You are on page 1of 35

Page 1 of 35

Basic Design Data Report

Project No: NL6075-01


Client: Luberef
Project Name: Yanbu Refinery Expansion Project

Jacobs Document No: NL6075-00/CP.02/0007


Client Document No: LEP-P1-GS-0001
Revision: 01

Issue Date

Revision Description

Prepared
by

23 May 2011

For Client Review

GOJW

LUTX

MASL

5 Aug 2011

Issue for Use

GOJW

LUTX

LUTX

GRJA

19 Oct 2011

Design Review Comments


Incorporated

MOSQ

GOJW

TIC

BAPN

00

10 Feb 2012

For Design

GOJW

SMJJ

TIC

BAPN

01

12 Apr 2012

Re-issued for Design

GOJW

TIC

TIC

GIA

NL6075-00_LEP-P1-GS-0001.DOC

Checked
by

Project
Discipline
Approved by Approved by

Rev.

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 2 of 35

TABLE of CONTENTS
1

INTRODUCTION ................................................................................................. 4

ABBREVIATIONS................................................................................................ 4

UNITS OF MEASUREMENT ............................................................................... 8

UNIT NUMBERING ........................................................................................... 11

SITE DATA........................................................................................................ 12

5.1

Location............................................................................................................. 12

5.2

Geotechnical Data ............................................................................................. 12

5.2.1

Seismic Load ..................................................................................................... 12

5.2.2

Seismic Design Data ......................................................................................... 12

5.3

Meteorological And Climatic Conditions............................................................. 13

5.3.1

Wind .................................................................................................................. 13

5.3.2

Rainfall .............................................................................................................. 13

5.3.3

Temperatures .................................................................................................... 14

5.3.4

Humidity And Pressure ...................................................................................... 15

PLANT DESIGN CRITERIA............................................................................... 16

6.1

Design Life......................................................................................................... 16

6.2

On Stream Time And Plant Availability .............................................................. 16

6.3

Site Elevation..................................................................................................... 16

6.4

Noise Control..................................................................................................... 16

6.5

Near Shore Location.......................................................................................... 16

6.6

Design Margins.................................................................................................. 17

FEEDS AND PRODUCTS ................................................................................. 17

UTILITIES.......................................................................................................... 18

8.1

Electrical Supply ................................................................................................ 18

8.2

Steam And Steam Condensate.......................................................................... 18

8.2.1

Steam ................................................................................................................ 18

8.2.2

Condensate Return............................................................................................ 19

8.3

Water................................................................................................................. 20

8.3.1

Sea Cooling Water............................................................................................. 20

8.3.2

Closed Cooling Water (Chemically Dosed Desalinated Water) .......................... 20

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 3 of 35

8.3.3

Open Cooling Water (Chemically Dosed Desalinated Water)............................. 21

8.3.4

Fire Water.......................................................................................................... 21

8.3.5

Drinking Water................................................................................................... 21

8.3.6

Tempered Water................................................................................................ 22

8.3.7

Desalinated Water And Process Water.............................................................. 22

8.3.8

Service Water (Reclaimed Water)...................................................................... 22

8.3.9

Demin Water...................................................................................................... 23

8.3.10

HP Boiler Feed Water........................................................................................ 23

8.3.11

Water Analysis................................................................................................... 24

8.4

Instrument And Plant Air .................................................................................... 28

8.4.1

Instrument Air .................................................................................................... 28

8.4.2

Plant Air............................................................................................................. 29

8.5

Nitrogen............................................................................................................. 29

8.5.1

Storage.............................................................................................................. 29

8.5.2

Distribution......................................................................................................... 29

8.6

Fuel Gas............................................................................................................ 30

8.7

Hydrogen........................................................................................................... 31

8.8

Air Cooling......................................................................................................... 32

8.9

Heat Tracing ...................................................................................................... 32

8.10

Flare System ..................................................................................................... 32

8.11

Effluent Pre-Treatment Plant ............................................................................. 32

8.12

Fuel Oil .............................................................................................................. 33

ECONOMIC DATA FOR DESIGN OPTIMIZATION ........................................... 33

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 4 of 35

INTRODUCTION
This document describes the basic design data and criteria to be applied for the
Yanbu Refinery Expansion Project.
The purpose of this document is to provide parameters applicable for the design
of the facilities. Variables to be set with the design as well as HSE aspects are
respectively defined in topic specific design philosophies and the design HSE
plan.

ABBREVIATIONS
150D
350D
730D
AACE
AAQS
AC
AG
AFC
APHA
Ar
ARU
ASHRAE
ASTM
ATB
ATM
BFW
BPCD
BPD
BPSD
BFD
BOD
BOD
BOR
BSS
BT
BTX
C1
C2
C2=
C3
C3=
C4
C4=

NL6075-00_LEP-P1-GS-0001.DOC

Distillate fraction with viscosity of 150 SUS


Distillate fraction with viscosity of 350 SUS
Distillate fraction with viscosity of 730 SUS
Association for the Advancement of Cost Engineering
Ambient Air Quality Standards
Alternating Current
Acid Gas
Air Fan Cooler
American Public Health Association
Argon
Amine Unit
American Society of Heating, Refrigeration, & Air-Conditioning Engineers
American Society for Testing and Materials (publisher of test methods)
Atmospheric Tower Bottoms
Atmospheric
Boiler Feed Water
Barrels Per Calendar Day
Barrels Per Day
Barrels Per Stream Day
Block Flow Diagram
Basis of Design
Biological Oxygen Demand
Base Oil Refinery (for Lubricating Oil production)
Bright Stock Solvent
Benzene, Toluene
Benzene, Toluene and Xylene
Methane
Ethane
Ethylene
Propane
Propylene
Butanes
Butylenes

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

C5
CAPEX
CDU
CLG
CO
CO2
COD
COS
CPI
DAO
DC
DCC
DSH
DWO
DWU
EB
EDMS
EP
EOR
EPC
ESD
ETP
ENVID
FBP
FEED
FEU
FFG
FG
G&HES
H2
H2O
H2S
HAZID
HAZOP
HCB
HCU
HDT
HFO
HFU
HMU
HP
HRU

NL6075-00_LEP-P1-GS-0001.DOC

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 5 of 35

Pentanes
Capital Expenditure
Crude Distillation Unit
Licensor Chevron Lummus Global
Carbon monoxide
Carbon dioxide
Chemical Oxygen Demand
Carbonyl Sulphide
Corrugated Plate Interceptor (for primary oil/water separation)
De Asphalted Oil
Direct Current
Document Control Centre
DeSuperHeated
De Waxed Oil
Dewaxing Unit
Ethyl Benzene
Electronic Document Management System (i.e. Infoworks)
End Point or FBP (for Distillations)
End of Run
Engineering, Procurement and Construction
Emergency Shut Down
Effluent Treatment Plant
Environmental Hazard Identification (study)
Final Boiling Point (for Distillations)
Front End Engineering Design
Furfural Extraction Unit
Flame Front Generator
Fuel Gas
Geotechnical & Hydraulic Engineering Services
Hydrogen
Water
Hydrogen Sulphide
Hazard Identification (study)
Hazard and Operability (study)
Hydrocracker Bottoms
Hydrocracker Unit
Hydro Treater
Heavy Fuel Oil
Hydrofinishing Unit
Hydrogen Plant
High Pressure
Hydrogen Recovery Unit

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

HSE
HSEIA
I&C
IC4
IBP
IGP
IRR
ITB
IP
IP
ISBL / OSBL
ISGOTT
KBR
KO
KTPA
LHC
LHDC
LHV
LODMAT
LP
LPG
LVGO
MBTU
MLDW
MHFO
MMSCFD
MP
MSD
MSL
MTPA
MUSD
N2
NC4
NCC
NH3
O2
NPSHa
NPSHr
NPV
OPEX
P&ID
PCC

NL6075-00_LEP-P1-GS-0001.DOC

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 6 of 35

Health, Safety and Environment


Health, Safety & Environment Impact Assessment
Instrumentation and Control
Isobutane
Initial Boiling Point (for Distillations)
Induced Gas Flotation (for secondary oil/water separation)
Internal Rate of Return
Invitation To Bid
Institute of Petroleum (publisher of test methods)
Intermediate Pressure
Inside Battery Limits / Outside Battery Limits
International Safety Guide for Oil Tankers and Terminals
Licensor KBR
Knock Out
Thousands of Tonnes Per Annum
Lube Hydrocracker
Lube Hydrocracking Distillate Catalyst
Lower Heating Value
Lowest One Day Mean Ambient Temperature
Low Pressure
Liquid Petroleum Gas
Light Vacuum Gas Oil
Million British Thermal Units (per hour)
Mobil Lube DeWaxing
Marine Heavy Fuel Oil
Million Standard Cubic Feet per Day
Medium Pressure
Material Selection Diagram
Mean Sea Level
Millions of Tonnes Per Annum
Million United States Dollars
Nitrogen
Normal butane
Non Contaminated Condensate
Ammonia
Oxygen
Net Positive Suction Head available
Net Positive Suction head required
Net Present Value
Operational Expenditure
Piping and Instrumentation Diagram
Potentially Contaminated Condensate

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

PDA
PD&P
PFD
PGA
ppmw / v
ppbw / v
PMC
PSA
PSD
RBI
RCO
RHC
RC
ROSE
RVP
SA
SCF / M
SCOT
SGU
SIF
SIL
SIS
SIS
SN
SOR
SOR
SOW
SOx
SRU
SWS
TDS
TGTU
TIC
TOR
TPCD
TPD
TPSD
TSS
UBC
USGS
UPS
USD

NL6075-00_LEP-P1-GS-0001.DOC

Propane Deasphalting
Plant Design & Piping
Process Flow Diagram
Peak Ground Acceleration
Parts per million (by weight / volume)
Parts per billion (by weight / volume)
Project Management Consultant
Pressure Swing Absorption
Process Safeguarding Diagram
Risk Based Inspection
Reduced Crude Oil
Raffinate Hydrocracker
Royal Commission
Residuum Oil Supercritical Extraction
Reid Vapour Pressure
Sulphuric Acid
Standard Cubic Feet / Meters
Shell Claus Off-gas Treating
Sulphur Granulation Unit
Safety Instrumented Function
Safety Integrity Level
Safety Instrumented System
Satellite Instrument Shelter
Solvent Neutral
Start of Run
Statement Of Requirements
Scope Of Work
Sulphurous Oxide
Sulphur Recovery Unit
Sour Water Stripper
Total Dissolved Solids
Tail Gas Treating Unit
Total Installed Cost
Terms of Reference
Tonnes Per Calendar Day
Tonnes Per Day
Tonnes Per Stream Day
Total Suspended Solids
Universal Building Code
United States Geological Survey
Uninterrupted Power Supply
United States Dollar

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 7 of 35

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

VDU
VTB
WHB
Zakat

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 8 of 35

Vacuum Distillation Unit


Vacuum Tower Bottoms
Waste Heat Boiler
Third of the Five Pillars of Islam: the giving of a fixed portion of one's
wealth to charity

UNITS OF MEASUREMENT
Reference is made to SAEP- 103, Metric units of weight and measures,
application of units of measurement as defined in this engineering practice is
preferred, yet all listed in this chapter can be applied.
The following units of measurement shall be used throughout the project:
Quantity
SPACE AND TIME
Length
Area
Volume
Time
Velocity
Acceleration
Volume Flow
Plane angle
Solid angle
Angular velocity
PERIODICITY
Frequency
Rotational
frequency
MECHANICS
Mass
Mass Flow
Molar Flow
Volumetric Flow
Normal Volumetric
Gas Flow
Standard
Volumetric Liquid
Flow
Density
Liquid Standard
Density
Momentum
Moment of inertia
Force
Moment of force
Loading (super)

NL6075-00_LEP-P1-GS-0001.DOC

Units for general application

m
m2
l
s
m/s
mm/s
m/s2

mm
mm2
m3
min

dm3
h

m3/h
rad
sr
rad/s

degree

minute

second

MHz
rev/s

kHz
rpm

kg
kg/h
kgmol/h
m3/h

tonne

Nm3/h

m3/h
(norm)
3
m /h
(std)

std m /h
3

kg/m
3
kg/m (std)
kg.m/s
2
kg.m
N
N.m
2
kN/m

Mg

BPSD

Sm /h

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Loading (linear)
Stress
Energy, Work
Power
Absolute pressure
Gauge pressure
Differential
pressure
Dynamic Viscosity
Kinematic Viscosity

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 9 of 35

(structural
design)
kN/m
2
N/m
MJ
MW
bara

kJ
kW
bar (abs)

bar(ga)
bar

barg
mbar

cP
(centipoise)
cSt

Pa.s

kcal
W
mmHg
(abs)
mmHg

kcal/h

m2/s

(centistokes)

Surface Tension

mN/m

N/m

kJ
MW
MM kcal/h

kcal
kcal/h
kW

HEAT
Customary
temperature
Heat Quantity
Heat rate
Heat Exchanger
Duty
Density of heat
flow rate(Heat
Flux)
Thermal
conductivity
Coefficient of heat
transfer
Specific heat
capacity
Specific entropy
Calorific value
(mass basis)
Specific energy,
specific enthalpy,
specific latent heat
Calorific value
(volume basis)

kW /m

W/ m2 oC

MW

kcal/ m

W/ m2.K

2 o

W/ m .K

kcal/h m C

kJ /kg C

kJ /kg.K

kcal/ kg C

kJ /kg. K
kJ /kg

J /kg.K
kcal/kg

kcal/kg.C

kJ /kg

kcal/kg

W/ m C

kJ /m

kcal/h m C

kcal/m

ELECTRICITY
AND MAGNETISM
Electric current
Electric charge,
quantity of
electricity
Electric potential
and electromotive
force
Electric field
strength
Capacitance

NL6075-00_LEP-P1-GS-0001.DOC

kA
kC

A
C

mA
C

kV

mV

pF

V/m
F

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Current density
Magnetic field
strength
Magnetic flux
Magnetic flux
density
Self inductance,
mutual inductance
Permeability
Resistance,
impedance,
reactance
Conductance
Resistivity
Active power
Reactive power
Apparent Power
Electrical energy
ILLUMINATION
Luminous intensity
Luminous flux
Illumination
Luminance
OTHER
Sound
Acidity / Basicity
Water hardness
Pipe Diameter
Nozzle Diameter
Insulation
Thickness
Heat Exchanger
Dimensions, Tube
Diameter and Pitch
Vessel Dimensions
and Tray Spacing
Vessel Mechanical
Design Stress
Stream
Composition

A/mm
A/m

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 10 of 35

A/m

Wb
T

mWb

mH

H/m
M

kS
m
MW
MVAr
MVA
MWh

S
m
kW
kVAr
kVA
Wh

mS

W
VAr
VA
MJ

kJ

cd
lm
lx
2
cd/m
dB
pH
mval/l
in.
in.
mm
mm

mm
Psi

Mpa

Mol%

Wt%

Vol%

Notes:
The inch-pound units shall be used for all piping system sizing & rating
o
Standard conditions are 15 C and 1.01325 bara
Normal conditions are 0C and 1.01325 bara.
o
Conditions for specific gravity are at 15 C
kcal is used by both Licensors KBR and CLG

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 11 of 35

UNIT NUMBERING
Reference is made to the project numbering procedure as well as to the P&ID
legends sheets for among others numbering of equipment and lines.
The assigned unit numbers are listed in Table 4-1.
Table 4-1, Yanbu Refinery Coordinates
Unit
Number
0000
0100
0500
1000
2000
3000
4000
4100
4200
4300
4500
4600
5000
6000
6100
6200
7000
7100
7200
7300
7400
8000
8100
8200
8300
8400
9000
9100
9200
9300
9400
9500
9800
9900
V29

Subproject Description
Refinery General
Buildings
Onsite General
Vacuum Distillation Unit
Propane Deasphalting Unit
Furfural Extraction Unit
Hydrocracker and Gas Plant
Dewaxing Unit
Fuel Gas
Nitrogen
Instrument/Plant Air
Emergency Power Generation
MLDW Unit (existing)
Hydrogen Unit (existing)
Hydrogen Manufacturing Unit
Hydrogen Recovery Unit
Sulphur Recovery Unit
Amine Unit
Sour Water Stripper
Sulphur Recovery Unit & Tail Gas Treating Unit
Sulphur Granulation Unit
Existing Utility Systems
Fire Water
Desalinated, Potable, Service Water
Cooling Water
Demin Water, Condensate, BFW & Steam
Feed, Product & Intermediate Storage (1)
Flare System
Effluent Treatment
Storm Water
Slop System
Lubeoil Product Truck Loading
Asphalt & Extract Truck Loading
Offsite (Out of Fence)
Jetty

(1) Propane system is included in Unit 9000

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 12 of 35

SITE DATA
Reference is made SAES-A-112, Meteorological and Seismic Design Data. It
shall be noted that any information provided in this Basic Design Data Report
prevails.

5.1

LOCATION
The site is located at Madinat Yanbu Al-Sinaiyah, Saudi-Arabia and is
approximately 800 m by 900 m in size.
Coordinates of the Yanbu Refinery are provided in Table 5-1. These coordinates
are equaled by the Refinery Grid System Origin coordinates S=0.0, W=0.0 at the
North East corner of the Site.
Table 5-1, Yanbu Refinery Coordinates
Parameter
Station Coordinates:
Latitude North
Longitude East

Value
2407'
3803'

Plant North is 50 Degrees 3 Minutes 42 Seconds Counter-Clockwise from Yanbu


Geographic (True) North.
For elevations refer Paragraph 6.3.
5.2

GEOTECHNICAL DATA

5.2.1

Seismic Load
The site is classified as UBC Zone 2A.

5.2.2

Seismic Design Data


Earthquake data applicable for the Yanbu Refinery are provided in Table 5-2. For
those design parameters for which Yanby specific information is not available the
Saudi Aramco Seismic Design Data from SAES-A-112 shall be used.
Table 5-2, Earthquake data
Parameter
Value
Short Period Acceleration (SS) in %g
20.4
1-Sec Period Acceleration (S1) in %g
5.8
Peak Ground Acceleration in %g (1)
4.00
Site Class
D
Notes: (1) The PGA values shall be used directly for the potential liquefaction
assessment.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 13 of 35

5.3

METEOROLOGICAL AND CLIMATIC CONDITIONS

5.3.1

Wind
Wind data applicable for the Yanbu Refinery are provided in Table 5-3.
Table 5-3, Wind data
Parameter
Value
Basic Wind Speed, 3-sec gust, km/h 50yr (1)
150
Mean wind velocity, cold season, km/h
18
Mean wind velocity, warm season, km/h
14
Exposure Category (2)
C
Prevailing Direction (3)
W
Notes: (1) As per SAES-A-112, table 1
(2) Exposure D shall be used within 0.46 km of the shoreline.
(3) True wind direction

With reference to SAES-A-112, adequate consideration shall be given to the


occurrence of sandstorms. During sandstorms, dust concentrations may reach
500 mg/m3 with a particle size distribution of 95% < 20 m and 50% < 1.5 m.
5.3.2

Rainfall
Overall rainfall data applicable for the Yanbu Refinery are provided in Table 5-4.
Table 5-4, Overall rainfall data
Parameter
Rainfall, Average Annual
Calculated Rainfall Maximum in 24 hours, 5 years frequency
Calculated Rainfall Maximum in 24 hours, 10 years frequency
Calculated Rainfall Maximum in 1 hour, 5 years frequency
Calculated Rainfall Maximum in 1 hour, 10 years frequency

Value
[mm]
36
40
49
28
35

Lightning occurs 7 days per year.


For the design of the storm water facilities the 5 year storm return frequency
shall be used, as stated in Paragraph 4.3 of SAES-S-030.
5.3.2.a

Rainfall Intensity
The calculated data provided in Table 5-4 are derived with the Steel formula:

Rainfall intensity I:

I=

K
t +b

Where:
I = rainfall Intensity in mm/h (in/h),
t = time of concentration in minutes, and
K & b are non-dimensional coefficients

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 14 of 35

Rainfall Intensity Coefficients:


These coefficients are provided for return periods of 5, 10, 25, 50 and 100 years.
The coefficients are used in the Steel Formula to calculate the average
maximum precipitation rates for storm durations up to two hours.
Table 5-5, Overall rainfall data
K

Freq.
[years]

SI units

5
10
25
50
100

2443
2941
3420
3810
4300

Customary
units
96.2
115.8
134.6
150.0
169.3

b
27.5
24.9
23.7
21.0
20.0

Customary units are in inches per hour of rainfall


SI units are in mm per hour of rainfall
5.3.3

Temperatures
Table 5-6 states the maximum design temperatures to be applied for the design
of the facilities; the minimum design temperature (dry bulb) is 12C (LODMAT).
For information Table 5-7 provides the temperatures applicable for the Yanbu
Refinery as derived from measurements.
Table 5-6, Maximum design temperature (dry bulb)
Parameter
Equipment General Design
Outdoor Electrical Equipment
Indoor Electrical Equipment
Non-Critical Service AFC Performance
Critical Service AFC Performance
Boiler Performance
Air Compressors Rating
Air Blower Capacity Rating Driver Sizing/Max. Flow Rate
Air Conditioning System

Value
[C]
48.6 (3)
50 (1,2)
40
40
48.6
27.5
41.1 (95%
Humidity)
10 / 42.8
43.9

Hot Insulation Design Ambient Temperature


40
Cold Insulation Design Ambient Temperature
6
Hot Insulation Design Wind Velocity
16 km/h
Cold Insulation Design Wind Velocity
16 km/h
Winterizing
Not Required
Notes: (1) For equipment installed outdoors under shade or in well-ventilated rooms
or shelters.
(2) Metal objects exposed to direct solar radiation shall be designed for 70C.
(3) The air coolers in the PDA unit have been designed based on an air
o
temperature of 42 C.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 15 of 35

The personnel protection temperature breakpoint shall be 60C.


Table 5-7, Ambient air and soil temperatures
Parameter
Average Annual Temperature
Average Daily Maximum Temp. (hottest month)
Monthly Normal Max. Temp. (hottest month)
Average Daily Soil Temp. (1 m below grade)
Mo. Normal Max. Soil Temp. (1 m below grade)
Lowest One-Day Mean Temperature
Highest One-Day Mean Temperature
Lowest Recorded Temperature
Highest Recorded Temperature
Summer Design Dry Bulb Temp. @ 1%
Mean Coincident Wet Bulb Temp. @ 1%
Summer Design Dry Bulb Temp. @ 2.5%
Mean Coincident Wet Bulb Temp. @ 2.5%
Summer Design Wet Bulb Temp. @ 1%
Mean Coincident Dry Bulb Temp. @ 1%
Summer Design Wet Bulb Temp. @ 2.5%
Mean Coincident Dry Bulb Temp. @ 2.5%
Summer Design Dry Bulb Temp. @ 5%
Mean Daily Range
Winter Design Dry Bulb Temp. @ 99%

5.3.4

Value
[C]
28
33
39
31
32
12
41
5
50
44
25
42
25
30
36
30
35
41
12
11

Humidity And Pressure


Table 5-8 states the data to be applied for the design of the facilities.
Table 5-8, Ambient air and soil temperatures
Parameter
General Relative Humidity
Design Wet Bulb Temperature for Cooling Towers (1)
Design Wet Bulb Temperature for Air Conditioning
Barometric Pressure

Value
60%
31 C
29.5 C
1.012 Bar

(1) Extreme conditions wet bulb temperature of 34 C is not applied for cooling
tower design.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

PLANT DESIGN CRITERIA

6.1

DESIGN LIFE

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 16 of 35

The design life of the facility equipment shall be as shown in Table 6-1 and 50
years for infrastructure.
Table 6-1, Plant equipment Design Life

6.2

Item
Reactors
Vessels
Exchangers:

HCU / DWU
30 Years
20 Years

Other Units
25 Year
25 Year

Shell
Carbon Steel Tubes in
Cooling water service
All Other tubes
Piping:
Carbon Steel
Stainless Steel

20 Years
10 Years

25 Year
25 Year

20 Years

25 Year

20 Years
20 Years

25 Years
25 Years

ON STREAM TIME AND PLANT AVAILABILITY


Plant availability shall be 97% including planned shutdown, which is equivalent to
354 days per year.

6.3

SITE ELEVATION
Table 6-2 states the plant base highest point elevation to be applied.
Table 6-2, Site elevation
Area
Process/Utility Area
Admin/Building Area
Other Offsite Area

Elevation
EL.100.00m
EL.100.00m
EL.99.40m

Relative elevation
3.45m above M.S.L.
3.45m above M.S.L.
2.85m above M.S.L.

M.S. L. Mean Sea Level


6.4

NOISE CONTROL
Reference is made to SAES-A-105, Noise control.

6.5

NEAR SHORE LOCATION


Given the limited distance between the facilities and the Red Sea shore the
facilities are to be designed as a near shore facility.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

6.6

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 17 of 35

DESIGN MARGINS
The following design margins (overcapacity factors) shall be applied to the
capacities derived from the heat and material balance of various types of
equipment; unless otherwise stated by licensor or in unit specific design bases.
For storage tanks the gross volume shall be set on a case by case basis, but at
least 110% of the required working volume.
For fractionation columns no oversizing will normally be considered over the
design case, yet this shall be confirmed on a case by case basis, depending on
the service and on whether foaming etc. may occur. The factors shall be
specified on the equipment data sheets.
For heat exchangers or air coolers:
For air coolers, if there is no phase change, 10% shall be added as extra
surface area.
For air coolers, if there is phase change, both duty and flow rate shall be
increased by 10%.
For heat exchangers in pumparound or reflux services flow rate shall be
increased by 20%.
For reboilers and condensers, both duty and flow rate shall be increased by
20%.
For product coolers flow rate shall be increased by 5%.
For heat exchangers the design shall be based on the heat and material
balance
For fired heaters no over-sizing shall normally be considered over the design
case. Supplier shall provide guarantee at design throughput.
For pumps rated flow shall be 110% of normal flow or vendor / licensor standard
if greater. Exceptions are reflux and pumparound pumps for which rated capacity
is set at 120%. For pumps in intermittent service the rated capacity is set at
100%.
For compressors the margin between the maximum and rated flow shall be as
per vendor / licensor standard.
For all other equipment including separators and filters a 10% design margin on
throughput shall apply.
For heat loss calculation of storage tanks a 30% design margin is applied to
account for the area of a cone type roof and for loss to soil.

FEEDS AND PRODUCTS


Reference is made to the unit specific design bases.
Reference is made to the licensor design packages for information on products
of these units.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 18 of 35

UTILITIES
Operating conditions provided for liquid streams are at grade elevation unless
specifically defined, e.g. at pump discharge.

8.1

ELECTRICAL SUPPLY
Table 8-1, Electrical supply for equipment
Description

< 0.25 kW
0.25 to 185 kW
185 to 3 000 kW
3 000 kW

Phase

Wire

1
3
3
3

2
3
3
3

Nameplate
voltage
[V AC]
115
460
4 000
13 200

Frequency
[Hz]
60
60
60
60

Table 8-2, Electrical supply for instrumentation


Voltage
Frequency
Phase

120 V
60 Hz
1

8.2

STEAM AND STEAM CONDENSATE

8.2.1

Steam
The generated steam conditions at the existing boiler outlet are 31 barg and
371C.
Table 8-3, Pressure levels
[barg]
HP Steam
MP Steam
IP Steam
(2)
IP Steam DSH
LP Steam
Notes:

Mechanical
Design

Maximum
Operating

36.5 / FV
13.6 / FV
5.5 / FV
5.5 / FV
3.7 / FV

33.0
11.8
(1)
4.5
4.0
2.0

Normal
Operating
at User
30.3
10.3
4.0
3.5
1.4

Minimum
Operating
at User
27.0
9.2
3.5
3.0
1.3

(1) Header pressure, 5.0 barg at the outlet of the steam turbine
(2) Desuperheated IP steam is required in the sulphur block, units 7100,
7200, 7300 and 7400.

Table 8-4, Temperatures


[oC]
HP Steam
MP Steam
IP Steam
IP Steam DSH (2)
LP Steam

NL6075-00_LEP-P1-GS-0001.DOC

Mechanical
Design

Maximum
Operating

418
378
378
190
374

390
350
350
162
346

Normal
Operating
at User
371
310 (1)
250 (1)
162
242 (1)

Minimum
Operating
at User
341
310
152
152
242

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Notes:

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 19 of 35

(1) Final header temperatures for MP, IP, and LP steam shall be based on the
purchased turbine efficiencies.
(2) Desuperheated IP steam is required in the sulphur block, units 7100,
7200, 7300 and 7400.

Table 8-5, Turbine Steam Conditions


Maximum

Pressure
Level
HP In
MP-Out
IP-Out

Temp
[C]
390
350 (1)
300 (1)

Press

[barg]
32.7
12.1
5.0

Press

[barg]
26.7
9
4.0

Temp
[C]
371
315 (1)
250 (1)

Mechanical
Design
Temp Press

[barg]
30
10.6
4.5

[C]
418
378
378

[barg]
36.5/FV
13.6/FV
5.5/FV

9
1.4

310 (1)
242 (1)

10.1
1.6

378
374

13/FV
3.7/FV

Minimum

Temp
[C]
341
315
200

Press

Normal

(1)

MP-In
LP-Out
Notes:

350
11.6
346 (2) 2.2

310
242

(1) Depends on the purchased turbine efficiencies.


(2) Based on blow by through the MP LP let down valve mechanical failure.

IP Steam shall not be used for turbines.


Table 8-6, Flange rating
HP Steam
MP Steam
IP Steam
LP Steam

ANSI CLASS 600


ANSI CLASS 300
ANSI CLASS 150
ANSI CLASS 150

Conditions that apply for steam-out operation are provided as follows:

Steam out with IP Steam case: Use vessel design pressure or 5.5 barg
(which ever is lower) and Full vacuum at 162 C.
Steam out with MP Steam case: Use vessel design pressure or 13.6 barg
(which ever is lower) and Full vacuum at 197 C.

It shall be noted that measures will be put in place to make sure the process set
vessel design pressure can not be exceeded during steam out.
8.2.2

Condensate Return
The normal steam condensate conditions are defined at the outlet of steam
traps.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 20 of 35

Table 8-7, Steam condensate


Mechanical
Design

Normal operation

Pressure
Level
HP
MP
IP
LP

Temp
[C]

[barg]

215
165
143
123

18.1
6.1
3.0
1.0

Press

Flange
Rating
[#]
300
150
150
150

Temp
[C]

[barg]

418
378
378
374

36.5 / FV
13.6 / FV
5.5 / FV
3.7 / FV

Press

Collected LP and IP condensate is pumped back to storage; the associated


conditions are defined in Table 8-8 and Table 8-9 respectively. The water
analysis of the returned condensate will be as per Table 8-29.
Table 8-8, Returned LP condensate (existing facility)
Mechanical Design
Temp
Press
[C]
[barg]
151
10.0

Table 8-9, Returned IP condensate (new facility)


Mechanical Design
Temp
Press
[C]
[barg]
130
10.0

8.3

WATER

8.3.1

Sea Cooling Water


For existing facilities only (Note that the project will eliminate the sea water
cooling system. This table is for reference only).
Table 8-10, Sea cooling water
Mechanical
Design
Temp Press
[C]
[barg]
42
9.2
Flange rating

8.3.2

Normal Operating
at Pump
Discharge
Temp
Press
[C]
[barg]
30.6
5.8
ANSI CLASS 150

Normal Operating
at Plant Inlet

Minimum Return

Temp
[C]
30.6

Temp
[C]
38.6

Press
[barg]
4.2

Closed Cooling Water (Chemically Dosed Desalinated Water)


For existing facilities only.

NL6075-00_LEP-P1-GS-0001.DOC

Press
[barg]
2.1

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 21 of 35

Table 8-11, Closed cooling water


Mechanical
Design
Temp Press
[C]
[barg]
65
9.1
Flange rating

8.3.3

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
35
7.4
ANSI CLASS 150

Normal Operating
at Plant User
Temp
Press
[C]
[barg]
35
4.9

Open Cooling Water (Chemically Dosed Desalinated Water)


Table 8-12, Cooling water supply
Mechanical
Design
Temp
[C]

Press
[barg]
9.1/FV
65
(1)
Flange rating

Normal Operating
at Pump
Discharge
Temp
Press
[C]
[barg]
35

7.4

Normal Operating at
Plant User
Temp
[C]

Press
[barg]

35

4.9

ANSI CLASS 150

(1) Full vacuum rating is required to protect against vacuum conditions due to
pump shutoff/failure and the effects of static heads causing a vacuum to be
created inside the pipe.
Table 8-13, Cooling water return
Mechanical
Normal Operating
Design
at Plant User
Temp
Press
Temp
Press
[C]
[barg]
[C]
[barg]
75
9.1/FV
45 (1)
3.0
Notes: (1) Maximum Outlet Temperature shall be 47C .

The quality of water that should be maintained in the recirculating cooling water
is provided in Table 8-30.
8.3.4

Fire Water
(Desalinated Water - Refer to Table 8-23 for water quality)
Table 8-14, Fire water
Mechanical
Design
Temp Press
[C]
[barg]
65
12.8
Flange Rating

8.3.5

Normal Operating
at Pump
Discharge
Temp
Press
[C]
[barg]
38
9.17
ANSI CLASS 150

Maximum
Operating at User
Temp
[C]
51

Press
[barg]
11.3

Minimum Operating
at User
Temp
[C]
38

Press
[barg]
6.9

Drinking Water
(Chemically Dosed Potable Water Refer to Table 8-26 for water quality)

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 22 of 35

Table 8-15, Drinking water


Mechanical
Design
Temp Press
[C]
[barg]
66
5.8
Flange Rating

8.3.6

Normal Operating
at Pump
Discharge
Temp
Press
[C]
[barg]
35
4.0
ANSI CLASS 125

Maximum
Operating at User
Temp
[C]
38

Press
[barg]
3.5

Minimum Operating
at User
Temp
[C]
18

Press
[barg]
3.0

Tempered Water
Existing facilities only.
Table 8-16, Tempered water
Mechanical
Design
Temp
Press
[C]
[barg]
110
7.0
Flange Rating

8.3.7

Normal Operating
Temp
Press
[C]
[barg]
51.7
5.1
ANSI CLASS 125

Desalinated Water And Process Water


(Refer to Table 8-23 for water quality)
Table 8-17, Desalinated water and process water
Mechanical
Design
Temp Press
[C]
[barg]
66
6.4
Flange Rating

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
38
3.9
ANSI CLASS 150

Minimum
Operating at User
Temp
Press
[C]
[barg]
38
3.0

Desalinated water from the Royal Commission is received from the pipeline at
the following conditions:
3.0 barg min, 3.5 barg normal, 4.0 barg maximum.
8.3.8

Service Water (Reclaimed Water)


(This water is not being used for the new facilities included for reference
purposes only)

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 23 of 35

Table 8-18, Service water


Mechanical
Design
Temp Press
[C]
[barg]
66
6.4
Flange rating

8.3.9

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
38
3.9
ANSI CLASS 150

Minimum
Operating at User
Temp
Press
[C]
[barg]
38
3.0

Demin Water
(Refer to Table 8-27 for water quality)
Table 8-19, BFW make-up
Mechanical
Design
Temp Press
[C]
[barg]
70
10.5
Flange rating

8.3.10

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
38
7.5
ANSI CLASS 150

Minimum
Operating at User
Temp
Press
[C]
[barg]
38
4.0

HP Boiler Feed Water


(Refer to Table 8-28 for water quality)
Table 8-20, HP BFW (existing facility)
Mechanical
Design
Temp Press
[C]
[barg]
181
61.3
Flange rating

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
138
43.3
ANSI CLASS 600

Minimum
Operating at User
Temp
Press
[C]
[barg]
138
41.0

Table 8-21, HP BFW (new facility)


Mechanical
Design
Temp Press
[C]
[barg]
222
80.0
Flange rating

Normal Operating
at Pump Discharge
Temp
Press
[C]
[barg]
105
52.0
ANSI CLASS 600

Minimum
Operating at User
Temp
Press
[C]
[barg]
105
45.0

Boiler Feed Water for new facility is produced from the new deaerator at 105C.
It is then preheated to 138C before being delivere d to the existing boiler feed
system.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

8.3.11

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 24 of 35

Water Analysis

ANIONS

CATIONS

Table 8-22, Seawater (For reference only not required in new facilities)
Component
Calcium (Ca2+)
Magnesium (Mg2+)
+
Sodium (Na )
+
Potassium (K )
Total Cations
Bicarbonate (HCO3 )
2Carbonate (CO3 ),
Hydroxide (OH )
Chloride (Cl )
Sulphate (SO42-)
Nitrate (NO3 )
Total Anions
Total Hardness
Phenolphthalein Alkalinity
Iron - Total
Methyl Orange Alkalinity
Carbon Dioxide - Free
Silica
Phosphate
Turbidity
Colour
pH
Total Solids (Dissolved)
Total Solids (Suspended)
Organics - Volatile
Continuous Dose of Chlorine
Shock Dose of Chlorine, 20 minutes at every
8 hours

NL6075-00_LEP-P1-GS-0001.DOC

ppm as
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
Fe
CaCO3
CO2
SiO2
2PO4
APHA
TDS
TSS
ClCl

1235
6284
27436
617
35572
115
16
0
32155
3316
4____
35606
7528
8
0.07
131
0.5
0.5
5
5
8.25
41521
2
5

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 25 of 35

ANIONS

CATIONS

Table 8-23, Desalinated water


Component
2+
Calcium (Ca )
2+
Magnesium (Mg )
+
Sodium (Na )
+
Hydrogen = FMA (H )
+
Potassium (K )
Total Cations
Bicarbonate (HCO3 )
2Carbonate (CO3 ),
Hydroxide (OH )
Chloride (Cl )
2Sulphate (SO4 )
Total Anions
Methyl Orange Alkalinity
Phenolphthalein Alkalinity
Iron - Total
Carbon Dioxide - Free
Silica
Phosphate
Turbidity
Conductivity
Color
pH
Total Solids (by Evaporation)
Total Solids (by Calculation)
Suspended Solids
Free Chlorine
Organics & Volatiles

ppm as
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
Fe
CO2
SiO2
2PO4
S/cm
APHA
TDS
Cl
-

3
4
21
0
1
29
8
0
0
17
4
29
CLEAR
68
none
6.5-9
38
0
-

ANIONS

CATIONS

Table 8-24, Softened Water (available for existing facilities only)


Component
2+
Calcium (Ca )
2+
Magnesium (Mg )
+
Sodium (Na )
+
Potassium (K )
Total Cations
Bicarbonate (HCO3 )
Chloride (Cl )
2Sulphate (SO4 )
Total Anions
Total Hardness
Conductivity
pH
Total Solids (by Calculation)

NL6075-00_LEP-P1-GS-0001.DOC

ppm as
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
CaCO3
S/cm
TDS

<0.5
<0.5
27
1
29
8
17
4
29
<1
68
6.5-9
38

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 26 of 35

Table 8-25, Reclaimed Water (available for existing facilities only)


Component
TGS
APPEARANCE
ODOUR
pH
TSS
TDS
DC
POD
COD
Chloride (Cl )
2Sulphur (S )
2Sulphate (SO4 )
Bicarbonate (HCO3 )
2Phosphate (PO4 )
2Nitrate (NO3 )
2+
Calcium (Ca )
2+
Magnesium (Mg )
+
Sodium (Na )
+
Potassium (K )
2+
Cadmium (Cd )
2+
Cobalt (Co )
+
Chromium (Cr )
2+
Copper (Cu )
3+
Iron (Fe )
+
Nickel (Ni )
+
Lead (Pb )
Phosphorous (Phenyl)

unit
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
mq/l
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l

value
G and GS
2Y/1YG,2Y/0,2Y/1G,2Y0/2Y
1A,2A
7.3-8.3
2-14
1220-2470
0-7.3
6 -30
20-132
262-650
<0.01-0.1
160-530
210-780
0.2-3.5
3.0-28.4
60-220
28-132
227-1520
12-60
0-0.01
0-0.02
0-0.05
0-0.05
0.03-0.58
0-0.1
0 - 0.22
0.1 - 0.4

unit
ppm
ppm
ppm

value
Clear
8.0
15
20
not detected
132

Table 8-26, Drinking water


Component
APPEARANCE
pH
2Sulphate (SO4 )
Chloride (Cl )
Oil & Grease
TDS

In addition, drinking water shall satisfy the minimum requirements set forth by the
World Health Organization (WHO) in their publication Guidelines for Drinking
Water 4th edition 2011)

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 27 of 35

Table 8-27, Treated water (new facilities only)


Component
pH
Total hardness (as CaCO3)
Conductivity at 25C
Iron
Copper
Silica (SiO2)
Total Sulphur
Free Carbon Dioxide
Total Chlorine

Unit

ppmw
S/cm
ppmw
ppmw
ppmw
ppmw
ppmw
ppmw
ppmw
Non Volatile TOC
Notes: (1) NIL from Demineralized Water Package

Value
Approx 7
NIL
<0.2
<0.02
<0.003
<0.02
<0.02
NIL
<0.1
<0.1(1)

Table 8-28, Boiler Feed Water (new facilities only)


Component
pH
Total hardness (as CaCO3)
Conductivity at 25C
Iron
Copper
Silica (SiO2)
Total Sulphur
Free Carbon Dioxide
Total Chlorine
Non Volatile TOC
Oxygen

Unit
ppmw
S/cm
ppmw
ppmw
ppmw
ppmw
ppmw
ppmw
ppmw
ppmw

Value
8.5-9.0
NIL
<0.2
<0.02
<0.003
<0.02
<0.02
NIL
<0.1
<0.1
<0.01

Table 8-29, Returned Condensate


Quality
pH
Suspended Solids
Total Solids (by Calculation)
Iron
Copper
Non Volatile TOC
Conductivity
Notes:
(1) Maximum 5.0
(2) Maximum 10.0

NL6075-00_LEP-P1-GS-0001.DOC

Unit
Typical
ppmw
ppmw
ppmw
ppmw
ppmw
S/cm

PCC
9.0-10.0
(1)
1.0
<=3.5
0.1
0.1
(2)
1.0
<5

NCC
9.0-10.0
(1)
1.0
<=3.5
0.1
0.1
NIL
<5

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 28 of 35

Table 8-30, Recirculating open loop cooling water


Parameter
Unit
pH
Oil and Grease
mg/l
Total Suspended Solids
mg/l
Ammonia, Total as N
mg/l
Chlorides
mg/l
Free Chlorine Residual
mg/l
Carbonate Hardness
mval/l
Non-Carbonate Hardness
mval/l
Total Dissolved Solids
mg/l
Langelier Index
Silica
mg/l
Zinc
mg/l
Fe
mg/l
Coliform Bacteria
CFU/ml
Phosporous, Total P
mg/l
Sulphates
mg/l
Chromium - Total
mg/l

Cooling Water System


7 8.5
< 25
< 25
< 10 (<1 Cu-alloys)
< 300
0.1 0.5
<5
< 15
< 2000
-1.5 < LSI < 2.5
< 150
< 1.5
<3
< 10000
<2
< 400
<2

The recirculating open loop cooling water contains large amounts of oxygen (up
to saturation).
8.4

INSTRUMENT AND PLANT AIR


The distributed air shall be oil free.
Pressure setpoints for the instrument and plant air are as follows:
Emergency shutdown (Group II/III facility)
Plant air shutdown
Standby compressor start
Low alarm instrument air

8.4.1

4.1 barg
5.5 barg
6.0 barg
7.8 barg

Instrument Air
Dew point is -15oC at system pressure.
Table 8-31, Instrument air
Mechanical Design
Maximum Operating
Normal Operating
Minimum Operating
Flange Rating

NL6075-00_LEP-P1-GS-0001.DOC

Temp
[C]
70
50
40
12
ANSI CLASS 150

Pressure
[barg]
10.5
8.6
8.2
7.8

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

8.4.2

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 29 of 35

Plant Air
Table 8-32, Plant air
Mechanical Design
Maximum Operating
Normal Operating
Minimum
Flange Rating

8.5

Temp
[C]
70
50
40
12
ANSI CLASS 150

Pressure
[barg]
10.5
9.0
8.6
8.2

NITROGEN
The gaseous nitrogen specification shall be as below table.
Table 8-33, Nitrogen specification
Components
N2

99.99% vol min

O2

5 ppmv max

CO2

1 ppmv max

CO
Other carbon
compounds
Chlorine
H2O

8.5.1

Limit

0.5 ppmv max


Negligible
Negligible
1 ppmv max

H2

Negligible

Noble gases

Remaining

Storage
Liquid nitrogen is stored at 9.3 barg, -196 C.

8.5.2

Distribution
Table 8-34, HP Nitrogen (existing facilities only)
Mechanical Design
Normal Operating
Flange Rating

NL6075-00_LEP-P1-GS-0001.DOC

Temp
[C]
10-43
10-43
ANSI CLASS 300

Pressure
[barg]
35
30

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 30 of 35

Table 8-35, LP Nitrogen


Temp
[C]
10-43
10-43
ANSI CLASS 150

Mechanical Design
Normal Operating
Flange Rating

Pressure
[barg]
9.5
8.0

Mechanical design temperature for equipment in contact with liquid nitrogen is


set at -200 C.
8.6

FUEL GAS
The fuel gas from various units within the refinery shall be collected into the
common header. These multiple fuel gas sources feed the Refinery Fuel Gas
system with varying flow rates, composition and heating values. There is an
expected excess demand, so sales gas will be imported with evaporating
propane as back-up. Hence, the fuel gas will be a blend of all these sources.
The fuel gas composition is provided in Table 8-36.
Table 8-36, Fuel gas composition from D-4201(vol%)
Typical Case

Max
C3 Case

Max H2
Case

9
65
7
5
2
2
1
8
1

16
13
6
54
4
4
2
0
1

40
42
5
4
1
1
1
5
0

H2S
Total Sulphur
Compounds

<10 ppmv

<10 ppmv

<10 ppmv

<10 ppmv

<10 ppmv

<10 ppmv

Mercaptans

<10 ppmv
<10 ppmv
20.4
10360
9435

<10 ppmv
<10 ppmv
34.1
11240
17117

<10 ppmv
<10 ppmv
14.5
11270
7280

21

31.4

14

Components
H2
C1
C2
C3
IC4
NC4
C5+
N2
H2O

NH3
Mol. Weight
LHV [kcal/kg]
3

LHV [kcal/ Nm ]
Dewpoint @ 4.5
barg (C)

Basis for the given composition is mixed fuel gas in the new fuel gas KO drum
D-4201 for the following cases:

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 31 of 35

The typical case is based on max fuel gas consumption (LVGO Gr III SOR) and
make-up by sales gas only.
The maximum propane case is based on max fuel gas consumption and
make-up by propane only.
The maximum hydrogen case is based on:
Hydrogen recovery unit out of operation. Full unit bypass rate is
assumed.
Remaining balance as per LVGO heat and material balance and make-up
by sales gas only
Table 8-37, Fuel gas conditions
Mechanical Design
Operating conditions from D-4201 at unit battery limit

Temp
[oC]
95
43

(1)

Normal Operating at Supply Header (Boiler)


Notes: (1) Existing facilities only

8.7

43

Pressure
[barg]
12.3
3.5 (min)
4.0
4.5 (max)
5.0

HYDROGEN
Table 8-38 and Table 8-39 provide the specification of the hydrogen product.
Table 8-38, Product Hydrogen
Mechanical Design
Normal Operating
Battery limit
Mechanical Design Existing Unit (D-5013)

Table 8-39, Product Hydrogen Composition


Component
Unit
Limit
H2
Vol %
>99.9
C1
Vol %
<0.1
H2S
ppmv
<15
NH3
ppmv
<1
CO+CO2
ppmv
20
CO
ppmv
10, target = 5
O2
ppmv
<100
N2
ppmv
traces
Ar
ppmv
traces
H2O
ppmv
<300

NL6075-00_LEP-P1-GS-0001.DOC

Temp
o
[ C]
75
45
45
100

Pressure
[barg]
27.0
21.0
20.5
25.0

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

8.8

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 32 of 35

AIR COOLING
Given the maximum occurring temperature of 50 C, a ir cooling is applied for
cooling streams down to medium temperatures of 60 C; to achieve lower
temperatures application of water cooling is required. On a case by case basis
exceptions to this could be defined and require approval by Luberef.

8.9

HEAT TRACING
Heat tracing of systems is in principle done by means of steam. Electrical tracing
can be applied for specific cases, where the use of steam tracing is not possible/
not practical e.g. the OSBL part of the product transfer line to the jetty.

8.10

FLARE SYSTEM
Table 8-40, Hydrocarbon flare headers
Flare header
LP hydrocarbon flare header
HP Hydrocarbon flare header

Relief valve set pressure break point [barg]


typical
HCU/DWU
< 9.0
< 70
9.0
70

The maximum back pressures set at the battery limit of the process area as well
as mechanical design conditions are provided in the table below for the identified
flare headers.
Table 8-41, Flare headers
Flare header

Max Operating
(1)
pressure
[barg]

Sour gas flare header


HP hydrocarbon flare header
LP Hydrocarbon flare header
Propane flare header

1.0
4.0
1.0
4.0

Mechanical design

Temp
[C]
0 / 200
0 / 370
0 / 340
-45 / 200

(1) Pressure equal to maximum battery limit pressure


8.11

EFFLUENT PRE-TREATMENT PLANT


Table 8-42, Influent to ETP
Maximum
Minimum
Operating at
Operating at ETP
ETP BL
BL
Temp
Press
Temp
Press
[C]
[barg]
[C]
[barg]
50
(1)
1.0
0.5
max
Notes: (1) As calculated

Marafiq is the external wastewater treatment plant

NL6075-00_LEP-P1-GS-0001.DOC

Pressure
[barg]

8.0 / FV
8.0 / FV
8.0 / FV
8.0 / FV

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 33 of 35

Table 8-43, Delivery Pressure at Marafiq pipeline


Case
Minimum
Normal
Maximum

8.12

Pressure [barg]
3.0
4.0
6.0

FUEL OIL
(PDA UNIT ONLY Fuel Oil is for emergency supply on loss of fuel gas)
Table 8-44, Influent, Fuel Oil Characteristics
Fluid
Furfural Unit Bright Stock
Extract (BSS)
Specific gravity
0.9893
@ 15C
Sulfur Content
Wt%
4.25
Calorific Value
Kcal/kg
9,559
(Net LHV)
Viscosity
@ 50 C
Cst
1500
@ 100 C
Cst
66
Distillation
mass %
C
IBP
262
10%
353
30%
423
50%
485
70%
514
90%
535
FBP
544
Table 8-45, Fuel Oil Pressure/Temperature
Normal
Operating
Pressure
[barg]
8.0

Mechanical
Design
Pressure
[barg]
9.5

Minimum
Oper
Temp
[C]
115

Normal
Oper
Temp
[C]
125

Maximum
Oper
Temp
[C]
135

Mechanical
Design
Temp
[C]
260

ECONOMIC DATA FOR DESIGN OPTIMIZATION


The following economic data shall be used for design optimization evaluations
completed during FEED. The data shall not be used as a basis for investment
decisions. Table 9-1 below indicates the basis for the calculation of the Internal
Rate of Return (IRR) and the Net Present Value (NPV); Table 9-2 and Table 9-3
provide the hydrocarbon values and utility costs to be used.

NL6075-00_LEP-P1-GS-0001.DOC

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 34 of 35

Table 9-1, Economic calculation basis


Parameter
Project Life
Operation
Processing Cost
Depreciation
Zakat on taxable income
Equity
Discount factor for NPV
Capital Investment Occurs
Inflation
Maintenance and Repair Costs
Sustaining capital
Allowance for Upkeep of Existing Units
Owners Costs for First Year of Operation
Marketing Costs
Royalties and Catalyst Lease
Currency

Value
25 years
354 days/year
USD 10 per bbl processed
(For unit level analysis)
Straight line
2.5%
100%
15% (with sensitivities for 20%
and 25%).
Year 0
Nil
5% of TIC annually
(For equipment level analysis
only)
Nil
Nil
Nil
Nil
Nil
USD

Table 9-2, Utilities cost


Parameter
Electricity
Fuel
Propane
Desalinated Water
Effluent Water
Seawater
Boiler Feed Water
HP Steam
Cooling Water

NL6075-00_LEP-P1-GS-0001.DOC

Value
0.032
0.75
650
1.59
0.95
15
2.5
5.0
0.086

Unit
USD/kWh
USD/MMBTU
USD/tonne
3
USD/m
3
USD/m
3
USD/1000m
3
USD/m
USD/tonne
3
USD/m

Project No
: NL6075-01
Client
: Luberef
Project Name : Yanbu Refinery Expansion Project

Basic Design Data Report


NL6075-00/CP.02/0007, rev. 01
Page 35 of 35

Table 9-3, Feedstocks / products value


Type
Naphtha
Diesel
Drilling Fluid up to 1 000 BPSD
Drilling Fluid in excess of 1 000 BPSD
Sulphur
Group II Lube Products
SN50-80 up to 1 000 BPSD
SN50-80 in excess of 1 000 BPSD
SN100
SN200-250
SN500
Group III Lube Products
SN50-80
SN50-80 in excess of 1 000 BPSD
SN100
SN200-250

NL6075-00_LEP-P1-GS-0001.DOC

Value
140
91
190
91
200

Unit
USD/bbl
USD/bbl
USD/bbl
USD/bbl
USD/tonne

140
65
150
160
170

USD/bbl
USD/bbl
USD/bbl
USD/bbl
USD/bbl

140
65
190
190

USD/bbl
USD/bbl
USD/bbl
USD/bbl