4439-YZ-SG-000000001

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

CT-EPC/017/SH/EPM/RPC-X/2023

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BASIC ENGINEERING DESIGN DATA - BEDD

12/Jul/24

07/May/24

IOC – Implementation of Comments

R. Montalbano

F. Posocco

F. Ghibaudo

IFA - Issued for Approval

M. Rao

F. Posocco

F. Ghibaudo

Issue

Date

Reason for Issue – Revision Description

Prepared

Checked

Approved

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Table of Contents

INTRODUCTION… 4 1.1 Reference Documents … 4

1.1.1

1.1.2

CA/COMPANY documents … 4

CONTRACTOR documents … 4

1.2 Order of precedence … 4

1.3

Abbreviations … 5

1.4 Definitions … 6

2 PURPOSE OF DOCUMENT … 6

3 PROJECT DESCRIPTION … 6

4 GENERAL INFORMATION … 11

4.1

Plant design life … 11

4.2 Operational flexibility… 11

4.3

4.4

Scope of facilities … 12

Feedstocks … 12

4.5

Systems of measurement units … 13 5 PROJECT REGULATIONS, CODES AND STANDARDS … 17

6 SITE AND METEOROLOGICAL DATA … 17

6.1

Site Data … 17

6.1.1 Geographical location and topography … 17

6.1.2

6.1.3

6.1.4

Soil and Geological Data … 17

Structural design basis and loads … 17

Available area in DEV1 … 18

6.2 Climatic and Meteorological Data … 19

6.2.1

6.2.2

6.2.3

6.2.4

Barometric Pressure and site elevation … 19

Temperature and Humidity … 20

Design temperatures … 21

Rainfalls and snow … 21

6.2.5 Wind … 21

6.2.6

Solar Radiation … 25

7 UTILITIES AT LAB COMPLEX (DEV1 AREA) … 25

7.1

7.2

Steam … 25

Steam condensate … 26

7.3 Demineralized water … 26

7.4

Boiler Feed Water … 26

7.5 Cooling water … 27

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7.6

Potable water … 27

7.6.1 Quality standards for potable water… 27

7.7

Industrial water … 29

7.8 Fire water … 30 7.9 Natural Gas … 30

7.10 Fuel Gas … 32

7.11 Plant air and instrument air … 33

7.12

Inert gas (Nitrogen) … 33

7.13 Electrical power … 36

7.14 Emergency Relief Systems … 36

8 UTILITIES AT RA1K REFINERY… 37

9 UTILITIES AT PORT … 37

10 SHIPPING FACILITIES … 38 11 OTHER APPLICABLE DETAILED DESIGN SPECIFICATIONS … 38

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INTRODUCTION

This document summarizes the basic engineering site and design data related to the EPC phase of the project REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE.

1.1 Reference Documents

In case of conflicts between two or more reference documents, the priority defined by contract shall apply.

1.1.1 CA/COMPANY documents

1CD1673A-8820-WP-0000-0020

BASIC ENGINEERING DESIGN DATA (BEDD)

Rev- 08F

1CD1673A-8820-WP-0000-0022

INDEX OF PROJECT CODES AND STANDARDS

Rev 02F

1.1.2 CONTRACTOR documents

4439-YZ-PC-000000001

Document numbering procedure

4439-PZ-PW-000000001

4439-YZ-PC-000000018

Project Work Breakdown Structure (WBS) & Plant Breakdown Structure (PBS) Index of project regulations, codes and applicable standards

1.2 Order of precedence

The EPC project shall be carried out based on the contract documents and fulfilling the requirements of any applicable Local Standards and Regulations. The order of precedence to adopt for the development of the Detail Design shall strictly follow the below sequence, in a top-down order, applied to both the relevant contractual documents and the regulatory references:

The Contract body (the so-called Terms&Conditions) and all its annexes from Annex I to

Annex XXIII,

Local Regulations (for sake of clarity: the Algerian Law),
Applicable nationals and international norms, codes and standards (last edition).

REMARKS:

a) Annex I prevails over all other Annexes; b) Within Annex I, the order of precedence is CEOT > DAO > Licensor / FEED documents.

Within the CEOT and DAO, the higher number prevails upon the lower number (chronological order from the latest to the earliest);

c) In case of conflict within the documents found at the same level of precedence, the most

stringent requirement prevails.

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1.3 Abbreviations

ARH

AGA

ANSI

API

ASTM

CEOT

CTC

DAO

DPEM

EDD

EIE

EPC

FEED

IEC

ISA

ISO

LAB

LP Steam

MP Steam

NFPA

N.A.

ONML

TBC

TBD

TCM

Autorité de régulation des hydrocarbures

American Gas Association

American National Standards Institute

American Petroleum Institute

American Society for Testing and Materials

British Standards

Contracting Authority (SONATRACH)

Commission d’Evaluation des Offres Techniques

Contrôle Technique de la Construction (Algerian Authority)

Dossier d’Appel d’Offres

Direction des Patrimoines Energétiques et Miniers

Etude de Dangers

Etude d’Impact sur l’Environnement

European norms

Engineering, Procurement and Construction

Front End Engineering Design Development

Factory Mutual

International Électrotechnique Committee

Institute of Petroleum (now Energy Institute)

Instrument Society of America

International Standards Organization

Linear-Alkyl-Benzene

Low Pressure Steam

Medium Pressure Steam

National Fire Protection Association

Not Available

Office Nationale de Métrologie Légale (Algerian Authority)

To Be Confirmed

To Be Defined

Tecnimont S.p.A., engineering company located in Milan (Italy) and performing

activities of Engineering Procurement and Construction for the PROJECT;

TCMPL

Engineering & Designs Tecnimont-Private Limited;

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Underwriters’ Laboratories, Inc.

1.4 Definitions

CA / COMPANY / Maitre de l’Ouvrage SONATRACH DC-EPM

CONTRACTOR / Entrepreneur

TECNIMONT SPA

TECHNOLOGY LICENSOR

HONEYWELL UOP

PROJECT

REALISATION

EPC D’INSTALLATIONS DE

PRODUCTION DE LINEAR-ALKYL-BENZENE <> A

SKIKDA ALGERIE

2 PURPOSE OF DOCUMENT

This document establishes the Basis and Design Criteria for the execution of the EPC phase of the

project “REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-

BENZENE <>”.

3 PROJECT DESCRIPTION

In order to fulfil its domestic needs in Linear-Alkyl-Benzene (LAB) used for the production of detergents and possibly export the excess to the international market, Sonatrach plans to build a new LAB production complex in Skikda (Algeria). The new complex will produce 100,000 tons of LAB per year and will be installed in the existing industrial zone of Skikda. Skikda is a coastal town located 350 km east of Algeri, Algeria.

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Figure 1 – Satellite view of plant location

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Figure 2 – Satellite view Skikda industrial area

The LAB project includes the following installations located on four different sites:

 New LAB complex (DEV1 area):

The new LAB complex includes the following three process units for the production of N- Paraffins:   

(U-100) Prefractionation of Kerosene feedstock, (U-200) Kerosene Hydrotreating to remove sulfur, nitrogen and aromatics contaminants, (U-300) Molex unit to extract N-paraffins through adsorption.

LAB is then produced from N-Paraffins in the following four units:    

(U-400) Pacol unit carrying out the dehydrogenation of n-paraffins to n-olefins, (U-500) Define unit carrying out the selective hydrogenation of di-olefins to n-olefins, (U-600) PEP unit removing the aromatics from the Pacol outlet stream, (U-700) Detal-Plus unit making alkylation of benzene with linear olefins to produce linear- alkyl-benzene LAB and separating the HAB by-product.

Utilities units consists of the following:

 U 805 – Power Plant  U 810 - Natural Gas and Fuel Gas  U 820 – Plant and Instrument Air

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 U 830 - Nitrogen  U 835 – Hydrogen Production Unit  U 840 – Industrial Water  U 850 – Demineralized Water system  U 860 – BFW, steam and condensate  U 870 – Cooling Water system  U 880 – Potable Water system  U 890 – Hot Oil system

Offsites units consists of the following:

 U 910 – Feedstock Kerosene and Benzene storage  U 920 – Intermediate and recycled products storage  U 930 – Final product storage  U 940 – Chemical storage facilities  U 950 – Flare system  U 960 – Closed Drainage system  U 965 – Sour Water treatment system  U 970 – Waste Water system  U 980 – Fire Water system

Figure 3 – Identification of main units of DEV1 area (from FEED)

 Skikda refinery RA1K:

The project includes all the necessary facilities:  To export from the RA1K refinery, Kerosene and Benzene to the new LAB complex,  To receive the by-products generated by the LAB complex.

 Skikda industrial area (DRIK):

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The project covers the interconnecting lines for raw materials, by-products, finished LAB product to the port and utilities.

 Port of Skikda:

The project includes all the facilities necessary to load finished LAB product on ships.

Project references:

Client Project Location Official name of each site

SONATRACH LAB – EPC phase Skikda, Algeria LAB Complex (Zone DEV1) RA1K Refinery DRIK (Direction Régionale Industrielle de Skikda) Port (Zone Portuaire)

Figure 4 - Layout of Skikda industrial area showing sites

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Figure 5 - DEV1 area reserved for erection of LAB complex

4 GENERAL INFORMATION

4.1 Plant design life

The project facilities are to be designed for a plant life of 30 years.

The frequency and duration of planned major turnarounds are every 5 years and for 30 days

respectively.

For rotating equipment, turnaround frequency of 3 years shall apply. Any more stringent maintenance

recommendation coming directly either from Licensor or Vendors shall apply.

4.2 Operational flexibility

The LAB complex unit shall be designed to produce 100,000 ton per year of LAB commercial grade

(nameplate capacity).

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The expected stream factor for the design of the LAB complex unit is 8160 hours (= 340 days per year).

The LAB complex shall be designed to achieve a stable turndown production rate of 50 % of its

nameplate capacity.

4.3 Scope of facilities

Please refer 4439-PZ-PW-000000001 - Project Work Breakdown Structure (WBS) & Plant

Breakdown Structure (PBS).

4.4 Feedstocks

The LAB complex plant is fed with Kerosene and Benzene streams from existing RA1K refinery.

The composition and properties of kerosene stream (rely-upon information from CA) to be

considered is reported in Table 1.

Table 1 – Kerosene feedstock (from FEED)

Source: RA1K Refinery Unit 10

Properties

Specific Gravity@ 15.5°C, by ASTM D-4052

Distillation, °C, by ASTM D-86

IBP 5% 10% 20% 30% 40% 50% 60% 70% 80% 90% 95% EP Composition, wt.%, by UOP- 411 Less than nC9 nC9 nC10 nC11 nC12 nC13 nC14 Greater than nC14 nC10-nC13

Value 792

166.5 179.6 183.1 187.2 191.4 195.1 198.6 202.1 205.5 209.6 214.7 218.7 225.5

0.5 1.1 3 5.6 5.6 2.9 0 0 17.1

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Source: RA1K Refinery Unit 10

Total Normal Paraffin, wt.% Aromatics, wt.%, by ASTM D-1319 Sulfur, wt.ppm, by ASTM D-4294 Nitrogen, wt.ppm, by ASTM D-4629 Smoke Point, mm, by ASTM D-1322 Freeze Point, C, by ASTM D-2386 Bromine Index

18.7 17.4 32 0.2 26.5 -51.2 154

The composition and properties of benzene stream (rely-upon information from CA) is reported in Table

Table 2 – Benzene feedstock (from FEED)

Property

Value

Test Method

Benzene, wt%

Sulfur, mg/kg

Thiophene, mg/kg

Toluene, wt%

Nonaromatic hydrocarbons, wt%

Nitrogen, max., wt. ppm

1,4 Dioxane, wt. ppm

Acid Wash Color

Bromine Index

Water

Appearance

99.90 min

1 max

0.6 max

0.05 max

0.1 max

0.2 max

1.0 max

Pass with 1

20 max

No free water

Clear Liquid at 18.3 to 25.6 deg. C

Color, on Pt-Co scale

20 max

Solidification Point, anhydrous, deg C 5.45 min

4.5 Systems of measurement units

D4492

D4045 or D6212 or D6313 or D6248

D1685 or D4735

D4492

D4629 or D6069 or D6366

D4492

D848

D1492 or D5776

E2680 (visual)

D1209 or D5386

D852

The units of measurement to be used for the detailed design of the present project are reported here

below. Preferred units are in bold character. The use of units not listed shall be kept to a minimum.

Table 3 – Units of Measurement

Quantity

Unit of Measurement

MASS, SPACE AND TIME

Length

Mass

Mole

Area

m mm (1) (2)

kg t

kmol mol

m2 mm2

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Quantity

Unit of Measurement

Volume

Time

Velocity

Acceleration

Plane angle

Solid angle

Molecular weight

Frequency

Rotational frequency

Concentration

Pipe size

Mass flow

Molar flow

Volume flow

Normal volumetric gas flow

Standard volumetric liquid flow

Density

m³ l (liter) ml

s h d

m/s m/s2 rad degree, minute, second

kg/kmol

Hz kHz MHz

rpm rad/s

vol % wt. % ppm wt.

Inches (2) mm

FLOW

kg/h kg/s t/d kt/y

kmol/h kmol/s

m³/h l/s

Nm³/h (4)

Sm³/h (3) BPSD

DENSITY

kg/m³

Liquid specific gravity

Density at 15.5°C/Density of water at 4.4°C

Pressure (absolute)

Pressure (vacuum)

Pressure (heaters draft)

Pressure (gauge)

Pressure drop

Momentum

Moment of inertia

Force

MECHANIC

bar a

mmHg

mmH2O bar g

bar mbar

kg.m/s kg.m2 N kN

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Quantity

Unit of Measurement

Moment of force

Loading (superficial)

Loading (linear)

Stress

Energy, work

Power

Dynamic viscosity

Kinematic viscosity

Surface tension

Temperature

Heat quantity

Heat flow rate

Heat flux

Thermal conductivity

Coefficient of heat transfer

Thermal resistivity / fouling factor

Specific heat capacity

Specific entropy

Specific enthalpy, latent heat

Calorific value (mass basis)

Calorific value (volume basis)

Nm kNm kN/m2 N/mm2 kN/m

kPa MPa N/mm2 MPa MJ kJ

MW kW W

cP (centipoise) Pa s

cSt (centistokes) m2/s dynes/cm mN/m

HEAT

°C K

kcal kJ

kcal/h Gcal/h kW MW

kcal/h.m2 kW/m2 kcal/h.m.°C W/m °C

kcal/h.m2.°C W/m2.°C m2.°C h/kcal m2.°C/W kcal/kg.°C kJ/kg °C

kcal/kg.K J/kg.K

kcal/kg kJ/kg

kcal/kg kJ/kg kcal/Nm3 kJ/Nm³

ELECTRICITY AND MAGNETISM

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Quantity

Unit of Measurement

Electric current

Electric potential

Electrical conductivity

Power (active)

Power (reactive)

Power (apparent)

Electrical energy

Frequency

Capacitance

Magnetic flux

Magnetic flux density

Resistance, impedance, reactance

Conductance

Inductance

Electric charge

Luminous intensity

Luminous flux

Illumination

Luminance

A kA mA

V kV mV µV

µS/cm S/m

MW kW W

Mvar kvar var

MVA kVA VA

kWh MWh kJ J

Hz kHz MHz

F µF pF

Wb mWb

Ω MΩ kΩ mΩ µΩ

µS S

H mH µH

ILLUMINATION

lx cd/m2

SOUND

Sound pressure or power level

Notes

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Quantity

Unit of Measurement

(1) (2) (3) (4)

Use mm for equipment dimensions and corrosion allowance. The inch-pound units shall be used for all piping system sizing and rating. Standard conditions are at 15.5 °C and 1.01325 bar a. Normal conditions are at 0 °C and 1.01325 bar a.

5 PROJECT REGULATIONS, CODES AND STANDARDS

In general, the new LAB complex facilities will be designed in accordance with internationally recognized codes and standards. The complete list of codes, standards and norms applicable to the EPC phase of LAB project and the associated utilities are listed in INDEX OF PROJECT REGULATIONS, CODES AND APPLICABLE STANDARDS 4439-YZ-PC-000000018.

6 SITE AND METEOROLOGICAL DATA

6.1 Site Data

6.1.1 Geographical location and topography

The different sites of the project (DEV1, RA1K, DRIK and Port) are located in Skikda in Algeria (refer to maps in section 3, Figure 1 to Figure 4).

6.1.2 Soil and Geological Data

The outcomes of soil survey conducted during FEED have been included in the report “Etude geotechinque Project: LAB SKIKDA Wilaya de Skikda Dossier 100/DR/DE/21/22/03 issued on 05/04/2022 by L.T.P Est/DRC”. Additional detailed soil and geotechnical investigation is going to be performed in EPC phase and reported in document 4439-AG-CS-100000004 “Geotechnical Factual Report”.

6.1.3 Structural design basis and loads

The structural design basis and loads shall be defined in accordance with the following regulations and norms:

• RNV 2013 DTR C 2-4.7 Reglement Neige et Vent (Algerian Snow and Wind Code) • RPA-99 / Version 2003 Regles Parasismiques Algeriennes (Algerian Seismic code) • CCM97 Règles de Conception et de Calcul des Structures en Acier • DTR BC-2.41 Règles de conception et de calcul des structures en béton armé C.B.A 93 Basis of structural design Actions on structures Design of concrete structures Design of steel structure Geotechnical design Foundation of dynamic equipment Machine foundations Structural design criteria

• EN 1990 • EN 1991 • EN 1992 • EN 1993 • EN 1997 • ACI351.3R-04 • DIN 4024 • PIP STC01015

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• ASCE 59-11 • SG-22

Design of blast resistant building petrochemical facilities Siting and construction of new control houses for chemical manufacturing plants

The project sites are in the following zones:

• Wind:

According to RNV 2013 « Règlement Neige & Vent» the wind area is Zone II.

• Snow:

According to RNV 2013 « Règlement Neige & Vent» the snow area is Zone B.

• Sand:

According to RNV 2013 « Règlement Neige & Vent» no sand load will be used.

• Seismicity:

According to RPA 99 V.2003 « Règles Parasismique Algériennes», the following parameters will be used:

o Earthquake zone: IIa, which corresponds to moderate seismicity.

Figure 6 – Seismic Zones

o Building classification: Groupe 1A, construction of vital importance o Acceleration factor: 0.25 o Soil classification: assumed S3 along with the FEED. The site survey report “Etude geotechinque Project: LAB SKIKDA Wilaya de Skikda Dossier 100/DR/DE/21/22/03 issued the 05/04/2022 by L.T.P Est/DRC”, issued during the FEED, classifies the site as Site Class S3 according to Vs values and Site Class S4 according to pressumeter tests results. From client response to TQ- TCM-039-CIVIL, the preliminary site class to consider is S4. Site class shall be checked after 2024 soil investigation results.

For further details and for the full list of applicable laws, codes and standards, please refer to document 4439-AX-SG-000000001 Specification for structural design for steel and r.c. structures.

6.1.4 Available area in DEV1

The area reserved for the LAB Complex consists of the 35ha space DEV1 hatched in pink and the 3ha space “Poche” hatched in blue in the plan presented hereafter.

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Setback of minimum 15m to be kept between project area and surrounding existing plants at DEV1 eastern boundary.

Figure 7 – Available area in DEV1

6.2 Climatic and Meteorological Data

Mediterranean climate with mild, rainy winters and hot, sunny summers. Atmospheric conditions: high humidity, coastal, severe industrial with splash, spillage and no sand.

6.2.1 Barometric Pressure and site elevation

The nominal barometric pressure to be used is 1025 mbar.

At Skikda site:

• Minimum site elevation: • Maximum site elevation:

0 m (at port level) 15 m above sea level for Process, Utilities and Offsites 33 m above sea level for LAB Truck Loading arm and HAB Drum filling Building.

Remark: Contractor is going to perform a complete topographic survey of the site for EPC phase

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6.2.2 Temperature and Humidity

Table 4 – Temperature Data (from FEED)

Jan 23,8 13,8 7,2 1,1 0,0 0,0 5,5 76

TM MM Mm Tm NC NF Tr H Notes:

Feb 26,1 14,4 7,2 1,6 0,0 0,0 5,5 74

Mar 31,1 17,2 8,8 1,6 0,0 0,0 7,2 79

Apr 30,5 18,8 10,0 2,7 0,0 0,0 8,3 71

May 38,8 21,6 13,3 7,7

0,0 11,6 71

Jun 38,8 25,0 16,6 11,1

0,0 15,0 70

Jul 41,1 28,3 19,4 15,0 7,0 0,0 17,2 69

Aug 46,6 28,8 20,5 14,4 8,2 0,0 18,3 70

Sep 38,8 26,6 18,8 12,7

0,0 16,6 75

Oct 36,1 22,7 15,0 8,8

0,0 12,2 70

Nov 31,1 18,3 11,6 4,4 0,0 0,0 8,8 70

Dec 25,0 15,0 8,8 1,6 0,0 0,0 6,6 73

AN 46,6 13,8 7,2 1,1

0,0 11,1 72

AN TM (°C) MM (°C) Mm (°C) Tm (°C) NC (°C) NF Tr (°C) H (%)

: overall annual : Maximum absolute temperature. : Average of daily maximum temperatures. : Average daily minimum temperatures. : Minimum absolute temperature. : Average number of days with maximum temperature greater than or equal to 32.2 ° C. : Average number of days with minimum temperature below 0 ° C. : Average dew point temperature : Average relative humidity.

Table 5 – Humidity Data (from FEED)

Recorded Relative Humidity (%) Annual average mean Average min (%) Average max (%) Design value for air fans, compressors and gas turbines (%) Design value for insulation thermal calculation (%)

Skikda 72 69 (July) 79 (March)

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6.2.3 Design temperatures

Table 6 – Design Temperature (from FEED)

Design Temperatures (°C)

For information: CW delivery temperature for existing installation (°C)

Wet bulb design temperature for cooling towers (°C)

Dry bulb design temperature for cooling towers (°C)

Dry bulb design temperature for HVAC system – summer case (°C)

Dry bulb design temperature for HVAC system – winter case (°C)

Design Temperature For Electrical Equipment in Air Conditioned Room (°C)

Design Temperature For Electrical Equipment located outdoor (min /max ) (°C)

Design Temperature For batteries in Battery Room (min /max ) (°C)

Dry bulb design temperature for air cooled heat exchangers (°C)

Dry bulb design temperature for Gas Turbine Generators (°C)

Design temperature for equipment submitted to solar radiation (°C)

Design temperature for equipment NOT submitted to solar radiation (°C)

Design maximum ambient temperature (3) (°C)

Design minimum ambient temperature (2, 3) (°C)

Notes:

Differential temperature for cooling water return: DT =13°C
Winterizing temperature.
Please refer to Specification for structural design for steel and r.c. structures

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6.2.4 Rainfalls and snow

Table 7 – Rainfall and Snow data (from FEED)

Rain and Snow Average total rainfall (mm/year) Wettest months average (mm/month) Driest months average (mm/month) Maximum rainfall recorded in 24 hours (mm) Maximum rainfall for rainwater drainage system design (mm/h) and related duration (h) Maximum snow depth (mm) Maximum snow load (kg/m2)

Design basis

837 270 5 100 mm

85 mm/h during 15 min

6.2.5 Wind

Normal and extreme basic dynamic pressures are those given in paragraph R.III 1 232 of rules RNV 99 V.2013 for region II (Normal : 70 daN/m2, Extreme : 122,5 daN/m2) ; site coefficient must be 1,3 (exposed site).

The prevailing wind direction is: North North West (NNW).

The graphs showing the frequency distribution of the winds according to a rose of eight (8) directions

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and three (3) force intervals are attached below.

The classic climatological representation is given below:

Line
Line
Line

corresponds to forces between 1 and 5 m/s corresponds to forces between 6 and 15 m/s corresponds to forces greater than 15 m/s

Frequencies below 1% have not been shown. For the monthly distributions, the circles have been drawn from 10% to 10% in order to facilitate the reading of the diagrams.

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Figure 8 – Frequency Distribution of Winds (from FEED)

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Figure 9 - Wind rose of Skikda area, year 2007 (from FEED)

For structural calculations, the reference mean wind speed velocity at 10m heigh and 50 years returning period is 27 m/s, corresponding to a reference dynamic pressure qref = 0.435 kPa.

6.2.6 Solar Radiation

Table 8 – Solar Radiation Data (from FEED)

Solar radiation

Design basis

Maximum solar radiation (W/m2)

Solar radiation summer average (W/m2)

Solar radiation winter average (W/m2)

Solar radiation for flare radiation calculation (W/m2)

Solar radiation for other design purposes (W/m2)

1040

7 UTILITIES AT LAB COMPLEX (DEV1 AREA)

7.1 Steam

New boilers and associated equipment are to be installed in order to cover the needs of the new LAB

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complex. MP steam will be produced by steam boilers and LP steam will be generated by let-down and desuperheat of MP steam.

The operating and design conditions are defined as per Table 20.

7.2 Steam condensate

It is expected that for the major continuous LP steam user(s) the condensate will be recovered. In particular, it is foreseen that the Air Pre-heating system of the Hot Oil heater and the Waste Liquids Heater 890-E-002 will be the largest condensate producers and this stream will be recovered in a common condensate recovery system together with steam condensate from other users.

The operating and design conditions are defined as per Table 20.

7.3 Demineralized water

A new demineralized production system is to be installed in order to cover the needs of the new LAB complex. It will be fed with industrial water. Characteristics of demineralized water produced by the new demineralization unit for the LAB complex are listed in Table 9.

Table 9 – Demineralized water characteristics (from FEED)

Suspended solids

Oily matter

Total dissolved solids

Electrical conductivity at 20 °C

Na + K

Ni Chlorides, as Cl- Silica, as SiO2

Unit

mg/l

µS/cm

mg/l

Specification

Not detectable

< 0.4

< 0.2

< 0.01

< 0.1

< 0.05

7 to 7.5

7.4 Boiler Feed Water

A new boiler feed water production system is to be installed as part of the steam production package. Boiler feed water will be produced by deaeration of demineralized water, with addition of conditioning chemicals including oxygen scavenger, pH stabilizer (amine solution). Anti-scale chemical (phosphate) is dosed in the boiler steam drum.

Boiler feed water will be used by the steam boiler and will be also distributed to Kerosene Prefractionation and Hydrotreating process units. Boiler feed water is delivered at the conditions shown in Table 20.

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7.5 Cooling water

A new cooling tower will be installed and will be dedicated to the new LAB complex. Make-up will be ensured with Industrial water. The Cooling Water main characteristics are reported in Table 10 below.

Table 10 – Cooling Water properties (from FEED)

Description

Calcium

Magnesium

M Alkalinity

P Alkalinity

Total Dissolved Solids

Chloride

Value

8.0 ÷ 8.5

hardness 330 ppmwt (as CaCO3)

hardness 225 ppmwt (as CaCO3)

458 ppmwt (as CaCO3)

45.8 ppmwt (as CaCO3)

1569 ppmwt

430 ppmwt

Note: These values to be confirmed by Cooling Tower package vendor

Cooling water is delivered to and returned from users at the conditions shown in Table 20.

7.6 Potable water

A new potable water system will be installed and will be dedicated to the new LAB complex. Industrial water will be conditioned with sodium hypochlorite to produce potable water with the following quality based on the standards required from the Algerian regulation: “Décret éxecutif n° 11- 219 du Rajab 1432 correspondant au 12 juin 2011 fixant les objectifs de qualité des eaux superficielles et souterraines destinées à l’alimentation en eau des populations”, published in the “Journal Officiel n. 34 (19 June 2011) de la Republique Algerienne Democratique et Populaire”.

7.6.1 Quality standards for potable water

Table 11 – Quality standard required for potable water as per Décret éxecutif n° 11-219

Group of parameters

Parameters organoleptic

Parameters

Unit

Color Odor (dilution rate at 25°) Chlorides

pH Conductivity

mg/l Echelle pt

mg/l Cl

µS/cm à 20°C

Maximum values

Surface water

Ground water

200 20

600

6,5 ÷ 9 2800

20 3

500

6,5 ÷ 9 2800

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Group of parameters

Physic-chemical parameters in relation with the natural structure of water

Chemical parameters

Microbiological parameters

Parameters

Unit

Maximum values

Surface water

Ground water

Biological Oxygen Demand (BOD 5) Chemical Oxygen Demand (COD) Total Suspended Solids (TSS) Sulfates Dissolved Oxygen saturation rate Temperature

Ammonium

Barium

Bore

Dissolved Iron

Fluor

Manganese

Nitrates

Phosphorus

Arsenic

Cadmium

Chrome

Copper

Cyanides

Mercury

Lead

Selenium

Zinc

Hydrocarbons polycyclic aromatics

Dissolved Hydrocarbons

Phenols

Agents de surface

Total Kjeldhal Nitrogen

Pesticides

Escherichia coli

Enterococci

Salmonella

mg/l O2

mg/l

mg/l SO4 % O2

°C

mg/l

mg/l NO3

mg/l

µg/l

mg/l

µg/l

mg/l

µg/l

mg/l

µg/l

n/100ml

400 30

100

1000

0,5

20.000

10.000

Absent in 1000 ml

< 3

400

70

0,5

0,7

0,3

1,5

0,05

0,2

0,5

0,2

0,5

Absent in 5000 ml

Source of water being desalinated seawater (which does correspond neither to surface nor groundwater), maximum values applicable to “Eaux souterraines” (Ground water) column in the local legislation, will be considered, deemed the most conservative scenario.

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Refer to Table 20 for conditions of the potable water system.

7.7

Industrial water

Industrial water will be made available by CA, from the existing DRIK network fed by Algerian water company ADE – Algerienne des Eaux. Industrial water quality available on site is produced from seawater desalination unit.

Industrial water will be used to cover all the water needs of the new LAB complex (cooling water, fire water, demineralized water, potable water, etc…)

Industrial water is provided at the following conditions at external Tie-in.

Table 12 – Industrial Water conditions of Supply (from FEED)

Description

Operating Pressure at grade (barg)

Operating Temperature (°C)

Design Pressure (barg)

Design Temperature (°C)

Industrial Water

4.5

For Industrial water system conditions inside LAB Complex, refer to Table 20. Expected properties of industrial water at tie-in are reported in following Table 13.

Table 13 – Industrial Water Properties at tie-in (from FEED)

Water Analysis

pH at 20°C

Turbidity

Suspended Solids

Total Diss. Solids

Ca-Hardness, as CaCO3

Sodium as CaCO3

Potassium as CaCO3

Magnesium, as CaCO3

M-alkalinity as CaCO3

Total hardness as CaCO3

Chloride, as Cl

Sulphates as SO4

Reactive Silica as SiO2

Iron, as Fe

Others matters as KMmnO4 Cu++ Conductivity

Nitrogen, NH3

Phosphates

Unit

NTU

ppm

µS/cm

mg/l

Industrial Water

Nil

453

273

201

0.01

0.2 max

5 max

1 max

728

N.A

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Bicarbonates

Sodium, as Na

COD5

BOD5

Ammonium

Barium

Bore

Fluor

Manganese

Nitrates

Phosphorus

Arsenic

Cadmium

Chrome

Copper

Cyanides

Mercury

Lead

Selenium

HC polycyclic aromatics

Dissolved HC

Phenols

Agents de surface

Total Kjeldhal Nitrogen

Pesticides

Unit

mg/l

mg/l NO3

mg/l

µg/l

mg/l

µg/l

mg/l

µg/l

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Industrial Water

N.A

7.8 Fire water

A dedicated Fire water system will be installed in the new LAB Complex. It will be fed with industrial water.

7.9 Natural Gas

Natural Gas will be made available by CA through the local provider GRTG - SONELGAZ. It will be filtered, quantified and letdown before feeding the Natural Gas & Fuel Gas System inside LAB Complex.

Natural Gas is provided at the following conditions at external Tie-in.

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Table 14 – Natural Gas condition at supply tie-in (from FEED)

Description

Natural Gas

Operating Pressure at grade (barg) Operating Temperature (°C) Design Pressure at grade (barg) Design Temperature (°C)

Note:

41 38 (1) 45 65

Natural Gas supply temperature may vary between 10 °C and 40 °C based on ambient

condition.

Expected properties of natural gas provided at tie-in are reported in following Table 15.

Table 15 – Natural Gas Properties (from FEED)

Description

Gross Heating Value (kcal/kg)

Net Heating Value (kcal/kg)

Mercaptan content (ppmw)

Total sulphur content (ppmw)

Water content (ppmw)

Water dew point (°C)

Hydrocarbon dew point (°C)

Molecular Weight (kg/kmol)

Specific gravity

Composition (vol%)

CH4

C2H6

C3H8

iC4H10

nC4H10

iC5H12

nC5H12

C6H14

CO2

Note:

Natural Gas

10 713

35.4

(1)

19.02

0.657

83.08

5.80

7.10

2.25

0.40

0.60

0.12

0.15

0.1

0.21

0.19

100

Total

Calculated according to gas composition.

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7.10 Fuel Gas

Inside LAB Complex, a fuel gas network is implemented. Process hydrogen- rich off-gases will be recovered from U200, complemented by natural gas and fed to the process furnaces and Flare system. For OSBL, the fuel gas network will only be fed with natural gas. Refer to Table 15 for the composition of Natural Gas, Table 16 for the composition of intermittent Hydrogen- rich Gas and to Error! No bookmark name given. for the conditions of the LP Fuel Gas system.

Table 16 – Hydrogen-rich Gas composition and condition

Component

Composition (mol%)

H2O

CH4

C2H6

C3H8

nC4H10

nC5H12

C6H14

Benzene

Total

Intermittent Mass Flow (kg/h)

Molecular Weight (kg/kmol)

Net Heating Value (kcal/kg)

0.518

0.002

0.005

93.46

2.53

2.54

0.63

0.155

0.039

0.117

0.003

100

268

3.7

19993

While for ISBL users and Flare, that present alternatives Fuel Gas composition, resulting from the mixing of natural gas with Hydrogen- rich gas, Table 17 shall be considered.

Table 16 – Fuel Gas composition and condition – Alternative case

Component

Composition (mol%)

CH4

C2H6

C3H8

iC4H10

66.57

6.16

1.92

0.32

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Component

Composition (mol%)

nC4H10

iC5H12

nC5H12

C6H14

H2O

Oxygen

Benzene

Total

Net Heating Value (kcal/kg)

Molecular Weight (kg/kmol)

Pressure (barg)

Temperature (oC)

0.51

0.10

0.13

0.10

4.61

0.17

0.11

19.30

Traces

100

11180

15.86

7.11 Plant air and instrument air

New facilities will be installed to produce plant and instrument air in order to cover the needs of the new LAB complex.

Properties required for the Compressed Air to be produced are reported in following Table 17.

Table 17 – Compressed Air Properties requirement

Description

Dust

Oil

Humidity

Dew point at 8 barg

Plant Air

Dust-free

Oil-free

Saturated

Instrument Air

Dust-free

Oil-free

-20°C

Refer to Table 20 for conditions of the plant air and instrument air systems.

7.12

Inert gas (Nitrogen)

Gaseous nitrogen will be made available both from a new liquid nitrogen storage with evaporator and from a new connection to the existing distribution network in the industrial zone from the local provider MESSER.

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Gaseous nitrogen is provided by MESSER at the following conditions at external Tie-in.

Table 18 – Nitrogen Condition at External Tie-In (from FEED)

Description

Operating Pressure at grade (barg)

Operating Temperature (°C)

Design Pressure at grade (barg)

Design Temperature (°C)

Nitrogen

Ambient

For nitrogen system conditions inside LAB Complex, refer to Table 20. Expected properties for nitrogen feedstock at tie-in are reported in following Table 19.

Table 19 – Inert Gas (Nitrogen) Properties (from FEED)

Description

Purity (mol%)

Oxygen content (ppmv)

CO content (ppmv)

CO2 content (ppmv)

C2H2 content (ppmv)

Chlorine (ppmv)

Sulfur content (ppmv)

Water (ppmv)

Hydrogen (ppmv)

Noble Gases (ppmv)

Dew Point (°C)

Nitrogen

99.99 minimum

≤ 10

≤ 1

≤ 5

≤ 20

Remainder

≤ minus 80°C (after vaporization, at atm pressure)

In addition, liquid nitrogen may be imported by trucks for back-up. Liquid storage and vaporization system will be implemented in order to feed the LAB complex nitrogen network.

Quality of imported liquid nitrogen is similar to gaseous nitrogen.

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Table 20 – Utilities conditions for LAB complex users

Fluid

Fluid code

Min Operating Condition

Normal Operating Condition

Max Operating Condition

Design Condition

Press bar g (3)

Temp °C

Press bar g (3)

Temp °C

Press bar g (3)

Temp °C

Press bar g

Temp °C

11.0 (1)

4.5

2.5

6.0

5.0 3.0 3.0 4.0

Boiler Feed Water

MP Steam

LP Steam

MBW

MPS

Steam condensate

LPC

2.5 (7)

LPS

3.5 (5)

155

100

9.0

Demineralized water Cooling water • Supply • Return Potable water Industrial water Fire Water

LP Fuel Gas HP Natural Gas (4) LP Natural Gas Plant Air Instrument Air Inert Gas (Nitrogen)

Flare

Notes:

CWS CWR PW IW FW

FG NG NG PA IA N FL

amb

4.0 (6) 3.0 (7)

8.0 (tbc) 10 (tbc) 8.0 (tbc)

5.0 4.0 5.0

5.0 35 5.0 7.5 7.0 7.0 0.2

110

205 (1)

160

105

amb

amb amb amb

40 35.2 40 amb amb 20 amb.

120

FV / 18.0

160

210

FV / 18.0

250

6.0

170

FV / 8.0

134

FV / 8.0

6.0

29 42

9.0 (tbc)

6.0 41 6.0 9.0 9.0 8.0

50 50 45

10.0 10.0

10.0 10.0 12.0 (tbc) 8.0 45 8.0 11.0 11.0 13.0 4.0

210

170

85 85

85 85 85 (tbc)

85 85 85 85 85 85 (tbd)

Intermittently used for start-up/shut-down operations. 1. 2. At steam condensate collection header on pipe rack. 3. All pressures are referred to grade level. 4. Natural Gas available at tie-in and used for Gas Turbine Generator (GTG) of Power Plant, HPU plant. 5. Minimum pressure at final user inlet (e.g. inlet of steam control valve for process exchangers provided with inlet

steam control valve or exchanger inlet flange for process exchangers without inlet steam control valve).

Minimum pressure at final user inlet (e.g. inlet of CW control valve for process exchangers provided with inlet CW

control valve or exchanger inlet flange for process exchangers without inlet CW control valve).

Minimum pressure required at outlet of process users at grade level.

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7.13 Electrical power

LAB complex will be fed from both national electrical grid (via 2 redundant HV lines) and a Gas Turbine Power Plant (ref. DAO AB N 006 -ITEM SH/8531/N 004 pag 156 of 216).

Table 21 – Electric Power at LAB Complex

Description

Tie-in location

Voltage (kV)

Frequency (Hz)

Notes:

Electrical power

(2)

60kV (1)

50 (1)

Characteristics of national Electrical grid (SONELGAZ).
The Electrical battery limits are the terminal of the SWG- US001-001 60kV two

incoming lines. Accordingly, the equipment installed upstream the above-mentioned Battery Limit (i.e. Transmission line, Gantry, Transition kiosk and 60kV cables located outside the LAB complex) are excluded from EPC scope of work (ref. CEOT- LAB-2022-AB-N008 of 13-08-2023).

For Utilization voltage Levels of new LAB Complex, refer to General Specification-

Electrical design Philosophy 4439-NN-SG-0000000001

7.14 Emergency Relief Systems

All the emergency relief streams of flammable or hazardous substances from the new complex will be collected in two flare networks:

• Main flare header • Acid flare header.

The main flare header will collect discharge to flare from following units:

Prefractionation unit (U100)
Unionfining unit (U200)
Molex unit (U300)
Pacol unit (U400)
Define unit (U500)
PEP unit (U600)
Detal Plus unit (U700)
Power Plant (U805)
Natural gas and fuel gas system (U810)
Hydrogen Production unit (U835)
BFW, Steam & Condensate systems (U860)
Hot Oil unit (U890)
Drainage & Effluents Systems (U960)
Waste Water Treatment Plant (U970)

The acid flare header will collect discharge to flare from following units:

Sour Water Stripper unit (U965)

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent.

BASIC ENGINEERING DESIGN DATA

BEDD

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-YZ-SG-000000001

SHEET 37 / 38

ISSUE 1

A constant back-pressure of 0.2 barg shall be taken into account for the design of pressure-relieving safety devices discharging to the flare.

8 UTILITIES AT RA1K REFINERY

Utilities at RA1K refinery will be provided by existing facilities at RA1K. The following Table 22 summarizes the utility conditions at battery limits, as provided by CA.

Table 22 - General utility data at RA1K battery limits (from FEED). Remark: all battery limits pressure are measured at grade.

Fluid

S. No.

Min Operating Condition

Press kg/cm2 g

3 5.5

5.5 5.0 4.0

2.0

Temp °C

Sat.

3 16

18 21 5

LP Steam Plant Air (Rehabilitation area) Instrument Air Nitrogen (Existing) Service Water (Rehabilitation area) Cooling Water make- up (TOWER C - Rehabilitation area)

Normal Operating Condition Press kg/cm2 g

3.5 6.5

6.5 6.5 4.5

2.5

Max Operating Condition

Design Condition

Temp °C

165 24

25 24 25

Press kg/cm2 g

3.75 7.0

7.0 6.5 5.0

2.5

Temp °C

Press kg/cm2 g

Temp °C

180 40

40 40 40

6.0 10.0

10.0 10.0 7.0

5.0

255 70

70 70 65

Electrical users voltages for new equipment are provided in Table 23.

Table 23 – Electrical users voltages (from FEED)

Equipment

Motors above 132kW

Motors rated 132 kW and below

Note:

Voltage

5.5kV ±10%, AC, 3 phase

380V ±10%, AC, 3 phase

Feeders in the existing switchgear / MCC/ Distribution panel in the existing substations in RA1K area will be used to feed new loads, based on details of the existing feeders to be provided by CA.

9 UTILITIES AT PORT

Utilities required at Port will be defined based on Package Vendor information. Electrical users voltages for new equipment are provided in Table 23 above.

Feeders in the existing switchgear / MCC/ Distribution panel in the existing substations in port area will be used to feed new loads, based on details of the existing feeders to be provided by CA.

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent.

BASIC ENGINEERING DESIGN DATA

BEDD

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-YZ-SG-000000001

SHEET 38 / 38

ISSUE 1

10 SHIPPING FACILITIES

Part of LAB production will be exported via boats. Details of shipping facilities mentioned in Table 24 will be developed according to Package Vendor information.

Table 24 – Shipping Facilities Information (from FEED)

Description

Data

National Regulations applicable to loading facilities

Customs requirements

Capacity and size of boats, capacity of compartments

Number of loading points required

Min height and min length required for loading arms

Min and max loading arm diameter

Maximum boat loading time (hr)

Operating hours per day

TBD

11 OTHER APPLICABLE DETAILED DESIGN SPECIFICATIONS

The present Basic Engineering Design Data has to be followed during the EPC phase along with the general specifications mentioned in Table 25.

Table 25 – Other applicable detailed design specifications

Sr No

Discipline

TCM Document Number

Document Title

2 Piping

4439-XZ-SG-000000001

Layout and Piping Design Criteria

3 Civil

4439-AX-SG-000000001

Specification for Structural Design for Steel and RC Structures

4 Electrical

4439-NN-SG-000000001

Electrical System Design

5 DHSE

4439-SZ-SG-0000000001

HSE Design Philosophy

6 Automation

4439-JK-SG-000000101

Basic Plant Control and Safety Philosophy

Instrumentation 4439-KK-SG-000000001

Instrument General Specification

8 SYSPA

4439-FZ-SG-000000001

General Specification Vendor Preservation

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent.

Project: Q-32976 - Tecnmont SKIKDA Folder: Reference Documents

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