BASIC ENGINEERING DESIGN BASIS PART- A Document No.

A702-011-02-41-PDB-001
For Debottlenecking of CDU/VDU/NSU at Rev. No. 1
BORL, Bina Page 1 of 13

Basic Engineering Design Basis Part A

for
Debottlenecking of
Crude / Vacuum Distillation units
and
Naphtha Stabiliser Unit

at

BORL- Bina Refinery

(Unit No. 11/12/13)

CLIENT : ___________________________________________

EIL : _________________________________________

1 16.10.2015 ISSUED FOR PACKAGE GN SA SA

CLIENT COMMENT INCORPORATED AND ISSUED FOR
0 29.04.2015 GN SA SA
APPROVAL
Reviewed Approved
Rev. No. Date Purpose Prepared by
by by

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 2 of 12

TABLE OF CONTENTS

Section # Contents Page #

1.0 INTRODUCTION 03

2.0 UNIT CAPACITY 03

3.0 PLANT TURNDOWN CAPACITY 04

4.0 MAJOR CONSTRAINT OF PRESENT DESIGN 04

5.0 FEEDSTOCK SPECIFICATIONS 04

6.0 FEED / PRODUCT SPECIFICATIONS 05

7.0 FEED AND PRODUCT BATTERY LIMIT CONDITIONS 07

8.0 CATALYST AND CHEMICALS 10

9.0 STORAGE INSIDE BATTERY LIMITS 10

10.0 PRIMARY EFFLUENT TREATMENT WITHIN BATTERY 10

LIMITS

11.0 SCOPE OF BATTERY LIMIT FACILITIES 10

12.0 SPECIFIC DESIGN CONSIDERATIONS & KEY ISSUES 10

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 3 of 12

1.0 INTRODUCTION

The CDU unit of BORL Refinery was implemented as part of the New Refinery Project and
commissioned in June-2010. Unit has been designed for 65: 35 weight blend of Arabian
Light and Arabian Heavy for a crude processing capacity of 6.0MMTPA.
BORL intends to augment the processing capacity of CDU from present 6 MMTPA to 7.8
MMTPA by Debottlenecking of the existing unit.

BORL has entrusted Engineers India Limited (EIL) with the job of preparation of BEDP for
debottlenecking of CDU/VDU & Naphtha Stabilizer.

Basic Engineering Design Basis (BEDB) for all facilities, containing technical information
agreed between Client and EIL shall be binding on the process design and engineering of
units, utility systems and offsite facilities. The BEDBs for each facility are in two parts:

Part A: Unit Design Basis providing necessary data for specific process unit / utility systems
and offsite facilities.

Part B: Basic Engineering Design Basis.

This document constitutes Part A of the Basic Engineering Design Basis for preparation of
the Basic Engineering Design Package for the debottlenecking of CDU/VDU & naphtha
stabilizer unit.

2.0 UNIT CAPACITY

Crude Distillation Unit : 7.8 MMTPA of crude feed.

Vacuum Unit : Of Matching capacity.
Naphtha Stabilizer Unit : Of Matching capacity.

2.1 ONSTREAM FACTOR

Stream factor : 8280 hrs / year

3.0 PLANT TURNDOWN CAPABILITY

Turndown desired is 50% of design capacity. However, actual achievable turndown shall
be governed by column / heater turndown limitations and shall be indicated later.

4.0 MAJOR CONSTRAINT OF PRESENT DESIGN

Following are the major constraints experienced during test run with 100% AM crude:

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 4 of 12

 Vacuum column overhead condensing capacity is limiting due to lower flow of Cooling
Water.
 Preheat train crude outlet temperature lower by 25 Deg C than design.
 Desalter outlet salt and BS&W are higher than design (salt 1.2 ~ 1.5 ptb against design
of 1.0 ptb and BSW 0.2 vol% againt design of 0.05 vol%)

 CDU overhead condensing capacity is limiting with column operating upto 2.7 kg/cm2g

 Corrosion/fouling issues in the following sections;

o CDU APH and ID fan corrosion (due to high H2S in hot well off gases up to 10.0
vol%)
o Fouling of the Kero reboiler resulting in the duty loss
o CDU overhead condenser tube side depositions resulting in tube leaks and
limiting service life to about one year

 Product qualities;
o VGO asphaltenes and CCR up to 200 ppmw and 0.6 wt% respectively against
the specification of 150 ppmw and 0.5 wt%
o Different hot and cold SRGO densities
o Lighters in VR (D1160 IBP and 5% in the range of 470 and 525 deg C
respectively) and sodium content in the range of 20~25 ppmw against the
desired value of 15 ppmw

 Vacuum column slop recycle pump not able to discharge slop to vacuum heater inlet
due to head limitation
 Crude heater ID fan is limiting resulting in partial opening of main stack damper at
110% throughput.

5.0 FEEDSTOCK SPECIFICATIONS

5.1 DESIGN CASE

Debottlenecking of CDU/VDU & Naphtha Stabilizer shall be carried out for following design
case:

 100% processing of Kuwait.

In addition, the following check cases to be studied:

5.2 CHECK CASES

1. 100% Processing of 65: 35 weight blend of Arabian Light and Arabian Heavy.
2. 100 % Basra Light.

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 5 of 12

For check cases PFDs, Stream Summary and heat & material balance indicating operating
conditions at key locations and Major Equipment limitation for each of the cases would be
provided.

Selected Crude Property:

CRUDES KUWAIT Arab Mix Basrah Light

(Design Case) (Check Case) (Check Case)
API 30.4 31.3 30.0
VISCOSITY@50 °C, cSt 7.3 7.7 7.6
VISCOSITY@40 °C, CSt 9.4 10.3 9.9
POUR POINT, °C -58.2 -44.3 -20.1

5.3 ASSAY DATA

The following Assay Data are adopted for design/check cases

(a) Kuwait (KUWAIT304) - Refer Attachment-I

(b) Arab Mix (AL: AH -65:35) (ARBLT332 +ARAHV277) - Refer Attachment-II

(c) Basra Light (BASRL300) - Refer Attachment-III

5.4 LIGHT ENDS QUANTITY

Wt% Existing Design Kuwait (From Kuwait

AM KUWAIT Assay) (Designed)

C1 0.000 0.000 0.000 0.0062

C2 0.011 0.028 0.004 0.022
C3 0.2702 0.3983 0.175 0.317
iC4 0.1702 0.2359 0.155 0.2808
nC4 0.943 0.8977 0.749 1.3524
iC5 0.5827 0.1319 0.720 0.3969
nC5 1.2498 0.0405 1.260 0.6911
TOTAL 3.227 1.732 3.064 3.064

Note: Based on operating experience, LPG product from NSU varies from 0.9 wt% to 1.9 wt% of
crude feed, depending upon type of crude blend being processed in the unit (1.9 wt% LPG for
Kuwait case). LPG yield, the FG, LPG and Naphtha section shall be checked for 140 % revamp.
However in case if it calls for hardware change which cannot be implemented in 40 day shutdown
period, the same will be restricted to maximum achievable capacity.

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 6 of 12

6.0 FEED / PRODUCT SPECIFICATIONS

6.1 Performance and Product Characteristics for Desalter.

6.1.1 Feed Characteristics (Min) To Be Considered For Design:

Desalter crude feed: The bulk crude feed characteristics e.g. API, Viscosity and pour point
shall be as per crude assay. Following characteristics, which depend upon crude
transportation/ receipt and storage, shall be adopted for desalter design

KUWAIT

RVP, kg/cm2a 0.25

Flowing vapour pressure
kg/cm2 a 6.6
Salt content, 30
Lb/1000 barrel (ptb)
1
Bottom sludge & water 2.0
(BS&W), (including
% vol sediment=0.4%max)

6.1.2 Desalter:
The existing unit has single stage desalter. To meet the required desalted crude salt and
BS&W content, an additional first stage desalter parallel to existing one and second stage
desalter series to both the new and existing first stage desalter with associated facilities
shall be considered.

Desalted crude characteristics shall be as follows:

Outlet salt content : 0.5 ptb max, based on inlet salt content of 8 – 30 ptb.
BS&W : 0.2 vol% (guarantee)
Oil content in brine : 250 ppmv (Guarantee)

However, desalter vendor is to confirm these values.

6.2 PERFORMANCE AND PRODUCT CHARACTERISTICS FOR CRUDE DISTILLATION / NAPHTHA

STABILIZER UNIT

Key Specifications for Products:

The units shall be designed to meet all product specifications that can be controlled by
distillation and indicated below. Other specifications such as sulphur, octane number,
cetane number etc, which are not controlled in the units need to achieved in downstream
units.

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 7 of 12

ASTM D 86/1160 distillation shall be reported for all column draw offs streams including
combined gas oil, RCO and VGO.

Products from Crude, Vacuum Distillation & Stabilizer Units

LPG
 Vapour Pressure at 40oC, kg/cm2g 10.4 max
 Evaporation temperature for 95 vol%, Co 2.0 max
 C2 & lighter content, wt% 0.2 max

Stabilized Naphtha
 Cut point IBP-150 C as feed to NHT unit
 C4 content : 0.5 wt% max.
 RVP : 0.4 kg/cm2a max

Kerosene
 Expected cut point 150 – 220 C on crude TBP.
 This stream is routed to ATF treating unit for production of ATF.
 Flash point : 40 C (minimum)
 Kero sulphur : 0.235 wt% max
 LGO section shall be suitable for dropping Kero to achieve;
o Kero sulphur as 0.235 wt% max
o Kero cut point 150- 220 C on crude TBP
Gas Oils
 This consists of Light gas oils (LGO), Heavy gas oils (HGO) from crude column and
vacuum diesel from Vacuum column.
 Expected cut point 220- 370 C on crude TBP.
 This stream is routed to DHT unit.
 Flash point : 66 C (minimum)
 ASTM D86 95% point not exceeds 368 C.

Hot well gasses

 Will be included in stream summary and reported as obtained. No specifications.

Hot well slop oil

 Report as obtained. No specifications

Vacuum Diesel
 This stream shall be blended to other diesel streams from Crude column with in
CDU/VDU battery limit.

Light Vacuum Gas oils (LVGO)

 Expected cut point 370-450 C on crude TBP.
 Shall be blended with HVGO inside CDU/VDU battery limit to get a Vacuum Gas oil
(VGO) stream.

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 8 of 12

Heavy Vacuum Gas oils (HVGO)

 Expected cut point 450-565 C on crude TBP.
 Shall be blended with LVGO inside CDU/VDU battery limit to get a Vacuum Gas oil
(VGO) stream.

VGO, which is to be routed to downstream Hydrocracker unit shall meet the following key
specifications.

S.No Properties Specifications

.
1 Total metals, (Ni+V) ppmw 2 max.
2 Asphaltenes, C7 insolubles, ppmw 150 max.
Chevrom Test Method (CTM)
3 Sodium, wppm max 1.0
4 CCR wt% 0.5 max

Vacuum slop

 Slop draw provision shall be retained and provision for slop recycled to vacuum
furnace as well as to VR circuit shall be kept. Slop is not a product.

Vacuum Residue
As feed to Delayed Coker Unit for further processing with max sodium limits as 15 ppmw.
The Sodium level in VR shall be controlled by desalter and caustic dosing system.
7.0 FEED AND PRODUCT BATTERY LIMIT CONDITIONS

Battery Limit Conditions:

The battery limit temperature and pressure conditions for the incoming and outgoing process
streams as per existing unit are indicted below.

Incoming/Outgoing Operating Mechanical design Source/Destination

Streams Conditions
Pres. Temp oC Pressure Temp oC
Kg/cm2 g Kg/cm2g
INCOMING LINES
Crude 1 8.0 30 13 65 Crude Storage Tank
Stripped sour water 3.0 70 17 120 SWS
Flushing oil 6.0 Amb 16.5 65 Offsite

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 9 of 12

Incoming/Outgoing Operating Mechanical design Source/Destination

Streams Conditions
Pres. Temp oC Pressure Temp oC
2
Kg/cm g Kg/cm2g
Caustic 20 wt% 6.0 40 18 65 Offsites
Hot Oil 11 260 14.8 275 MS block

OUTGOING LINES
LPG 19.5 40 31.9 65 LPG Treating Unit
Stabilised Naphtha 1 3.0 40 14.5 65 NHT feed tank
6.0 108 14.5 218 NHT unit feed
Kerosene 5.0 40 16.5 65 Product Storage (out
side Bina Refinery)
5.0 40 16.5 65 ATF treating Unit
5.0 40 16.5 65 Diesel blending

1 3.0 40 16.5 65 Fuel oil blending

Gas Oil (LGO+HGO), 6.0 40 24 65 DHDT Feed Tank
Slop oil (from Hot
11.0 160 24 190 DHDT unit hot feed
well) and Vacuum
diesel 3.0 40 24 65 FLO Tank
VGO 1 12.0 80 29.3 100 HCU Feed Tank
(HVGO +LVGO)
13.0 170 29.3 190 HCU unit hot feed
Vacuum Residue 9.5* 170 1 31 180 VR Storage
8.0 186 31 220 DCU hot feed
Sour water 1 4.5 45 1 13.0 65 Sour water stripper
White slops 7.0 40 24 65 White Slop tank
Black slops 4.0 80~160 31 180 Black Slop tank
Brine 3.0 45 31.4 65 ETP
*@75% Flow
The above are the minimum pressure values at the battery limit of CDU/VDU. Designer to update
these values consistent with the downstream units and tankage requirements during the progress
of the offsite design.
8.0 CATALYST AND CHEMICALS

Suitable provision for chemical dosing along with CI probes shall be kept in the unit for
higher TAN and Calcium crude processing. Maximum TAN will be limited to 1.0 with
existing conventional metallurgy along with chemical dosing.

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9.0 STORAGE INSIDE BATTERY LIMITS

No additional facility required.

10.0 PRIMARY EFFLUENT TREATMENT WITHIN BATTERY LIMITS

None.

11.0 SCOPE OF BATTERY LIMIT FACILITIES

Facilities within battery limits to be finalised during design shall be consistent with offsite
to facilitate smooth transfer of feed, products, utilities and chemicals.

12.0 SPECIFIC DESIGN CONSIDERATIONS & KEY ISSUES

12.1.0 ATMOSPHERIC/VACUUM DISTILLATION UNIT

1) Following over-design philosophy shall be considered.

 For checking adequacy of the existing equipment, no de-rating factor shall be

considered assuming that all existing equipments are available as per original design.
No over-design margin to be considered for existing equipment adequacy check.

 In case of new/replaced equipment, over-design margin to be considered as per EIL’s

standard practices.

2) Constraints in any of the section shall be studied & suitably mitigated for design case.

3) Hotwell off gases after suitable H2S removal facilities shall be routed to CDU heaters or
safely vented to atmosphere. Hotwell off gases Treatment facility should be designed for
100% Kuwait crude oil processing case. The following is the flow and composition of Hot
well off gases:

HOT WELL GAS Design Case 1 Design Case 2

MOL% WT% MOL%
H2S 10.17 13.57 13.02
H2 4.28 0.26 4.3
N2 - 0.86 1.00
CO - - -
CO2 - - -
O2 - 0.26 0.26
C1 30.67 16.79 34.25

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
For Debottlenecking of CDU/VDU/NSU at A702-011-02-41-PDB-001
Rev. No. 1
BORL, Bina Page 11 of 12

C2 17.46 11.02 11.99

C3 14.47
C3= 1.44 23.09 17.13
Total C3 15.91
i-C4 8.61
n-C4 3.99
iC4= 2.71
1C4= 0.672 22.82 12.84
Cis C4= 0.2
Trans C4= 1.77
Total C4 17.95
i-C5 1.41
n-C5 2.1
11.33 5.2
C5+ -
C6 0.08
Total C5 + C6 3.59
TOTAL 100 100 100
FLOW (KG/HR) 2580
Design case 1: Actual Plant operating Data.
Design case 2: Theoretically Calculated Data.
4) The existing overhead ejector system originally designed as 3 stage ejector system is to be
implemented for debottlenecking as Hybrid system with last stage as LRVP (to be
reviewed)

5) EIL shall ensure that all revamp modifications shall be implementable in 40 engineering
days during turnaround.

6) Each section of crude and vacuum column shall be revamped to the maximum possible
achievable capacity with hardware modifications that can be implemented in 40 days shut
down period. Section wise hydraulic study report with max loading in each section shall be
provided.

7) As per “OWNERS REQUIREMENT” Preflash drum will be considered in design.

However CDU heater will be revamped to the max possible achievable capacity with
modifications which can be implemented in 40 days shut down time.

8) Adequacy of existing vacuum column feed inlet flash device shall be checked if found not
adequate then latest generation and proven Vacuum column feed inlet device shall be
considered.

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 BASIC ENGINEERING DESIGN BASIS PART- A Document No.
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9) Provision for routing CDU overhead excess gases (from accumulator) to heater after amine
treatment shall be considered.

10) CDU Column overhead condenser shall be modified by addition of a new third shell (11-EE-
00-101C) in parallel to existing two shells (11-EE-00-101A/B)

To improve the reliability of crude overhead condensers, following requirements shall be

considered;
o Crude preheat temperature (inlet temperature for first stage condensers EE101)
shall be increased to avoid the shock condensation which is currently being
experienced
o Based upon the current experience of frequent failure of overhead condensers, a
third condenser shall be considered for redundancy.

11) TI shall be provided in crude outlet of each exchanger in preheat trains

12) New Cooling Water Booster Pump for VDU overhead ejector condenser to improve VDU
column vacuum

13) Strainer in the cooling water for VDU overhead ejector condenser to arrest fills from
cooling tower

14) High TAN crude processing study shall be included. Provision for Corrosion/Fouling
protection for processing high TAN crudes shall be considered

i. High temp corrosion inhibitor dosing points

ii. Corrosion probes at strategic locations

iii. Provision of Antifoulant dosing in crude

iv. Wash water injection in crude preheat train shall be considered

15) Margin shall be kept for slop processing of 20 Mt/hr

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