit of Measure
(1)
Density @ 15C 740.8 -
Kinematic Viscosity @ To be -
37.8C provided
Kinematic Viscosity @ To be -
100C provided
To be -
Total Nitrogen Content
provided
To be -
Paraffine Content
provided
To be -
Pour Point
provided
To be -
K UOP
provided
To be
H2S -
provided
To be
Flash Point -
provided
To be
RVP @ 37.8C -
provided
Distillation TBP
IBP 42 C
5% vol 60 C
10% vol 80 C
20% vol 95 C
30% vol 105 C
40% vol 113 C
50% vol 121 C
60% vol 128 C
70% vol 135 C
80% vol 142 C
90% vol 150 C
95% vol 158 C
FBP 167 C
Residue 1 % vol
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ATM Middle
LCGO HCGO
Residue Distillates
Unit of
Property Measureme
nt
- To be To be To be To be
SpGr provided provided provided provided
Kinematic cSt
To be To be To be To be
Viscosity @ 50C
provided provided provided provided
(122 F)
Kinematic cSt
To be To be To be To be
Viscosity @
provided provided provided provided
100C (210 F)
wt% To be To be To be To be
Sulphur Content provided provided provided provided
Total Nitrogen ppmwt To be To be To be To be
Content provided provided provided provided
Paraffine wt% To be To be To be To be
Content provided provided provided provided
C To be To be To be To be
Pour Point provided provided provided provided
- To be To be To be To be
K UOP provided provided provided provided
To be To be To be To be
H2S ppmwt provided provided provided provided
To be To be To be To be
Flash Point C provided provided provided provided
To be To be To be To be
CCR wt% provided provided provided provided
To be To be To be To be
Salts Content Lb/MBls provided provided provided provided
To be To be To be To be
Chloride Content ppmwt provided provided provided provided
Naphtha into
To be To be To be To be
Crude Oil (IBP-
provided provided provided provided
200 C) wt%
To be To be To be To be
Distillation
provided (*) provided provided provided
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PRODUCTS SPECIFICATION
TBP cut points for product from Atmospheric and Vacuum Units are indicated in
Table 5.1.
All These values have to be confirmed.
(*) This data has to be confirmed considering the available Dilution Naphtha
characteristics.
The refinery processes the above mentioned feedstocks in order to produce the
following final products:
LPG
NAPHTHA pro Petrochemical
NAPHTHA pro Reformer
DIESEL @ EU5 Spec
Pet-Coke
Sulphur
Diesel end point will be maximized within the limits of the European spec
(95% ASTM LT 360C) and therefore a nominal TBP cut point of 370C will
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be used, unless lower end points are required to meet cold flow
properties.
The tables below report the typical market specifications of the final products.
Product Specifications shall be confirmed / updated.
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U.M. LOCATION
Mediterranean Northern Germany
Area Europe
Winter
C max -12 -15
1 Oct 31 March
Summer
C max -2 -5
1 April 30 Sept
U.M. LOCATION
Mediterranean Northern Germany
Area Europe
Winter
C max 0 -5 -7
1 Oct 31 March
Summer To be To be
C max To be reported
1 April 30 Sept reported reported
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AVAILABILITY OF UTILITIES
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The electric power and steam required by the complex will be produced
in a combined cycle power plant.
All the heaters and boilers will be fired by treated combustible gas that
is generated in the refinery or by Natural Gas.
The proposed cooling water system is an open system based on cooling
tower package, using service raw water as make-up.
Nitrogen will be internally produced by PSA Unit.
Storage is provided for the liquid Nitrogen to supply peak requirements.
Hydrocarbon Flare and Blowdown System is provided in order to receive
all relieves during emergency and in case of any upset; a separate Acid
Flare will also be provided.
The utilities will be available at unit battery limit at the following conditions
(TO BE CONFIRMED).
1.16.1 Steam
Pressure (bar g) Temperature (C)
Nor
Min Max Des Min Norm Max Des
m
Distribution
1 High Pressure (HS) 38 40 42 44 385 400 420 450
2 Medium Pressure (MS) 10 12 16 20 280 295 320 350
3 Low Pressure (LS) 3.5 4 4.2 6 150 165 180 210
Note:
Steam will be produced by Power Plant and SMR Unit at a pressure level of 80
barg (To be confirmed during FEED Phase).
The number of steam distribution levels (two or three) to the refinery units will
be confirmed during FEED Phase, based on techno-economic considerations.
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Service
Description Cooling
Potable
Tower
Water
Water
4 Supply Pressure min. bar g 3.5
5 norm bar g 4.0
6 max. bar g 3.5
7 Return Pressure bar g 2
8 Supply Temperature C 35 Amb.
9 Max. Return Temp. C 45
10 Design Pressure bar g 6
11 Design Temperature C 70
12 Fouling Factor S&T H.E. m2hrC/kcal 0.0004
13 Cleanliness Factor kcal/m2hrC 0.8
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Service
Description Instrum. Service
Nitrogen
Air Air
1 Pressure: min. bar g 6 6 6
2 norm. bar g 7 7 7
3 max. bar g 8 8 8
4 Design Pressure bar g 10 10 10
5 Temperature: min. C -5
6 norm. C 47 47 5
7 max. C 50 50 40
8 Minimum Temperature C
9 Design Temperature C 75 75 70
Dew Point at Normal
10 C -5
Pressure
QUALITY OIL FREE
99 - To be
11 Nitrogen Purity Vol.% min.
Confirmed
12 Carbon Dioxide ppm vol max. 1
13 Carbon Monoxide ppm vol max. 0
14 Hydrocarbons ppm vol max. 1
15 Oxygen ppm vol max. 5
16 Noble Gases ppm vol max.
17 Water ppm vol max. 1
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The Battery Limits for inlet / outlet streams are defined as follows:
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Pressure Temperature
Source Destination kg/cm g C State
Oper. Design Oper. Design
FEEDSTOCK
Diluted Crude To be Provided
Upstream Crude Unit To be Provided Liquid
Oil (1)
Atmosph. To be Provided
PetroMonagas Vacuum Unit To be Provided Liquid
Residue (1)
Middle To be Provided
PetroMonagas HDS Unit To be Provided Liquid
Distillate (1)
Light Coker To be Provided
PetroMonagas HDS Unit To be Provided Liquid
Gasoil (1)
Heavy Coker To be Provided
PetroMonagas HDC Unit To be Provided Liquid
Gasoil (1)
PRODUCTS
Notes:
(1) It is assumed that the feedstock will be received at a pressure sufficient to be
stored in the storage tanks of the Complex.
(2) The Operating and Design Pressures will be finalized based on the following
information:
Ship Size;
Availability of existing Jetty or location of a New Jetty for loading through MLA;
Bathymetry;
Distance from Storage to Existing or new Jetty / Distance from Storage to buoy.
(3) Solid Sulphur shipping from Open Storage Area to users by others.
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FEEDSTOCKS Hold-Up
Days
DILUTED CRUDE OIL TBD
ATM RESIDUE FROM PETROMONAGAS TBD
HCGO FROM PETROMONAGAS TBD
LCGO+MIDDLE DISTILLATES FROM PETROMONAGAS TBD
FINAL PRODUCTS
LPG TBD
NAPHTHAS TBD
DIESEL OILS TBD
INTERMEDIATE PRODUCTS
OFF SPECS
The general basis that will be followed for the definition of the minimum
required hold up time for services requiring storage are summarized below:
FEEDSTOCKS
A minimum hold-up of 14 days has been foreseen for Crude Oil and 7 days for
each stream imported from PetroMonagas Refinery.
INTERMEDIATE PRODUCTS
Intermediate products tanks are needed to compensate fluctuations of
production rates between upstream / downstream units and to allow unit
operation in case of shutdown of upstream / downstream unit (unexpected
shutdown or scheduled outages for catalyst replacement).
Intermediate product tanks shall be designed for a minimum hold-up of 7
days: it shall be operated partially full, with 3.5 days minimum empty space, to
cover the downstream unit unscheduled shutdown and with a volume of stored
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FINAL PRODUCTS
A minimum storage volume of 14 days production will be foreseen for final
products.
In addition to the criteria above, at least two tanks have been foreseen for
each product to be delivered by ship.
o One tank (or more if necessary) having a total capacity of one cargo
plus one day to cover ship delay.
o One tank to store the product for process units during ship loading
SLOPS
Light and heavy slops are collected via segregated systems in dedicated tanks.
Slops are the transferred to the crude feed pump suction to be reprocessed in
the Atmospheric Distillation Unit.
Diesel and Naphtha are loaded into ship carriers through two single buoy
mooring (one for Diesel and one for Naphtha).
LPG is loaded through Loading Arms.
It is assumed that the existing jetty in Jose coastal area can accommodate
additional Loading Arms.
Pet Coke and Solid Sulphur are conveyed to a storage area, outside plant
fence.
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SITE CONDITIONS
Latitude: To be provided
Longitude: To be provided
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Design Temperatures
Minimum design ambient temperature 15 C
Design air temperature (Dry Bulb) for air cooled heat exch. 34 C
Design air temperature (Wet Bulb) for air cooled heat exch. 30 C
Stack-design air temperature shall be based on __ C
Electric motor design air temperature shall be based on 40 C
Design air temp. for electrical equipment installed outdoor 40 C
Design air temp. for electrical equipment installed in substations 40 C
Design air temp. for electrical equipment installed in buildings 40 C
Sunshine temperature __ C
Winterizing temperature __ C
Air Compressors and fans design 34 C
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Relative Humidity
Annual average mean 76 % at ___ C
Summer average mean ___ % at ___ C
Winter average mean ___ % at ___ C
Summer Maximum 100 % at ___ C
Summer Design 79 % at ___ C
Wind
Direction of prevailing wind is from the: NNE / ESE / NNE
Maximum recorded wind velocity sustained 95 HOLD km/h
Wind Velocity Column designs
Velocity 145 HOLD km/h
Height coefficient (if any):
Flare radiation shall be based on:
Rain
Maximum 1 year duration rainfall ___ mm
Maximum 24 hour duration rainfall ___ mm
1 hour duration rainfall:
number of recordings per years: ___
1st value (max. value): 63.4 mm/h
2nd value (max. value): ___ mm/h
3rd value: ___ mm/h
4th value: ___ mm/h
Maximum rainfall recorded in 5 minutes: 17.9 mm
Snow
Maximum snow depth mm
Earthquake
Seismic zone X Yes No
Seismic degree:
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The following table indicates the normal dimensions of main properties in various
systems of measurement units.
Temperature C C F
Pressure Pa abs kg/cm2 abs psi abs
Mass kg kg lb
Length M m-mm ft-in
Relative Density Spec.Gravity Spec.Gravity Spec.Gravity
@T,C/15C @T,C/15C @T,F/60F
Absolute Density kg/m3 kg/m3 API or
@15C @15C lb/gal @60F
Flowing Density kg/m3 kg/m3 lb/ft3
Flowing Quantities
Standard Quantities
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ENVIRONMENTAL REQUIREMENTS
1.23 ATMOSPHERE
The pollutant standards for each of the emission sources into consideration are:
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World bank
Italian regulations
X Local regulations
Other:
The pollutant standards for each of the effluent sources at the fence of the
complex into consideration (according to receiver) are:
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The purpose of this section is to define the design criteria to be applied for the
development of Petro Bicentenario Project, including sizing and general design
and functional criteria.
General
The Design Pressure is the max and/or the min. pressure for which the
mechanical calculations shall be performed.
The following summarizes the criteria to be followed for pressurized equipment:
OPERATING DESIGN
PRESSURE PRESSURE
Additional Consideration
Full Vacuum design condition shall be specified for:
Equipment normally operating under vacuum conditions or those that are
subject to evacuation during start up, shut down and /or regeneration.
Vessel and heat exchangers which handle fluids having a vapour
pressure lower than atmospheric pressure at minimum ambient
temperature normally operating liquid full, and that can be blocked in
and cooled down.
Fractionating columns and associated equipment that can undergo a
vacuum condition through loss of heat input.
Steam Turbine condensers
For equipment specified for full vacuum, the design temperature relevant to full
vacuum conditions shall be specified.
For Equipment protected by a downstream installed safety valve, the design
pressure shall be calculated as the design pressure of the equipment where the
safety valve is installed + 120% the estimated pressure drop from the affected
equipment and the equipment where the safety valves is installed + static
head (if any).
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Heat Exchangers
Heat Exchanger shall be designed by following the 10/13 rule in accordance
with the latest edition of ASME VIII Div.1. This means to set a design pressure
of the lower pressure side of the Heat Exchanger not lower than 77% of the
design pressure of the higher pressure side. This design rule allows to protect
the equipment against tube rupture without installing a PSV. The design
pressure set following the 10/13 rule will be extended also to inlet and outlet
piping connected to the lower pressure side of the Heat exchanger including
the isolation valves.
Compressors
Minimum design pressure at compressor discharge:
MOP + 1 kg/cm2 for MOP 10 kg/cm2 g,
MOP + 10% for MOP > 10 kg/cm2 g.
Pumps
Centrifugal Pumps
The design pressure for equipment and piping on the delivery side of a pump is
equal to the shut-off discharge pressure of the pump, calculated by adding the
maximum head of the pump to the maximum suction pressure.
When pump characteristic curves are known, the design pressure has to be
calculated with the actual shut-off head.
When the shut-off pump head is not available, this pressure can be estimated
by means of the following formula:
Where:
Pd = design pressure at pump discharge (kg/cm2 g)
Ps max = maximum suction pressure (design pressure of upstream vessel +
static pressure due to the maximum static head) (kg/cm2 g)
Head = head of the pump at design point (m)
SG max = maximum specific gravity of pumped liquid under normal operating
conditions.
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Volumetric Pumps
The design pressure for equipment and piping on the delivery side of a pump is
calculated as 115% of the discharge gage pressure, or as a minimum, the
discharge gauge pressure plus 1.8 kg/cm2.
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The design Temperature is the maximum temperature value for which the
mechanical calculation of the equipment shall be performed.
The design temperature shall be calculated keeping into account all the criteria
listed below:
The Minimum Design Metal Temperature (i.e. MDMT) shall be specified at least
of the lowest of the following:
Minimum Operating Temperature (MOT)
Minimum Ambient Temperature
Minimum metal temperature calculated as a result of depressurization
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Exploration & Production Division
Drums
No oversizing is considered. Suitable hold up times is considered according to
the services the drums are specified for.
The following minimum liquid surge time shall be provided between low and
high liquid level, unless otherwise dictated by process reasons and / or licensor
requirements:
Service Surge Time, min
Drums feeding other equipment for
further processing 10
Feedstock surge drum 15
Overhead receivers Note 1
Product Storage 2
Flow to sewer or drain 2
Water pot 2
Note 1: 4 min. hold up shall be considered with respect to the reflux flow rate
or 2 min. with respect to the net product flow rate whichever is the greater.
Heat Exchangers
Unless otherwise dictated for process reasons and / or licensor requirements, a
design margin of 10% shall be specified on required surface for coolers,
condensers (including air), reboilers and heat exchangers on pumparound
circuit.
Fired Heaters
Unless otherwise dictated for process reasons and/or Licensor requirements,
10% overdesign margin shall be considered on duty.
Columns
Unless otherwise specified for process reasons and /or Licensor requirements,
the columns shall be sized in order to obtain a percent flooding not higher than
70% for columns that work under vacuum and a value not higher than 75% in
columns that work in all other services.
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Exploration & Production Division
Pumps
Unless otherwise dictated for process reasons and / or Licensor requirements,
the rated pump capacity shall be the maximum normal flowrate multiplied by
the following factors:
- Pumparound, reflux and circulation pumps: 1.2
- Other pumps: 1.1
Compressors
Unless otherwise dictated for process reasons and / or Licensor requirements,
an overdesign factor of 10% on flowrate has to be considered.
In general, sparing equipment is based on the concept that the facilities shall
be designed to operate for a minimum period of 4 years without major
turnaround.
Consequently, spare equipment shall be provided when:
The failure or routine maintenance of the equipment is expected to fall
outside the timeframe of planned unit/facility Turn-Around(s).
The downtime associated with these events has unacceptable cost,
safety, and / or environmental impact on the facility or makes the safe
operation of the unit/facility uncertain.
The general sparing philosophy to be applied for the main process and utility
equipment is as follows:
Vessels: no spare
Columns: no spare
Heat exchangers (heaters and reboiler excluded): no spare
Reboilers: no spare
Heaters: no spare
Furnaces: no spare
Pumps: n+1
Fans (for air coolers): no spare
Filters: n+1 (*)
Reciprocating Compressors: n+1
Centrifugal /Axial compressors: no spare
(*) No spare can be considered in case the filter can be put off-line and
bypassed for the time necessary for any maintenance operation (i.e.
replacement of the filtering elements), without any appreciable problem which
could occur on regular plant operation.
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Exploration & Production Division
The predicted rate of corrosion during the service of designed equipment and
piping is an extremely significant factor that governs material selection. Each
type of equipment has a certain design life that is considered the minimum
time that it must be in service before replacement. Design life of equipment
shall be in accordance with Table 16.1
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