CLIENT : CONTRACTOR :

[A] SUMMARY
Heat duty Water Demand
kW kg/hr
E-170 MS Cooler 198.00 17036 (Note-2)
P-160 A/B Feed Pump - 3000 (Note-4) Used as water sealing
P-100 A/B Fractionation Reflux Pump - 3000 (Note-4) Used as water sealing
P-140 A/B Kerosene Pump - 0 (Note-4) Used as water sealing
P-150 A/B Diesel Pump - 0 (Note-4) Used as water sealing
23036
P-201 A/B NHT Feed Pump - 3000 (Note-4) Used as water sealing
P-203 A/B Stripper Bottom Pump - 3000 (Note-4) Used as water sealing
P-202 A/B Stripper Reflux Pump - 3000 (Note-4) Used as water sealing
P-206 NHT Wash Water Pump - 30 (Note-4) Used as washing water
9030.00
P-302 Caustic Recycle Pump - 0 (Note-4) Used as water sealing
E-302 HP Absorber Feed Cooler 210.00 18069 (Note-4) (Note-3)
P-301 A/B Separator Bottom Pump - 3000 (Note-4) Used as water sealing
P-303 A/B LPG absorber Bottom Pumps - 3000 (Note-4) Used as water sealing
E-305 Reformate Trim Cooler 512.00 44054 (Note-4) (Note-3)
E-304 Stabilizer Overhead Cooler 350.00 30115 (Note-4) (Note-3)
P-304 A/B Stabilizer Reflux and Distillate Pump - 3000 (Note-4) Used as water sealing
P-305 A/B Stabilizer Reboiler Pump - 3000 (Note-4) Used as water sealing
E-309 LPG Product Trim Cooler 12.00 1033 (Note-4) (Note-3)
E-307 Deethanizer Condenser 128.00 11013 (Note-4) (Note-3)
116282.98
P-402 Heavy Napfta Pump - 0 (Note-4) Used as water sealing
P-404 Low Octane Pump - 0 (Note-4) Used as water sealing
P-401 A/B Truck Loading Pump - Light Product - 0 (Note-4) Used as water sealing
P-401 C/D Truck Loading Pump - Heavy Product - 0 (Note-4) Used as water sealing
P-415 Truck Fillling Shed Pump - 0 (Note-4) Used as water sealing
P-413 Make up Water Pump - 0 (Note-4) Used as water sealing
P-405 Cooling Water Circulation Pump - 3000 (Note-4) Used as water sealing
P-407 Booster Pump - 0 (Note-4) Used as water sealing
P-410/420 Electric/Diesel Fire Pump - 3000 (Note-4) Used as water sealing
P-460 Jockey Pump - 3000 (Note-4) Used as water sealing
P-400 Flare KO Drum Pump - 0 (Note-4) Used as water sealing
9000
188819 kg/hr 189 m3/hr
43236 kg/hr 43 m3/hr
Notes :
1 The calculation of cooling water demand is based on differential temperature of 10
o
C across the exchanger.
2 The off-spec cooler is intermittent basis, use during commissioning/ start-up Fractionation Unit.
During commissioning of fractionation there is no requirement of cooling water on the CRU.
3 The cooling water demand for CRU is calculated based on heat duty requirement from Axens (for NHT & CRU Capacity 2500 BOPD)
Assumption temperature differential of 10
o
C across exchanger.
4 Cooling water consumption for pump is given as per Vendor information and be summarised as below and used for mechanical sealing :
Assume that for pump with power more than 5 bkW will utilize sealing water
Cooling Water Demand Power
m
3
/h bkW
P-160 A/B 3 5.20 During normal operation
P-100 A/B 3 8.20 During normal operation
P-140 A/B 0 3.00 During normal operation
P-150 A/B 0 4.10 During normal operation
P-201 A/B 3 48.00 During normal operation
P-203 A/B 3 71.00 During normal operation
P-202 A/B 3 7.00 During normal operation
P-206 0.03 2.20 Intermittent
P-302 0 4.20 During normal operation
P-301 A/B 3 26.00 During normal operation
P-303 A/B 3 20.00 During normal operation
P-304 A/B 3 27.00 During normal operation
P-305 A/B 3 43.00 During normal operation
P-402 0 4.30 During normal operation
P-404 0 4.30 During normal operation
P-401 A/B 0 4.80 During normal operation
P-401 C/D 0 4.80 During normal operation
P-415 0 3.50 During normal operation
P-413 0 1.00 During normal operation
P-405 3 51.00 During normal operation
P-407 0 0.07 During normal operation
P-410/420 3 132.00 Intermittent
P-460 3 13.00 During normal operation
P-400 0 2.13 During normal operation
CFU 5000 BPD
ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR
5,000 BPD CAPACITY CONDENSATE FRACTIONATION
PLANT
COOLING WATER CONSUMPTION CALCULATION
Remarks Description Equipment Tag Number Plant
UTILITY
Total water demand =
Total water demand =
Pump Tag No. Remarks
NHT 2500 BPD
UTILITY
CRU 2500 BPD
Total water demand =
Total water demand =
Total (with 20%margin)
CFU 5000 BPD Area
NHT 2500 BPD Area
Total sealing water (with 20%margin)
CRU 2500 BPD Area
FANKAM REFINERY LTD
P.T. ISTANA KARANG
LAUT
CLIENT : CONTRACTOR :
COOLING WATER CONSUMPTION CALCULATION
[A] CALCULATION FOR EACH COOLER
1 CFU 5000 BPD
E-170 (MS Cooler)
Duty = 198 kW 1.0 kW = 1.0 kW = 3600.0 kJ/hr
712800 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 17036 kg/hr
So, the cooling water flowrate of E-170 is = 17036 kg/hr
2 CRU 2500 BPD
E-302 (HP Absorber Feed Cooler)
Duty = 210 kW
756000 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 18069 kg/hr
So, the cooling water flowrate of E-302 is = 18069 kg/hr
3 E-304 (HP Stabilizer Overhead Cooler)
Duty = 350 kW
1260000 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 30115 kg/hr
So, the cooling water flowrate of E-304 is = 30115 kg/hr
4 E-305 (Reformate Trim Cooler)
Duty = 512 kW
1843200 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 44054 kg/hr
So, the cooling water flowrate of E-305 is: 44054 kg/hr
5 E-307 (Deethanizer Condenser)
Duty = 128 kW
460800 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 11013 kg/hr
So, the cooling water flowrate of E-307 is = 11013 kg/hr
6 E-309 (LPG Product Trim Cooler)
Duty = 12 kW
43200 kJ/hr
Cp of water = 4.184 kJ/kg
o
C
T = 10
o
C
m = Q
Cp x T
m = 1033 kg/hr
So, the cooling water flowrate of E-309 is = 1033 kg/hr
ENGINEERING, PROCUREMENT AND
CONSTRUCTION FOR 5,000 BPD
CAPACITY CONDENSATE
FRACTIONATION PLANT
Conversion Factor :
P.T. ISTANA
KARANG LAUT
FANKAM REFINERY LTD
Refer to Axen Document for 2500 BPD NHT & CRU will have typical man power as below :
1
1/2
1/4
Then, here is summary of man power demand operating the plant
[A] NHT area
4 employee
2 employee
1 employee
Total : 7 employee (assumed)
[B] CRU area
4 employee
2 employee
1 employee
Total : 7 employee (assumed)
[C] CFU + UTILITY area
4 employee
2 employee
1 employee
1 employee
Total : 8 employee (assumed)
[D] E & I Department
2 employee
1 employee
Total : 3 employee (assumed)
[E] MECHANICAL Department
4 employee
1 employee
Total : 5 employee (assumed)
[F] HSE Department
1 employee
Board/DCS operator per shift :
Supervisor per shift :
Field operator per shift :
Board/DCS operator per shift :
Field operator per shift :
Board/DCS operator per shift :
Supervisor per shift :
Field operator per shift :
Supervisor per shift :
Technician per shift :
Supervisor per shift :
Supervisor per shift :
Field operator per shift :
Board/DCS operator per shift :
Supervisor per shift :
Plant Mng :
Technician per shift :
HSE staff per shift :
1 employee
Total : 2 employee (assumed)
[G] FACILITY ENGINEERING Department
1 employee
1 employee
1 employee
1 employee
1 employee
1 employee
Total : 6 employee (assumed)
[I] SUMMARY
38 employee (assumed)
[J] PLANT AREA
3000
m
2
refer to plant layout
3750
m
2
refer to plant layout
6750
m
2
employee or m
2
liter/m
2
/day liter/person/day
38 employee - 2~5
38 employee - 0~75
38 employee - 5~70
- - -
6750 m2 50 -
188.8
m
3/
hr
831.3 gpm
45
o
C
Total =
Supervisor per shift :
Total of employee :
Engineering Spt :
Engineering Mng :
Process Engineer :
Instrumentation Engineer :
Mechanical Engineer :
Electrical Engineer :
Recirculation Cooling Water Flow :
Hot Water Temperature :
Cleaning process area
-
Drinking water
Sanitation services
Bathing
Emergency shower/eye
wash/face wash
CFU & SRU Area :
NHT & CRU Area :
Total of plant area :
RANGE RECOMMENDED MINIMUM
Total =
PURPOSE
liter/person/day
5
20
15
NUMBER OF
PEOPLE OR
PLANT SURFACE
AREA
-
113
o
F
30
o
C
86
o
F
15
o
C
27
o
F
16.8 gpm
3.8
m
3/
hr
2.0 %
10
0.4
m
3/
hr
1.9 gpm
0.0
m
3/
hr
0.0 gpm
4.2
m
3/
hr
18.7 gpm
4.3
m
3
/hr as permeate
4.8
m
3
/hr as raw water
(if using branckish water)
8.6
m
3
/hr as raw water
(if using sea water)
Blow Down Rate :
Drift + Other Loss Rate :
Temperature Difference :
Evaporation Rate :
Cycle of Concentration :
Cooling Tower Water Make Up Rate :
Cold Water Temperature :
Water Treatment Package Capacity :
PERMEATE
REJECT
RAW WATER
REVERSE
RAW WATER
KATION
EXCHANG
ANION
EXCHANG
4.3
m
3
/hr
19.0 gpm
Duty : 1 x 100%
4.8
m
3
2.1 m as ID
1.4 m as H
Balance Volume : 1.00
8.7
m
3
2.5 m as ID
1.7 m as H
Balance Volume : 1.00
4.4
m
3
2.0 m as ID
1.4 m as H
Balance Volume : 1.00
19.3
m
3/
hr
Raw Water Tank Capacity : residence time is 1 hr
residence time is 1 hr
residence time is 1 hr
Raw Water Tank Capacity :
Raw Water Tank Capacity :
Raw Water Pump Capacity : 15 minutes filling time for raw water tank
Water Treatment Package Capacity :
CLEAN WATER
RAW WATER
TANK
RAW WATER PUMP
34.7
m
3
/hr
17.4
m
3
/hr
Duty : 2 x 100%
8.6
m
3
2.5 m as ID
1.7 m as H
Balance Volume : 1.00
0.05
m
3/
hr
Duty : 2 x 100%
0.07
m
3/
hr
Duty : 2 x 100%
5.00
m
3/
hr
Duty : 1 x 100%
Cleaning Pump Capacity : 10 % tolerance
Distribution Pump Capacity : 10 % tolerance
Distribution Pump Capacity : 10 % tolerance
Raw Water Pump Capacity :
15 minutes filling time for raw water tank
15 minutes filling time for raw water tank
Product Water Tank Capacity : residence time is 2 hr (Note-1)
Note-1 : residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration
time during regeneration of water treatment package
Raw Water Pump Capacity :
PRODUCT
WATER TANK
CLEANING PUMP
DISTRIBUTION
EMERGENCY SHOWER
188.82
m
3/
hr
Duty : 1 x 100%
188.82
m
3/
hr
Duty : 2 x 100%
43.24
m
3/
hr
Duty : 2 x 100%
43.2
m
3
5.3 m as L
1.5 m as H
Cooling Tower Capacity : 20 % tolerance
Sealing Water Collection Pit Capacity : residence time is 1 hr
Recirculating Water Pump Capacity : 20 % tolerance
Sealing Pit Pump Capacity : 20 % tolerance
COOLING TOWER
RECIRCULATING WATER PUMP
SEALING PIT PUMP
AG
UG
SEALING WATER COLLECTION
5.4 m as W
Continuous Intermittent
liter/day m
3
/hr
190 - Treated water
760 - Treated water
570 - Treated water
- 4.5 Treated water
0.06 m3/hr
1000 - Un - treated water
(assumed that cleaning is conducted daily but partially which density is 1000 liter for 20 m
2
area per day)
0.04 m3/hr
Treated (clean) water
Un - treated (raw) water
TYPE OF WATER
WATER DEMAND
15 minutes filling time for raw water tank
15 minutes filling time for raw water tank
15 minutes filling time for raw water tank
Note-1 : residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration
time during regeneration of water treatment package
(assumed that cleaning is conducted daily but partially which density is 1000 liter for 20 m
2
area per day)
Raw Water Pump
Recirculatin
g Water
River
Oily Water
from NHT
2500 BPD -
Continuously
Oily Water from
Tank Area - during
hard rain -
Intermittent
Oily Water - if any
- Intermittent
[1] To Condensate-Column
Overhead Vapor Heat
Exchanger
[2] To Flare System
[1] Vapor-Liquid from
Air Cooled Overhead
Condenser
[2] From Fuel Gas
System
Water from Deep
Well
Reverse
Osmosis/Demineralize
d
[1] Reductor
[2] Antiscalant
[3]
Permeate as CT Make
Up Water -
Reject -

Cooling Tower
[assumed : wet type]
CT Blow Down
- Continuously
[1] Antiscalant
[2] Microbiologycal
Treatment
[3] pH Adjusment

Reflux
Accumulator

Reflux back to top of CFU

Oily Water
Collection Pit

Oily Water
from CRU
2500 BPD -
Continuousl
API
Separator

Equalizing Pond

Slop HC
Tank
Oil back to
Condensate Feed
Tank
Effluent
Treatment
Package
Water from Slop HC
Tank - Intermittent
Water from API
Separator -
Continuously
Used chemical after
regeneration -
Raw Water
Tank
Water as cleaning of
plant area -
Heat Exchangers in
Plant
Cold
Hot Water
Sealing Water
Collection Pit
Pumps in Process
Plant Area
Evaporation + Drift
Water purpose for
drinking, sanitation,
Cleaning
Product
Water Tank
Distribution
Emergency Shower Pump
Water purpose for
emergency shower during
Sealing Pit
Pump
Reduce to 390 ppm TDS CW from 400 ppm
Evap = 75 L/s
TDS = 0 mg/L
CW = 5000 L/s
TDS = 400 mg/L
2,000,000 mg/s RCW =
TDS =
Maintain 400 ppm TDS CW
Evap = 75 L/s
TDS = 0 mg/L
CW = 5000 L/s
TDS = 400 mg/L

FILL/SPLASH BAR
OF
COOLING TOWER

FILL/SPLASH BAR
OF
COOLING TOWER
2,000,000 mg/s RCW =
TDS =
BD = 125 L/s
TDS = 406 mg/L
50,761 mg/s
With blowdown :
CW = 5000
TDS = 1,951,239
390
4925 L/s
406 mg/L
2,000,000 mg/s Without Blow Down :
CW = 4925
TDS = 2,000,000
MU = 75
TDS = 2000
MU = 200 L/s
TDS = 10 mg/L TDS = 400.4
2000 mg/s
BD = 11 L/s
TDS = 406 mg/L
4,277 mg/s
With Blow Down :
CW = 5000
TDS = 2,000,000
400

BASIN
OF
COOLING TOWER

BASIN
OF
COOLING TOWER
4925 L/s
406 mg/L
2,000,000 mg/s Without Blow Down :
CW = 4925
TDS = 2,000,000
MU = 75
TDS = 4277
MU = 86 L/s
TDS = 50 mg/L TDS = 400.86
4277 mg/s
L/s
mg/s
mg/L
L/s
mg/s
L/s
mg/s
mg/L
L/s
mg/s
mg/L
L/s
mg/s
L/s
mg/s
mg/L