GENERAL Document Number PSFT-GD-10-001-A4 PROCESS DESIGN BASIS Rev.

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PEMBERI KERJA KONTRAKTOR NAMA PROYEK LOKASI TANGGAL KONTRAK

: PT PERTAMINA (PERSERO) : PT WIJAYA KARYA (PERSERO) Tbk. : PENGEMBANGAN TERMINAL BBM PULAU SAMBU : PULAU SAMBU - KEPULAUAN RIAU :

13 Mar 14

Issued For Review

SYN

NK

ADW

PREPD

CHECKED

APPROVED

CHECKED

APPROVED

APPROVED

REV.

DATE

STATUS
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. 2. 3. INTRODUCTION.......................................................................................................................... 4 CODES, STANDARDS, AND REFERENCE DOCUMENTS .................................................................. 4 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 PROJECT SCOPE.......................................................................................................................... 6 4.1 GENERAL ................................................................................................................................. 6 4.2 NEW FACILITIES .......................................................................................................................... 7 4.3 PROCESS DESCRIPTION ................................................................................................................. 8 DESIGN DATA ............................................................................................................................. 9 5.1. PRODUCT DATA ..................................................................................................................... 9 DESIGN BASIS ........................................................................................................................... 10 6.1. PRODUCT TRANSFER FACILITIES ....................................................................................... 10 6.2. TANKAGE ......................................................................................................................... 11 6.3. OFFSHORE REQUIREMENT ............................................................................................... 12 6.4. UTILITIES.......................................................................................................................... 12 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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5. 6.

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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 facility 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 x API RP 14E Recommended Practice For Design And Installation Of Offshore Products Platform Piping Systems, 2007. x API 650 Welded Tanks for Oil Storage, Eleventh Edition, 2010 x API Std. 2350 Overfill Protection for Storage Tanks in Petroleum Facilities, Third Edition, 2005. x API Std.2000 Venting Atmospheric and Low-pressure Storage Tanks, Sixth Edition. x API RP 520 Design and installation of pressure relieving systems in refineries, 2007. x API RP 521 Guide for pressure relieving and depressurising systems, 2007. x Process Flow Diagram, latest revision x Utility Flow diagram, latest revision x Piping and Instrumentation Diagram, latest revision x 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 ( office, warehouse, mosque, etc.). 3.2. SITE INFORMATION
3.2.1.

LOCATION OF TERMINAL The project site plan: Pulau Sambu Fuel Terminal is located in Northwest of Pulau Batam.

3.2.2.

METEOROLOGICAL CONDITION Ambient Temperature x Max : 35 deg. C. x Min : 19 deg. C. Relative Humidity x Max : 96.8% x Average : 84.6% x Min : 64.0% Rainfall x x Daily rainfall maximum 45,5 mm Average of monthly rainfall 195,3 mm / month

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Maximum monthly rainfall 300 mm / month occurred in December x Total of annual rainfall 2344 mm / month Wind Conditions x Wind direction dominant Operating / Normal Non-Operating / Extreme Earthquake Seismic Zone Seismic Load : South : 23.0m/ls (3 sec gust) : 35.0m/s (3 sec gust)

: Zone 2 (SNI 03-17262002) : 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: x Two HSD Tanks with capacity of 25,000 KL i.e. T-40 and T-41. x Two HSD Tanks with capacity of 50,000 KL i.e. T-42 and T-43. 2) Pump for products: x HSD Pumps i.e. P-5001/5002/5003 with capacity of 1500 KL/h each. x MFO 180/ MFO 180 Comp. Pumps i.e. P-5004/5005/5012 with capacity of 1000 KL/h each. 5006/5007 with capacity of 500 KL/h each. x Bunker 380/VR Pumps i.e. P-5006/5007 x LSFO Pumps i.e. P-5008/5009 with capacity of 1000 KL/h each. x 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. HSD Tank. 5) Heating system for non-HSD

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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 T40/41/42/43 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 received from the vessel GP. Each component could be filled into New Tank TT then blended with HSD 0.2% sulfur to 40/41/42/43 or to the Existing tank T-8, obtain HSD 0.25% sulfur delivered to the vessel MR. MFO 180 Component received from the vessel and is delivered to the tank Tr 33/34/22/23, whereas LSWR received from the vessel MR and GP. LCO re-

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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 9, and T-32. HD tank T-32. VR received from the GP then delivered to T-32, T-9, 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 T37/38/9/18. DCO received from the vessel GP and to be delivered into tank T37/38/21. LCO received from Small vessel and to be delivered into tank T37/38/17. Furthermore VR,DCO, and LCO blended in the tank T-37/38 to produce 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: SG @16 C 0.9500 0.9800 0.9990 0.8700 0.9600 0.9910 0.9476 Viscosity @ Handling Temp. (cSt) 320 350 180 36 90 180 180 Handling Temp (C) 60 77 50 25 60 50 25 Sulfur Content (%WT) 0.35 0.35 0.30 0.35 0.30 3.5 0.16

Component/ Product LSWR VR DCO HSD LSFO MFO 180 LCO

Pour Point (C) 48 48 24 18 45 24 42

Flash Point (C) 66 88 55 60 70 66 56

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MFO 180 Comp MFO 380 Comp. HD Bunker 380

0.9910 0.9500 1.0360 0.9500

180 2000 490 380

50 25 25 50

24 30 -6 30

66 90 100 90

3.5 1.0 1.78 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 HSD products, ranging from 500 m3/hr to 1500 m3/hr, provided in for non-HSD 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 P-5001 1 , P-5002, P 5002, PP-5004 , P-5005 P-5006 , P-5007 P-5008 , P-5009 P-5010 , P-5011 PRODUCT HSD MFO 180 / COMPCOMPMFO 180 BUNKER 380 / VR LSFO LSWR / DCO / LCO PUMP CAPACITY (m3/hr) 1,500 1,000 500 1,000 500

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6.2.

TANKAGE The dimensions and storage capacities are listed as follows: TAN K NO. T-6 T-8 T-9 T-17 T-18 T-21 T-22 T-23 T-30 T-32 T-33 T-34 T-36 T-37 T-38 T-40 (NEW ) T-41 (NEW ) T-42 (NEW ) T-43 (NEW ) T-19 TS-5 SIZE OF TANK PRODUCT HSD 0.35% S HSD 0.35% S VR LCO VR DCO Component MFO 180 Component MFO 180 HSD 0.35% S BUNKER 380 MFO 180 MFO 180 LSWR LSFO LSFO HSD 0.35% S HSD 0.35% S HSD 0.35% S HSD 0.2% S SLOP SLOP DIA.(m) 23.986 24.008 23.792 27.914 24.375 32.971 36.016 35.996 23.475 36.001 36.005 36.004 35.994 35.977 39.006 42 42 60 60 32.966 12.017 HT (m) 13.175 13.2 10.58 13.213 9.117 14.792 13.32 13.089 11.715 13.185 13.22 13.2 13.225 16.327 16.595 19.8 19.8 19.2 19.2 11.568 11.573

IT E 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1

TANK CAPACITY (m3) 5,773 5,880 4,505 7,824 4,131 12,264 13,142 12,911 4,889 13,149 13,004 13,234 13,026 16,270 19,477 25,000 25,000 50,000 50,000 9,649 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 T43 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. 6 (NEW) 1 (NEW) 3 4 6.4. UTILITIES Utilities system will be described in Utility Design Basis document. JETTY BERTHING CAPACITY - DWT 50,000 ~ 100,000 17,500 ~ 50,000 3,500 ~ 40,000 100 ~ 400

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7. DESIGN CRITERIA 7.1. EQUIPMENT DESIGN CRITERIA 7.1.1. DESIGN MARGIN Equipment Storage Tank Pumps Impounding Basin Basis Capacity Flow Flow % Design Margin (Note 1) No margin (Note 2) No Margin 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 capacity 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 international 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 barg <1 1-10 >10 Operating Pressure, Design Pressure, barg 3.5 barg based on safety valve to atm. MOP+1 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 Storage Tank Filter Basin Centrifugal pumps Maximum Operating Pressure Highest pressure resulting in out breathing through Breather valve Maximum shut-in of pump Atmospheric Operating suction pressure + 1.25 times the normal differential pressure developed by the pump plus suction pressure of tank or maximum 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 maximax mum design will be considered of 60 oC only based on solar radiation temperature.

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7.1.5. MINIMUM DESIGN TEMPERATURE Minimum design temperature shall be the minimum ambient temperature 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 Minimum residence time 5 minute Minimum residence time 5 minute Minimum residence time 5 minute To be determined based on net working capacity requirement.

Centre Inlet Nozzle LLLL Between LLLL - LLL Between HLL - HHLL LLL - HLL

7.2.2. PUMP SIZING

Inline with Section 5 and 7.1.1, further No design margin shall be applied for design flow rate of a pump. No margin shall be added to the differential head. The procedure for pump calculations shall be: x Determine the size of the pump discharge piping based on pump rated flow rate. The line pressure drop should be calculated based

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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. x Calculate the pump differential head based on the line size determined above. x 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 For fire case relief 21% For multiple RVs 7.2.4. CONTROL VALVE 10% 16% (to achieve the required area)

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 cases a minimum velocity (self cleaning velocity) is required to prevent water accumulation and bacterial growth. Liquid line sizing shall be in accordance with API-RP14E.

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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.