Process Design Basis Process Design Basis

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PROCESS DESIGN BASIS

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PEMBERI KERJA : PT PERTAMINA (PERSERO)

KONTRAKTOR : PT WIJAYA KARYA (PERSERO) Tbk.

NAMA PROYEK : PENGEMBANGAN TERMINAL BBM PULAU SAMBU

LOKASI : PULAU SAMBU - KEPULAUAN RIAU

TANGGAL KONTRAK :

0 13 Mar ’14 Issued For

Review SYN NK ADW

REV. DATE STATUS

PREP’D CHECKED APPROVED CHECKED APPROVED APPROVED

PT.WIJAYA KARYA PT.AUDEX INDONESIA PT.PERTAMINA

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REVISION SHEET

No

Revision

Date

List of Revision

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TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................................... 4

2. CODES, STANDARDS, AND REFERENCE DOCUMENTS .................................................................. 4

3. PROJECT OVERVIEW ................................................................................................................... 5

3.1. GENERAL ............................................................................................................................. 5

3.2. SITE INFORMATION ................................................................................................................. 5

3.2.1. LOCATION OF TERMINAL ............................................................................................... 5

3.2.2. METEOROLOGICAL CONDITION ..................................................................................... 5

4. PROJECT SCOPE .......................................................................................................................... 6

4.1 GENERAL ................................................................................................................................. 6

4.2 NEW FACILITIES .......................................................................................................................... 7

4.3 PROCESS DESCRIPTION ................................................................................................................. 8

5. DESIGN DATA ............................................................................................................................. 9

5.1. PRODUCT DATA ..................................................................................................................... 9

6. DESIGN BASIS ........................................................................................................................... 10

6.1. PRODUCT TRANSFER FACILITIES ....................................................................................... 10

6.2. TANKAGE ......................................................................................................................... 11

6.3. OFFSHORE REQUIREMENT ............................................................................................... 12

6.4. UTILITIES .......................................................................................................................... 12

7. DESIGN CRITERIA ..................................................................................................................... 13

7.1. EQUIPMENT DESIGN CRITERIA ................................................................................................. 13

7.1.1. DESIGN MARGIN .............................................................................................................. 13

7.1.2. DESIGN PRESSURE ............................................................................................................ 13

7.1.3. MAXIMUM OPERATING PRESSURE ......................................................................................... 14

7.1.4. MAXIMUM DESIGN TEMPERATURE .......................................................................................... 14

7.1.5. MINIMUM DESIGN TEMPERATURE ........................................................................................... 15

7.2. EQUIPMENT SIZING CRITERIA .................................................................................................. 15

7.2.1. TANK SIZING ........................................................................................................................ 15

7.2.2. PUMP SIZING ....................................................................................................................... 15

7.2.3. RELIEF VALVE ...................................................................................................................... 16

7.2.4. CONTROL VALVE .............................................................................................................. 16

7.2.5. IMPOUNDING BASIN ............................................................................................................ 16

7.3. LINE SIZING CRITERIA ............................................................................................................ 16

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1. INTRODUCTION

PT.PERTAMINA (Persero) Direktorat Pemasaran & Niaga plans to refurbish and

develop the fuel terminal in Pulau Sambu. The purpose of the Project is to start a

new business in the field of storage providers, as well as a means of improving fa-

cility utilization of Pulau Sambu Fuel Terminal which mostly idle today.

The Work shall be developed based on Indonesia Code and Standards as well as

the International Maritime Standards, Best Practices and Guidelines.

2. CODES, STANDARDS, AND REFERENCE DOCUMENTS

· API RP 14E Recommended Practice For Design And Installation Of Offshore

Products Platform Piping Systems, 2007.

· API 650 Welded Tanks for Oil Storage, Eleventh Edition, 2010

· API Std. 2350 Overfill Protection for Storage Tanks in Petroleum Facilities, Third

Edition, 2005.

· API Std.2000 Venting Atmospheric and Low-pressure Storage Tanks, Sixth Edi-

tion.

· API RP 520 Design and installation of pressure relieving systems in refineries,

2007.

· API RP 521 Guide for pressure relieving and depressurising systems, 2007.

· Process Flow Diagram, latest revision

· Utility Flow diagram, latest revision

· Piping and Instrumentation Diagram, latest revision

· SAFE Chart, latest revision

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3. PROJECT OVERVIEW

3.1. GENERAL

Existing facilities of Pulau Sambu Fuel Terminal consist of storage tanks,

pumping sytem, metering system, utility system, and supporting facilities ( of-

fice, warehouse, mosque, etc.).

3.2. SITE INFORMATION

3.2.1. LOCATION OF TERMINAL

The project site plan: Pulau Sambu Fuel Terminal is located in North-

west of Pulau Batam.

3.2.2. METEOROLOGICAL CONDITION

Ambient Temperature

· Max : 35 deg. C.

· Min : 19 deg. C.

Relative Humidity

· Max : 96.8%

· Average : 84.6%

· Min : 64.0%

Rainfall

· Daily rainfall maximum 45,5 mm

· Average of monthly rainfall 195,3 mm / month

METEOROLOGICAL CONDITIONMETEOROLOGICAL CONDITION

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· Maximum monthly rainfall 300 mm / month occurred in De-

cember

· Total of annual rainfall 2344 mm / month

Wind Conditions

Wind direction domi-

nant

: South

Operating / Normal : 23.0m/ls (3 sec gust)

Non-Operating / Ex-

treme

: 35.0m/s (3 sec gust)

Earthquake

Seismic Zone : Zone 2 (SNI 03-1726-

2002) Seismic Load : 0.1g

4. PROJECT SCOPE

4.1 GENERAL

This section will indicate the part of scope to be covered in this project. The

scope described in this section is required for additional equipment and re-

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habilitation of Fuel Terminal system. The scope covers the new installation

and modification of existing facilities. The tentative layout is shown bellow;

4.2 NEW FACILITIES

New facilities are given bellow:

1) HSD Tanks complete with ATG and nozzles and pipeline system to Jetty:

· Two HSD Tanks with capacity of 25,000 KL i.e. T-40 and T-41.

· Two HSD Tanks with capacity of 50,000 KL i.e. T-42 and T-43.

2) Pump for products:

· HSD Pumps i.e. P-5001/5002/5003 with capacity of 1500 KL/h each.

· MFO 180/ MFO 180 Comp. Pumps i.e. P-5004/5005/5012 with capacity

of 1000 KL/h each.

· Bunker 380/VR Pumps i.e. P-5006/5007 with capacity of 500 KL/h each.

· LSFO Pumps i.e. P-5008/5009 with capacity of 1000 KL/h each.

· LSWR/LCO/DCO Pumps i.e. P-5010/5011 with capacity of 500 KL/h

each.

3) Fire fighting system.

4) Service water system including 1 unit of 1000 KL Water Tank and the

pumps.

5) Heating system for non-HSD Tank. Heating system for non-HSD Tank.

5006/5007 with capacity of 500 KL/h each.

HSD Tank.HSD Tank.

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6) Electric heat tracing system.

7) Blending system for 7 unit of tanks.

8) Slop oil and oily water treatment system

9) New Jetties, i.e. Jetty 1 with berthing capacity 17500 – 50000 DWT and

Jetty 6 with berthing capacity 50000 – 100000 DWT.

4.3 PROCESS DESCRIPTION

Facility of Pulau Sambu Fuel Terminal consists of receiving facilities from the

ship, storage tanks system, blending at the tank, and delivery to the ship. Fuel

product could be produced are HSD 0.35% sulfur, HSD 0.25% sulfur, MFO 180,

Bunker 380, and LSFO (Low Sulfur Fuel Oil).

HSD 0.35% sulfur is produced from blending HSD 0.2% sulfur and HSD 0.5%

sulfur. HSD 0.25% sulfur is produced from blending HSD 0.2% sulfur and HSD

0.05% sulfur or HSD 0.01% sulfur. MFO 180 is produced from blending MFO

180 Component, LSWR (Low Sulfur Waxy Residue), and DCO (Decant Oil).

Bunker 380 is produced from blending MFO 380 Component, VR (Vacuum

Residue) and HD (High density Oil). LSFO is resulted from blending VR, DCO,

and LCO (Light Cycle Oil).

Receiving of HSD 0.2% sulfur, HSD 0.5% sulfur, HSD 0.05% sulfur and HSD

0.01% sulfur are from Jetty 6 by LR ship and MR ship, including in Jetty 1 by

MR ship and GP ship. HSD 0.2% then filled to New tank T-40/41/42/43 and

existing tank T-8. Furthermore, HSD 0.5% delivered to New tank T-

40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If

topping up is needed the majority of product to be delivered into existing

tank T-8. Product HSD 0.35% sulfur is delivered to vessel LR, vessel MR and

vessel GP. Later, HSD 0.25% sulfur product

HSD 0.05% sulfur received from the vessel MP, while HSD 0.01% sulfur is re-

ceived from the vessel GP. Each component could be filled into New Tank T-

40/41/42/43 or to the Existing tank T-8, then blended with HSD 0.2% sulfur to

obtain HSD 0.25% sulfur delivered to the vessel MR.

MFO 180 Component received from the vessel and is delivered to the tank T-

33/34/22/23, whereas LSWR received from the vessel MR and GP. LCO re-

New Jetties, i.e. Jetty 1 with berthing capacity 17500

Blending system for 7 unit of tanks.

tank T-8. Product HSD 0.35% sulfur is delivered to vessel LR, vessel MR and

vessel GP. Later, HSD 0.25% sulfur product

40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If 40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If

40/41/42/43 or to the Existing tank T

33/34/22/23, whereas LSWR received from the vessel MR and GP. LCO r


sulfur. HSD 0.25% sulfur is produced from blending HSD 0.2% sulfur and HSD

0.05% sulfur or HSD 0.01% sulfur. MFO 180 is produced from blending MFO

180 Component, LSWR (Low Sulfur Waxy Residue), and DCO (Decant Oil).

Bunker 380 is produced from blending MFO 380 Component, VR (Vacuum

Residue) and HD (High density Oil). LSFO is resulted from blending VR, DCO,

and LCO (Light Cycle Oil).

40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If 40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If 40/41/42/43 to blend with HSD 0.2% sulfur producing HSD 0.35% sulfur. If


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ceived from the small vessel and to be delivered to the tank T-33/34/17. MFO

180 Component, LSWR, and LCO blended in the tank T33/34 to produce MFO

180. Afterward MFO 180 product delivered into the vessel MR, GP, and Small

vessel.

MFO 380 Component received from the vessel MR and GP delivered to the

tank T-32. VR received from the GP then delivered to T-32, T-9, and T-32. HD

received from the Small vessel then delivered to the tank T-32. Furthermore

MFO 380 Component, VR, and HD blended in the tank T-32 producing Bunker

380. Product Bunker 380 sent into the Barge.

VR received from the vessel GP and Small vessel then delivered into T-

37/38/9/18. DCO received from the vessel GP and to be delivered into tank T-

37/38/21. LCO received from Small vessel and to be delivered into tank T-

37/38/17. Furthermore VR,DCO, and LCO blended in the tank T-37/38 to pro-

duce LSFO. Then the LSFO product delivered to the MR.

5. DESIGN DATA

5.1. PRODUCT DATA

The following are the product specifications / properties that are handled in

the terminal:

Component/

Product

SG

@16º

C

Viscosity @ Han-dling Temp. (cSt)

Han-

dling

Temp

(ºC)

Pour

Point

(ºC)

Flash

Point

(ºC)

Sulfur

Con-

tent

(%WT)

LSWR 0.9500 320 60 48 66 0.35

VR 0.9800 350 77 48 88 0.35

DCO 0.9990 180 50 24 55 0.30

HSD 0.8700 3 – 6 25 18 60 0.35

LSFO 0.9600 90 60 45 70 0.30

MFO 180 0.9910 180 50 24 66 3.5

LCO 0.9476 180 25 42 56 0.16

9, and T-32. HD

320

350

60

77

320

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MFO 180 Comp 0.9910 180 50 24 66 3.5

MFO 380 Comp. 0.9500 2000 25 30 90 1.0

HD 1.0360 490 25 - 6 100 1.78

Bunker 380 0.9500 380 50 30 90 1.0

6. DESIGN BASIS

6.1. PRODUCT TRANSFER FACILITIES

There are total of Eleven (12) nos. of Product Pumps. Three (3) nos. of

centrifugal pumps for HSD and nine (9) nos. of positive displacement pumps

for non-HSD products, ranging from 500 m3/hr to 1500 m

3/hr, provided in

relation to 4 jetties with jetty pipelines connected to the jetties. This is to

realize optimal flexibility in tanker and barge loading, as this arrangement

allows both tanker and barge jetties to be served simultaneously. Some of

the pumps are equipped with variable speed drive. All pumps can be

switched to the specified tank line using valves which allows the following

operation:

1) Transfer of product from one tank to another tank;

2) Product re-circulation;

3) Receipt directly from ship to tank;

4) Delivery from tank to ship.

Flow Rates And Pumping Equipment

The following normal flow rates apply for the different products:

PUMP PRODUCT PUMP CAPACITY

(m3/hr)

P-5001 , P-5002, P- HSD 1,500

P-5004 , P-5005 MFO 180 / COMP-

MFO 180

1,000

P-5006 , P-5007 BUNKER 380 / VR 500

P-5008 , P-5009 LSFO 1,000

P-5010 , P-5011 LSWR / DCO / LCO 500

There are total of Eleven (12) nos. of Product Pumps. Three (3) nos. of

P-5001 , P1 , P1 , P-5002, P-

-MFO 180 / COMPMFO 180 / COMPMFO 180 / COMPMFO 180 / COMPMFO 180 / COMP-

HSD products, ranging from 500 m3/hr to 1500 mHSD products, ranging from 500 m /hr to 1500 m

500

5002,

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6.2. TANKAGE

The dimensions and storage capacities are listed as follows:

IT

E

TANK NO.

PRODUCT

SIZE OF TANK

TANK CAPACI-TY (m3)

DIA.(m)

HT (m)

1

T-6

HSD 0.35% S

23.986

13.175

5,773

2

T-8

HSD 0.35% S

24.008

13.2

5,880

3

T-9

VR

23.792

10.58

4,505

4

T-17

LCO

27.914

13.213

7,824

5

T-18

VR

24.375

9.117

4,131

6

T-21

DCO

32.971

14.792

12,264

7

T-22

Component MFO

180

36.016

13.32

13,142

8

T-23

Component MFO

180

35.996

13.089

12,911

9

T-30

HSD 0.35% S

23.475

11.715

4,889

1

0

T-32

BUNKER 380

36.001

13.185

13,149

1

1

T-33

MFO 180

36.005

13.22

13,004

1

2

T-34

MFO 180

36.004

13.2

13,234

1

3

T-36

LSWR

35.994

13.225

13,026

1

4

T-37

LSFO

35.977

16.327

16,270

1

5

T-38

LSFO

39.006

16.595

19,477

1

6

T-40 (NEW)

HSD 0.35% S

42

19.8

25,000

1

7

T-41 (NEW)

HSD 0.35% S

42

19.8

25,000

1

8

T-42 (NEW)

HSD 0.35% S

60

19.2

50,000

1

9

T-43 (NEW)

HSD 0.2% S

60

19.2

50,000

2

0

T-19

SLOP

32.966

11.568

9,649

2

1

TS-5

SLOP

12.017

11.573

1,270

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The scope of Work shall include all statutory clearances, design, supply, of

material, fabrication, erection, inspection, testing, painting, coating,

calibration of Four (4) new product storage tanks, T- 40, T-41, T-42 and T-

43 as listed above and in accordance with the respective data sheets,

specifications and drawings, with a total of 150, 000 m additional storage

capacity. Refurbishment works for the rest of the 17 units of existing tanks

as in the above list, shall include but not limited to using FRP lining/repair

as per the Technical Proposal for Existing C.S Tanks FRP Lining. The Tank

inspection report provided shall act as a reference and does not relieve

the responsibility of the Contractor to carry out further inspection as

necessary to carry out modifications and to refurbish the existing tanks to

its operational requirements. The Contractor shall also carry out all

necessary checks and precaution measures prior to the execution of the

refurbishment works. For this Phase, 21 tanks with a total capacity of

320,000 m3 including 2 numbers of slop tanks will be made available.

6.3. OFFSHORE REQUIREMENT

For this Phase, the offshore facilities shall consist of Two (2) new jetties

and Two (2) existing jetties as follows. The new Jetties are designed to

operate for 30 years and 20 years for other facilities. Flow metering

system will be separately located at the metering platforms along the jetty

trestle for the two new jetties. Additional Fire pump station will be located

near new Jetty 6. Marine loading arms at jetty platforms will be used for

loading and unloading of products. Other major equipments on the new

jetties are the gangway tower with crane and oily sump pump.

JETTY NO. JETTY BERTHING CAPACITY - DWT

6 (NEW) 50,000 ~ 100,000

1 (NEW) 17,500 ~ 50,000

3 3,500 ~ 40,000

4 100 ~ 400

6.4. UTILITIES

Utilities system will be described in Utility Design Basis document.

specifications and drawings, with a total of 150, 000 m additional storage

system will be separately located at the metering platforms along the jetty

trestle for the two new jetties. Additional Fire pump station will be located

For this Phase, the offshore facilities shall consist of Two (2) new jetties

and Two (2) existing jetties as follows. The new Jetties are designed to

1 (NEW)

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7. DESIGN CRITERIA

7.1. EQUIPMENT DESIGN CRITERIA

7.1.1. DESIGN MARGIN

Equipment Basis % Design Margin (Note

1)

Storage Tank Capacity No margin (Note 2)

Pumps Flow No Margin

Impounding Basin Flow 10%

Note:

1. No design margin will be provided in to new equipment but to be

inline with section 6.3.

2. No design margin will be provided into tank, since net working ca-

pacity is designed based on capacity in between HLL up to LLL.

7.1.2. DESIGN PRESSURE

Systems and components shall be protected according to relevant in-

ternational recommended practices such as API STD 2000 for tank and

API RP 520/521 for pump and piping.

For equipment / systems protected by PSV, the criteria defined in the

following table should be applied as a minimum.

Design Pressure Criteria

Maximum Operating Pressure,

barg

Design Pressure, barg

<1 3.5 barg based on safety

valve to atm.

1-10 MOP+1

>10 MOP+10%

Atmospheric tanks shall be designed to be water filled to the highest

point high high high liquid level during loading.

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Equipment located downstream of pump shall either be designed for

the shut off pressure or a PSV installed.

7.1.3. MAXIMUM OPERATING PRESSURE

The maximum operating pressure shall be defined as follows:

Maximum Operating Pressure

Equipment

Maximum Operating Pressure

Storage Tank Highest pressure resulting in out breathing

through Breather valve

Filter Maximum shut-in of pump

Basin Atmospheric

Centrifugal pumps Operating suction pressure + 1.25 times the

normal differential pressure developed by the

pump plus suction pressure of tank or maxi-

mum developed pressure due to surge in

piping or pipeline whichever is applicable.

Care shall be taken not to define the pressure higher than required, if

it affects the selection of material and pressure class rating.

The maximum operating pressure may be limited by installation of

surge Pressure Control Valve.

7.1.4. MAXIMUM DESIGN TEMPERATURE

Since normal liquid temperature is specified 30 oC, further the maxi-

mum design will be considered of 60 oC only based on solar radiation

temperature.

Since normal liquid temperature is specified 30 oC, further the max

will be considered of 60 oC only based on solar radiation will be considered of 60 oC only based on solar radiation

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7.1.5. MINIMUM DESIGN TEMPERATURE

Minimum design temperature shall be the minimum ambient temper-

ature at site condition.

7.2. EQUIPMENT SIZING CRITERIA

Equipment sizing criteria will be used as sizing basis of the new equipment

and be applied into design for new and modification of equipment for Pulau

Sambu Fuel Terminal

7.2.1. TANK SIZING

Tank sizing shall be in accordance with spec API, API 2350 and API Std.

2000.

Vertical storage tank should be provided with a coned down bottom

having a slope not less than 1 : 30 to lowest point sump.

Based on API 650, Appendix A

Centre Inlet Nozzle -

LLLL

Minimum residence time 5 minute

Between LLLL - LLL Minimum residence time 5 minute

Between HLL - HHLL Minimum residence time 5 minute

LLL - HLL To be determined based on net working

capacity requirement.

7.2.2. PUMP SIZING

Inline with Section 5 and 7.1.1, further No design margin shall be ap-

plied for design flow rate of a pump.

No margin shall be added to the differential head. The procedure for

pump calculations shall be:

· Determine the size of the pump discharge piping based on pump

rated flow rate. The line pressure drop should be calculated based

Tank sizing shall be in accordance with spec API, API 2350 and API Std.

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on farthest destination point and the 10% design margin added to

the pressure drop/100 m to confirm the line size is acceptable.

· Calculate the pump differential head based on the line size deter-

mined above.

· Calculate the NPSHA at maximum flow. Design margin of 1 (one) m

between NPSHA and NPSHR should be provided

7.2.3. RELIEF VALVE

Relief valves shall be designed in accordance with API RP 520 / 521.

The allowable accumulation for pressure relieving devices shall be:

For general relief 10%

For fire case relief 21%

For multiple RVs 16% (to achieve the required area)

7.2.4. CONTROL VALVE

At maximum flow rate the calculated CV shall be no greater than 80%

of the valve maximum Cv. At the minimum flow rate, the process CV

shall be greater than 10% of the maximum valve CV subject to vendor

minimum flow requirements.

7.2.5. IMPOUNDING BASIN

The holdup for the impounding basin facility shall be at least 50% of

the volume of the largest tank draining to it.

7.3. LINE SIZING CRITERIA

Liquid velocities shall in general be kept low enough to prevent problems

with erosion, pressure surges, and vibration and reaction forces. In some cas-

es a minimum velocity (self cleaning velocity) is required to prevent water ac-

cumulation and bacterial growth. Liquid line sizing shall be in accordance

with API-RP14E.

IMPOUNDING BASIN

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The velocity on pump discharge should in between range 2.1 - 3.7 m/s (7 - 12

fps) at maximum flow rates, and velocity on pump suction should in between

range 0.91 – 1.5 m/s (3 - 5 fps) to minimize pressure drop and to meet NPSH

requirement.

Gravity lines includes drains (closed and open drains), and other lines where

the liquid flows due to gravity instead of pressure difference. Generally, a

minimum downward slope 1:500 or maximum liquid velocity of 0.76 m/s (2.5

fps) for straight flow.

Pipes that are running full, and do not require a minimum downward slope to

avoid particle deposition, shall be sized according to the total available static

pressure head, and the maximum allowable velocities for liquid lines.

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