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JUNN 5 DOWNSTREAM PROJECT

PETRO BICENTENARIO REFINERY

BASIC DESIGN INPUT DATA

QUESTIONNAIRE

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A1 PRELIMINARY ISSUE C. BELLONI G.L. BIELLA G.L. BIELLA 09-03-2012

Rev. Description Prepared by Checked by Approved by Date

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Table of Contents

1 INTRODUCTION............................................................................4
1.1 OBJECT..................................................................................................................... 4
1.2 PLANT LOCATION....................................................................................................4
1.3 REFERENCE DOCUMENTATION.............................................................................4
1.4 ACRONYMS..............................................................................................................4
2 PROJECT OVERVIEW.....................................................................5
2.1 DOWNSTREAM COMPLEX OVERVIEW..................................................................5
2.2 GENERAL PROCESS SCHEME...............................................................................8
3 REFINERY CAPACITY.....................................................................9
3.1 FACILITY CAPACITY.................................................................................................9
3.2 DESIGN CAPACITY OF PROCESS UNITS.............................................................10
3.3 TURNDOWN............................................................................................................ 10
3.4 ON STREAM FACTOR............................................................................................10
4 FEEDSTOCKS CHARACTERISTICS.................................................11

5 PRODUCTS SPECIFICATION.........................................................15
5.1 CUT POINTS FOR CRUDE DISTILLATION UNIT PRODUCTS..............................15
5.2 END PRODUCT SPECIFICATION...........................................................................15
6 AVAILABILITY OF UTILITIES......................................................20
6.1 RAW WATER CHARACTERISTICS........................................................................20
6.2 NATURAL GAS CHARACTERISTICS.....................................................................21
6.3 MAIN FEATURES OF UTILITY SYSTEMS (TO BE CONFIRMED).........................22
6.4 PROPOSED CHARACTERISTICS OF UTILITY SYSTEMS....................................22
7 BATTERY LIMITS (TO BE CONFIRMED)........................................25

8 STORAGE SYSTEM PHILOSOPHY..................................................27

9 PRODUCT SHIPPING PHILOSOPHY (TO BE CONFIRMED).............28

10 SITE CONDITIONS.......................................................................29
10.1 SITE LOCATION......................................................................................................29
10.2 SITE CONDITIONS..................................................................................................29
10.3 SOIL CONDITIONS..................................................................................................29
10.4 REFERENCE ELEVATION......................................................................................30
10.5 CLIMATIC DATA......................................................................................................30
10.6 SPECIAL ENVIRONMENTAL CONDITIONS...........................................................31
11 SYSTEM OF MEASUREMENT UNITS..............................................32

12 ENVIRONMENTAL REQUIREMENTS..............................................33
12.1 ATMOSPHERE........................................................................................................ 33
12.2 WATER EFFLUENT.................................................................................................34
13 PROCESS DESIGN CRITERIA........................................................35

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13.1 DESIGN PRESSURE...............................................................................................35

13.2 DESIGN TEMPERATURE........................................................................................38
13.3 DESIGN OVERSIZING FACTOR.............................................................................39
13.4 SPARING PHILOSOPHY.........................................................................................40
13.5 DESIGN LIFE OF EQUIPMENT...............................................................................41

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INTRODUCTION

1.1 OBJECT
The object of this document is to define the Design Basis for the
development of the Basic Engineering and of the Front End Engineering
Design (FEED) for the Petro Bicentenario Refinery Project.
It includes the plant location, design capacity of the facilities, feedstock
characteristics and product specifications, utility characteristics, storage
capacity and battery limit conditions.
Part of the document is dedicated to the Process Design Criteria that
summarize criteria and methodology to be used for specifying major
equipment or systems and piping.
The information needed for this early phase of the project are
indicated as to be provided. Client is requested to provide the
missing information and to confirm the available data.

1.2 PLANT LOCATION

The Refinery is a grass root refinery that will be built in the existing
coastal industrial complex of Jose, in the northeast region of Venezuela.
Jose is located 35 km from Barcelona, the capital of the State of
Anzotegui.

1.3 REFERENCE DOCUMENTATION

SAIPEM Document N 0004801.DOFBRV.00465: Downstream Facilities
Concept Selection Phase Final Report.

1.4 ACRONYMS
AGO: Atmospheric Gasoil
BPSD: Barrel per stream day
DCO: Diluted Crude Oil
EHO: Extra Heavy Oil
FEED: Front End Engineering Design
HDC: Full Conversion Hydrotreating Unit
HCGO: Heavy Coker Gasoil
HDT: Naphtha Hydrotreating Unit
HDS: Gasoil Hydrodesulphurization Unit
LCGO: Light Coker Gasoil
LVGO: Light Vacuum Gasoil
MLA: Marine Loading Arm
PDVSA: Petrleos de Venezuela S.A.
SMR: Steam Methane Reforming
SBM: Single Buoy Mooring
VGO: Vacuum Gasoil
VR: Vacuum Residue

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PROJECT OVERVIEW

In 2010 PDVSA has formed two Joint Ventures Companies with Eni
Lasmo for the exploitation of Extra Heavy Oil (EHO) in Orinoco Faja:

- Petro Junn SA, the Upstream company

- Petro Bicentenario SA, the Downstream company

The overall Project comprises the following main parts:

Upstream Production Facilities, in Orinoco Faja (Junn 5 field)
Pipelines, to convey the Diluted Crude Oil to the Downstream
Complex and send back the Diluent Naphtha to the oil fields
Downstream Complex, in the existing coastal industrial complex
of Jose

1.5 DOWNSTREAM COMPLEX OVERVIEW

The Downstream Complex (i.e. Petro Bicentenario Refinery) is a grass

root refinery that will be built in the existing coastal industrial complex
of Jose, in the northeast region of Venezuela. Jose is located 35 km from
Barcelona, the capital of the State of Anzotegui.
The plant will convert 8API heavy crude oil, produced in the Orinoco Oil
Belt, into final products, such as LPG, Naphtha and Euro 5 Diesel.
The refinery, which will be integrated with the existing nearby
PetroMonagas Upgrader, is designed to process 240,000 BPSD of Zuata
Crude Oil from Upstream Complex and 110,000 BPSD of Intermediate
Products from PetroMonagas plant.
Significant key features and objectives of the Downstream Complex are:
The refinery will process high sulphur extra heavy oil from Oricoco
Faja.
The complex will be integrated with PetroMonagas Upgrader.
Refinery configuration was selected to maximize production of
ultra low sulphur diesel, complying with European grade EN 590
diesel.
No residual fuel is produced. Delayed coking technology is used to
maximize conversion of vacuum residue.
For each refinery unit, equipment sizes are limited to maximum
current commercially demonstrated. Where necessary, multiple
production / treatment trains will be considered.
Natural gas, available at the refinery battery limits, is used as
feedstock to the Hydrogen Production Unit, Steam and Power
Generation Unit and to cover the internal fuel demand.
All refinery heaters will burn fuel gas (FG recovered from process
units or imported NG).
Except for raw water and natural gas, all the Utilities required by
the complex are produced internally.

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The Refinery, designed and optimized for integration with PetroMonagas,

will also be verified for stand-alone operation (i.e. operation during
periods of unavailability of streams imported from PetroMonagas).
In addition, a sensitivity alternate design case will be provided, in which
the refinery will be designed only to process the EHO from Junn 5
fields, without any integration or import of streams form existing
Upgraders. For this sensitivity case a complete heat and material
balance will be provided, together with a class III investment cost
estimate (+/- 25%)

The refinery configuration will include the following ISBL Units:

Crude Distillation Unit
Delayed Coking Unit
Naphtha Hydrotreating Unit
Gasoil Hydrotreating Unit
Full Conversion Hydrocracking Unit
Steam Methane Reforming Unit
Saturated Gas Plant
Amine Regeneration Unit
Sour Water Stripper (Phenolic water) Unit
Sour Water Stripper (not Phenolic water) Unit
Sulphur Recovery Unit, Tail Gas Treatment Unit and
Incinerator

To support the ongoing operation of the various process units, the utility
facilities listed below are required.
Raw Water System
Service Water System
Potable Water System
Demineralization Water System
Oily and Clean Condensate System
Boiler Feed Water System
Cooling Water System
Compressed Air System
Nitrogen System
Natural Gas and Fuel Gas Distribution System
Steam and Power Generation System
Pressure Relief and Disposal System

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Main Flare System

Acid Flare System
Process Tank and Loading System
Waste Water Treatment System
Sulphur Storage and Handling System

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1.6 GENERAL PROCESS SCHEME

Note: the SMR unit figure is referred to hydrogen chemical consumption only

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REFINERY CAPACITY

1.7 FACILITY CAPACITY

The Petro Bicentenario Refinery is designed to process the 312,000 BPSD of

Diluted Crude Oil (240,000 BPSD of Zuata Crude Oil and 72,000 BPSD of
dilution Naphtha) and additional 110,000 BPSD of Intermediate Products from
PetroMonagas Refinery.
Petro Bicentenario Refinery feedstocks are reported in Table 3.1

Table 3.1: Petro Bicentenario Refinery Feedstocks

CAPACITY
FEEDSTOCK SOURCE
(BPSD)
Petro Bicentenario
312,000
Diluted Crude Oil (DCO) (*) Upstream Complex
to be
Atmospheric Residue PetroMonagas Refinery
provided

to be
Middle Distillates PetroMonagas Refinery
provided

to be
Light Coker Gasoil PetroMonagas Refinery
provided

to be
Heavy Coker Gasoil PetroMonagas Refinery
provided

(*) = Diluted Crude Oil is a blend of 240,000 BPSD of EHO and 72,000 BPSD of
Dilution Naphtha.

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1.8 DESIGN CAPACITY OF PROCESS UNITS

The Design Capacities of the process Units are summarized in the Table 3.2.

Table 3.2: Process Units Design Capacity

PROCESS UNIT CAPACITY (1)
Atmospheric Distillation 312,000 BPSD
Vacuum Distillation 252,000 BPSD
Delayed Coking 163,300 BPSD
Naphtha Hydrotreater Unit 43,800 BPSD
Gasoil Hydrodesulphurization Unit 123,600 BPSD
Full Conversion Hydrocracking Unit 142,000 BPSD
Amine Regeneration Unit, m3/h 2 x 1,000 m3/h
Sour Water (phenolic) Stripper, m3/h 275 m3/h
Sour Water (not phenolic) Stripper, m3/h 275 m3/h
Sulphur Recovery Unit, Ton/d 4 x 560 t/d
Tail Gas Treatment Unit, Ton/d 2 x 840 t/d
Steam Methane Reformer, Nm3/h 4 x 176,200 Nm3/h
Sulphur Solidification Unit, Ton/d 1,668 t/d

(1) Indicative values. To be finalized during FEED phase.

In particular the capacities have been based on preliminary assumptions
of qualities and quantities of the streams from PetroMonagas Upgrader, to
be reviewed and finalized prior to start the FEED

1.9 TURNDOWN

All the Refinery Units shall be designed for sustained on-spec operation under a
turndown condition of 50% of design flow.

1.10 ON STREAM FACTOR

The on stream time specification will be 97% (8500 hours per year) outside
general turnarounds and turnarounds for catalyst replacement.
Due to the peculiar refinery configuration, it has been assumed that
Hydrocracker/Hydrotreaters units will need a turnaround for catalyst
replacement/regeneration every two years (24 months of operations).
According to the experience with similar units these shut down will last 45 days
(production loss). The general turnaround of catalytic units will coincide with
the above said turnarounds and so no additional general turnaround period has
to be considered for these units.
The general turnaround of non-catalytic units will be coincident with one of the
above said turnaround of catalytic units, i.e. in principle a general turnaround
every 4 years, lasting 45 days (production loss).
To be confirmed during FEED and in accordance with Process Licensors.

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FEEDSTOCKS CHARACTERISTICS

The Petro Bicentenario Refinery feedstocks characteristics are reported below.

Extra Heavy Oil (EHO)

The EHO processed by Petro Bicentenario Refinery is a Zuata Crude Oil coming
from the Upstream Complex. The available characterization of Zuata Crude Oil
is reported in the Table 4.1. Please provide any updated or more complete data
for narrow cuts if available.

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Table 4.1: Extra Heavy Oil Crude Assay

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Diluent Naphtha
The main properties of Diluent naphtha indicated in the Table 4.2 are relevant
to a Hydrotreated full range Coker Naphtha from a reference project and shall
be confirmed during the FEED.

Table 4.2: Diluent Naphtha Characteristics

Value
Property Unit of Measure
(1)
Density @ 15C 740.8 -
Kinematic Viscosity @ To be -
37.8C provided
Kinematic Viscosity @ To be -
100C provided
To be -
Total Nitrogen Content
provided
To be -
Paraffine Content
provided
To be -
Pour Point
provided
To be -
K UOP
provided
To be
H2S -
provided
To be
Flash Point -
provided
To be
RVP @ 37.8C -
provided
Distillation TBP
IBP 42 C
5% vol 60 C
10% vol 80 C
20% vol 95 C
30% vol 105 C
40% vol 113 C
50% vol 121 C
60% vol 128 C
70% vol 135 C
80% vol 142 C
90% vol 150 C
95% vol 158 C
FBP 167 C
Residue 1 % vol

1) Diluent Naphtha characteristics shall be confirmed

(2): da confermare che i dati di distillazione sono TBP in volume.

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Stream from PetroMonagas Refinery

The characteristics of intermediate product imported from PetroMonagas
Upgrader are reported in the Table 4.3.

Table 4.3: Characteristics of streams from PetroMonagas

ATM Middle
LCGO HCGO
Residue Distillates
Unit of
Property Measureme
nt
- To be To be To be To be
SpGr provided provided provided provided
Kinematic cSt
To be To be To be To be
Viscosity @ 50C
provided provided provided provided
(122 F)
Kinematic cSt
To be To be To be To be
Viscosity @
provided provided provided provided
100C (210 F)
wt% To be To be To be To be
Sulphur Content provided provided provided provided
Total Nitrogen ppmwt To be To be To be To be
Content provided provided provided provided
Paraffine wt% To be To be To be To be
Content provided provided provided provided
C To be To be To be To be
Pour Point provided provided provided provided
- To be To be To be To be
K UOP provided provided provided provided
To be To be To be To be
H2S ppmwt provided provided provided provided
To be To be To be To be
Flash Point C provided provided provided provided
To be To be To be To be
CCR wt% provided provided provided provided
To be To be To be To be
Salts Content Lb/MBls provided provided provided provided
To be To be To be To be
Chloride Content ppmwt provided provided provided provided
Naphtha into
To be To be To be To be
Crude Oil (IBP-
provided provided provided provided
200 C) wt%

To be To be To be To be
Distillation
provided (*) provided provided provided

(*) ATM Residue 370+ from Zuata Crude Oil

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PRODUCTS SPECIFICATION

1.11 CUT POINTS FOR CRUDE DISTILLATION UNIT PRODUCTS

TBP cut points for product from Atmospheric and Vacuum Units are indicated in
Table 5.1.
All These values have to be confirmed.

Table 5.1: TBP Cut Point

ATMOSPHERIC DISTILLATION UNIT

Product TBP Cut Point
(C)
Offgas C1-C4
Naphtha C5-160 (*)
AGO (*) 160-360
VGO 360-520
VR 520+

(*) This data has to be confirmed considering the available Dilution Naphtha
characteristics.

1.12 END PRODUCT SPECIFICATION

The refinery processes the above mentioned feedstocks in order to produce the
following final products:

LPG
NAPHTHA pro Petrochemical
NAPHTHA pro Reformer
DIESEL @ EU5 Spec
Pet-Coke
Sulphur

As general criteria, the products will be separated in the process units

according to the following rules:

naphtha end point will be minimized in order to maximize diesel

production and to improve naphtha quality in terms of paraffins content.
Therefore a nominal TBP cut point of 160C will be considered for
fractionation between naphtha and gasoil in all process units.

Diesel end point will be maximized within the limits of the European spec
(95% ASTM LT 360C) and therefore a nominal TBP cut point of 370C will

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be used, unless lower end points are required to meet cold flow
properties.

The tables below report the typical market specifications of the final products.
Product Specifications shall be confirmed / updated.

Table 5.2: LPG Specification

CHARACTERISTICS U.M. VALUE METHOD

Vapour Pressure @ kPa max 1550 EN ISO 4256-8973
40C
Density @15C kg/m3 max 565 EN ISO 3993-8973
Residue on mg/kg max 60 EN15470, EN15471
evaporation
Copper strip Corrosion Index max 1 EN ISO 6251
(1h @40C)
Concentration C5+ % mol max 2 EN 27941
Sulphur ppm max 50 EN 24260;ASTM
D3246-05; ASTM
D6667-04
1-3 Butadiene % max 0.1
(m/m)

Table 5.3: Naphtha Pro Petrochemical Specification

CHARACTERISTICS U.M. VALUE METHOD

Density @ 15C kg/l 0.66-0.735 ASTM D 4052
Vapour Pressure @ 100 psi 12 max ASTM D 323
F
Distillation ASTM D 86
I.B.P. C 30 min
5% To be Reported
50% 125 max
95% 180 max
F.B.P. 190 max
Composition % vol. ASTM D 5134-90
Total Paraffins 65 min
n-paraffins To be Reported
iso-paraffins To be Reported
naphthenes To be Reported
olefins 1 max
12 max
aromatics
Water wt% 0.5 max ASTM D 1364
Sulphur ppmw 500 max ASTM 3120

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Table 5.4: Naphtha Pro Reformer Specification

CHARACTERISTICS U.M. VALUE METHOD

Density @ 15C kg/l To be Reported ASTM D 4052
Distillation ASTM D 86
I.B.P. C 30 min
F.B.P. 170 max
Composition % vol.
Paraffins To be Reported
Naphthenes To be Reported
Aromatics To be Reported
Naphthenes + Aromatics 40 min PRE 1273
Olefins To be Reported
Sulphur ppm 200 max ASTM D 4294
H2S ppm 2 max UOP 163
Mercaptane Sulphur ppm 150 max ASTM D 3227
Lead ppb To be Reported UOP 350
Chlorides ppmwt To be Reported
Colour 20 min ASTM D 6045
Nitrogen ppm To be Reported
R.V.P. psi 7.5 max ASTM D 5191
Oxygenates (MTBE, ETBE) ppmwt 50 max
Copper Corrosion 1b max

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Table 5.5: Diesel Specification

CHARACTERISTICS U.M. VALUE METHOD

Cetane Number Min 51 EN ISO 5165
EN 15195
Cetane Index Min 46 EN ISO 4264
Density @ 15C kg/m3 Min / Max 820 / 840 EN ISO 3675
EN ISO 12185
Polycyclic aromatic % (m/m) Max 8 EN 12916
hydrocarbons
Sulphur Content mg/kg Max 10 EN ISO20846
EN ISO 20884
Flash Point C Min > 55 EN ISO 2719
Carbon Residue % (m/m) Max 0.3 EN ISO 10370
(on 10% distillation
residue)
Ash Content % (m/m) Max 0.01 EN ISO 6245
Water Content ppmwt Max 200 EN ISO 12937
Total Contamination mg/kg Max 24 EN ISO 12662
Copper strip corrosion Rating Min / Max Class 1 EN ISO 2160
(3h @ 50C)
Fatty acid methyl ester %(v/v) Max 7 EN 14078
content
Oxidation Stability g/m3 Max 25 EN ISO 12205
EN 15751
h Min 20
Lubricity, corrected m Max 460 EN ISO 12156-
wear scar diameter 1
(wsd 1.4) @ 60C
Distillation recovered %(v/v) Max <65 EN ISO 3405
@ 250C

Distillation recovered %(v/v) Min 85

@ 350C

95% (V/V) recovered C Max 360

at

Viscosity @ 40C mm2/s Min / Max 2 / 4.5 EN ISO 3104

CFPP C Table 5.6
Cloud Point C Table 5.7

(*) Diesel Specification as per UNI EN-590.

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Table 5.6: Diesel CFPP Specification

U.M. LOCATION
Mediterranean Northern Germany
Area Europe
Winter
C max -12 -15
1 Oct 31 March
Summer
C max -2 -5
1 April 30 Sept

Table 5.7: Diesel Cloud Point Specification

U.M. LOCATION
Mediterranean Northern Germany
Area Europe
Winter
C max 0 -5 -7
1 Oct 31 March
Summer To be To be
C max To be reported
1 April 30 Sept reported reported

Table 5.8: Sulphur Specification

CHARACTERISTICS U.M. VALUE

Sulphur (on Dry Basis) % (m/m) 99.5 min
Colour Yellow
Ash % (m/m) 0.05 max
As, Te,Se ppm 3 max
H2S ppmwt 10 max

Pet-Coke: No market specification is foreseen for Pet-Coke.

Pet-Coke characteristics will be provided by Licensor.

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AVAILABILITY OF UTILITIES

Petro Bicentenario Downstream Complex will be designed to produce internally

all the required Utilities, except Natural Gas and Raw Water.

1.13 RAW WATER CHARACTERISTICS

Raw water source is river water assumed to be available at Battery Limit in a

quantity sufficient to satisfy the process requirements (preliminary estimate
equal to 1370 m3/h).

Raw water characteristics are reported in Table 6.1.

Table 6.1: Raw Water Characteristics

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1.14 NATURAL GAS CHARACTERISTICS

Natural Gas is assumed to be available at Battery Limit in a quantity sufficient
to satisfy the process requirements (preliminary estimate equal to 3148
Gcal/h).
Two distribution pressure levels are envisaged:
o High Pressure Gas, fed to Gas Turbine power Plant and Hydrogen
production unit.
o Low Pressure Gas, fed to Refinery heaters and boilers. LP gas network is
fed mainly by fuel gas provided by the Refinery Units. In case of fuel gas
shortage, it is complemented by imported Natural Gas.
Natural Gas characteristics are reported in Table 6.2.

Table 6.2: Natural Gas Characteristics

DESCRIPTION Natural Gas
at B.L.
1 Supply Pressure: min. kg/cm g2
To be Provided
1 norm. kg/cm g 2
To be Provided
1 max. kg/cm2g To be Provided
4 Design Pressure kg/cm g2
To be Provided
5 Normal Temperature C To be Provided
6 Design Temperature C To be Provided
7 Low Heating Value (LHV) kcal/kg 11015
Composition Normal Case
Average Range
1 Hydrogen H2 vol% 0.1 To be Provided
2 Nitrogen N2 vol% 1.0 To be Provided
3 Carbon Monoxide CO vol% 0.1 To be Provided
4 Carbon Dioxide CO2 vol% 2.0 To be Provided
5 Methane CH4 vol% 80.21 To be Provided
6 Ethane C 2H 6 vol% 12.0 To be Provided
7 Ethylene C 2H 4 vol% To be Provided To be Provided
8 Propane C3H8 vol% 3.0 To be Provided
9 Propylene C3H6 vol% To be Provided To be Provided
10 Butanes C4H10 vol% 1.5 To be Provided
11 Pentanes C5H12 vol% To be Provided To be Provided
12 C5+ vol% To be Provided To be Provided
13 C6+ vol% To be Provided To be Provided
14 H2S MAX ppm To be Provided To be Provided
15 COS ppm To be Provided To be Provided
16 RSH ppm To be Provided To be Provided
17 H2O vol% 0.09 To be Provided
TOTAL 100 To be Provided
Molecular Weight 19.88 To be Provided
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1.15 MAIN FEATURES OF UTILITY SYSTEMS (TO BE CONFIRMED)

The electric power and steam required by the complex will be produced
in a combined cycle power plant.
All the heaters and boilers will be fired by treated combustible gas that
is generated in the refinery or by Natural Gas.
The proposed cooling water system is an open system based on cooling
tower package, using service raw water as make-up.
Nitrogen will be internally produced by PSA Unit.
Storage is provided for the liquid Nitrogen to supply peak requirements.
Hydrocarbon Flare and Blowdown System is provided in order to receive
all relieves during emergency and in case of any upset; a separate Acid
Flare will also be provided.

1.16 PROPOSED CHARACTERISTICS OF UTILITY SYSTEMS

The utilities will be available at unit battery limit at the following conditions
(TO BE CONFIRMED).

1.16.1 Steam
Pressure (bar g) Temperature (C)
Nor
Min Max Des Min Norm Max Des
m
Distribution
1 High Pressure (HS) 38 40 42 44 385 400 420 450
2 Medium Pressure (MS) 10 12 16 20 280 295 320 350
3 Low Pressure (LS) 3.5 4 4.2 6 150 165 180 210

Note:
Steam will be produced by Power Plant and SMR Unit at a pressure level of 80
barg (To be confirmed during FEED Phase).

The number of steam distribution levels (two or three) to the refinery units will
be confirmed during FEED Phase, based on techno-economic considerations.

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1.16.2 Cooling Water and Potable Water

Service
Description Cooling
Potable
Tower
Water
Water
4 Supply Pressure min. bar g 3.5
5 norm bar g 4.0
6 max. bar g 3.5
7 Return Pressure bar g 2
8 Supply Temperature C 35 Amb.
9 Max. Return Temp. C 45
10 Design Pressure bar g 6
11 Design Temperature C 70
12 Fouling Factor S&T H.E. m2hrC/kcal 0.0004
13 Cleanliness Factor kcal/m2hrC 0.8

1.16.3 Demineralized Water and B.F.W.

Service
Description Boiler Feed Water Demin.
H.P. M.P. Water Water
1 Supply Pressure min. bar g
2 norm. bar g 52 25
3 max. bar g 8
4 Supply Temperature C 120 120 50
5 Design Pressure bar g 70 50 11
6 Design Temperature C 150 150 70
7 Fouling Factor S&T H.E. m2hrC/kcal 0.0002 0.0002 0.0002
8 Fouling Factor Plate H.E. m2hrC/kcal
9 Conductivity S/cm 0.2 0.2 0.2
10 pH 6.5/7.5
11 Hardness as CaCO3 ppmwt <0.02 <0.02 <0.02
12 Na+ + K+ as Na ppmwt
13 Cl- ppmwt 0.1 0.1
14 SiO2 ppmwt <0.02 <0.02 <0.02
15 Oxygen as O2 ppmwt <0.02 <0.02
16 Total Iron (Fe) ppmwt <0.02 <0.02 <0.02
17 Total Copper (Cu) ppmwt <0.002 <0.002 <0.002
18 SO4 +SO3 ppmwt 0.02 0.02

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1.16.4 Air and Nitrogen

Service
Description Instrum. Service
Nitrogen
Air Air
1 Pressure: min. bar g 6 6 6
2 norm. bar g 7 7 7
3 max. bar g 8 8 8
4 Design Pressure bar g 10 10 10
5 Temperature: min. C -5
6 norm. C 47 47 5
7 max. C 50 50 40
8 Minimum Temperature C
9 Design Temperature C 75 75 70
Dew Point at Normal
10 C -5
Pressure
QUALITY OIL FREE
99 - To be
11 Nitrogen Purity Vol.% min.
Confirmed
12 Carbon Dioxide ppm vol max. 1
13 Carbon Monoxide ppm vol max. 0
14 Hydrocarbons ppm vol max. 1
15 Oxygen ppm vol max. 5
16 Noble Gases ppm vol max.
17 Water ppm vol max. 1

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BATTERY LIMITS (TO BE CONFIRMED)

The Battery Limits for inlet / outlet streams are defined as follows:

- Crude Oil from Petro Junn Upstream Complex: Plant fence

- Streams imported from PetroMonagas: PetroMonagas Plant fence
- Diluent Naphtha to Petro Junn Upstream Complex: Plant fence
- Diesel / Naphtha / LPG products: Marine shipping system
- Coke / Sulphur: Plant fence
- Natural Gas: Plant fence
- Raw Water: Plant Fence

The Petro Bicentenario Downstream Complex shall be designed to receive the

feedstocks and to deliver the products at the pressure (measured at grade)
and temperature conditions at the Refinery Battery Limit reported in Table 7.1.

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Table 7.1: Battery Limit Conditions

Pressure Temperature
Source Destination kg/cm g C State
Oper. Design Oper. Design
FEEDSTOCK
Diluted Crude To be Provided
Upstream Crude Unit To be Provided Liquid
Oil (1)
Atmosph. To be Provided
PetroMonagas Vacuum Unit To be Provided Liquid
Residue (1)
Middle To be Provided
PetroMonagas HDS Unit To be Provided Liquid
Distillate (1)
Light Coker To be Provided
PetroMonagas HDS Unit To be Provided Liquid
Gasoil (1)
Heavy Coker To be Provided
PetroMonagas HDC Unit To be Provided Liquid
Gasoil (1)
PRODUCTS

Storage MLA (2) (2) AMB 70 Liquid

LPG
Naphtha Storage SBM (2) (2) AMB 70 Liquid
Diesel Storage SBM (2) (2) AMB 70 Liquid
Open
Pet-Coke Storage - - - - Solid
Storage
Solidification Open
Sulphur - - - - Solid
Unit Storage(3)
INTERMEDIATES
Diluent To be Provided
Crude Unit Pipeline To be Provided Liquid
Naphtha (1)
UTILITIES
Hydrogen / To be Provided
Natural Gas Pipeline To be Provided Gas
FG (1)
Water To be Provided
Raw Water Pipeline To be Provided Liquid
Treatment (1)
Waste Water Water Treatment Pipeline HOLD HOLD Liquid

Notes:
(1) It is assumed that the feedstock will be received at a pressure sufficient to be
stored in the storage tanks of the Complex.
(2) The Operating and Design Pressures will be finalized based on the following
information:
Ship Size;
Availability of existing Jetty or location of a New Jetty for loading through MLA;
Bathymetry;
Distance from Storage to Existing or new Jetty / Distance from Storage to buoy.
(3) Solid Sulphur shipping from Open Storage Area to users by others.

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STORAGE SYSTEM PHILOSOPHY

The Storage system provides handling facilities for crude, intermediate

products and final products, to support Petro Bicentenario Refinery operations.
The list of services for which storage has been foreseen is reported here
following:

FEEDSTOCKS Hold-Up
Days
DILUTED CRUDE OIL TBD
ATM RESIDUE FROM PETROMONAGAS TBD
HCGO FROM PETROMONAGAS TBD
LCGO+MIDDLE DISTILLATES FROM PETROMONAGAS TBD

FINAL PRODUCTS

LPG TBD
NAPHTHAS TBD
DIESEL OILS TBD

INTERMEDIATE PRODUCTS

DILUENT NAPHTHA TBD

VACUUM RESIDUE TBD
FEED TO GASOIL HDS TBD
FEED TO HDC TBD

OFF SPECS

LIGHT OFF SPEC TBD

HEAVY OFF SPEC TBD
NAPHTHA TO NAPHTHA HDT TBD
LPG TO NAPHTHA HDT TBD

The general basis that will be followed for the definition of the minimum
required hold up time for services requiring storage are summarized below:

FEEDSTOCKS
A minimum hold-up of 14 days has been foreseen for Crude Oil and 7 days for
each stream imported from PetroMonagas Refinery.

INTERMEDIATE PRODUCTS
Intermediate products tanks are needed to compensate fluctuations of
production rates between upstream / downstream units and to allow unit
operation in case of shutdown of upstream / downstream unit (unexpected
shutdown or scheduled outages for catalyst replacement).
Intermediate product tanks shall be designed for a minimum hold-up of 7
days: it shall be operated partially full, with 3.5 days minimum empty space, to
cover the downstream unit unscheduled shutdown and with a volume of stored

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product equivalent to 3.5 days minimum of operation of the downstream unit,

to cover the upstream unit unscheduled shutdown.
In addition, the intermediate tanks hold up shall be adequate to allow
operation during shutdowns for catalyst replacement.

FINAL PRODUCTS
A minimum storage volume of 14 days production will be foreseen for final
products.
In addition to the criteria above, at least two tanks have been foreseen for
each product to be delivered by ship.
o One tank (or more if necessary) having a total capacity of one cargo
plus one day to cover ship delay.
o One tank to store the product for process units during ship loading

SLOPS
Light and heavy slops are collected via segregated systems in dedicated tanks.
Slops are the transferred to the crude feed pump suction to be reprocessed in
the Atmospheric Distillation Unit.

PRODUCT SHIPPING PHILOSOPHY (TO BE CONFIRMED)

Diesel and Naphtha are loaded into ship carriers through two single buoy
mooring (one for Diesel and one for Naphtha).
LPG is loaded through Loading Arms.
It is assumed that the existing jetty in Jose coastal area can accommodate
additional Loading Arms.
Pet Coke and Solid Sulphur are conveyed to a storage area, outside plant
fence.

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SITE CONDITIONS

1.17 SITE LOCATION

Details on location: Jose eastern coast of Venezuela

Country: Venezuela
Province: Anzotegui

Latitude: To be provided
Longitude: To be provided

Reference to area map and site plot:

Dwg: To be provided
Dwg: To be provided

1.18 SITE CONDITIONS

General description of the current state of the site

Hilly wooded cultivated marshy rocky built-up
X Other: The area is partially grass root and needs to be graded

Existing or expected constraints in areas surrounding the plant:

Existing plants are present at Petro Bicentenario Project fence

Current site elevations:

From 9.5 to 2.5 m s l sloping to north side (HOLD)

Reference to topographic survey:

Dwg: To be provided

1.19 SOIL CONDITIONS

General information on soil characteristics:

The stratigraphy is generally formed by an alternance of the following layers,
2.00 to 3.00 m. thick.
a) silty, sandy clay
b) silty sand, with some gravel.

Load bearing capacity: To be provided

Ground water level is: To be provided
Depth of frost line below grade m To be provided
Piling or soil improvement, if any: To be provided
Reference to soil investigation report: To be provided
Soil electrical resistivity (upper layer average value): To be provided
Soil thermal resistivity: To be provided

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1.20 REFERENCE ELEVATION

All elevations are referred to ______ (high point of paving) which is at

elevation ____ m above
X Mean sea level
Other

1.21 CLIMATIC DATA

Dry Bulb Air Temperature Data

Highest maximum on record 37 C
Hottest month average of max. temperatures C
Summer average mean C
Annual average mean 27 C
Lowest minimum on record 15 C
Coldest month average of min. temperature C
Winter average mean C
High one-day mean C
Lowest one-day mean C
Day/night temperature max. fluctuation C

Wet Bulb Air Temperature Data

Annual mean 24 C
Summer mean C
Winter mean C

Design Temperatures
Minimum design ambient temperature 15 C
Design air temperature (Dry Bulb) for air cooled heat exch. 34 C
Design air temperature (Wet Bulb) for air cooled heat exch. 30 C
Stack-design air temperature shall be based on __ C
Electric motor design air temperature shall be based on 40 C
Design air temp. for electrical equipment installed outdoor 40 C
Design air temp. for electrical equipment installed in substations 40 C
Design air temp. for electrical equipment installed in buildings 40 C
Sunshine temperature __ C
Winterizing temperature __ C
Air Compressors and fans design 34 C

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Relative Humidity
Annual average mean 76 % at ___ C
Summer average mean ___ % at ___ C
Winter average mean ___ % at ___ C
Summer Maximum 100 % at ___ C
Summer Design 79 % at ___ C

Wind
Direction of prevailing wind is from the: NNE / ESE / NNE
Maximum recorded wind velocity sustained 95 HOLD km/h
Wind Velocity Column designs
Velocity 145 HOLD km/h
Height coefficient (if any):
Flare radiation shall be based on:

Rain
Maximum 1 year duration rainfall ___ mm
Maximum 24 hour duration rainfall ___ mm
1 hour duration rainfall:
number of recordings per years: ___
1st value (max. value): 63.4 mm/h
2nd value (max. value): ___ mm/h
3rd value: ___ mm/h
4th value: ___ mm/h
Maximum rainfall recorded in 5 minutes: 17.9 mm

Snow
Maximum snow depth mm

Earthquake
Seismic zone X Yes No
Seismic degree:

1.22 SPECIAL ENVIRONMENTAL CONDITIONS

X Slightly corrosive (marine ambient)

Highly corrosive
X Salt
Dust storms
Other:

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SYSTEM OF MEASUREMENT UNITS

The following table indicates the normal dimensions of main properties in various
systems of measurement units.

SI X Metric English Other

Temperature C C F
Pressure Pa abs kg/cm2 abs psi abs
Mass kg kg lb
Length M m-mm ft-in
Relative Density Spec.Gravity Spec.Gravity Spec.Gravity
@T,C/15C @T,C/15C @T,F/60F
Absolute Density kg/m3 kg/m3 API or
@15C @15C lb/gal @60F
Flowing Density kg/m3 kg/m3 lb/ft3

Flowing Quantities

Mass kg/s kg/h lb/hr

Vapor m3/s m3/h ft3/sec
Liquid m3/s m3/h U.S. gal/min.

Standard Quantities

Vapor m3/s @15C Nm3/h 106 scfd

Liquid m3/s @15C std/m3/h BPSD
Enthalpy kJ/kg kcal/kg Btu/lb
Heat Rate MW Gcal/h MM Btu/h

If special instruction relating to the system of measurements or

conversion factors is available, please provide.

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ENVIRONMENTAL REQUIREMENTS

1.23 ATMOSPHERE

1.23.1 Emission standards

The atmospheric emissions will be verified according to:

World bank
Italian regulations
Local regulations
Other:

The pollutant standards for each of the emission sources into consideration are:

Pollutant Unit Standards

SO2 mg/Nm3 To be provided
NOX mg/Nm3 To be provided
CO mg/Nm3 To be provided
TSP / PM mg/Nm3 To be provided
HC mg/Nm3 To be provided
VOC mg/Nm3 To be provided
H2S mg/Nm3 To be provided
HBr mg/Nm3 To be provided
HF mg/Nm3 To be provided
HCl mg/Nm3 To be provided
Others To be provided

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1.24 WATER EFFLUENT

The liquid discharges will be verified according to:

World bank
Italian regulations
X Local regulations
Other:

The pollutant standards for each of the effluent sources at the fence of the
complex into consideration (according to receiver) are:

Pollutant Unit Standards

PH To be provided
Temperature C To be provided
BOD5 mg/l To be provided
COD mg/l To be provided
Metals mg/l To be provided
Ammonia mg/l To be provided
Chlorides mg/l To be provided
Fluorides mg/l To be provided
Sulphides mg/l To be provided
Sulphates mg/l To be provided
Phenols mg/l To be provided
TSS mg/l To be provided
Oil & Grease mg/l To be provided
T C To be provided
Others To be provided

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PROCESS DESIGN CRITERIA

The purpose of this section is to define the design criteria to be applied for the
development of Petro Bicentenario Project, including sizing and general design
and functional criteria.

1.25 DESIGN PRESSURE

General
The Design Pressure is the max and/or the min. pressure for which the
mechanical calculations shall be performed.
The following summarizes the criteria to be followed for pressurized equipment:

OPERATING DESIGN
PRESSURE PRESSURE

0 to 18 kg/cm2 g Max value between 1.8 and (MOP+1.8 kg/cm2)

18 to 40 kg/cm2 g max norm. operating pressure x 1.10
40 to 80 kg/cm2 g max norm. operating pressure + 4 kg/cm2
> 80 kg/cm2 g max norm. operating pressure x 1.05

For operating pressures below the atmospheric pressure, it is necessary to

specify the minimum design pressure as absolute vacuum, the Maximum
design pressure equal to 1.8 kg/cm2 (or 3.5 kg/cm2 for equipment with PSV(s)
discharging to flare network) and the external pressure equal to the
atmospheric pressure of the area where the equipment will be installed.

Additional Consideration
Full Vacuum design condition shall be specified for:
Equipment normally operating under vacuum conditions or those that are
subject to evacuation during start up, shut down and /or regeneration.
Vessel and heat exchangers which handle fluids having a vapour
pressure lower than atmospheric pressure at minimum ambient
temperature normally operating liquid full, and that can be blocked in
and cooled down.
Fractionating columns and associated equipment that can undergo a
vacuum condition through loss of heat input.
Steam Turbine condensers
For equipment specified for full vacuum, the design temperature relevant to full
vacuum conditions shall be specified.
For Equipment protected by a downstream installed safety valve, the design
pressure shall be calculated as the design pressure of the equipment where the
safety valve is installed + 120% the estimated pressure drop from the affected
equipment and the equipment where the safety valves is installed + static
head (if any).
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Heat Exchangers
Heat Exchanger shall be designed by following the 10/13 rule in accordance
with the latest edition of ASME VIII Div.1. This means to set a design pressure
of the lower pressure side of the Heat Exchanger not lower than 77% of the
design pressure of the higher pressure side. This design rule allows to protect
the equipment against tube rupture without installing a PSV. The design
pressure set following the 10/13 rule will be extended also to inlet and outlet
piping connected to the lower pressure side of the Heat exchanger including
the isolation valves.

Compressors
Minimum design pressure at compressor discharge:
MOP + 1 kg/cm2 for MOP 10 kg/cm2 g,
MOP + 10% for MOP > 10 kg/cm2 g.

Consideration shall be given to compressor arrangement to determine the

settling pressure of the isolated system. The settling pressure is the
equilibrium pressure reached between the suction and discharge isolating
valves of the compressor system when the compressor is stopped or shut
down. Generally the design pressure of the equipment and piping at
compressor suction should be above this settling pressure in order to avoid the
use of additional PSV's.

Pumps
Centrifugal Pumps
The design pressure for equipment and piping on the delivery side of a pump is
equal to the shut-off discharge pressure of the pump, calculated by adding the
maximum head of the pump to the maximum suction pressure.
When pump characteristic curves are known, the design pressure has to be
calculated with the actual shut-off head.
When the shut-off pump head is not available, this pressure can be estimated
by means of the following formula:

1.2 head SG max

Pd Ps max
10.2

Where:
Pd = design pressure at pump discharge (kg/cm2 g)
Ps max = maximum suction pressure (design pressure of upstream vessel +
static pressure due to the maximum static head) (kg/cm2 g)
Head = head of the pump at design point (m)
SG max = maximum specific gravity of pumped liquid under normal operating
conditions.

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Volumetric Pumps
The design pressure for equipment and piping on the delivery side of a pump is
calculated as 115% of the discharge gage pressure, or as a minimum, the
discharge gauge pressure plus 1.8 kg/cm2.

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1.26 DESIGN TEMPERATURE

The design Temperature is the maximum temperature value for which the
mechanical calculation of the equipment shall be performed.
The design temperature shall be calculated keeping into account all the criteria
listed below:

Design temperature equal to operating temperature plus the following

margin
Top < -29C Tdes min=Top min
Tdes = 70C

-29C <Top< 343C Tdes = Top max + 30C

Top>343C Tdes = Top + 15C
Top: Maximum Operating Temperature (C)
Top min: Minimum Operating Temperature (C)
Tdes: Design Temperature (C)
Tdes min: Minimum Design Temperature (C)

Maximum Temperature during start-up, shutdown, purging, catalyst

regeneration or upset conditions (eg reactor runway, loss of cooling, etc).

Equipment subject to Steam out shall be designed for the following

alternative design conditions valid for steam out, according to equipment
design pressure:

Equipment with design pressure >=MP Steam Design Pressure:

o MP Steam Design Pressure at MP Steam Max. Operating Temp.
o Half Vacuum at MP Steam Max. Operating Temperature
Equipment with design pressure < MP Steam Design Pressure:
o LP Steam Design Pressure at LP Steam Max. Operating Temp.
o Half Vacuum at LP Steam Max. Operating Temperature
Equipment with design pressure < LP Steam Design Pressure:
o Equipment Design Pressure at LP Steam Max. Operating Temp.
o Half Vacuum at LP Steam Max. Operating Temperature

Minimum Design Metal Temperature

The Minimum Design Metal Temperature (i.e. MDMT) shall be specified at least
of the lowest of the following:
Minimum Operating Temperature (MOT)
Minimum Ambient Temperature
Minimum metal temperature calculated as a result of depressurization

The Minimum Design Temperature shall be indicated together with the

coincidental pressure.

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1.27 DESIGN OVERSIZING FACTOR

The criteria of design oversize factors to be used to determine the dimensions

and/or rating capacity of equipment and machinery are listed herein below.

Drums
No oversizing is considered. Suitable hold up times is considered according to
the services the drums are specified for.
The following minimum liquid surge time shall be provided between low and
high liquid level, unless otherwise dictated by process reasons and / or licensor
requirements:
Service Surge Time, min
Drums feeding other equipment for
further processing 10
Feedstock surge drum 15
Overhead receivers Note 1
Product Storage 2
Flow to sewer or drain 2
Water pot 2
Note 1: 4 min. hold up shall be considered with respect to the reflux flow rate
or 2 min. with respect to the net product flow rate whichever is the greater.

Heat Exchangers
Unless otherwise dictated for process reasons and / or licensor requirements, a
design margin of 10% shall be specified on required surface for coolers,
condensers (including air), reboilers and heat exchangers on pumparound
circuit.

Fired Heaters
Unless otherwise dictated for process reasons and/or Licensor requirements,
10% overdesign margin shall be considered on duty.

Columns
Unless otherwise specified for process reasons and /or Licensor requirements,
the columns shall be sized in order to obtain a percent flooding not higher than
70% for columns that work under vacuum and a value not higher than 75% in
columns that work in all other services.

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Pumps
Unless otherwise dictated for process reasons and / or Licensor requirements,
the rated pump capacity shall be the maximum normal flowrate multiplied by
the following factors:
- Pumparound, reflux and circulation pumps: 1.2
- Other pumps: 1.1

Compressors
Unless otherwise dictated for process reasons and / or Licensor requirements,
an overdesign factor of 10% on flowrate has to be considered.

1.28 SPARING PHILOSOPHY

In general, sparing equipment is based on the concept that the facilities shall
be designed to operate for a minimum period of 4 years without major
turnaround.
Consequently, spare equipment shall be provided when:
The failure or routine maintenance of the equipment is expected to fall
outside the timeframe of planned unit/facility Turn-Around(s).
The downtime associated with these events has unacceptable cost,
safety, and / or environmental impact on the facility or makes the safe
operation of the unit/facility uncertain.

The general sparing philosophy to be applied for the main process and utility
equipment is as follows:
Vessels: no spare
Columns: no spare
Heat exchangers (heaters and reboiler excluded): no spare
Reboilers: no spare
Heaters: no spare
Furnaces: no spare
Pumps: n+1
Fans (for air coolers): no spare
Filters: n+1 (*)
Reciprocating Compressors: n+1
Centrifugal /Axial compressors: no spare

(*) No spare can be considered in case the filter can be put off-line and
bypassed for the time necessary for any maintenance operation (i.e.
replacement of the filtering elements), without any appreciable problem which
could occur on regular plant operation.

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1.29 DESIGN LIFE OF EQUIPMENT

The predicted rate of corrosion during the service of designed equipment and
piping is an extremely significant factor that governs material selection. Each
type of equipment has a certain design life that is considered the minimum
time that it must be in service before replacement. Design life of equipment
shall be in accordance with Table 16.1

Table 16.1: Design Life of Equipment

EQUIPMENT TYPE LIFE, YEARS
Piping 20
Furnace Tubes 10
Vessel Shells (including nozzle) 20
Internals (non-removable) 20
Internals (removable) 10
Trays 10
Exchanger Shells (including nozzles) 20
Exchanger Tubes: Carbon Steel 5
Exchanger Tubes: Alloy Material 10
Air Cooled Exchangers (excluding tubes) 10
Pump 20
Tankage 20
Rotating Equipment 20
Electrical systems (excluding electronic
systems which have a high degree of 20
obsolescence)

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