CLIENT : CONTRACTOR :

COOLING WATER CONSUMPTION CALCULATION

[A] SUMMARY

Plant Equipment Tag Number DescriptionHeat duty Water Demand

RemarkskW kg/hr

CFU 5000 BPD

E-170 MS Cooler 198.00 17036 (Note-2)

P-160 A/B Feed Pump - 3000 (Note-4) Used as water sealing

P-100 A/B Fractionation Reflux Pump - 3000 (Note-4) Used as water sealing

P-140 A/B Kerosene Pump - 0 (Note-4) Used as water sealing

P-150 A/B Diesel Pump - 0 (Note-4) Used as water sealing

Total water demand = 23036

NHT 2500 BPD

P-201 A/B NHT Feed Pump - 3000 (Note-4) Used as water sealing

P-203 A/B Stripper Bottom Pump - 3000 (Note-4) Used as water sealing

P-202 A/B Stripper Reflux Pump - 3000 (Note-4) Used as water sealing

P-206 NHT Wash Water Pump - 30 (Note-4) Used as washing water

Total water demand = 9030.00

CRU 2500 BPD

P-302 Caustic Recycle Pump - 0 (Note-4) Used as water sealing

E-302 HP Absorber Feed Cooler 210.00 18069 (Note-4) (Note-3)

P-301 A/B Separator Bottom Pump - 3000 (Note-4) Used as water sealing

P-303 A/B LPG absorber Bottom Pumps - 3000 (Note-4) Used as water sealing

E-305 Reformate Trim Cooler 512.00 44054 (Note-4) (Note-3)

E-304 Stabilizer Overhead Cooler 350.00 30115 (Note-4) (Note-3)

P-304 A/B Stabilizer Reflux and Distillate Pump - 3000 (Note-4) Used as water sealing

P-305 A/B Stabilizer Reboiler Pump - 3000 (Note-4) Used as water sealing

E-309 LPG Product Trim Cooler 12.00 1033 (Note-4) (Note-3)

E-307 Deethanizer Condenser 128.00 11013 (Note-4) (Note-3)

Total water demand = 116282.98

UTILITY

P-402 Heavy Napfta Pump - 0 (Note-4) Used as water sealing

P-404 Low Octane Pump - 0 (Note-4) Used as water sealing

P-401 A/B Truck Loading Pump - Light Product - 0 (Note-4) Used as water sealing

P-401 C/D Truck Loading Pump - Heavy Product - 0 (Note-4) Used as water sealing

P-415 Truck Fillling Shed Pump - 0 (Note-4) Used as water sealing

P-413 Make up Water Pump - 0 (Note-4) Used as water sealing

P-405 Cooling Water Circulation Pump - 3000 (Note-4) Used as water sealing

P-407 Booster Pump - 0 (Note-4) Used as water sealing

P-410/420 Electric/Diesel Fire Pump - 3000 (Note-4) Used as water sealing

P-460 Jockey Pump - 3000 (Note-4) Used as water sealing

P-400 Flare KO Drum Pump - 0 (Note-4) Used as water sealing

Total water demand = 9000

Total (with 20% margin) 188819 kg/hr 189 m3/hr

Total sealing water (with 20% margin) 43236 kg/hr 43 m3/hr

Notes :

1

2 The off-spec cooler is intermittent basis, use during commissioning/ start-up Fractionation Unit.

During commissioning of fractionation there is no requirement of cooling water on the CRU.

3 The cooling water demand for CRU is calculated based on heat duty requirement from Axens (for NHT & CRU Capacity 2500 BOPD)

4 Cooling water consumption for pump is given as per Vendor information and be summarised as below and used for mechanical sealing :

Assume that for pump with power more than 5 bkW will utilize sealing water

Pump Tag No. Cooling Water Demand Power

RemarksbkW

CFU 5000 BPD Area

P-160 A/B 3 5.20 During normal operation

P-100 A/B 3 8.20 During normal operation

P-140 A/B 0 3.00 During normal operation

P-150 A/B 0 4.10 During normal operation

NHT 2500 BPD Area

P-201 A/B 3 48.00 During normal operation

P-203 A/B 3 71.00 During normal operation

P-202 A/B 3 7.00 During normal operation

P-206 0.03 2.20 Intermittent

CRU 2500 BPD Area

P-302 0 4.20 During normal operation

P-301 A/B 3 26.00 During normal operation

P-303 A/B 3 20.00 During normal operation

P-304 A/B 3 27.00 During normal operation

P-305 A/B 3 43.00 During normal operation

UTILITY

P-402 0 4.30 During normal operation

P-404 0 4.30 During normal operation

P-401 A/B 0 4.80 During normal operation

P-401 C/D 0 4.80 During normal operation

P-415 0 3.50 During normal operation

P-413 0 1.00 During normal operation

P-405 3 51.00 During normal operation

P-407 0 0.07 During normal operation

P-410/420 3 132.00 Intermittent

P-460 3 13.00 During normal operation

P-400 0 2.13 During normal operation

ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR 5,000 BPD CAPACITY CONDENSATE FRACTIONATION PLANT

The calculation of cooling water demand is based on differential temperature of 10oC across the exchanger.

Assumption temperature differential of 10 oC across exchanger.

m3/h

FANKAM REFINERY LTD

P.T. ISTANA KARANG LAUT

CLIENT : CONTRACTOR :

COOLING WATER CONSUMPTION CALCULATION

[A] CALCULATION FOR EACH COOLER

1 CFU 5000 BPD

E-170 (MS Cooler) Conversion Factor :

Duty = 198 kW 1.0 kW = 1.0 kW = 3600.0 kJ/hr

712800 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 17036 kg/hr

So, the cooling water flowrate of E-170 is = 17036 kg/hr

2 CRU 2500 BPD

E-302 (HP Absorber Feed Cooler)

Duty = 210 kW

756000 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 18069 kg/hr

So, the cooling water flowrate of E-302 is = 18069 kg/hr

3 E-304 (HP Stabilizer Overhead Cooler)

Duty = 350 kW

1260000 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 30115 kg/hr

So, the cooling water flowrate of E-304 is = 30115 kg/hr

4 E-305 (Reformate Trim Cooler)

Duty = 512 kW

1843200 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 44054 kg/hr

So, the cooling water flowrate of E-305 is: 44054 kg/hr

5 E-307 (Deethanizer Condenser)

Duty = 128 kW

460800 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 11013 kg/hr

So, the cooling water flowrate of E-307 is = 11013 kg/hr

6 E-309 (LPG Product Trim Cooler)

Duty = 12 kW

43200 kJ/hr

Cp of water = 4.184

ΔT = 10

m = Q

Cp x ΔT

m = 1033 kg/hr

So, the cooling water flowrate of E-309 is = 1033 kg/hr

ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR 5,000 BPD CAPACITY

CONDENSATE FRACTIONATION PLANT

kJ/kgoC

oC

kJ/kgoC

oC

kJ/kgoC

oC

kJ/kgoC

oC

kJ/kgoC

oC

kJ/kgoC

oC

P.T. ISTANA KARANG LAUT

FANKAM REFINERY LTD

Refer to Axen Document for 2500 BPD NHT & CRU will have typical man power as below :

Field operator per shift : 1

Board/DCS operator per shift : 1/2

Supervisor per shift : 1/4

Then, here is summary of man power demand operating the plant

[A] NHT area

Field operator per shift : 4 employee

Board/DCS operator per shift : 2 employee

Supervisor per shift : 1 employee

Total : 7 employee (assumed)

[B] CRU area

Field operator per shift : 4 employee

Board/DCS operator per shift : 2 employee

Supervisor per shift : 1 employee

Total : 7 employee (assumed)

[C] CFU + UTILITY area

Field operator per shift : 4 employee

Board/DCS operator per shift : 2 employee

Supervisor per shift : 1 employee

Plant Mng : 1 employee

Total : 8 employee (assumed)

[D] E & I Department

Technician per shift : 2 employee

Supervisor per shift : 1 employee

Total : 3 employee (assumed)

[E] MECHANICAL Department

Technician per shift : 4 employee

Supervisor per shift : 1 employee

Total : 5 employee (assumed)

[F] HSE Department

HSE staff per shift : 1 employee

Supervisor per shift : 1 employee

Total : 2 employee (assumed)

[G] FACILITY ENGINEERING Department

Process Engineer : 1 employee

Instrumentation Engineer : 1 employee

Mechanical Engineer : 1 employee

Electrical Engineer : 1 employee

Engineering Spt : 1 employee

Engineering Mng : 1 employee

Total : 6 employee (assumed)

[I] SUMMARY

Total of employee : 38 employee (assumed)

[J] PLANT AREA

CFU & SRU Area : 3000 refer to plant layout

NHT & CRU Area : 3750 refer to plant layout

Total of plant area : 6750

PURPOSERECOMMENDED MINIMUM RANGE

liter/person/day liter/person/day

Drinking water 38 employee - 5 2~5

Sanitation services 38 employee - 20 0~75

Bathing 38 employee - 15 5~70

- - - -

Total =

Cleaning process area 6750 m2 50 - -

Total =

Recirculation Cooling Water Flow : 188.8

831.3 gpm

Hot Water Temperature : 45

113

Cold Water Temperature : 30

m2

m2

m2

NUMBER OF PEOPLE OR PLANT

SURFACE AREA

employee or m2 liter/m2/day

Emergency shower/eye wash/face wash

m3/hr

oC

oF

oC

86

Temperature Difference : 15

27

Evaporation Rate : 16.8 gpm

3.8

2.0 %

Cycle of Concentration : 10

Blow Down Rate : 0.4

1.9 gpm

Drift + Other Loss Rate : 0.0

0.0 gpm

Cooling Tower Water Make Up Rate : 4.2

18.7 gpm

Water Treatment Package Capacity : 4.3

4.8 (if using branckish water)

8.6 (if using sea water)

oF

oC

oF

m3/hr

m3/hr

m3/hr

m3/hr

m3/hr as permeate

m3/hr as raw water

m3/hr as raw water

PERMEATE

REJECT

RAW WATERREVERSE OSMOSIS

RAW WATER

CLEAN WATER

KATION EXCHANGE

R

ANION EXCHANGE

R

Water Treatment Package Capacity : 4.3

19.0 gpm

Duty : 1 x 100%

Raw Water Tank Capacity : 4.8 residence time is 1 hr

2.1 m as ID

1.4 m as H

Balance Volume : 1.00

Raw Water Tank Capacity : 8.7 residence time is 1 hr

2.5 m as ID

1.7 m as H

Balance Volume : 1.00

Raw Water Tank Capacity : 4.4 residence time is 1 hr

2.0 m as ID

1.4 m as H

Balance Volume : 1.00

Raw Water Pump Capacity : 19.3 15 minutes filling time for raw water tank

Raw Water Pump Capacity : 34.7 15 minutes filling time for raw water tank

Raw Water Pump Capacity : 17.4 15 minutes filling time for raw water tank

Duty : 2 x 100%

m3/hr

m3

m3

m3

m3/hr

m3/hr

m3/hr

CLEAN WATER

RAW WATER TANK

RAW WATER PUMP

Product Water Tank Capacity : 8.6 residence time is 2 hr (Note-1)

2.5 m as ID

1.7 m as H

Balance Volume : 1.00

Cleaning Pump Capacity : 0.05 10 % tolerance

Duty : 2 x 100%

Distribution Pump Capacity : 0.07 10 % tolerance

Duty : 2 x 100%

Distribution Pump Capacity : 5.00 10 % tolerance

Duty : 1 x 100%

m3

Note-1 : residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration time during regeneration of water treatment package

m3/hr

m3/hr

m3/hr

PRODUCT WATER TANK

CLEANING PUMP

DISTRIBUTION PUMP

EMERGENCY SHOWER PUMP

Cooling Tower Capacity : 188.82 20 % tolerance

Duty : 1 x 100%

Recirculating Water Pump Capacity : 188.82 20 % tolerance

Duty : 2 x 100%

Sealing Pit Pump Capacity : 43.24 20 % tolerance

Duty : 2 x 100%

Sealing Water Collection Pit Capacity : 43.2 residence time is 1 hr

5.3 m as L

1.5 m as H

5.4 m as W

m3/hr

m3/hr

m3/hr

m3

COOLING TOWER

RECIRCULATING WATER PUMP

SEALING PIT PUMP

AG

UG

SEALING WATER COLLECTION PIT

WATER DEMAND

TYPE OF WATERContinuous Intermittent

liter/day

190 - Treated water

760 - Treated water

570 - Treated water

- 4.5 Treated water

0.06 m3/hr Treated (clean) water

1000 - Un - treated water

0.04 m3/hr Un - treated (raw) water

m3/hr

(assumed that cleaning is conducted daily but partially which density is 1000 liter for 20 m2 area per day)

15 minutes filling time for raw water tank

15 minutes filling time for raw water tank

15 minutes filling time for raw water tank

residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration time during

which density is 1000 liter for 20 m2 area per day)

Raw Water Pump

Recirculating Water Pump

River

Oily Water from NHT 2500 BPD - Continuously

Oily Water from Tank Area - during hard rain - Intermittent

Oily Water - if any - Intermittent

[1] To Condensate-Column Overhead Vapor Heat Exchanger [2] To Flare System[1] Vapor-Liquid from Air

Cooled Overhead Condenser[2] From Fuel Gas System

Water from Deep Well

Reverse Osmosis/Demineralized

[assumed]

[1] Reductor[2] Antiscalant[3] Disinfectant

Permeate as CT Make Up Water - Continuosly

Reject - Continuously

Cooling Tower[assumed : wet type]

CT Blow Down - Continuously

[1] Antiscalant[2] Microbiologycal Treatment[3] pH Adjusment

Reflux AccumulatorReflux back to top of CFU

Oily Water Collection Pit

Oily Water from CRU

2500 BPD - Continuously

API Separator

Equalizing Pond

Slop HC Tank

Oil back to Condensate Feed

Tank

Effluent Treatment Package

Water from Slop HC Tank - Intermittent

Water from API Separator - Continuously

Used chemical after regeneration - Intermittent

Raw Water Tank

Water as cleaning of plant area - Continuosly

Heat Exchangers in Plant

Cold Water

Hot Water

Sealing Water Collection Pit

Pumps in Process Plant Area

Evaporation + Drift

Water purpose for drinking, sanitation, bathing

Cleaning Pump

Product Water Tank

Distribution Pump

Emergency Shower PumpWater purpose for emergency shower during accident

Sealing Pit Pump

Reduce to 390 ppm TDS CW from 400 ppm

Evap = 75 L/s

TDS = 0 mg/L

CW = 5000 L/s

TDS = 400 mg/L

2,000,000 mg/s

Maintain 400 ppm TDS CW

Evap = 75 L/s

TDS = 0 mg/L

CW = 5000 L/s

TDS = 400 mg/L

2,000,000 mg/s

FILL/SPLASH BAROF

COOLING TOWER

FILL/SPLASH BAROF

COOLING TOWER

BD = 125 L/s

TDS = 406 mg/L

50,761 mg/s

RCW = 4925 L/s

TDS = 406 mg/L

2,000,000 mg/s

MU = 200 L/s

TDS = 10 mg/L

2000 mg/s

BD = 11 L/s

TDS = 406 mg/L

4,277 mg/s

RCW = 4925 L/s

TDS = 406 mg/L

2,000,000 mg/s

BASINOF

COOLING TOWER

BASINOF

COOLING TOWER

MU = 86 L/s

TDS = 50 mg/L

4277 mg/s

With blowdown :CW = 5000 L/s

TDS = 1,951,239 mg/s

390 mg/L

Without Blow Down :CW = 4925 L/s

TDS = 2,000,000 mg/s

MU = 75 L/s

TDS = 2000 mg/s

TDS = 400.4 mg/L

With Blow Down :CW = 5000 L/s

TDS = 2,000,000 mg/s

400 mg/L

Without Blow Down :CW = 4925 L/s

TDS = 2,000,000 mg/s

MU = 75 L/s

TDS = 4277 mg/s

TDS = 400.86 mg/L