REQUEST FOR PROPOSAL

PART 4.1 SCOPE OF WORK and DESIGN BASIS

4.1.1

SCOPE OF WORK GENERAL

4.1.1.1 Overall Responsibilities

CONTRACTOR shall have overall responsibility for the EPC Work, which includes
Pre-commissioning, Commissioning and Performance Test-Run, of Cilacap RFCC
PROJECT (PROJECT), which consists of Process Units, Utility Units and Offsite
Facilities (collectively, PLANT), on the Fixed Lump-sum and Turnkey Basis. The EPC
includes the design and engineering of the PLANT, procurement of all equipment and
materials including two years operation spare parts, preparation of the SITE for
construction, construction and installation of the PLANT at the proper SITE locations, which
leads to Completion of Erection.
After the Completion of Erection, CONTRACTOR shall conduct Pre-commissioning Works
such as mechanical checking, pressure testing and other cold testing.
The Pre commissioning Works also include preparatory works for starting operation of
the PLANT and normally includes drying-out of the system, loading of catalysts,
chemicals and lubricants, and systems airtight tests, etc. Upon completion of these
Pre-commissioning activities, the PLANT attain MECHANICAL COMPLETION, or in
other words Ready For Feed-In. During this period, catalysts/ chemicals, fuels and
utilities shall be provided by CONTRACTOR. Where some of them are supplied by
OWNER, it will be at CONTRACTORs account.
CONTRACTOR shall be responsible for conducting the start-up activities after
MECHANICAL COMPLETION and for providing catalyst/chemicals and items other than
those supplied by CONTRACTOR to start and to operate the PLANT. Operators and
feedstock (atmospheric residue and vacuum distillate) shall be supplied by OWNER.
CONTRACTOR shall also be responsible for providing supervisors, labors, materials,
equipment/tools and consumables.
CONTRACTORs responsibility for the time for Completion is the time of OPERATIONAL
ACCEPTANCE of the PLANT. At the OPERATIONAL ACCEPTANCE, the risk of loss and
the responsibility for custody/control of the PLANT shall be transferred from
CONTRACTOR to OWNER.
CONTRACTOR shall also be responsible for any defects of the WORKs until FINAL
ACCEPTANCE of the PLANT (expiration of the Warranties Period).
The Scope of WORK is detailed in PARTs 4.1.2, 4.2, 4.3, 4.4 and 4.5 of this RFP.
CONTRACTOR shall coordinate its activities and the activities of suppliers, manufacturers,
sub-contractors and others under its control in order to achieve OPERATIONAL
ACCEPTANCE and its obligations thereafter with the standard of care and performance
set forth in this RFP.

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4.1.1.2 Design and Engineering

CONTRACTOR, using the engineering design specifications stipulated in PART 4 hereof,
shall perform all engineering and design services, prepare and deliver the complete
engineering (including process, mechanical, instrument, electrical and civil /architect
engineering), covering those portions not expressly provided in PART 4 but inferred as
necessary for safe and stable commercial operation of the PLANT.
The PLANT shall be engineered and designed to enable it to meet the performance
guarantees specified in PART 3A EPC Contract Form and its relevant EXHIBIT.
Engineering and design shall include without limitation the preparation of studies and
calculations, general assembly and construction drawings, equipment and technical
specifications, field construction specifications, definitive specification lists, equipment and
materials lists and revisions thereof pertaining to all systems, general arrangements of
equipment of the PLANT, all other required drawings, surveys, soil reports, maps,
specifications required for the procurement of all equipment and materials, the
performance of all construction and installation services, and any other works required
up to OPERATIONAL ACCEPTANCE of the PLANT, and all relevant technical data,
including, without limitation, layouts, flow diagrams and material balances.
CONTRACTOR shall be familiar with the International Code and Standards, UOP
Schedule-A, Axens design packages, Indonesian National Standards and Government
Regulations which are related to this PROJECT. Wherever those standards for
equipment and installations have duplication or contradiction, CONTRACTOR shall use the
optimum technical standards for OWNERs advantage.
4.1.1.3 Procurement
CONTRACTOR shall supply all equipment and materials, construction equipment,
temporary facilities, services, catalysts, chemicals and other supplies, construction
consumables, utilities, power and fuel required for the construction and commissioning of
PLANT, commissioning and achievement of the performance guarantees of the PLANT.
CONTRACTOR shall be responsible for the procurement of all construction, and
commissioning spare parts and special tools required up to OPERATIONAL
ACCEPTANCE.
CONTRACTOR shall ensure that all Equipment and Materials which become the
property of OWNER shall be new and of the most suitable grade.
CONTRACTOR shall procure all Equipment and Materials, component and part of the
Facilities in a manner to ensure that each of such system, component and parts will comply
with Refinery International Code and Standard.
CONTRACTOR shall also prepare and recommend, for OWNER's review and approval,
lists of two years operation spare parts in consultation with vendors/suppliers. These lists
shall be prepared and submitted on the vendors proposal. After approval by OWNER of
these lists, CONTRACTOR shall be responsible for procurement of these operation
spare parts. The price for two years operation spares will be treated as a provisional
sum, apart from the Fixed Lump Sum, at the time of the EPC Contract conclusion.
All procurement shall be accomplished in accordance with the Project Procedure as
prescribed in PART 3A and 3B hereof. CONTRACTOR shall obtain and deliver to OWNER
all vendor manuals not later than 12 (twelve) months prior to MECHANICAL
COMPLETION.

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CONTRACTOR's procurement obligations shall include,

i) preparation and issuance of CONTRACTORs tendering documents (i.e. bid
invitations, instructions for tendering, forms of contract, general conditions, special
conditions, specifications and terms of payment), obtaining bids and analysis of
bids, including vendors offer of recommended two years operation spares,
awarding contracts or purchase orders.
Where vendors are specified for equipment and materials by OWNER/
Licensor in PART 3A and 3B or PAR 4 of this RPF, CONTRACTOR is not
allowed to purchase those items from other venders without prior approval of
OWNER.
ii) negotiating and adjusting prices for changes in contracts and purchase orders, and
preparation of the change order procedure, and
iii) administration and follow-up of purchase orders or contracts and coordination
thereof to ensure deliveries from vendors to meet the Project Schedule

4.1.1.4

Logistics

CONTRACTOR shall be responsible for arranging the complete handling and protection
of all equipment and materials, all construction equipment, all temporary facilities, all other
materials and supplies and all fuel used in the performance of the WORK including
shipping, forwarding, transporting, storage in transit, expediting, unloading, receiving and
storage thereof at SITE, subject to the provisions of this RFP.
CONTRACTOR's obligations for materials handling shall include:
i)

Provision of all necessary documentation for obtaining import licenses for all
shipments arriving in Indonesia;
ii) Obtaining customs clearance of all such shipments upon arrival at the
Indonesian port of entry;
iii) Inspection of all shipments at the time of off-loading, at the SITE or at any other
appropriate time, with timely notice to OWNER so that OWNER may participate in
any such inspection if it so requires, provided that CONTRACTOR shall not be
required to unpack, uncrate or unseal shipments, where, by the judgment of
CONTRACTOR, the proper procedure is to leave the particular item in its closed
condition unless Governmental Authorities otherwise require; and
iv) Developing procedures for the uniform crating and marking of shipments, for the
procurement of insurance (according to the provisions of the EPC Contract
Form) and for processing claims for losses and damages arising under all
insurances. It will be advised to TENDERERS in due course which party,
OWNER or CONTRACTOR, shall procure the cargo insurance.

CONTRACTOR shall establish with OWNER, within one (1) month after the Effective
Date, the details of all customs documentation required and the procedures and time
schedule for processing such documentation in order to obtain customs release.
CONTRACTOR shall be responsible for all financial guarantees and bonds required for
the temporary importation of equipment, materials and tools. OWNER will provide
assistance to obtain such permits and documentations.

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4.1.1.5

Construction

CONTRACTOR shall, in the shortest practicable time, provide the services, staffs and
labors (skilled and unskilled), materials, tools, machineries, equipments, facilities
(including temporary facilities and construction utilities) and supplies not furnished by
OWNER, and do all things necessary to construct the PLANT, all in accordance with
PART 3 and 4.
CONTRACTOR's obligations for construction shall include;
i)

Warehousing and protection of all materials, machineries, equipment, and spare

parts, the erection of all machineries, equipment, and tankages and materials,
the arranging for suppliers and manufacturers of equipment and machineries to
provide supervision of the erection and installation thereof, construction of all
interconnected piping, the installation of electrical wirings and instrumentations, all
civil works, all pressure/mechanical tests, electrical and instrumental tests for the
PROJECT, the loading/ filling/ preparing/ checking/ testing of catalysts and
chemicals, lubricants and sealing fluids. In addition, all other works and services
necessary to achieve MECHANICAL COMPLETION and OPERATIONAL
ACCEPTANCE of the PLANT in accordance with the provisions of this RFP,

ii)

Provision of all materials, engineering and quality assurance, field material control
and testing, arranging survey services for layout of the PLANT at the SITE and
provision of all necessary Site grading and paving, except as actually provided
by OWNER,

iii)

Preparation and coordination of construction and manning schedules, developing

and maintaining uniform Project labor practices ; developing and maintaining
proper standards for safety and housekeeping at the SITE, for conduct on the
SITE , for security of the SITE and for other related protective services, and

iv)

Provision of and administration of construction shelters, camps, and offices,

developing and administering on-the-job training programs for construction
workers retained on the SITE, procurement of all insurances in accordance with
the requirements of the EPC Contract Form. In addition, administration of
insurance programs for CONTRACTOR and its sub-contractors (in coordination
with OWNER), administration and resolution of labor matters, provision of field
office services and administration and maintenance of field vehicles and equipment.

It will be advised to TENDERERS in due course which party, OWNER or

CONTRACTOR, shall procure the CAR and CGL insurances.

4.1.1.6 QUALITY ASSURANCE / QUALITY CONTROL

(1) QA/QC PLAN AND PROCEDURES
Contractor shall be responsible for the inspection and testing of Equipment and
Material, machinery, spare parts, tools and appliances to be furnished for the
Facilities, or used in connection with the Work, throughout all phases of design,
procurement, field construction and start-up/ commissioning.
Contractor shall operate a quality management system that meets the intent of ISO
9000 families or other equal and approved quality management system, covering all
aspects of the Work and shall impose a commensurate level of quality on all
Sub-Contractors and Vendors. The system shall ensure that quality management of

4/39

the Work is applied from inception to completion of the Work.

During procurement and field construction, Contractor shall implement additional
procedures that may benefit to the quality control of the Work, provided that
Contractor obtains Owners Approval before implementing any such additional
procedures. Inspection, Testing and Quality Control personnel shall be dedicated to
the Project and not involved in the expediting of the goods.
All QA/QC procedures shall be subject to Owner's prior approval.
Contractor shall make or cause to be made all necessary or prudent field and
laboratory tests of Equipment and Materials either at site or at any time or place as
may be necessary or appropriate or as Owner after consultation with CONTRACTOR
may require.
CONTRACTOR shall report to Owners in writing as to the conformity or
non-conformity to specifications of the Workmanship and materials of items tested.
All test equipment, materials and consumable are to be supplied by CONTRACTOR.
Inspection Agencies used by CONTRACTOR shall be informed to Owners.
(2) THIRD PARTY INSPECTION
Owner may place a SUBCONTRACT with a Third Party Inspector(s).
CONTRACTOR shall enable the Third Party Inspector to perform, in an independent
manner, any inspection on CONTRACTOR QA/QC program and operations to
ensure that all related requirements specified in the CONTRACT are met.
CONTRACTOR shall deal with the WORK, shall provide information and access to
the Third Party Inspector, and shall process QA/QC related matters in a manner that
will enable the Third Party Inspector to perform inspections of WORK and witness
tests in a timely manner in accordance with the WORK TIME SCHEDULE.
CONTRACTOR shall not be entitled to a CHANGE ORDER in respect of
requirements as may be specified by the Third Party Inspector within the inspection
Scope of WORK outlined herein or elsewhere in the CONTRACTS.
Inspection performed by the Third Party Inspector on behalf of Owners and/or the
Certifying Authority shall not be construed as releasing the CONTRACTOR from
performing its inspection program.
(3)

MIGAS INSPECTION
All Equipment and Material (such as heat exchangers, columns, pressure vessels,
tanks, rotating equipments, lifting equipments, electrical equipments, relief valves,
etc. ) shall be subject to inspection by MIGAS and all other required Indonesian
Government agencies. CONTRACTOR'S scope of Work is arranging for and
obtaining all inspections and documentation as required by MIGAS and all other
required Indonesian Government agencies. All cost incurred (allowance and
transportation) for MIGAS inspector or third party inspector on behalf MIGAS will be
paid by Owners and all cost for arranging and obtaining all inspections and
documentation as required by MIGAS and all other required Indonesian Government
agencies shall be born by CONTRACTOR..

(4)

DEPNAKER CERTIFICATES
CONTRACTOR shall obtain from DEPNAKER relevant certificates and Operating
Permit for the Boilers and other equipment as required by the regulation. All cost
incurred (allowance and transportation) for DEPNAKER inspector or third party

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inspector on behalf DEPNAKER will be paid by Owners and all cost for arranging
and obtaining all inspections and documentation as required by DEPNAKER and all
other required Indonesian Government agencies shall be born by CONTRACTOR.
(5)

DIMET CERTIFICATES
CONTRACTOR shall obtain DIMET relevant certificates and Operating Permits for
the custody Metering and Tanks as required by regulation. All cost incurred
(allowance and transportation) for DIMET inspector or third party inspector on behalf
DIMET will be paid by Owners and all cost for arranging and obtaining all
inspections and documentation as required by DIMET and all other required
Indonesian Government agencies shall be born by CONTRACTOR.

4.1.1.7 Estimates, Schedules, Lists and Reports.

CONTRACTOR shall prepare and deliver to OWNER all estimates, schedules, lists and
reports necessary or appropriate for the most diligently and orderly performance of the
PLANT. These shall be prepared in accordance with the Project Procedures under PART 3
and shall include, but not limited to:
i) Estimates of,
-

manpower requirements, by category, for all phases of the WORK, including

field staff labor and personnel.

quantities of equipment and materials and construction equipment.

cost of modifications, and changes in the WORK.

ii) Schedules of,

-

proposed sequence of the works, with dates of anticipated commencement and

completion of the various phases of the WORKs and the portions or units thereof.

Work schedules and manpower build-up charts for all phases of the WORKs both general and detailed and showing, by category, the labor (skilled and
unskilled) and personnel to be used.

procurement schedules showing dates for requisitions, required approvals,

release of purchase orders, anticipated delivery and dates required at SITE.

iii)

Lists of:

all equipment and materials, including spare parts and special tools.

critical items of equipment and materials.

construction spare parts through MECHANICAL COMPLETION, up to
OPERATIONAL ACCEPTANCE.

two years operation spare parts.

iv)

Reports of,

progress reports - general and specific - with respect to all phases of the
WORK and all portions of the PLANT.

deliveries of equipment and materials.

modifications, change orders and changes in the Scope of WORK.

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4.1.1.8 Project Scheduling.

CONTRACTOR shall perform the planning and scheduling in accordance with the
requirements as provided in PART 3.

4.1.1.9 Operation and Maintenance Manuals and Data Books.

CONTRACTOR shall furnish OWNER with definitive operation and maintenance
manuals , mechanical catalogues, and data and design calculation books for the PLANT,
including all systems and parts thereof. Such manuals, catalogues and books will be
prepared in accordance with, and delivered at the times required by the Project
Procedures and in the quantities stated therein. The definitive operation and
maintenance manuals are to be delivered 12 (twelve)months before MECHANICAL
COMPLETION.
CONTRACTOR shall periodically supply, free of charge, to OWNER information generally
made available to its customers to reflect technical development and operating experience
gained from other similar installations by CONTRACTOR.

4.1.1.10

CONTRACTORs Responsibility after MECHANICAL COMPLETION

CONTRACTOR shall be responsible for conducting the start-up activities after

MECHANICAL COMPLETION and for providing catalyst/chemicals and items other than
those supplied by CONTRACTOR to start and to operate the PLANT. CONTRACTOR
shall also be responsible for providing supervisors, labours, materials, equipment/tools
and consumables. Operators and feedstock (atmospheric residue and vacuum distillate)
shall be supplied by OWNER.

4.1.1.11 Responsibilities Following OPERATIONAL ACCEPTANCE

CONTRACTOR shall also be responsible for any defects of the WORKs until FINAL
ACCEPTANCE of the PLANT (expiration of the Warranties Period).

4.1.1.12 Support Services.

Except for items provided or arranged for by OWNER, CONTRACTOR shall provide all
services required for the support of its obligations unless otherwise expressly described in
PART 3 and 4 of the RFP.
CONTRACTOR's obligations for such support services shall include:
i)

The provision of liaison facilities in Indonesia and at the SITE for the
administration of personnel and for the performing of the procurement services
required of CONTRACTOR under this RFP,

ii)

The provision of all appropriate home office services necessary or appropriate

to enable CONTRACTOR to perform its obligations under this RFP, and

iii) The provision of assistance to OWNER, as it may request, in connection with

7/39

press releases, public statements or other public relations activities

undertaken in connection with the PROJECT.
4.1.1.13 Miscellaneous Final Clean-up.
Prior to FINAL ACCEPTANCE of the WORK:
i) CONTRACTOR shall remove, as requested by OWNER, all temporary
structures, debris, wastage, spoil and utilities furnished by it and its
sub-contractors, relocate excess equipment and materials at locations
designated by OWNER and leave all building interiors and the SITE in a clean
and orderly condition.
ii) CONTRACTOR shall turn over to OWNER or sell, at OWNERs option, all
surplus items including salable scrap, and remit or credit the proceeds of such
sales to OWNER. Unless otherwise directed by OWNER, the purchases and
sales prices of such surplus items shall be subject to approval by OWNER.
iii) CONTRACTOR shall prepare and furnish in accordance with the Project
Procedures record drawings and specifications to show construction "as built"
of the PLANT as provided in PART 3 hereof. These record drawings shall be
prepared by correcting drawings (including OWNERs drawings) prepared for
construction purposes or, where construction drawings cannot be satisfactorily
revised for record purposes by preparation of appropriate new drawings. These
drawings are also to include those supplied by vendors and suppliers of
equipment and materials.
iv) CONTRACTOR shall prepare final fixed asset records and inventory lists of
surplus materials and spare parts in accordance with PART 3 of the RFP.

4.1.2 DESIGN BASIS

4.1.2.1 PLANT Description
OWNER briefly presents the outline of the PLANT hereinafter to help a TENDERER
understand OWNERs PLANT philosophy.
PLANT construction work includes the pre-FEED stage, FEED stage, EPC stage and
commissioning stage which could be ready for commercial operation by OWNER.
PLANT shall be stand-alone basis which means independent facility from Pertamina
existing refineries. OWNER desires PLANT shall be operable in the manner of
minimum interaction from and to PERTAMINA existing refineries. In line with the
above OWNERs PLANT operation philosophy TENDER shall be required to strictly
comply with OWNERs requirements which will be stipulated in this RFP.
Further to the above, OWNER has intended to construct PLANT with 62,000 BPSD
capacity at the initial operation period and to expand its capacity up to 70,000 BPSD in
future. For the design capacity of 62,000 BPSD, the design crudes are the
atmospheric residue of 57,980 BPSD, and the vacuum distillate of 4,020 BPSD to be
supplied from the existing Pertaminas Refinery.
The products produced in PLANT shall be transferred back to Pertamina through the
storage facility in PLANT.

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In this regard, PLANT shall have the interconnection and interfaces with Pertaminas
existing refinery facilities including common utilization of certain facilities, such as fire
station and fire cars, and some tanks from capital expenditure minimization point of
views.
In general a bidder shall take into consideration the operation philosophy,
maintenance philosophy and safety philosophy which OWNER will describe and
require in the RFP.
The design philosophy shall be established in line with the above three philosophies in
the manner of the Life Cycle Cost (LCC) minimization concept.
The following description represents the general information of PLANT and its
products for the purpose of bid preparation. In addition to general information,
TENDERER shall refer to technical documents enclosed in this RFP
Major units and facilities

RFCC Unit
Gasoline Hydro-treating Unit
Amine Treating Unit
LPG Extraction Unit
Propylene Extraction Unit
Hydrogen Purification Unit
Sour Water Stripping Unit
Spent Caustic Treatment Unit
Waste Water Treatment Unit
Offsite and Utility Facilities

Products

Treated Fuel Gas

Mixed LPG
Propylene
Gasoline
Light Cycle Oil ( LCO)
Decant Oil (DCO)

Process Licensors
The following License Agreements have been concluded between OWNER and
selected Licensors:

4.1.2.2

UOP LLC (USA) for Fluid catalytic Cracking Process for Resid
UOP LLC (USA) for Caustic MEROX Extraction Process for LPG
AXENS ( France) for PRIME G+ Gasoline Hydrotreating Process

Plant Design Basis

(1) Design Concept

The PLANT shall be designed and constructed for a design capacity of 62,000

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BPSD of Feed-1 (see (2) Design Feedstock below).

The Feed-1 is the design feedstock.
However it is expected that, in future, PLANT capacity will be increased to 70,000
BPSD when processing Feed-1 or Feed-2 to get gasoline to meet Euro III.
The future modifications required to debottleneck PLANT shall be minimum, the
basic design of the licensed units (UOP and AXENS) has considered a 15% over
design capacity as design margins in order to enable to accommodate the future
capacity of 70,000 BPSD.
The performance tests will be carried out based on 62,000 BPSD of Feed-1 and
related performance guarantees refer to this design capacity.
(2) Design Feedstock
The design feedstock Feed-1 is an atmospheric residue originating from domestic
Indonesian crudes and vacuum distillate originating from Middle East crudes.
Feed-1 quality is described in the following table, also the quality of Feed-2 is
described.

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TABLE 1: FEED STOCKS FOR RFCC

Component

Feed-1
( DESIGN
CASE)
100
Atm. Residue
based on
Blended
Domestic
Crude +
Vacuum
Distillate

Blend %
Type of feed

API or specific gravity

ASTM distillat. (D 1160) C
IBP
10% (LV%)
30%
50%
70%
90%
EP
UOP K
Sulfur, wt %
Nitrogen, wt -PPM
Conradson Carbon ,wt %
Hydrogen, wt %
Metals :

Nickel , wt
ppm

Vanadium wt ppm

Sodium wt ppm

Iron, wt ppm
Viscosity @ 210 F (99C) , cSt

(3)

Feed-2

20.81

100
Atm.Residue
based on
mixture of
Blended
Domestic
Crude and
Imported Sour
Crude +
Vacuum
Distillate
20.32

389

388

527

521

723

718

12.0
0.34
3000
6.2

11.93 ~ 11.60
1.95
3000
6.2

13
0.6
6
20

13
17
6
20

29

27

Products Specifications
PLANT is designed to produce the following products, listed below:

Fuel Gas
Mixed LPG
Propylene
Gasoline
Light Cycle Oil (LCO)
Decant Oil (DCO).

(4) Turn-down capacity

PLANT shall be designed to be capable of operating continuously at between 60%
and 100% of design capacity when processing the design feedstock.

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(5) Continuous operation period

The PLANT shall be designed and constructed to be capable of operating
continuously for at least 36 consecutive months without unplanned shut down.
(6) Operation Mode
The gasoline max.operation mode shall be considered in designing the PLANT for
each feedstock.
(7) Service life
The equipment service life to be considered for materials selection and applied
corrosion allowances shall be as follows:

Columns & reactors ( excluding internals)`

Pressure Vessels ( excluding internals)
Tanks
Air-cooled exchangers ( including tubes)
Shell & Tube Heat Exch. ( excluding tubes)
Fired Heaters Tubes
Pumps
Centrifugal Compressor
Steam Turbines

: 30 years
: 20

: 30
: 20
: 20
: 100,000 hr
: 20 years
: 30
: 30

(8) Offsite and Utilities Facilities

The PLANT shall be designed and constructed as a self standing facility, basically
able for operation independently from operation of the existing Pertaminas Cilacap
Refinery.
However the PLANT shall be interconnected to existing Refinery because of:

Acid Gas is to be fed to existing SRU

Feedstocks are fed from existing refinery
Hydrogen which is purified in PSA unit in PLANT required for Gasoline
Hydrotreating Unit is imported as hydrogen rich gas from existing refinery
Some utilities , including MP Steam Heavy Gas Oil (HGO), naphtha, demin
water, and LPG will be imported from existing Refinery for start-up
requirements
Potable water is imported from existing refinery
Fire & Gas detecting system protecting new facilities shall be
interconnected for safety reasons

Furthermore following existing facilities are to be available also for PLANT:

Main access gate and internal roads up to PLANT area.

Fire fighting building
First Aid building

Modification and extension of existing facilities :

Modification of existing Marine (jetty) facilities (Jetty # 64 & # 68).

- Jetty # 64 : Construct a small annex platform for MLA, 2 BD and 4 MP
- Jetty # 68 : Refurbished Jetty existing and Install 1 MLA on existing

12/39

loading platform. Refurbishment shall be proposed to Pertamina for

approval.
Extension of existing maintenance shop.
Modification of existing tank for feedstock (35T-4).
DCS modification in Existing SRU (at Reaction Furnace).

New offsite and utilities facilities shall include:

Pumps and flow meter system for existing feedstocks storage tanks
Final products storage tanks.
Marine loading facilities for LPG and Propylene export.
Fuel system
Flare system
Flushing oil system
Slop facilities
Power generation and distribution system
Steam generation and distribution system
Condensate collection and treatment system
Cooling Water system
Demin-water system
BFW System
Service water system
Drinking/potable water system
Compressed air system
Nitrogen system
Fire fighting and Fire & Gas detection system
Spare parts & Catalyst Warehouse
Administrative building
MCR building
New substations / LAR
UPS system
Catalyst handling system
Cathodic protection
Telecommunication
CCTV system
Sewer and waste waters collection
Effluent treatment system ( including spent caustic and chemicals waters)
Segregated closed drain system for amine, sour water, Light Hydrocarbon,
and Heavy Hydrocarbon.
Emergency System including Emergency Diesel Generator System
Interconnecting system
Laboratory building ( equipment included)
Chemical storage building
Chemical storage shed
Fire shelter
Field operator houses
Roads, paving, sewers
Lightings system
Grounding & Lightning protection system

(9) Overall Plot Plan

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An overall plot plan of PLANT and the existing Cilacap Refinery facilities area is
shown in attachment A. These plans have been developed based on the
following conditions:

The new PLANT is planned to be located adjacent to the existing Refinery

on West side.
The new tanks for LPG and Propylene products will be located in an area
adjacent to existing Jetty Units 67 & 68, separately from main PLANT
facilities.
Some existing tanks to be used for PLANT feed-stocks storage are located
in the existing tank yard.

4.1.2.3

PROCESS UNITS DESCRIPTION

The following description represents the proposed scope of facilities for the process units.
The process design of the units represented by these process descriptions, process flow
diagram, equipment lists, etc. will be subject to review and further development by EPC
CONTRACTOR. In particular, the unit process design and hence unit configuration, yield,
material balances, etc. will refer to the LICENSORs BED and FEED Engineering
documentation which all of those requirement has been included.
(1) RFCC Unit
(a) Objective
The RFCC Unit consists of a reactor, a regenerator, a main fractionators section,
and a gas concentration section. The reactor section is designed to convert the
residue feed to maximize gasoline while minimizing the coke, gas and fuel oil.
The main fractionators section is designed to separate efficiently the cracked
products to gas, gasoline, LCO and DCO. The gas concentration is designed to
separate efficiently gas and gasoline to off gas, LPG and gasoline. Block flow
diagram of the RFCC Unit is described in the Attachment B.
(b) Feed
The RFCC Unit is designed to process the feedstock as described in the Table-1
in previous page.
(c)

Effluent from RFCC Unit

The RFCC Unit exhausts the regenerator flue gas from the RFCC regenerator,
and sour water drained from overhead separators, and produces intermediate
products, cracked naphtha, cracked LPG and sour gas, and also produces final
products, LCO and DCO.

Regenerator flue gas

Regenerator flue gas is designed to make a maximum energy recovery. Since
flue gas contains CO, the gas shall be burned in the CO boiler provided in the
ISBL.

Sour water
Sour water is sent to the Sour Water Stripping Unit to remove H2S, NH3 and
other volatile materials.

14/39

Intermediate products
Cracked Naphtha is sent to the Gasoline Hydrotreating Unit for desulphurization.
Cracked LPG is sent to the Amine Treating Unit to remove H2S. Cracked sour
gas is sent to the Amine Treating Unit to remove H2S.

Products
LCO is sent to LCO tank as RFCC product.
DCO is sent to DCO Tank as RFCC product.
LCO from the RFCC Unit meets the LCO product specifications described in the
Attachment C. DCO from the RFCC Unit meets the DCO product specifications
described in the Attachment C.

(d) Capacity and Turndown Capacity

The RFCC Unit is designed to process 62,000 BPSD of feedstock. The unit is
capable of operating at between 60% and 100% of design capacity. The unit is
capable of operating of cycles for at least 36 consecutive months.
(2) Gasoline Hydrotreating Unit
The Gasoline Hydrotreating Unit is designed to process total naphtha from the
RFCC Unit.
(a) Turndown Capacity
The unit shall be capable of operating at between 60% and 100% of design
capacity when processing the design feedstock.
The unit is designed to be capable of operating for cycles of at least 36
consecutive months.
(b) Product Properties
The gasoline from the unit meets the specifications for gasoline product in the
Attachment C.

(3) Hydrogen Purification Unit

(a)

Hydrogen feedstock
The hydrogen used in Gasoline Hydrotreating Unit is produced by the Hydrogen
Purifiction (HP) Unit with purifying the H2 rich gas to 99v% Hydrogen. The
composition of typical H2 rich gas fed from the existing refinery is described below.

mol%
H2
C1
C2
C3
iC4

73.6
7.8
9.0
5.5
1.5

Pressur
e

Temperatur
e

Max. flow
rate

16.5
kg/cm2g

37C

6,977 Nm3/h

15/39

hC4
iC5
nC5
C6+

1.2
0.5
0.3
0.6

Refer to FEED package in detail.

(b)

Hydrogen purity
Product hydrogen is produced with more than 99v% cont. of hydrogen.

(c)

Raffinate gas
Raffinate gas from the HP Unit is sent to the fuel gas system in the PLANT.
Make-up gas compressor and Raffinate gas compressor
shall be included in HP
Unit.
The HP Unit is capable of operating for cycles of at least 36 consecutive months.

(4) Gasoline Oxidation Stability Chemical Injection System

The Gasoline Oxidation Stability Chemical Injection System is designed to improve
oxidation stability of RFCC gasoline product from Gasoline Hydrotreating Unit.

(5) Amine Treating Unit

The Amine Treating Unit is designed to process
untreated off gas and
LPG from the RFCC Unitand untreated off gas from the PRIME G+ Unit.

mixed

(a) Objective
The Amine Treating Unit is designed to remove H2S in untreated off gas from the
RFCC and PRIME G+ Unit and mixed LPG derived from the RFCC Unit to meet
treated off gas and LPG product specification described in the Attachment C.
(b) Effluent

The gas scrubbed in the Amine Treating Unit is sent to the fuel gas system
in the PLANT and/or existing refinery.
The mixed LPG scrubbed in the Amine Treating Unit is sent to the LPG
Extraction Unit.
Acid gas from the Amine Treating Unit is sent to the existing sulfur recovery
unit.

(c) Capacity and Turndown Capacity

The unit is designed to process the total gas and mixed LPG derived from RFCC
Unit.
The unit is capable of operating at between 60% and 100% of design capacity.
The unit is capable of operating of cycles for at least 36 consecutive months.
(d) Product Property

16/39

The treated gas from the unit meets refinery fuel gas specifications set forth in the
Attachment C.
The concentration of H2S in mixed LPG outgoing from the Amine Treating Unit is
removed to a low level to prevent caustic soda in the next LPG Extraction Unit
from the damage from such H2S.
(6) LPG Extraction Unit
The LPG Extraction Unit is designed to process total Mixed LPG product from the
Amine Treating Unit.
(a)

Feed Definition
The feedstock for the LPG Extraction Unit is LPG derived from the Amine Treating
Unit. The product LPG Extraction Unit can be processed as the Propylene
Recovery from feedstock for Unit or can be used as LPG finished product.

(b)

Product Properties
The LPG from the unit meets the Propylene Recovery Unit feed specifications or
Mixed LPG for domestic market product specifications described in the Attachment
C.

(c)

Turndown Capacity
The unit is capable of operating continuously at between 60% and 100% of the
design capacity when processing the design feedstock.
The unit is capable of operating continuously for at least 36 consecutive months.

(7) Propylene Recovery Unit

The Propylene Recovery Unit is designed to process the LPG product (C3/C4
stream) from the LPG Extraction Unit.
(a) Feed Definition
The feedstock for the Propylene Recovery Unit is Mixed LPG fraction derived from
the LPG Extraction Unit. The feedstock can be processed to Mixed LPG product.
(b) Product Properties
The Propylene and Mixed LPG from the Propylene Recovery Unit meets
Propylene and Mixed LPG product specifications described in the Attachment C.
(c) Capacity and Design Feed
The Propylene Recovery Unit is designed to process total LPG from the LPG
Extraction Unit. The unit is capable of operating for at least 36 consecutive
months.
(d) Turndown Capacity
The Propylene Recovery Unit is capable of operating continuously at between
60% & 100% of the design capacity when processing the design feedstock.

17/39

(8) Sour Water Stripping Unit

The Sour Water Stripping Unit processes sour water drained from the RFCC Unit.

(a) Objective
The Sour Water Stripping Unit is designed to strip NH3, H2S and other volatile
materials contained in sour water and to convert the harmless treated water. The
sour water shall be once stored in new sour water reserver tank and sent to the
Sour Water Stripping Unit. Treated water is sent to the Waste Water Treating Unit
in OSBL. NH3 and H2S acid gas stripped from sour water is treated to meet the
environmental regulation.
(b) Process Unit Capacity
The Sour Water Stripping Unit is designed to treat the total sour water derived from
the RFCC Unit.
(c) Effluent Property
NH3 and H2S in sour water are removed up to low enough concentration to send
the stripped water to the Waste Water Treating Unit for safe operation.
(d) NH3 Acid Gas
NH3 acid gas shall be burnt in an independent NH3 acid gas flare stack
(e) Turndown Capacity
The unit is capable of operating continuously at between 60% & 100% of the
design capacity when processing the design feedstock.
(9) Amine Regeneration Unit
The Amine Regeneration Unit is designed to remove the H2S from rich amine from
the RFCC Unit.
(a) Objective
The Amine Regeneration Unit is designed to remove H2S from rich amine solution
and return the lean amine solution (regenerated) to the LPG Amine Treating Unit
and the sour gas amine treating unit in the RFCC and Prime G+ Unit.
(b) Effluent
Lean Amine regenerated in the Amine Regeneration Unit is sent to the Amine.
Treating Unit in the PLANT.
Acid gas from the Amine Regeneration Unit is sent to the existing sulfur
recovery unit and RFCC acid gas flare stack..
(c) Capacity and Turndown Capacity
The unit is designed to process the total rich amine derived from the RFCC Unit.

18/39

The unit is capable of operating at between 60% and 100% of design capacity.
(d) Product Property
The lean amine from the Amine Regeneration Unit shall meet the requirements of
Amine Treating Units specifications set forth in the licensors basic engineering
design documents.
(10) Waste Water Treatment Unit
The Waste Water Unit is designed to treat RFCC waste water that may be contain
oil and also organic compound from the open drain system in ISBL, open drain
system in OSBL, Laboratory, sour water from Sour Water Unit, and neutralized
water from Spent Caustic Treatment Unit. Before sending to the Waster Water
Treatment, those streams will be treated first in the CPI Separator for oil removal.
The effluent water from the CPI Separator will be send to Waste Water Tank that is
provided with oil skimmer. The skimmed oil after recycle back to the CPI Separator
is sent to Slop Tank.
(a) Objective
The Waste Water Unit is designed to treat RFCC waste water that may be
contained oil and also organic compound to meet with enviromental regulation.
(b) Process Unit Capacity
Capacity of the Waste Water Treatment Unit is designed to treat the waste water
that contaminate with oil and organic compound from the RFCC Unit according to
FEED package.
(c) Effluent Property
The effluent property from the Waste Water Treatment Unit shall comply with
enviromental regulation.
(d) Turndown Capacity
The unit is capable of operating continuously at between 60% & 100% of the design
capacity when processing the design feedstock.
(11) Spent Caustic Treatment Unit
The Spent Caustic Treatment Unit is designed to neutralize the sodium sulfide and
bi-sulfide contained in the caustic effluent from LPG Extraction Unit.
The low pH treated effluent with reduced BOD/COD characteristics is sent to the
waste water treatment unit for further treatment .
(a) Capacity and Turndown Capacity
The unit is designed to process the total spent caustic effluent from LPG Extraction
unit.
The unit is capable of operating at between 60% and 100% of design capacity.
4.1.2.4

UTILITY FACILITIES AND OFFSITE

19/39

(1) UTILITY FACILITIES

This part is supplementary explanation of Design Basis and Philosophy of utilities
facilities of the existing Cilacap refinery. TENDERER shall refer to FEED package
on the detailed requirement.
In several projects that will be implemented in Cilacap refinery, it is forecasted
some shortage of raw water, de-mineralized water, steam, instrument air, nitrogen,
fuel gas and fuel oil.
In order to fulfill the requirement therefore Owner intends to separately install the
following utility facilities from existing utility facilities:

Unit
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Unit

: Common Facilities for Utility Area

: Steam & Power Generation System
: Donan River Raw water Treating Unit
: Raw Water System and Potable Water System
: Demineralized Water System
: Cooling Water and Potable System
: Instrument Air & Plant Air System
: Nitrogen Generation System
: Fuel Oil & Fuel Gas System

The existing utility facilities location is almost fully occupied therefore new utility
facilities are decided to be placed in the new area.
Detailed description of each facility has been provided in the BED packages and
FEED package where CONTRACTOR should be refer to.
(a)

Steam and power generation system

(a)-1

Purpose
The new steam generation, boiler feed water and condensate facilities shall
supply the necessary steam and boiler feed water to new utility area, ISBL and
recover steam condensate from the ISBL and OSBL.

Electric power for the entire PLANT including process units, utilities, ancillaries,
offsite and all other infrastructure facilities shall be self-generated.
Electric power shall be generated by steam-turbine-driven generating sets
housed in a power station located in a utilities area.
Electric power shall be distributed from the power station at high voltage to
substations located conveniently for the load blocks. Voltage transformation to
lower levels is made at each substation as required for the connected load.
Electric power for start-up will not be supplied from the existing refinery,
therefore an emergency generator driven by diesel oil shall be provided for
emergency and boiler start-up. UPS system shall be provided to supply the
power for instrument. Emergency lighting shall be powered from emergency
power source. Emergency fitting with one hour back up battery package shall be
provided for critical building (for example Control Room, Substations, and
Administration Building).

20/39

(a)-2

Design Specification
The detail shall be referred to the FEED package.
HP BFW pumps and upstream facilities, such as deaerators, shall be designed
to serve not only utility facilities but also other consumers.
The detail specifications of the above equipment are provided in FEED
package.

(a)-3

Design Consideration
The boilers are provided with local control for start-up. But normal operations
are controlled from the process and utility control room. Additional facilities are
provided to continuously monitor and optimize the boiler e.g. :
Boiler efficiency
Air flow rate from a Forced Draft fan will be minimized based on residual
oxygen contents in fuel gas.
Boiler load allocation
Load distributor shall be provided.
Overall steam and power allocation
Let down steam quantity (HP-MP and MP-LP) shall be monitored and
consequent switch over of drivers will be advised.
In the case of one boiler shutdown during one boiler periodical shutdown
maintenance, the balance steam is imported from existing utilities.
The boiler qualities of feed water, boiler water, steam and condensate is
continuously monitored for quality at all critical points. For example, the
analyzers and/or sampling points shall be provided such as;
Conductivity

pH
Oil

- At demineralizer outlet
- At deaerator outlet
- At cold condensate line
- At deaerator outlet
- At hot condensate tank inlet

Detail analyzers requirement shall refer to FEED package.

Condensate recovery system is provided to minimize the used of make up

demineralized water. Condensate is collected, and returned to the steam
Condensate facilities for reuse via collection systems.
Hot Condensate
The Condensate from HP/MP/LMP steam users in process units is flashed at
low pressure in the LP condensate and then is cooled and collected in the hot
condensate tank.
Condensate flash drum located at ISBL, shall be designed considering the
condensing system in OSBL.
Steam and condensate operating condition are given in the FEED package.
Cold Condensate
Recovered cold condensate from condenser in process area is sent to
deaerator through the heat exchanger with the hot condensate. The cold
condensate conductivity shall be checked with an inline analyzer at the
following points. If the conductivity of the cold condensate increase to above
pre-set value, the cold condensate shall be dumped to sewer line
automatically.

21/39

EPC CONTRACTOR
to verify and conduct the load sharing study between new boilers and boilers in
existing utility during detail design phase.

(a)-4

Driver Philosophy
TENDERER shall refer to Sparing Philosophy of FEED package.

(a)-5

HP BFW pumps:

1 motors and 2 back pressure turbine

driven with automatic starting system

DFW Pumps

1 motor and 1 back pressure turbine

driven with automatic starting system

Chemical Pumps:

All motor Driven

FDF:

steam turbine driven

CO Boiler

Objective
CO gas from the RFCC regenerator shall be burned to harmless gas in the
CO boiler which generates HPL steam.
CO boiler shall be designed to isolate from the RFCC regenerator for
maintenance and inspection in spite of RFCC operation.

Fuel

CO gas from RFCC regenerator

Fuel gas from RFCC fuel gas system
Fuel oil from PLANT fuel oil system
CO boiler shall be designed to generate steam at design capacity even
without CO gas.
Flue gas

CO boiler flue gas shall be designed to be emitted to meet the "Effluent

Standard for gas and water" as the Attachment D.
(a)-6

Auxiliary Boilers

Objective
Auxiliary boilers shall be designed to meet steam demand during start-up
and normal operation to back up the CO boiler operation.

Fuel
Fuel gas from RFCC fuel gas system
Fuel oil from PLANT fuel oil system
Flue gas

Auxiliary boiler flue gas shall be designed to be emitted to meet the "Effluent
Standard for gas and water" as the Attachment D.
22/39

(b)

Raw Water Treating Unit

Donan River as a main source of water intake is place right adjacent to the Plant
and existing Cilacap refinery. The river water is introduced into grid chamber
through the gates and traveling screens. Then, the water is pumped up by the
river water intake pumps and transferred to clarifiers. The water from clarifier is
directly feed to the Desalination Unit by filtered water pumps. The treated water
from the Desalination Unit is then transferred to the PLANT.

(b)-1

Basis of design
Refer to FEED package.

(b)-2

Additional equipment

The following is minimum requirement for equipment to be added to meet the

new capacity target. All of the below requirements based on existing design
concept however TENDERER could propose an alternative of the latest
technology available.
The CONTRACTOR ( and or Vendors ) shall furnish all necessary equipment
to make the system complete. The CONTRACTOR ( and or Vendors ) shall
provide all equipment, instrumentation, electrical wiring, control panels and
inter-connecting piping (including all alloy pipes) necessary to ensure proper
system operation.

(c)

Raw water system and potable water system

The raw water and potable water system shall supply water to process units,
utility facilities, offsite facilities, ancillaries and new utility facilities.

(c)-1 System Description

Raw Water is transferred from the water intake facilities via a pipeline, and
after treatment in Clarifier and Desalination Unit is sent to desalinated water
tanks. The desalinated water is pumped up as make-up to cooling water
system and boiler feed water via Polisher.
The potable water is supplied from existing refinery, and distributed to the
users . . (Refer to FEED package for detail)
(d)

New De-mineralized Unit

TENDERER shall refer to FEED package.

(e)

Cooling Tower Unit

The cooling water unit shall supply cooling water to ISBL and OSBL.

(e)-1 System Constituents

The following new equipment to be added to meet the new utility demand
- cooling tower trains
- cooling tower pumps
- start up cooling water pump.

23/39

side stream filters

Chemical dosing unit

(e)-2 System Description

Service water is fed to cooling towers according to the level control of the
cooling tower basin.
The cooling water is sent to the users by cooling water pumps. After being used,
the cooling water is returned to the cooling towers and is cooled to the supply
temperature in the cooling tower. Around 2% of re-circulating water is sent to
side filters for the removal of suspended solids.
For the start up of utility facilities, a small capacity cooling water circulation
pump, which is filters, is provided in addition to the main pumps.
(e)-3

Capacity

The system has a sufficient capacity to satisfy the cooling water requirement of
the ISBL and OSBL.
i)
Cooling tower
The cooling towers have a capacity to satisfy of the normal maximum
requirements of the Refinery as a duty base. An approximate 10% excess
duty shall be considered.
ii) Side stream filters
Around 2% of re-circulating cooling water shall be filtrated by the side stream
filters.
iii) Cooling water pumps
Normal two steam turbine driven pumps shall be operated to supply the
cooling water for the Refinery. One motor driven pump stand-by.
iv) Start up cooling water pump
This pump shall have a sufficient capacity to satisfy the side filter
requirement or the utility facilities start up requirement
(e)-4

Design Considerations
i) The system operating conditions shall be supervised at the control
room of process and utility.
ii) The cooling tower basin has a capacity to hold 10 minute supply of the
cooling water re-circulating rate.
iii) The cooling water shall be treated with poly-phosphate plus zinc type
corrosion inhibitor during operation.
iv) The cooling water supply conditions are given in the BED packages and
FEED package.
v) The cooling water line for process and utility facilities can be isolated.
vi) In order to keep balance flow of cooling water supply and cooling water
return, flow indicator and control valve may consider which located at battery
limit

(e)-5

Driver philosophy
TENDERER shall refer to Sparing Philosophy of FEED package.
i) Cooling water pump
2 (Two) back pressure turbine driven and 1 (one) motor driven with
automatic starting system.
ii) Cooling tower fans
All fans are motor driven

24/39

iii) Side filter/start up cooling water pump

Motor driven
(f)

Instrument Air and Plant Air system

(f)-1

Purpose
The instrument air ( IA ) and plant air ( PA ) system shall supply instrument air
and plant air to including the ISBL and OSBL area.

(f)-2

System Constituents
The new IA/PA system consists of the following equipment.

2 (Two) compressors for IA

2 (Two) compressors for PA

2 (Two) air receivers ( IA Receiver & PA receiver )

1 (One) independent air drying system for each IA and PA

(f)-3

Design Specification
Refer to FEED package in detail.

(f)-4 Design Consideration

a. The compressors are an oil-free centrifugal type.
b. The air dryer is an adsorption type with electric heater regeneration.
The dryer shall be periodically regenerated using a timer.
c. Instrument air and plant air piping system from new utility have a
connection with isolation valve at battery limit
Refer to FEED package in detail.
(g) Nitrogen Generation System
Refer to FEED package in detail.
(g)-1

Purpose
The new nitrogen system shall supply nitrogen to ISBL and OSBL.

(g)-2 System Constituents

The system consists of the following new equipment.
Cryogenic nitrogen generators
Liquid nitrogen holders
Nitrogen vaporizer
(g)-3

Design Specification
Refer to FEED package in detail.

(g)-4

Design Consideration
Refer to FEED package in detail.
i)

The Nitrogen Generators are designed for the maximum continuous

nitrogen requirements for gaseous nitrogen, plus filling of one liquid
storage tank in 10 days.
ii) The capacity of liquid nitrogen stored in the two vacuum insulated tanks
are enough for two times of purging requirements of the largest
consumer and emergency shutdown of the consumers.
iii) The Nitrogen Generator is provided with two (2) compressor one
operation and one standby. .
iv) Liquid nitrogen vaporizers are provided for meeting peak demand.

25/39

v)

The Nitrogen generators are monitored and controlled at the local

control panel. Major alarms and trip signal are indicated in the control
room of process and utility. However the start up will be carried out at
the local panel.
vi) The Nitrogen supply conditions are given in the FEED package.
(g)-5

Driver Philosophy

Feed air compressor

All motor driven

Refrigerator
All motor driven

Air fan (if installed)

All motor Driven.

(h) Fuel Oil & Fuel Gas

(h)-1

Fuel Gas
Purpose
The units collect various fuel gas sources and distribute them to the existing
Cilacap refinery as fuel gas. It shall be provided with LPG vaporizer and K.O
drum for RFCC unit start-up.
Destination consumers

Boilers in new utility area

Process Unit ( ISBL )

Priority as Fuel gas sources

a) 1st priority is ISBL off gas & raffinate gas from Hydrogen Purification
Unit. .
b) LPG from LPG storage tank are vaporized in the existing LPG vaporizer
continuously under pressure control and other sources be manually
routed to the vaporizer depend on circumstances. The fuel gas bleed to
flare system shall be minimized to cover the requirement whole of the
refinery fuel.

Additional equipment
No additional equipment to be considered, however piping system peripheral
need to be modified in order to meet the new fuel gas distribution.

(h)-2

Fuel Oil

Purpose
The units collect various fuel oil sources and distribute them to the PLANT as
fuel oil. Fuel oil demand is increased due to maximize utilization of fuel oil &
minimized fuel gas consumption.
New boiler unit should be designed . to operate continously by 100% fuel oil ,
100% fuel gas and dual firing .

Destination consumers
Boilers in new utility area and furnace in ISBL.

26/39

Fuel oil system

Existing fuel supply system consists of following equipment.
Fuel Oil tank
Fuel Oil pump (existing)
Fuel Oil heater
Two existing fuel oil heater are available. 1 (one) fuel oil heater will be
newly added.

Additional Equipment
The system is envisaged to consist of the following new equipment
a) Fuel oil pump:
b) Fuel oil heater: BEU
c) Civil, piping, instrument and electrical work as per required by design
Refer to FEED package in detail.

(i)

Common Facilities for Utility Area

In order to support New Utility
facility/equipment shall be provided :
- Desuperheater (HS-MS)
- Oily Rain Water Pit
- Clean Rain Water Pit
- Clean Oily Water Pump
- Oily Water Pump

Area,

the

following

additional

(2) OFF SITE FACILITIES

This document covers the explanation of Design Basis and Philosophy of Offsite
Facilities. New Offsite facilities is developed and constructed by CONTRACTOR to
support the Project.
The facility are as follows:
Marine Facility (including Blackish Water Intake System)
Tankages
Jetty facility for loading and loading arm
Tie in/piping interconnection
Detailed description of each facility has been provided in the BED packages and
FEED package, where CONTRACTOR should be refer to.
(a) Design Basis
i) Propylene product transfer line from process unit to storage. Propylene
rundown from ISBL is expected.
ii) LPG mix product transfer line from process unit (ISBL Unit) to LPG Mix
Storage tank. LPG rundown from ISBL is expected.
iii) RFCC Gasoline product transfer line from process unit to Gasoline
storage. Gasoline component rundown from ISBL is expected.
iv) Interchangeability pipeline of Propylene product storage tank.
rundown line should be connected to each propylene storage tank.

27/39

The

v) Interchangeability pipeline of LPG product storage tank The LPG rundown

should be connected to each LPG storage tank.
The LPG loading system shall have capabilities to load LPG to expanded
LPG Jetties and existing bottling facilities.
vi) Independency of LPG and Propylene Storage handling. These are
should be avoided the utilization of common line of LPG and propylene.
Some possibilities of LPG contaminated into propylene system should
strictly be avoided.
vii)Re-processing facility for off spec propylene product to RFCC unit. Off
spec propylene which is collected in all of the propylene tank shall have
the capabilities to be treated in RFCC unit.Re-processing facility for
off-specification LPG product from all LPG tanks to RFCC unit and LPG
vapourizer shall be provided.
viii) Propylene transfer line from storage tank and (New Tank) to
Jetty shall be installed.

Loading

New Propylene tank equipped with the tank gauging system. Redundant
level indicators are provided on each tank which can be accessed from Offsite
Control Room and local. Temperature compensations are provided.
New propylene metering unit which is connected to loading jetty pipe line
can be utilized as loading metering.
Propylene loading pump and its spare is dedicated for loading to Jetty.
Propylene metering system and meter prover are provided for propylene
loading to jetty.
ix) LPG transfer line from storage tank to existing and expanded Loading
Jetty
The philosophy should cover the flexibility of LPG transfer either to
expanded Loading rate to jetty and existing facility.
LPG metering system and meter prover for LPG loading to jetty
and transfer to Pertamina LPG filling plant will use the existing
facilities.
x) Propylene vapor return line from Propylene ship to Propylene Storage
Tank
The philosophy should cover propylene vapor return system from
loading jetty to propylene storage tank. The system are include
vapor return arm and vapor return pipe line.
The lines should have capabilities to return the propylene vapor back
to the dedicated loading tank.
The Propylene vapor return line shall be equipped with metering system
xi) LPG vapor return line from LPG ship to LPG Storage Tank
The philosophy should cover LPG vapor return system from loading
jetty to LPG storage tank. The system includes vapor return arm and
vapor return pipe line. The lines should have capabilities to return the
LPG vapor back to the dedicated loading tank.
The LPG vapor return line shall be equipped with metering system.
xii) Gasoline, LCO & DCO product transfer line to existing

Facilities of gasoline transfer line to existing shall be installed

Transfer philosophy should cover the gasoline to RFCC and existing

28/39

facilities.
xiii) Venting system from LPG and propylene tank to flare header shall be
provided.
Refer to FEED package in detail.

(b)

Loading Jetty (Expansion to the Existing Jetty)

The utilities to be provided on jetty include: Instrument air, Nitrogen, Service water
and Fire water shall be provided in accordance with FEED Package.
Two loading arms for Propylene and one loading LPG shall be installed.
Loading arm are operated by hydraulic power and equipped with ERC
(emergency release coupler).
Nitrogen purge and double block with spectacle blind are provided on each
loading arm inlet

(3) OTHER FACILITIES

The following description represents the proposed scope of other facilities. The
process design of the facilities represented by these process descriptions, process
flow diagrams, equipment lists, etc. will be subject to review and further
development by CONTRACTOR and the Process Licensors during project
execution.
Process Flow Diagrams for each facility, unit process design, unit configuration,
yield, material balances, utility summary, disposal system etc. will refer to BED
Packages and FEED Package.
(a) Refinery Fuel System
(a)-1

Introduction

Fuel Gas and Fuel Oil will be used in this project. The fuel gas and fuel oil systems
is provided for the Process Unit, and New Utility .
The fuel gas system is designed to collect the following gases and distribute them
to the consumers not only in the process units but also in the Utility Facilities.
(a)-2

Process flow scheme

Fuel gas system consists of a new fuel gas and holder piping. Off gas from
above-mentioned process units, enters the fuel gas header and is mixed together
in the fuel gas holder then distributed to consumer.
Excess Fuel Gas from Process Unit will be exported and will be controlled by
pressure controller.
Note : For Start-up purposes only, Fuel Gas and Fuel Oil to new boiler system
shall be supplied from the vaporized LPG which is generated by new evaporator,
and oil system. Cross tie-in to the fuel gas and oil system shall be installed.
(b)

Hydrogen Distribution System

The requirement of Hydrogen gas for reaction in Process Unit will be supplied from
H2 Purification Unit. Feed for H2 Purification Unit is from existing refinery. Cross
tie-in to the Hydrogen Purification Unit shall be installed included its distribution

29/39

system. .
(c)

Flare System

(c)-1

Introduction

The flare system that to be constructed is designed to dispose of flare gas from
the process units so as to protect equipment from fatal damage, even if the largest
relieving failure is caused. The design capacity is subject to verification during
detailed engineering. The governing case for this system is an electric failure.
The system consists of equipment as follow:

Flare Stack
Flare K.O. Drum
Process main flare header
Water seal system

All equipment in the flare system is designed in accordance with API-RP 521 and
API 520 latest edition.
Acid gas flame stack shall be provided beside hydro carbon flare stack to relieve
the NH3 Acid gas from sour water stripper, amine regeneration unit, and spent
caustic treatment unit. Refer to FEED package in detail.
(c)-2

Process Flow Scheme

Relieved gas from various sources, such as PSV, gas disposal, de-pressuring, etc.
are gathered in the sub-header of each unit, and then goes to the flare gas
knockout drum through a main process flare header. Entrained liquid in the gas is
separated in the flare knockout drum and is intermittently pumped out to the
existing light slops tanks by the Slop Pump. The gas from the drum goes to the
flare stack through the seal drum. Sour water from the acid flare KO Drum and
from Water Seal Drum drain is sent to Sour Water Stripping Unit.
(d) Slop system
(d)-1

Introduction

There are two slop systems, light slop and heavy slop. The light slops system is
designed to collect only Light Slops produced in the Process Unit and New Flare
System.
Light and other contamination are routed to light slops tanks prior to transferring
slops separately back to existing process unit for reprocessing. Heavy slop
system is designed to collect off spec DCO, RFCC feed and other heavy oil like a
API oil etc.
Referring to the operating philosophy of process unit, the off-spec product from
Process Unit shall be routed to finish product as blending component.
(d)-2

Design basis

The slops system is designed to collect slops produced in the Plant.

The Light slops system is designed to collect saturated and unsaturated
off-specification products. Light slops consisting of LCO and materials with boiling
points lower than LCO, excluding the C4 minus fractions, are routed to a floating

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roof tank. The light slope are pumped from the light slops tanks to RFCC unit for
reprocessing. Heavy slops are also pumped to RFCC unit for reprocessing.
(d)-3

Description of facilities

The slop system is capable of operating as an independent facility. Light slops are
collected in light slops systems from process units, utilities and off-sites. The
recovered slops will be stored in new slops tanks and reprocessed.
CONTRACTOR shall develop and construct the slop collecting system from
process units, offsite, utility and flare system and routed to the slops line header
and shall be stored in the new slop tanks.
Refer to FEED package in detail.
(e)

Caustic System

The existing Caustic System is designed to be capable of dissolving solid caustic

to produce a caustic solution. The requirement of caustic solution for Process Unit
should be designed by CONTRACTOR.
Spent Caustic from Process Unit shall be routed to the New Spent Caustic
Treatment to be neutralized. Neutralized aqueous material will be disposed To
the new waste water treatment system followed by the neutralization system.
(f) Sewage and Effluent Treatment Facilities
TENDERER shall refer to Process Description of FEED package
The effluent treatment facilities shall be provided to treat any kind of effluent from
the Plant. All liquids discharged from the Plant are treated to a level of purity
consistent with 'Waste Water Quality" in the BEDD and refer to Indonesian
Regulation (Peraturan Menteri Lingkungan Hidup No. 04 / 2007 date of 08 Mei
2007).
In order to ensure the correct treatment, different types of effluent are treated
separately. In particular, any streams not requiring treatment prior to discharge are
kept separate from contaminated streams.

i)

Oily rain water

These following rainwater are treated as oily:
The rain water in process and utility areas which includes oil is gathered into
oily water buffer pits.
Rain water inside dike in an emergency case.
This rainwater is sent to the oil separator.
Separated water is aerated to remove contaminators, and then the treated effluent
is discharged to an impounding basin before routing to the river.
Separated oil is sent to the recovered oil facilities.

ii) Non-oily rain water

The following rain water does not include oil under normal operation.
Rain water inside dikes
Rain water from non-oily utility area.

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This rain water is gathered into the impounding basin prior to discharge to public
water. The location of impounding basin shall be closed to discharge point closed to
existing Paraxylene holding basin.
iii) Clean rain water
The following rain water is always clean and is discharged to the river without
treatment.
Rain water on unpaved
Rain water on buildings
Rain water on roads & parking lot.
iv) Oily waste water from process plants
This oily waste water is sent to Neutralization pit.
Neutralized waste water is sent to the oil separator.
Separated water is sent to the activated sludge facilities and then is
gathered into impounding basin.
Separated oil is sent to the recovered oil facilities.
v)

Oily water other than item 1) and 4)

Tank drains
Fire fighting water on oily area
Fire fighting water inside dike in an emergency case.
These oily are treated as same as above oily rain water in Item 1).

vi) Non-oily water except rain water

The following waste water is gathered into the impounding basin to dilute and to be
diluted before discharge from the Plant.
Blow down water and neutralized water from demineralizer during
regeneration operation
Blow down water from boiler
Blow down water from cooling tower
Fire fighting water inside dike in normal operation
Fire fighting water on non-oily area of utility facilities
vii) Sanitary water
Sanitary water is treated in the activated sludge facilities through the septic tank
and then sent to WWT.
viii)

Laboratory waste water

The laboratory waste water is neutralized in the neutralization pit and then sent
to WWT.

The above waste water and other water having any possibility of including oil are
gathered into the new impounding basin to check the oil content. An oil skimming
device is provided at the impounding basin.
The capacity of the impounding basin meets a 30-minute holding period.
Note:
1.

Additional Equipment or Facilities shall be developed and constructed at the

Effluent Water Treatment Area due to additional discharging effluent or
disposal capacity from the Plant are
New CPI: with capacity 2 x 100 % design flowrate (for maintenance

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2.

(g)

consideration).
New CPI oil sump
New CPI skimmed oil Pump
New API oil Sump
New API skimmed oil Pump
New Impounding Basin

CONTRACTOR must review, develop and construct new Interconnection

facilities either underground or above ground systems to send the effluent
from Process Unit, Utility and Offsite to the existing facilities for further
treatment.

Flushing Oil System

The flushing oil system for the PLANT shall be designed by CONTRACTOR which
can cover but not limited to activities below :

(h)

To optimize operation mode for using 3 source of flushing oil media which are
LCO, HCO, HGO. Since HGO is imported from existing refinery with limited
source and basically use for initial start-up, PLANT shall maximize usage of
flushing oil media produced by its own operation which are LCO and HCO.
To cover simultaneous flushing activities and HGO/LCO during initial / normal
start-up.
To cover flushing activities for all liquid lines equipped with steam tracing to
prevent blocking due to no steam availability during PLANT turn around.
Catalyst Handling System

The catalyst handling system shall be designed by CONTRACTOR which include

as minimum are :
1. 2 units Fresh catalyst hopper receiving facility from bags and ISO Tanks to Fresh
Cat. Hopper.
2. 1 unit Spent catalyst discharge facility from EQ Hopper to truck.
3. Temporary catalyst warehouse facility for :
a. Storing fresh catalyst receiving from catalyst manufacturer for 30 Days cat.
Make-up rate.
b. Storing catalyst receiving from catalyst manufacturer for 30 Days catalyst.
Make-up rate.

c. Minimum warehouse area = 500 m2.

d. Warehouse shall completed with overhead traveling crane (3Ton)
facility.
4. 2 units vehicle truck lorry for transferring fresh catalyst from catalyst ware house
to fresh catalyst hopper and transferring spent catalyst from EQ hopper to
catalyst warehouse.
Contractor shall propose the specification for vehicle truck lorry to OWNER for
approval.

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5. Spent catalyst Warehouse facility

Contractor shall perform New Spent Catalyst Warehouse Facility with total
warehouse area 1000 m2. Warehouse shall completed with the following
facility :
a.

b.
c.
d.
e.
f.
g.

2 Units Overhead traveling Crane (Cap. 3 ton). Overhead travelling Crane

shall be designed to handle flexible containers, bulk lorry and suppliers
trucks.
Forklift
Weigher.
Dust Collector (for bagging and lorry Loading)
Spent catalyst Hopper (Net Capacity 60 m3) .
Rotary valve and Slide gate valve.
Spent Catalyst Warehouse location see DWG No.Pr.E-FSK=1430-1 Rev.0

6. Work Flow of Catalyst handling as shown in the Fig.1.

(i)

Tie in Works with Existing Facilities

(i)-1

Tie in Work

Based on process requirement, minimum piping tie in list is provided in FEED

package. CONTRACTOR shall identify and furnish all necessary tie in under
Owner supervision (include tie in for Electrical, Instrument, telecommunication ,
etc.) to make the system complete and function properly.
All works related to tie-in including materials and accessories, tools and labors
(including evacuation, isolation, hot tapping, drain and purge work of the existing
facilities) shall be Contractor responsibility

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(i)-2

Evacuation of the existing facilities.

If tie-in with the existing facilities is necessary, the existing facilities should be
evacuated and isolated for the work by Owner and should be supported by
CONTRACTOR.
(j)

Flare & Facilities.

Refer to Plot Plan Drawing No. 000-T4311-011-3 Rev.4, previous RFCC
Flare & Facilities location will be use for other Existing RU IV purpose.
Regarding to this matter New RFCC Flare and facilities location shall be
move to nearest existing SRU Flare (tentative). Contractor shall evaluate
and study both in terms of operations, construability as well as safety and
regulation requirements for the design and construct combining two units
Flares (New RFCC Flare & Existing SRU Flares) in one flares structure
support.

4.1.3

SITE INFORMATION (MOVE TO EXHIBIT D)

The site is located in the town of Cilacap on the southern coast of Central Java
(see the map below).

Cilacap

Cilacap is situated on a peninsular surrounded by Donan river in the west.

Donan river is not really a river, even though some document indicates so, but is a
small sea inlet around the peninsular of Cilacap (see attached Map 1) from the
Indian Ocean. Flow in the Donan is tidal, with the difference in level indicated in
the BEDD of the FEED package.
The existing Cilacap Refinery site is located in the northwest part of the town,
facing with Donan river (see attached Map 2 and 3). The proposed site for the
PROJECT will be the area indicated by the shadowed frame in the Map 2.
The proposed two sites are located within the confines of the existing Cilacap
Refinery site in Pertamina propertys land.
Both sites are located in the west part of the existing Cilacap Refinery area.
The larger site is planned to be allocated to process units, utilities facility and offsite
facility, excluding tankages.
Most of tankages will be constructed in the smaller site located in the west-south

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area of the existing Cilacap Refinery site.

These sites are separated by the existing Cilacap Refinery facilities, such as pipe
trestles, barge dock, metering house and LPG/SRU facilities. (See the Attachment
A (2/2) Plant Layout to the Part 4.1.2 DESIGN BASIS of this RFP.
The reclamation of the sites is reported to have commenced in 1992, using
dredged marine sand from the harbor located to the south of the refinery. The edge
of the sites facing the river is protected by sheet piles.
It is reported that 3m to 5m thickness of marine sand was placed.
The topographical data will be available at a later stage as a part of FEED
package; however it is suggested that the general topography of the refinery area
is relatively flat, forming part of a coastal plain and reclamation area. The south and
east areas outside the refinery area are bordered by Lomanis and Donan villages.
According to the AMDAL (Analisis Mengenai Dampak Lingkungan Environmental
Impact Assessment) document for LPG/SRU Project in 2003, the refinery area is
underlain by Quaternary alluvial deposits, which are recorded to consist of sand
and clayey sand, fine grained, loose to dense and moderately to well graded. It
also suggests that rockhead, consisting of siltstone, is siyuated at a depth of
approximately between 24m and 30m below the original ground level.
The proposed sites are areas of reclaimed land as mentioned in the above, which
seems to consist of river sands deposited directly on tidal mud flats and consisting
of soft silts and clays.
Both of the sites are mostly undeveloped and are no-paved areas within this site
boundary. The site elevation will be confirmed with the topographical survey data
which will be separately provided at a later stage. (Refer to the site elevation in
the BEDD of the FEED package)
The smaller site has 4 operational sediment beds, two in the north with
approximately 30mx30m in size, and other two in the south with approximately
100mx45m in size.
The drying beds are separated by soil banks, approximately 2m above from the
original ground level.
The crest of such banks are approximately 1-3m width at the top.
The banks shall be demolished for obtaining the tank foundation area, including a
certain soil improvement work to be done by CONTRACTOR.
The mixed LPG spherical tank exists outside banks at the north-east corner area of
the smaller site.
The above is just for reference, subject to confirmation by CONTRACTOR.
The proposed sites consist of reclaimed land which has been filled with land
materials originating from harbor deepening operations to the south of the site
during 1992-1995.
The ground water level is reported to be generally less than 2.5 mbgl.
There are dug wells in the refinery site and the water quality is saline due to being
salified by Donan river (sea) water.

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Map 1

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Map 2

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Map 3

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