Process Description Og LPG Train 4

PROCESS DESIGN BASIS

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LPG Train-4 Project at MAA RefineryContract CA/CSPD/0009

LPG Train-4 Projectat

MAA Refinery

Contract CA/CSPD/0009

PROCESS DESIGN BASIS(S090768.231-3.00-004-A-E)

B 26-Oct-11 Revised as Marked J.M.Jung J.M.Mun G.P.Moon S.K.KIM

A 16-Aug-10 Issue For Approval G.P.Moon S.M.Choi B.J.Yi S.K.KIM

REV. DATE DESCRIPTION ORIGINAL/REVISED BY

CHECKEDBY

CHECKEDBY

APPROVEDBY


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INDEX

1. GENERAL ............................................................................................................................................ 6

1.1 Plant Facilities .......................................................................................................................... 7

2. OVERALL DESIGN BASIS................................................................................................................... 9

2.1 Design Throughput ................................................................................................................... 9

2.2 Feed Stream Condition and Composition ............................................................................... 9

2.2.1 Feed Gas Condition and Composition ......................................................................... 9

2.2.2 Condensate Feed Condition and Composition .......................................................... 11

2.2.3 LPG Feed Compositions ............................................................................................. 13

2.2.4 Exceptional Operation ................................................................................................. 15

2.3 Product Specifications ........................................................................................................... 15

2.3.1 Ethane / Propane / Butane Recovery .......................................................................... 15

2.3.2 Residue Gas Specification .......................................................................................... 15

2.3.3 Ethane Product Specification ..................................................................................... 16

2.3.4 Propane Product Specification ................................................................................... 17

2.3.5 Butane Product Specification ..................................................................................... 18

2.3.6 Kuwait Natural Gasoline Product Specification ......................................................... 18

2.3.7 Fuel Gas Specification ................................................................................................ 18

2.4 Battery Limit Conditions ........................................................................................................ 19

2.4.1 Battery Limits Conditions for Feed Gas ..................................................................... 19

2.4.2 Battery Limits Conditions for Condensate Feed ........................................................ 19

2.4.3 Battery Limits Conditions for LPG Feed..................................................................... 20

2.4.4 Battery Limit Condition for Product ........................................................................... 20

2.4.5 Battery Limits Conditions for Propane Refrigerant System ...................................... 21

2.4.6 Battery Limits Conditions for Deep Refrigerant System ........................................... 21

2.5 Design Consideration ............................................................................................................. 22

2.5.1 Plant Design Life ......................................................................................................... 22

2.5.2 Plant Availability .......................................................................................................... 22

2.5.3 Effluent Treatment ....................................................................................................... 22

2.5.4 Physical Properties ..................................................................................................... 22

2.5.5 Remote/Emergency Depressurization ........................................................................ 22


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2.5.6 Pressure Relief System and HIPPS ............................................................................ 22

2.5.7 Source and Compressing of Regeneration Gas......................................................... 23

3. DESIGN BASIS FOR FEED PRETREATMENT UNIT(UNIT 231) ........................................................ 24

3.1 DESIGN BASIS FOR FEED GAS COMPRESSION .................................................................. 24

3.1.1 Feed Gas Compressor ................................................................................................ 24

3.1.2 Product specifications ................................................................................................ 24

3.1.3 Water Content .............................................................................................................. 24

3.1.4 Feed Gas Specification for Mercury Guard Bed......................................................... 24

3.1.5 Product specifications for Mercury Guard Bed.......................................................... 25

3.2 SPECIFICATION FOR CONDENSATE AND LPG DEHYDRATION .......................................... 25

3.2.1 Product specifications for condensate dehydration .................................................. 25

3.2.2 Product Specifications for LPG dehydration ............................................................. 25

3.3 GDESIGN BASIS FOR HP FUEL GAS CONDITION .............................................................. 25

3.3.1 System Capacity .......................................................................................................... 25

3.3.2 HP Fuel Gas Specification ......................................................................................... 26

3.4 GENERAL DESIGN CONSIDERATION .................................................................................... 25

3.4.1 Feed Gas Compressor ................................................................................................ 25

3.4.2 Feed Gas Dehydrator, Condensate and LPG Dehydrator .......................................... 26

3.4.3 Feed Gas Compressor Discharge Air Cooler ............................................................. 26

3.4.4 Gas Filters .................................................................................................................... 27

3.4.5 Mercury guard bed ...................................................................................................... 27

3.4.6 Regeneration Gas Heater ............................................................................................ 27

3.4.7 Dryer Regeneration Compressor ................................................................................ 27

3.4.8 Feed Gas Compressor Suction Drum ....................................................................... 28

3.4.9 HP Fuel Gas / Gas Exchanger ..................................................................................... 28

3.4.10 HP Fuel Gas Chiller ..................................................................................................... 28

3.4.11 HP Fuel Gas KO Drum ................................................................................................. 28

3.4.12 HP Fuel Gas KO Drum Pump ..................................................................................... 28

4. DESIGN BASIS FOR NGL RECOVERY AND CONDENSATE STRIPPING UNIT(UNIT 232) ............. 29

4.1 DESIGN BASIS FOR NGL RECOVERY SECTION................................................................... 29


4.1.2 Equipment Design Consideration ............................................................................... 29


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4.2 DESIGN BASIS FOR CONDENSATE STRIPPING SECTION .................................................. 31



5. DESIGN BASIS FOR NGL FRACTIONATION UNIT(UNIT 233).......................................................... 32

5.1 DESIGN BASIS ........................................................................................................................ 32


5.1.2 Recovery and purity .................................................................................................... 32

5.1.3 Battery limits conditions ............................................................................................. 32

5.1.4 Equipment design consideration ................................................................................ 32

6. DESIGN BASIS FOR PRODUCT TREATING (UNIT 234) ................................................................... 34

6.1 C3 TREATING .......................................................................................................................... 34

6.1.1 Feed Specification ....................................................................................................... 34

6.1.2 Product Specification .................................................................................................. 34

6.2 C4 TREATING .......................................................................................................................... 34

6.2.1 Feed Specification ....................................................................................................... 34



6.3.1 Equipment design requirements ................................................................................ 34

7. DESIGN BASIS FOR REFRIGERATION UNIT(UNIT 235) .................................................................. 36

7.1 DESIGN BASIS FOR PROPANE REFRIGERANT FACILITY ................................................... 36

7.1.1 Feedstock Characteristics and Capacity .................................................................... 36

7.1.2 Equipment Design Requirements ............................................................................... 36


7.1.4 Propane and Deep Refrigerant Accumulator Pressure .............................................. 38

7.2 DESIGN BASIS FOR DEEP REFRIGERANT FACILITY .......................................................... 38

7.2.1 Feedstock Characteristics and Capacity .................................................................... 38

7.2.2 Equipment Design Requirements ............................................................................... 38


7.2.4 Deep Refrigerant Accumulator Pressure .................................................................... 39


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8. DESIGN BASIS FOR SOUR WATER STRIPPER (UNIT 236) ............................................................. 40

8.1 DESIGN BASIS ........................................................................................................................ 40

8.1.1 Design capacity ........................................................................................................... 40

8.1.2 Feed Condition and Compositions ............................................................................. 40


8.1.4 Battery Limits Conditions for Sour Water Stripping Unit .......................................... 41


8.2.1 Equipment design requirements ................................................................................ 41


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1. GENERAL

Feed Gas supplied to LPG Train-4 (LPG 4) facilities consist of mixture of Associated Gasand Condensate from the KOC Gathering Centers Southeast Kuwait (SEK) and NorthKuwait (NK) oilfields. In addition, existing KNPC Refinery Gases from the Shuaiba (SHU)AGRP and the Mina Al-Ahmadi (MAA) AGRP are supplied to the Fourth Gas Plant facilities.Future Non-associated Gas from the Dorra Gas field is considered in the design cases.

The range of the Feed Gas composition is covered by the six defined design cases, whichgovern the design of Liquefaction and Fractionation Sections. And JT valve operation caseof Winter Without Dorra feed is also considered in design. These cases are presented in theDesign Basis and summarized below:

1. Summer Case Without Dorra2. Summer Case With Dorra3. Winter Case Without Dorra4. Winter Case With Dorra5. Rich Case6. Lean Case7. JT Valve Operation Case

A separate design Feed quality has been defined to represent the maximum content of 2.5mol% CO2 and 2000 ppm H2S (2400 ppm for metallurgical purpose).

To support the operations of the LPG Train-4, C3 Refrigeration and general Utility Facilitiesare provided. These facilities consist of Fuel Gas System, Heat Recovery Steam GenerationSystem, Sea Water System, Closed Cooling Water System, Nitrogen Generation System,Instrument and Plant Air Systems, Water Treatment and Distribution Systems, PressureRelief and Flare, Liquid Disposal Systems, Fire Fighting System, Effluent Treating, and HPFuel Gas Conditioning etc.

The design of the NGL section is based on the GSP (Gas Sub-cooled Process), which is aTurbo Expander, based cryogenic technology. The GSP (Gas Sub-cooled Process) wasselected among 4 candidate processes, which are two open-art and two licensed processes,i.e. GSP (Gas Sub-cooled Process, Open Art), OHR (Over Head Recycle, Open Art), SFR


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(Split Flow Reflux, Licensed by Ortloff), and the CRR (Cold Residue Recycle, Licensed byOrtloff) during the development of the Feasibility Study by Fluor Daniel.

This plant capacity is designed to process 805 MMSCFD of Feed Gas and 106.3 MBPD ofexternal Condensate in addition to the Condensate produced in the NGL Recovery Sectionof the process. Product Recoveries of at least 75% C2, 97% C3 and 99% C4 are expected.The Percent Recovery varies based on the Feed composition. Among the 6 different FeedCases, the Lean Case will have the highest Percent Recovery

1.1 Plant FacilitiesThe Plant facilities are provided as follows to allow operations for 6 different cases:

Feed Pretreatment Unit (Unit 231)Two gas turbine driven compressor trains to get driving force of ethanerecovery.Feed Gas, Condensate and LPG Dehydration to prevent ice and hydrateformation in the down stream NGL Recovery Unit (Unit 232) which would causeblockage of lines and equipment.Mercury Guard Bed is provided downstream of the Feed Gas Dehydrator. Thepurpose of Mercury Guard Bed is to remove trace quantities of mercury thatcould be present in the feed to the NGL Recovery Unit (Unit 232) to protect thebrazed aluminum plate heat exchanger against rapid corrosion of aluminum.Mercury, even in trace quantities, has been found to corrode aluminum rapidlyunder certain conditions.

NGL Recovery Unit (Unit 232)The purpose of the NGL Recovery Unit (Unit 232) is to produce and recover theC2 heavier component. The selected process is GSP process which is usingTurbo Expander and C3 Refrigeration System as a cooling medium.Condensate Stripping System is to separate stripped condensate from the feedcondensate and to inject separated light ends into the Demethaniser(V-232-001).

NGL Fractionation Unit (Unit 233)Single NGL fractionation facilities including Deethaniser, Depropaniser,


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Debutaniser system.The objectives of a fractionation unit are to produce ethane, propane, butane,pentane and KNG for using as a fuel gas or storage.

Product Treating Unit (Unit 234)Propane sweetening and dryingButane sweetening and dryingPurpose of Propane and Butane Treatment Facilities are to remove the residualmercaptan and sulphur compounds (H2S, COS) in order to meet commercialgrade specifications.

Propane Refrigeration & Deep Refrigeration System (Unit 235)The purpose of C3 Refrigeration System is to provide main cooling duty toliquefying the C2 heavier component.The purpose of Deep Refrigeration System is to provide cooling duty forpropane product cooling down to -49 (-45 )

Sour Water Stripping Unit (Unit 236)Sour water stripping unit are provided with inlet feed drums, stripping tower andassociated equipment, etc. The purpose of sour water stripping unit is to stripout H2S in sour water. The H2S gas is sent to existing SRU.


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2. OVERALL DESIGN BASIS

2.1 Design ThroughputThe throughput or flow rate to the LPG 4 is shown in Table 2-1. Depending on thedesign case, the LPG 4 can be broken down into two parts:

Gas feed for NGL Recovery Unit Condensate and LPG Feed for Fractionation Unit

The facilities pertaining to Dorra Gas/Condensate sweetening and glycol Dehydrationfacilities have been excluded from the scope of work of LPG 4 Project.

Table 2-1 Feed Case Overview for the new Gas TrainGas Feed Liquid Feed

805 MMSCFD 106.3 MBPD

2.2 Feed Stream Condition and Composition2.2.1 Feed Gas Condition and Composition

The operating window for CO2 and H2S in sour gas will be as follows.CO2: Max. 2.5 mol% (normal average is 2 mol%)H2S: Max. 2400 ppm(Max quantity to be considered for metallurgical purpose

only) (normal average is 1000 ppm)

The following tables 2-2 though 2-4 show the condition and compositions of thefeed stream:

Table 2-2 The feed gas condition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean

Temperature ( ) 96.9(36.1)

103.1(39.5)

96.8(36.0)

102.9(39.4)

105.1(40.6)

103.7(39.8)

Pressure psig(barg)

508.9(35.1)

508.9(35.1)

509.1(35.1)

508.9(35.1)

550.4(38.0)

529.4(36.5)

FlowMMSCFD 805 805 805 805 805 805

kgmol/h 40172 40170 40172 40167 40488 40170


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Table 2-3 The feed gas composition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean

Unit Mol% Mol% Mol% Mol% Mol% Mol%

Hydrogen H2 0.00 0.00 0.00 0.00 0.21 0.00

Nitrogen N2 0.57 0.38 0.45 0.30 0.16 0.11

Oxygen O2 0.01 0.01 0.01 0.01 0.00 0.00

H2S H2S 0.20 0.20 0.20 0.20 0.20 0.20

CO2 CO2 2.30 2.50 2.30 2.50 2.10 1.38

Methane C1 73.12 78.15 71.03 76.84 63.21 80.42

Ethane C2 14.71 10.99 15.22 11.31 17.18 10.41

Propane C3 6.56 4.93 8.33 6.05 10.73 4.57

i-Butane IC4 0.67 0.75 0.60 0.70 1.30 0.56

n-Butane NC4 1.37 0.99 1.31 0.95 3.13 1.29

i-Pentane IC5 0.16 0.24 0.24 0.29 0.56 0.31

n-Pentane NC5 0.18 0.20 0.17 0.20 0.68 0.38

n-Hexane NC6 0.03 0.57 0.03 0.56 0.41 0.38

n-Heptane NC7 0.01 0.01 0.01 0.01 0.05 0.00

n-Octane NC8 0.00 0.00 0.00 0.00 0.01 0.00

Water H2O 0.10 0.07 0.10 0.07 0.05 0.00

Impurities Note1ppmw 111 114 108 112 92 117

Total 100 100 100 100 100 100

Note 1 : Refer to Table 2-4 for the components and quantities of impurities.


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Table 2-4 The feed gas impurities are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean

Unit ppmw ppmw ppmw ppmw ppmw ppmw

Carbon Disulphide 0.48 0.50 0.47 0.49 0.40 0.52

Carbonyl Sulphide 20.63 21.22 20.14 20.89 17.89 21.77

Methyl Mercaptan 24.58 25.28 23.99 24.89 21.08 25.94

Ethyl Mercaptan 48.47 49.86 47.32 49.09 40.53 51.14

Dimethyl Mercaptan 0.07 0.07 0.07 0.07 0.05 0.06

i-Propyl Mercaptan 11.83 12.17 11.54 12.00 9.15 12.47

n-Propyl Mercaptan 1.80 1.85 1.76 1.82 1.28 1.88

Methyl Ethyl Sulphide 0.47 0.48 0.46 0.48 0.35 0.48

Methyl Propyl Sulphide 1.52 1.57 1.49 1.54 0.91 1.62

n-Butyl Mercaptan 0.06 0.06 0.06 0.06 0.03 0.04

Tert Bytyl Mercaptan 0.27 0.28 0.27 0.28 0.20 0.31

Dimethyl Disulphide 0.28 0.28 0.28 0.29 0.16 0.32

Diethyl Disulphide 0.04 0.04 0.04 0.04 0.01 0.06

2-Methyl Thiophene 0.15 0.16 0.14 0.15 0.08 0.14

2.2.2 Condensate Feed Condition and CompositionThe following tables 2-5 and 2-7 show the condition and compositions of the case1for Condensate:

Table 2-5 The Condensate condition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean

Temperature ( )102.0(38.9)

106.4(41.3)

102.1(38.9)

106.4(41.3)

106.1(41.2)

106.4(41.3)

Pressure psig(barg)

565.6(39.0)

565.6(39.0)

565.6(39.0)

565.6(39.0)

536.6(37.0)

565.6(39.0)

Flow MBPD 59.4 66.3 59.4 66.3 55.1 66.3


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Table 2-6 The Condensate composition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean


Hydrogen H2 0.00 0.00 0.00 0.00 0.00 0.00

Nirtrogen N2 0.09 0.07 0.09 0.07 0.09 0.07

Oxygen O2 0.00 0.00 0.00 0.00 0.00 0.00

H2S H2S 0.09 0.07 0.09 0.07 0.09 0.07

CO2 CO2 0.28 0.44 0.54 0.65 0.27 0.65

Methane C1 9.11 10.46 9.08 10.44 9.01 10.44

Ethane C2 15.49 13.10 13.46 11.48 15.44 11.48

Propane C3 30.15 25.04 28.54 23.73 30.17 23.73

i-Butane IC4 8.05 7.26 8.41 7.53 8.06 7.53

n-Butane NC4 21.54 17.61 24.07 19.59 21.58 19.59

i-Pentane IC5 5.03 5.00 4.95 4.94 5.04 4.94

n-Pentane NC5 6.12 5.68 5.81 5.43 6.15 5.43

n-Hexane NC6 3.07 14.47 3.24 14.69 3.08 14.69

n-Heptane + NC7 0.89 0.71 1.60 1.27 0.89 1.27

Propylene 0.00 0.00 0.00 0.00 0.00 0.00

H20 H2O 0.08 0.06 0.08 0.06 0.09 0.06


Total 100 100 100 100 100 100

Note 1 : Refer to Table 2-7 for the components and quantities of impurities.


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Table 2-7 The Condensate impurities are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean





Ethyl Mercaptan 119.52 110.58 117.01 108.81 119.41 108.79

Dimethyl Mercaptan 0.31 0.29 0.30 0.28 0.31 0.28

i-Propyl Mercaptan 105.01 97.20 102.81 95.6 89.17 124.24

n-Propyl Mercaptan 11.11 10.28 10.88 10.11 11.42 10.40

Methyl Ethyl Sulphide 4.79 4.44 4.70 4.36 4.78 4.36

Methyl Propyl Sulphide 28.50 26.38 27.90 25.94 28.46 25.93

n-Butyl Mercaptan 1.50 1.39 1.47 1.36 1.51 1.37

Tert Bytyl Mercaptan 2.74 2.55 2.70 2.51 2.74 2.49

Dimethyl Disulphide 7.11 6.59 6.97 6.48 7.10 6.47

Diethyl Disulphide 5.05 4.68 4.95 4.59 5.05 4.602-Methyl Thiophene 4.22 3.89 4.12 3.83 4.22 3.84

2.2.3 LPG Feed CompositionsThe following tables 2-8 and 2-10 show the condition and compositions of the 1for LPG:

Table 2-8 The LPG condition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean

Temperature ( )100.4(38.0)

100.4(38.0)

100.4(38.0)

100.4(38.0)

100.4(38.0)

100.4(38.0)

Pressure psig(barg)

580.2(40.0)

580.2(40.0)

580.2(40.0)

580.2(40.0)

580.2(40.0)

580.2(40.0)

Flow MBPD 47.1 40.2 47.1 40.2 47.1 40.2


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Table 2-9 The LPG composition are :Case Without

DorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean


Hydrogen H2 0.00 0.00 0.00 0.00 0.00 0.00

Nirtrogen N2 0.00 0.00 0.00 0.00 0.00 0.00

Oxygen O2 0.00 0.00 0.00 0.00 0.00 0.00

H2S H2S 0.00 0.00 0.00 0.00 0.00 0.00

CO2 CO2 0.00 0.00 0.00 0.00 0.00 0.00

Methane C1 0.41 0.41 0.41 0.41 0.41 0.41

Ethane C2 6.02 6.02 6.02 6.02 6.02 6.02

Propane C3 44.50 44.51 44.50 44.51 44.50 44.51

i-Butane IC4 16.66 16.65 16.66 16.65 16.66 16.65

n-Butane NC4 28.39 28.39 28.39 28.39 28.39 28.39

i-Pentane IC5 2.57 2.56 2.57 2.56 2.57 2.56

n-Pentane NC5 1.44 1.44 1.44 1.44 1.44 1.44

n-Hexane NC6 0.00 0.00 0.00 0.00 0.00 0.00

n-Heptane + NC7 0.00 0.00 0.00 0.00 0.00 0.00

Propylene 0.00 0.00 0.00 0.00 0.00 0.00

H20 H2O 0.00 0.00 0.00 0.00 0.00 0.00


Total 100 100 100 100 100 100

Note 1 : Refer to Table 2-10 for the components and quantities of impurities.Table 2-10 The LPG impurities are :

CaseWithoutDorraSummer

WithDorraSummer

WithoutDorraWinter

WithDorraWinter

Rich Lean





Ethyl Mercaptan 54.20 54.19 54.20 54.19 54.20 54.19


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2.2.4 Exceptional Operation JT Valve Operation Case

During transient operation – i.e. start-up or shutdown operation – or whileexpander is under shutdown, expander could not be operated due to turndown operation ( < 30%), high pressure gas letdown is performed throughpressure control valve installed as a by-pass of the Feed Gas Expander. Inthis case, Residue Gas Compressor is not anymore mechanically driven andshall be by-passed. During this operation mode, Demethaniser columns shallbe operated at higher pressures than normal.

2.3 Product Specifications2.3.1 Ethane / Propane / Butane Recovery

The calculated Ethane recovery is to be 76.9 mol%. The calculated propanerecovery is to be 97 mol%. The calculated butane recovery is to be 99.7 mol%.The Guaranteed Recovery based on the exhibit D for “PROCESSPERFORMANCE AND CONSUMPTION GUARANTEES” are given below :Recovery is applicable for all cases except Rich and J-T case.

Compositions Guaranteed RecoveryEthane 75.4% of Feed

Propane 96.75% of FeedButane 99.45% of Feed

2.3.2 Residue Gas SpecificationAfter the removal of ethane and heavier components, residue gas from theRecovery Unit (Unit 232) will be sent to the new ERP Unit downstream of theexisting trains 1,2, and 3. The maximum H2S concentration in the residue gas is800 ppmv. The LPG 4 will be sent to the Ethane Recovery Plant (ERP), CO2

content in the residue gas should not exceed 2 mole percent.HP Fuel gas from Ethane Recovery Plant residue gas shall be supplied to GasTurbine as a fuel and to Dryer Regeneration Heater and Treater RegenerationHeater as a regeneration gas and to letdown facility of LP Fuel gas Knock-outDrum in which LP fuel gas will be supplied for the process heaters and boiler. Theresidue gas from LPG 4 will be used for back-up for fuel of above consumptionfacilities.


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2.3.3 Ethane Product SpecificationThe Ethane Product gas shall meet the specifications listed Table 2-11.

Table 2-11 Ethane Product SpecificationProduct Specification (vol.%)

Min. Max.Methane 7.1

(1)11.5

(1)

Ethane 85.6 90.8Propane 0.1

(1) 2.5C4 0 0.1CO2 2.3

(1) 11H2S 0.4

(1,2) 0.6

(1) Value is allowed to be lower than shown in table.(2) H2S content in FEED gas shall be limited 700 ppm to meet product

specifications.


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2.3.4 Propane Product SpecificationThe Propane Product shall meet the specifications listed below.

Table 2-12 Propane Product SpecificationTest

Method UnitLimits

Min MaxCompositionC2 and Lighter D 2163 mol% 2.0C3 (Propane) “ “ 96.0C4 and Heavier “ “ 2.5Hydrogen Sulphide (H2S) D2420 NegativeMoisture Content D2713 PassOlefins D2163 mg/L Report

Residual Matter D2158‘R’ Number “ 10‘O’ Number “ 33Residue on Evaporation D2158 mass% ReportSulphur, Total D2784/3246 mg/kg 20CorrosionCorrosion, Copper Strip 1h @37.8 °C

D1838 No.1

VolatilityDensity @ 15 °C D1657/2598 lb/ft3 (Kg/L) ReportVolatile Residue95% vol. Evaporated @ D1837 (°C) Report(760 mm Hg)Vapor Pressure @ 37.8 °C D1267 kPa

(psia)1380(200)

Note: Confirm to Gas Processor Association (GPA) Standard


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2.3.5 Butane Product SpecificationThe Butane Product shall meet the specifications listed below.Table 2-13 Butane Product Specification

Test Method UnitLimits

Min MaxCompositionC4(Butane) D 2163 mol% 95.0C5 and Heavier “ “ 2.0Hydrogen Sulphide(H2S) D2420 NegativeFree Water Content (Note 2) Visual NoneOlefins D2163 mol% ReportResidue on Evaporation D2158 mass% ReportSulphur, Total D2784/3246 mg/kg 20CorrosionCorrosion, Copper Strip 1h @37.8 °C

D1838 No.1

VolatilityDensity @ 15 °C D1657/2598 lb/ft3 (Kg/L) ReportVolatile Residue95% vol. evaporated @ D1837 °F (°C) Report(760 mm Hg)Vapor Pressure @ 37.8 °C D1267 kPa

(psia)483(70)

Note: 1. Confirm to Gas Processor Association (GPA)2. Water shall be determined by visual inspection of the samples used for

the density determination

2.3.6 Kuwait Natural Gasoline Product SpecificationFor Kuwait Natural Gasoline (KNG), the RVP should not exceed 10.5 psia.There are no other specific requirements of the KNG product.

2.3.7 Fuel Gas SpecificationThe H2S content is to be not more than 2,400 ppmv.


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2.4 Battery Limit Conditions2.4.1 Battery Limits Conditions for Feed Gas

The conditions of the main streams to the Feed gas compression are listedhereafter :Table 2-14 Feed Gas battery limit conditions

Feed Gas Operating Condition(1) Design ConditionPressure

psig (barg)Temperature

°F ( )Pressure


°F ( )From NK 542.3 (37.4) 100.4 (38) 1209.6

(83.4) 141.8 (61)

From SEK 563.3 (38.8) 100.4 (38) 1055.9(72.8) 170.6 (77)

From AGRP MAA 557.5 (38.4) 118.4 (48) 764,4(52.7) 199.4 (93)

From AGRP SHU 550.5 (38.0) 118.4 (48) 638.2(44.0) 167 (75)

Battery Limit pressure is referenced to grade at the LPG 4 IBL battery limit.

2.4.2 Battery Limits Conditions for Condensate FeedThe operating conditions of the main streams to Dehydration Facilities are listedhereafter.

Table 2-15 Condensate Feed battery limitCondensate Feed Operating Condition(1) Design Condition

Pressurepsig (barg)

Temperature°F ( )

Pressurepsig (barg)

Temperature°F ( )

From SEK 591.8 (40.8) 100.4 (38) 1375.0(94.8) 181.4 (83)

From NK 590.7 (40.7) 100.4 (38) 1375.0(94.8) 156.2 (69)

From AGRP MAA 596.1 (41.1) 100.4 (38) 1215.4(83.8) 199.4 (93)

From Slug Catcher 589.7 (40.7) 100.4 (38) 1026.9(70.8) 167 (75)

From ERPCondensate 591.9 (40.8) 100.4 (38) 1348.9

(93.0) 167 (75)

Battery Limit pressure is referenced to the LPG 4 IBL battery limit.


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2.4.3 Battery Limits Conditions for LPG FeedThe operating conditions of the main streams to Dehydration Facilities are listedhereafter.

Table 2-16 LPG Feed battery limit

LPG FeedOperating Condition(1) Design Condition

Pressurepsig (barg)

Temperature°F ( )

Pressurepsig (barg)

Temperature°F ( )

From MAB & SHU 607.4 (41.9) 100.4 (38) 799.2(55.1) 167 (75)

From MAA 592.3 (40.8) 100.4 (38) 1375.0(94.8) 181.4 (83)


2.4.4 Battery Limit Condition for ProductThe battery limit conditions are below shown in Table 2.17.

Table 2.17 Product Battery limit conditionsOperating Condition(2) Design Condition

Pressurepsig (barg)

Temperature°F ( )

Pressurepsig (barg)

Temperature°F ( )

Residue Gas 438(30.2)

100.4(38)

520(35.9)

180(82.2)

LP Fuel Gas 72.5(5)

100.4(38)

126.2(8.7)

284(140)

Ethane 325(22.4)

100.0(37.8)

460(31.7)

280 / -57.3(138/-49.6)

Propane 202.9(15.0)

-49(-45

(1))

554.5(38.2)

-59.8(-51)

Butane 94.3(6.5)

14(-10

(1) )

300.3(20.7)

-20(-29)

Pentane 91.4(6.3)

100(37.8)

206.6(14.3)

150.8(66)

KNG 69.6(4.8)

100(37.8)

237.1(16.4)

140(60)

(1) Propane, butane, pentane and KNG product rundown to be cooled below theboiling point and at a temperature suitable for storage at atmospheric level.

(2) Battery limit pressure is referenced to the LPG 4 IBL battery limit.


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2.4.5 Battery Limits Conditions for Propane Refrigerant SystemPropane make-up is performed from propane product at normal operation. Forinitial charge during start-up, propane is provided from existing gas plant. Thefollowing Table 2-18 shows the condition of the case specific feed streams:Propane blow down, in case of unit 235 emptying, is sent to the existing propanetank.The conditions at the battery limit of propane for make-up and empting are shownblow table 2-18:

Table 2-18 Battery limit for propane make up.

PropaneOperating Condition(1) Design Condition

Pressurepsig (barg)

Temperature°F ( )

Pressurepsig (barg)

Temperature°F ( )

From Existing GasPlant

243.7(16.8)

-49(-45)

488.8(33.7)

-58(-50)

To Existing PropaneTank ()

-49(-45)

554.5(38.2)

-59.8(-51)


2.4.6 Battery Limits Conditions for Deep Refrigerant SystemDeep refrigerant is ethane and propylene mixture. Propylene make-up isperformed from existing gas plant or . Ethane make-up is performed from ethaneproduct line.Deep refrigerant blow down, in case of Deep Refrigerant System (Unit 235)emptying, is sent to the flare stack.Table 2-19 Battery limit for propylene and ethane make up

Propylene / Ethane Operating Condition(1) Design ConditionPressure


°F ( )Pressure


°F ( )Propylene FromExisting Gas Plant () 77 (25) 1299.5

(89.6)180 / -70.6

(82.2) / (-57)Ethane From ERP(Ethane RecoveryPlant)

290(20.0)

101(38.3)

460(31.7)

280 / -57.3(138 /-49.6)

Battery Limit pressure is referenced at the LPG 4 IBL battery limit.Ethane shall be provided above the 99.9 mol% purity to prevent corrosion.

2.5 Design Consideration


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2.5.1 Plant Design LifeIndustry Standard design approaches will be used in equipment design. Plantdesign life is 20 years for economic evaluation.

2.5.2 Plant AvailabilityThe plant availability is defined at 8,000 hours per year for the economic.

2.5.3 Effluent TreatmentEffluents will be collected and treated in accordance with common industrypractices, maximizing use of existing MAA Refinery facilities, such to meet theKuwait EPA standards.

2.5.4 Physical PropertiesThe physical properties of the streams will be determined from a processsimulation in the software package HYSYS Version 7.1."Normal" vapour conditions (e.g. for volume in Nm3):P = 14.7 psia (1 Atm), T=60 °F (15.6 °C)

2.5.5 Remote/Emergency DepressurizationIt should be designed to include for remote/emergency depressurization facilities.The minimum design temperatures shall comply with DEP 30.10.02.31– MetallicMaterials – Prevention of Brittle Fracture and API 521.

2.5.6 Pressure Relief System and HIPPSAll pressure safety vents route via common header to the Flare K.O Drum.Cooling water thermal relief vents located at exchangers route safely toatmospheric location. For control valve discharging to Flare K.O Drum, the controlvalve is used tight shut designation in order to mitigate inadvertent product lossesto flare system. The HIPPS system has also been identified to limit flaring rate toflare system.

2.5.7 Source and Compressing of Regeneration GasThe high pressure fuel gas from Ethane Recovery Plant (ERP) should be used asthe primary source of the regeneration gas for all the system. The H2S and water


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contents of this gas would be provided with 40 ppmv and trace respectively.The regeneration gas from the three driers (Feed Gas Dryer, Condensate Dryer,LPG Dryer) will be excessive and should be routed to the high pressure fuel gasand installed a common centrifugal compressor, (to boost spent regeneration gasto the high-pressure Fuel Gas pressure), Air Cooler and Discharge Drum at thedischarge of the Compressor.


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3. DESIGN BASIS FOR FEED PRETREATMENT UNIT(UNIT 231)

3.1 DESIGN BASIS FOR FEED GAS COMPRESSION3.1.1 Feed Gas Compressor

Two (2) Feed Gas Compressor trains have been provided (2 x 50%). Each train isdriven by a dedicated gas turbine. Gas turbine is heavy-duty industrial type andcapable of dual firing (fuel gas & gas oil). Fuel gas is normally used for turbineoperation and when fuel gas is not available, then gas oil will be used to run theturbines. The exhaust gas from each gas turbine will be directed to the respectiveHeat Recovery Steam Generator (one HRSG per gas turbine train) to recoverheat and produce high pressure steam.The discharge pressure is controlled by Gas Turbine Speed Control Device. Ananti-surge system is provided down stream of the Feed Gas CompressorDischarge Water Cooler to ensure stable Compressor operations. The Feed Gasis compressed to a pressure so that when it is cooled and expanded through theTurbo-Expander.

3.1.2 Product specificationsThe maximum concentration of water in the dry gas at the outlet of theDehydration Facilities shall be 0.1 ppmv (free water dew point lower than -148 °F(-100°C) at 440.9 psia (30.4 bara)).This value is defined considering hydrate formation temperature in thedownstream units as hydrates are likely to form in the downstream NGL Recoveryunit (unit 232) where temperatures can be reached to -148 °F (-100 °C) @ 440.9psia (30.4bara)(Feed to Demethaniser V-232-001).

3.1.3 Water ContentAll Feed vapor streams have water contents of 803 ppmv for the Rich Caseexcept Dorra Gas. All liquid streams in the feed are water saturated. The LPG 4will be designed for an upset condition where all vapor streams are watersaturatedat 86 °F (30 °C) in accordance with MOM-FGTP-SKE-001.

3.1.4 Feed Gas Specification for Mercury Guard BedThe dry gas coming from feed gas dehydrator, which will have mercury


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concentration design value of 100 ng/Nm³.

3.1.5 Product specifications for Mercury Guard BedThe maximum concentration of mercury in the treated gas at the outlet of theshall be 10 ng/Nm³.

3.2 SPECIFICATION FOR CONDENSATE AND LPG DEHYDRATION3.2.1 Product specifications for condensate dehydration

The saturated water content at the feed temperature 113 °F (45 °C) with 5.4 °F(3 °C) margin in water content will be applied with design case.The maximum concentration of water in the dry condensate at the outlet of theDehydration Facilities shall be 1.0 ppmw.

3.2.2 Product Specifications for LPG dehydrationThe saturated water content at the feed temperature 102 °F (38.9 °C) in watercontent will be applied with design case.The maximum concentration of water in the dry LPG at the outlet of theDehydration Facilities shall be 1.0 ppmw.

3.3 DESIGN BASIS FOR HP FUEL GAS CONDITIONING

3.3.1 System CapacityInlet Design Flow : Max. 403.3 MMSCFD , 50% of Feed Gas in case 2,

Without DORRA Summer plus inclusion of 10% design margin. Outlet Design Flow : Max. 384.2 MMSCFD plus inclusion of 10% design

margin.

3.3.2 HP Fuel Gas Specification LHV(Low Heating Value) of conditioned HP Fuel Gas shall be 1088 BTU/SCF. The outlet temperature of conditioned HP Fuel Gas is 50.1

3.4 GENERAL DESIGN CONSIDERATION3.4.1 Feed Gas Compressor

For centrifugal or axial compressor, the design pressure of upstream


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equipment should be set at a safe margin above the settle-out pressure. Downstream equipment design pressure will be set at blocked in condition.

However, to prevent excess over design, the design pressure can be loweredwith proper protection system such as HIPPS or PSV.

Centrifugal CompressorThe choking capacity shall be not less than 115 percent of the ratedcapacity while the surge capacity shall be less than 75 percent of therated capacity at the rated speed.Unless otherwise specified, compressors will be started on full recyclewith the system at specified "Settling-Out Conditions". The recycle pipingwill be designed to handle a minimum 110 percent of surge flow atmaximum continuous speed.

A dedicated anti-surge controller is to be provided protection of the Feed GasCompressor.

3.4.2 Feed Gas Dehydrator, Condensate and LPG DehydratorThe Dryers are designed to accommodate the molecular sieve inventory asproposed by the main suppliers.The adsorbent material is supported on a fixed grid, with layers of ceramic balls atthe top and bottom of the bed. The Dryers are externally insulated (heat and coldconservation)..As the Dryers will be cycling through the adsorption and regeneration sequences,mechanical design of the Dryers shall take into account the effects of thermalfatigue.The water content of the dry liquid shall be guaranteed, the molecular sievelifetime shall be guaranteed to be at least three years, the pressure drop acrossthe drier during adsorption step shall be guaranteed to be a maximum of psi (0.bar).

3.4.3 Feed Gas Compressor Discharge Air CoolerOutlet temperature of air cooler should be designed as 140 °F (60 ) andcontrolled by motor on/off or louver opening.


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3.4.4 Gas Filters Mercury guard filter

Treated gas outlet filter will be installed downstream the mercury guard bed.There are two 100% cartridge filters designed to remove fines 5 m andlarger. The pressure drop through the fouled filter shall not exceed 7.3 psi (0.5bar).

Feed gas compressor suction drumFeed gas compressor suction drum includes the function of filtering.Refer to item 3.4.8.

3.4.5 Mercury guard bedMercury guard shall be alumina impregnated catalyst or equivalent process. Thecatalyst will not be regenerated on site, but will be removed and disposed off. Themaximum available pressure drop across the mercury guard adsorber shall be 7.3psi (0.5 bar).The Mercury(Hg) content is to be more than 10 ng/Nm3.

3.4.6 Regeneration Gas HeaterOne regeneration gas heater for the three dryers (Feed Gas Dehydrator,Condensate Dehydrator, LPG Dehydrator) would be required for regenerationsystem design.The heater is provided by a cylindrical fired heater.As there is no regeneration gas flow in furnace during cooling and bed switchingsteps, two alternatives may be foreseen by the supplier: Pilots operating continuously and burners maintained to the minimum

sustainable flame (preferred option). Pilots operating continuously and burners stopped (automatic restart

provided).The relevant flame detection devices shall be provided (UV detection for burnersand pilots).

3.4.7 Dryer Regeneration Compressor The Dryer Regeneration Compressor(C-231-002) is a centrifugal type, driven


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by steam turbine and is provided with anti-surge devices. Regeneration Compressor Discharge Air Cooler(E-231-007) is designed to

cool compressor discharge down and uses air as a cooling media. Regeneration Compressor Discharge Drum (V-231-007) is to separate gas

and potential liquid. This vertical drum is equipped with a mesh to avoid anyliquid carry-over to residue gas header.

3.4.8 Feed Gas Compressor Suction Drum The Feed gas compressor suction drums are designed to remove fines

5 m and larger that is contained in the feed gas. This drum is equippedwith the lower sump to collect bulk contaminants and Cyclotube withindependent second stage sump to remove and collect entrainedcontaminants. The pressure drop through the Feed gas compressorsuction drum shall not exceed 2 psi (0.14 bar).

3.4.9 HP Fuel Gas/Gas Exchanger (E-231-031) The conditioned HP fuel gas is heated by Feed Gas and thus the Feed Gas is

pre-cooled in the process

3.4.10 HP Fuel Gas Chiller (E-231-032)The pre-cooled Feed Gas is cooled by C3 Refrigerant to 10.4 in order toachieve 1088 BTU/SCF of Fuel gas LHV and heavy component is liquefied

3.4.11 HP Fuel Gas KO Drum (V-231-031) The purpose of HP Fuel Gas KO Drum is to separate the liquid and gas

formed after the chilling of Feed Gas .

3.4.12 HP Fuel Gas KO Drum Pump The separated liquid is pumped to Feed Condensate Drum (V-231-011)


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4. DESIGN BASIS FOR NGL RECOVERY AND CONDENSATE STRIPPING UNIT(UNIT 232)

4.1 DESIGN BASIS FOR NGL RECOVERY SECTION4.1.1 Product specifications

Products of NGL Recovery Unit (Unit 232) are: Residue Gas to Ethane recovery Unit or High pressure fuel gas header, NGL to the Deethaniser of Fractionation Unit (Unit 233),

The residue gas is normally routed to new Ethane Recovery Plant (ERP).However in case of excess quantity, it shall be diverted to HP fuel gas header.The specifications of the residue gas from the unit 232 shall comply with thefollowing specifications: H2S max. 800 ppmv CO2 max. 2 mol%

At the outlet of the Deethaniser bottom, the NGL shall meet the ethane and thepropane product specification of NGL fractionation unit (233) in terms ofhydrocarbons contents.

The Ethane and Propane product specification shall meet the specificationspecified on para.2.3.3 and 2.3.4 of this document.

4.1.2 Equipment Design ConsiderationColumn V-232-001 Demethaniser

The operating pressure of the Demethaniser is set to ensure residue gas andethane recovery at an optimum pressure without any recycle compressor.There are packing in the top section and trays for the bottom. The twosections are defined by a different column diameter.The below special devices are provided:

Two nozzle on the mixed feed from Feed Gas Expander to ensure aproper distribution at the column inlet,One demister on column top to avoid any liquid carry-over.


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Compressor C-232-001 Residue Gas Compressor

The Residue Gas Compressor is driven by the Feed Gas Expander,L-232-001. Recovered energy from the Feed Gas Expander is used toincrease the pressure of the Residue Gas to the design conditions based onthe Lean Case.

Drums V-232-003 Chilled Feed Gas K.O Drum

This horizontal drum purpose is to separate the liquids and gases formedafter the chilling of the Feed Gas to the Demethaniser. It is equipped with asymmetrical, dual-entry inlet distributor and an outlet vapor mesh pad to avoidany liquid carry-over to the Feed Gas Expander.

Exchangers V-232-E001/002/003 Cold Box

In the Cold Box, one stream is cooled down :Warm dried gas.

Simultaneously, cold streams are reheated :Demethaniser overhead gas,Demethaniser side withdrawals.

E-232-003 Demethaniser Reflux SubcoolerThis plate fin heat exchanger purpose is to cool down stream used asDemethaniser reflux while heating up residue gas. This exchanger is part ofthe cold box.

E-232-006 Demethaniser Trim ReboilerThis is a vertical thermosyphon type reboiler using low pressure steam asheating medium. It will be used during start-up and JT valve operation case.

E-232-004 Dry Feed Gas ChillerThis kettle type shell and tube heat exchanger uses propane as coolingmedium for chilling of feed gas.


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Expander L-232-001 Turbo Expander

This Expander allows for drop both temperature and pressure by an isentropicletdown. Energy is recovered in the associated Residue Gas Compressor.By-pass valve of the Expander is provided for start-up, transient andshutdown operations.

4.2 DESIGN BASIS FOR CONDENSATE STRIPPING SECTION4.2.1 Product specifications

Products of unit 232 condensate stripping section are : Condensates from condensate stripper sent to Deethaniser,

C1 : Max. 2 mol%

4.2.2 Equipment Design ConsiderationColumn V-232-002 Condensate Stripper

Raw condensate from Condensate Dehydrators is treated in the CondensateStripper V-232-002. Lighter components are removed as vapor overheadproduct and supplied to the demethanizer V-233-001.The column is equipped with :

Reboiler E-232-008, heated by low pressure steam,Side reboiler E-232-007, in which liquid coming out from column is heatedand sent back to column after exchanging heat with column bottom

The E-232-008 is fed with low pressure steam under flow control reset bybottom trays temperature.The condensate stripper bottom temperature is about 221 °F (105 °C).The condensate flow rate is controlled by the level of V-232-002. whichchanges the flow to the Deethaniser V-233-001

Exchangers E-232-008 Condensate Stripper Reboiler

This is a kettle type reboiler using low pressure steam as heating medium.


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5. DESIGN BASIS FOR NGL FRACTIONATION UNIT(UNIT 233)

5.1 DESIGN BASIS5.1.1 Product specifications

The product from NGL fractionation unit shall meet the specification specified onpara.2.3.3, 2.3.4, 2.3.5 and 2.3.6.

5.1.2 Recovery and purityThe recovery and purities from NGL fractionation unit shall meet the specificationslisted below. Guaranteed product quality is applicable for all cases except J-Tcase.

Product Recovery, mol% Purity, mol%Ethane(C2) 75 ~ 76 (Calculated) Min. 85.6Propane(C3) 97 (Calculated) Min. 96.0Butane(C4) 99 (Calculated) Min. 95.0

5.1.3 Battery limits conditionsThe Battery limit conditions of the main streams are listed on para. 2.4.4

5.1.4 Equipment design consideration V-233-001:Deethaniser

The operating condition of the Deethaniser is set to ensure Ethane recoveryat an optimum pressure. High Integrated Pressure Protection System (HIPPS)will be considered at the column overhead line to mitigate flare load.

V-233-002: DepropaniserThe operating condition of the Depropaniser is set to ensure the condensationof the propane . High Integrated Pressure Protection System (HIPPS) will beconsidered at the column overhead line to mitigate flare load.

V-233-003: DebutaniserThe operating condition of the Debutaniser is set to ensure the condensationof the butane Debutaniser Overhead Condenser. High Integrated PressureProtection System (HIPPS) will be considered at the column overhead line to


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mitigate flare load.

LP steam flow rate and quantity to reboilers :The LP steam flow rate to the Reboiler of the column is indirectly controlled bycondensate level controller in condensate pot which is reset by thetemperature of the sensitive tray of the corresponding column of which thetemperature is to be controlled. The quantity of reboiler shall be limited two (2)to install symmetrically.


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6. DESIGN BASIS FOR PRODUCT TREATING (UNIT 234)

6.1 C3 TREATING6.1.1 Feed Specification

The feed specifications listed below (specified for the existing trains) will beadopted and applied to the design of the LPG 4..H2S 100 ppmwMeSH 100 ppmwCOS 93 ppmw

6.1.2 Product SpecificationThe maximum concentration of total sulphur, H2S and COS in the treated PropaneProduct at the outlet of the Propane Treater will be 20 ppmw, NIL for H2S and 3.0ppmw for COS, respectively.

6.2 C4 TREATING6.2.1 Feed Specification

The feed specifications listed below (specified for the existing trains) will beadopted and applied to the design of the LPG 4..MeSH 108 ppmwEtSH 363 ppmw

6.2.2 Product specificationsThe maximum concentration of total sulphur and COS in the treated butane at theoutlet of the treater facilities shall be 20 ppmw and 3.0 ppmw respectively.

6.3 GENERAL DESIGN CONSIDERATION6.3.1 Equipment design requirements

Heaters Regeneration Heater

One regeneration gas heater for the two treaters (C3 / C4 treaters) would berequired for regeneration system design.The heater is designed to heat and vaporize the regeneration flow stream.The heater is to be a natural gas fired cylindrical type heater. The outlet


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temperature of the heater shall be 68 °F (20 °C) above the requiredregeneration temperature.Regeneration of the product treaters involves a hot regeneration stage andfinally a cooling stage. The regeneration uses ERP HP fuel gas. Fuel gas isheated to regeneration temperature in the fired heater H-234-001 before it ispassed over the molecular sieves for regeneration

Exchangers E-234-005/009/012/013: Regeneration Air Cooler

Outlet temperature of air cooler should be designed as 140 °F (60 ) andcontrolled by pitch or louver opening. However, air cooler outlet temperatureof E-234-009 is 150 °F (65.5 ) to prevent a partial condensing in the air fincooler and balance heat load to sea water cooler, E-234-010A/B.

E-234-006/010: Regeneration Water CoolerThe shell and tube exchanger is designed to subcool the propane/butane tominimize the duty of the downstream refrigeration system.

E-234-001/002/003, E-234-007 Propane Product Refrigerant Cooler / ChillerThe shell and tube exchanger is designed to meet the B/L temperature of-49 °F (-45 °C) for C3 and 14 °F (-10 °C) for C4.

E-234-011: Treater Regeneration Gas PreheaterThe Preheater is designed to exchange heat of ERP high pressure fuel gaswith hot regeneration gas and sent into regeneration gas heater. The outlettemperature of the preheater is designed to ensure a vapour phase intoH-234-001.

Filters F-234-001/003: Treater Outlet Filters

The filter is designed to remove any molecular sieve material 99% down to asize of 5 µm from the propane and butane product. The fouled filter pressuredrop should be limited to 7.0 psi (0.48 bar).

F-234-002/004/005/006: Regeneration Gas FilterThe regeneration gas filter is designed to remove particle from regenerationgas coming out of treaters. The filter will be sized to remove 99% of 5µm sizeparticles and larger particles. The fouled pressure drop should be limited tomaximum of 7.0 psi (0.48 bar).


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7. DESIGN BASIS FOR REFRIGERATION UNIT(UNIT 235)

7.1 DESIGN BASIS FOR PROPANE REFRIGERANT FACILITY

7.1.1 Feedstock Characteristics and CapacityThe composition and properties of the propane refrigerant used in this facility, areas below:

Ethane: maximum 0.5 mol% Propane: minimum 99.0 mol% C4 and heavier: maximum 0.5 mol%

The Propane Refrigeration Unit consists of a closed loop in which the propane isflashed, vaporized, recompressed and condensed.

Compressor shall be capable of restart-up from settle-out conditionThe settle out condition is determined from bubble pressure at maximum ambienttemperature 140°F (60 °C). When the temperature of system is over 140°F(60 °C), the propane will be vented to the Low Pressure Fuel Gas system.

7.1.2 Equipment Design RequirementsAll equipment and lines in the Propane Refrigeration Unit will be designed toaccommodate the required flow rates to supply the cooling duties of the LPGTrain-4 Plant.As the Feed Gas compositions provided by KNPC are very wide for the designcases, the Rich Feed case will not have any design margins applied to the sizingof the equipment. For the other cases, the design margins will be included in theEquipment Data Sheets as 20 percent. In case of compressor suction vessel, thedesign margins will be applied in Equipment Data Sheets as 25 percent.

7.1.3 Equipment Design ConsiderationCompressor

C-235-001A/B Propane Refrigerant CompressorTwo (2) Propane Refrigerant Compressors have been provided (2 x 50%).Each compressor is driven by a dedicated gas turbine. Gas turbine is heavy-duty industrial type and capable of dual firing (fuel gas & gas oil). Fuel gas is


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normally used for turbine operation and when fuel gas is not available, thengas oil will be used to run the turbines. The exhaust gas from each gasturbine will be directed to the respective Heat Recovery Steam Generator(one HRSG per gas turbine train) to recover heat and produce high pressuresteam.

Heat Exchangers E-235-001 Propane Refrigerant Condenser

Propane Refrigerant Condensers (E-235-001) are designed to coolcompressor discharge down to condensing temperature and uses sea wateras a cooling media.

E-235-002 Propane Refrigerant SubcoolerPropane Refrigerant Subcooler (E-235-002) is designed to cool down liquidpropane refrigerant coming out from V-235-001 and uses cold heat of ethaneproduct.

Drums V-235-001 Propane Refrigerant Accumulator

This horizontal drum purpose is to provide a liquid propane refrigerant buffer(Surge) to overcome any process or propane refrigerant system upsets.

V-235-002 Propane Refrigerant Compressor LP Suction DrumThis vertical drum separates Propane vapor and liquid from the vapor to thesuction of the Propane Refrigerant Compressor. It is equipped with a meshpad in the vapor outlet to avoid any liquid carry-over to the Low pressuresuction of the Propane Refrigerant Compressor. This drum also serves as theinventory of LP Propane Refrigerant used to cool the Propane Product in E-235-003, the Propane Product LP Refrigerant Cooler. It is also provided witha special diffuser pipe to cool down the hot anti-surge stream, by vaporizingthe liquid Propane Refrigerant contained in the bottom section.

V-235-003 Propane Refrigerant Compressor MP Suction DrumThis vertical drum separates Medium Pressure Propane vapor and liquids. Itis equipped with a mesh pad to avoid any liquid carry-over to the second-stage, Propane Refrigerant Compressor suction. It is equipped with a specialdiffuser pipe to cool down the hot anti-surge stream, by vaporizing the liquid


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Propane Refrigerant contained in the bottom section. V-235-004 Propane Refrigerant Compressor HP Suction Drum

This vertical drum separates High Pressure Propane vapor and liquids. It isequipped with a mesh pad to avoid any liquid carry-over to the third-stagePropane Refrigerant Compressor suction. It is equipped with a special diffuserpipe to cool down the hot anti-surge stream, by vaporizing liquid PropaneRefrigerant contained in the bottom section.

7.1.4 Propane Accumulator PressureThe pressure in Propane Refrigerant Accumulator, V-235-001 is maintained bymeans of hot gas by-pass around the Propane Refrigerant Condenser, E-235-001.A differential pressure controller (PDC) maintains a constant pressure dropthrough the Propane Refrigerant Condenser, E-235-001, to keep the hot gas bypass valve under control whatever the flow through the E-235-001.

7.2 DESIGN BASIS FOR DEEP REFRIGERANT FACILITY

7.2.1 Feedstock Characteristics and CapacityThe composition of the deep refrigerant which has been considered:

Ethane: 30 mol% or Ethane: 37 mol% Propylene: 70 mol% Propane: 63 mol%

The Deep Refrigeration Unit consists in a closed loop in which the deeprefrigerant (ethane and propylene mixture) is flashed, vaporized, recompressedand condensed.Compressor shall be capable of restart-up from settle-out conditionThe settle out condition is determined from bubble pressure at maximum ambienttemperature 140°F (60 °C). When the temperature of system become over 140°F(60 °C), the will be vented to flare system. De-ethaniser ovhd will be used asmake up for ethane.

7.2.2 Equipment Design RequirementsAll equipment and lines in the Deep Refrigeration Unit will be designed toaccommodate the flow rate required to supply the cooling duty of the PropaneProduct Deep Refrigerant Chiller, E-234-003.As the Feed Gas compositions provided by KNPC are very wide for the design


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cases, the Rich Feed case will not have any design margins applied to the sizingof the equipment. For the other cases, the design margins will be included in theEquipment Data Sheets as 20 percent. In case of compressor suction vessel, thedesign margins will be applied in Equipment Data Sheets as 25 percent.

7.2.3 Equipment Design ConsiderationCompressor

C-235-011 Deep Refrigerant CompressorThe Deep Refrigerant Compressor(C-235-011) is a centrifugal type, driven bysteam turbine with load controller and is provided with anti-surge devices.

Heat Exchangers E-235-011 Deep Refrigerant Condenser

Deep Refrigerant Condenser (E-235-011) is designed to cool compressordischarge down to condensing temperature and uses sea water as a coolingmedia.

E-235-012 Deep Refrigerant SubcoolerDeep Refrigerant Subcooler(E-235-012) is designed to cool down liquid deeprefrigerant coming out from V-235-011 to sub-cooled condition and uses coldheat of propane refrigerant.

Drums V-235-011 Deep Refrigerant Accumulator

This horizontal drum purpose is to provide a liquid deep refrigerant buffer toovercome any process or deep refrigerant system upsets.

V-235-012 Deep Refrigerant Compressor Suction DrumThis vertical drum is to separate gas and potential liquid. It is equipped with amesh to avoid any liquid carry-over to Deep Refrigerant Compressor suction.

7.2.4 Deep Refrigerant Accumulator PressurePressure in Deep Refrigerant Accumulator, V-235-011 is maintained by means ofpressure control valve to .


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8. DESIGN BASIS FOR SOUR WATER STRIPPER (UNIT 236)

8.1 DESIGN BASIS8.1.1 Design capacity

Design capacity of 40 Sm3/h is composed of existing gas plant, slug catcher andLPG 4 and its composition is based on LPG 4.

Table 8-1 Sour Water Feed Flow RateSource Definition Existing gas plant Slug catcher LPG 4 Total feedFlow rate ,Sm3/h 20 10 10 40

8.1.2 Feed Condition and CompositionsThe following tables 8-2 and 8-3 show the condition and compositions of the casespecific feed streams for Condensate:

Table 8-2 The sour water condition are :Pressure psig (barg) 21.8 (1.5)Temperature °F ( ) 104 (40.0)Total Flow Rate kg.mol/hr 2,249

Table 8-3 The sour water composition are :

Component Composition, mol%H2S 500 ppmH2O 99.87CO2 800 ppm

8.1.3 Product specificationsThe Treated Water from the Sour Water Stripper shall have the followingspecification.H2S: Not more than 10 ppmw

Acid Gas from New Sour Water StripperThe composition and amount of Acid Gas from OVHD of Sour Water Stripper areestimated as below.


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Table 8-4 The sour gas composition are :

Component Composition, mol%H2S 34.63H2O 9.95CO2 55.41

8.1.4 Battery Limits Conditions for Sour Water Stripping Unit Incoming:

Sour water to new Sour Water Stripper from existing gas plant:

Outgoing:Treated water to existing WWT from new Sour Water Stripper:Acid gas to existing SRU from new Sour Water Stripper:

Table 8-5 Battery limit for sour water and gas treatingCommodity Operating Condition(1) Design Condition

Pressurepsig (barg)

Temperature°F ( )

Pressurepsig (barg)

Temperature°F ( )

Sour Water 29 (2.0) 104 (40) 50.8 (3.5) 248 (120)Treated Water 240.7 (16.6) 100.4 (38) 435.1 (30.0) 167 (75)Sour Gas 18.9 (1.3) 190.4 (88) 50.8 (3.5) 248 (120)


8.2 GENERAL DESIGN CONSIDERATION8.2.1 Equipment design requirements

Column V-236-001: Sour Water Stripper

The Sour Water Stripper column is designed to strip H2S out of the SourWater feed, down to a concentration of 10 ppmw or less. The column isequipped with one-pass, valve trays.

Drum V-236-002: Sour Water Feed Separator

The separator is sized for minimum storage to accommodate any surge insour water feed to the Sour Water Stripper and for removing slop from feed


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water.

V-236-003: SWS Reflux SeparatorThe SWS Reflux Separator is sized for a liquid residence to support the SWSreflux Pump. In addition, the vapor space above the feed nozzle is designedto minimize entrainment of liquid into the Sour Gas stream. A mesh Pad isalso included in the top of the vessel to minimize entrainment carry-over.

Exchanger E-236-001: SWS Overhead Condenser

This Air Cooler/Condenser is designed to partially condense the Sour WaterStripper overhead stream, producing a concentrated Sour gas stream to berouted to the existing Sulfur Plant and a sour liquid reflux stream.

E-236-003A/B: Feed/Bottoms ExchangerThis exchanger is designed to recover heat from the Stripped Water bottomsproduct and transfer it to the Sour Water Feed stream, thereby reducing theReboiler requirements during normal operations.

E-236-004A/B: Stripped Water Trim CoolerThis exchanger is designed to cool the Stripped Water exiting theFeed/Bottoms Exchanger to a temperature of 100 oF (37.8 oC). Seawater isused as the cooling medium.

E-236-002: SWS ReboilerThis is a kettle-type exchanger using Low-pressure steam as the heatingmedium. The Reboiler will generate the required stripping steam to achieve abottoms product composition of 10 ppmw or less of H2S.

Process Description Og LPG Train 4

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