Jones D.S.J., Pujado P.R. Handbook of Petroleum Processing

ECONOMICS 835

Or

r

A guaranteed daily cost of all the utilities as a percentage of the expected normal

consumption

The description of the remaining items that make up the guarantee document are self

explanatory and are illustrated in the example of a typical process guarantee given

in Appendix 17.1.9. This example is based on the study case for the thermal cracker

illustrated in the various sections of this Chapter.

In this example it is assumed that the contract has been awarded on a lump sum basis

for engineering, all other home ofﬁce functions and the contractor’s proﬁt fee. The

other costs such as equipment, materials and the installation of the plant is on a cost

payable directly by the client basis.

836 CHAPTER 17

APPENDICES

Appendix 17.1.1. Reﬁnery plant inadequacies report—example work sheet.

1782

1596

1410

1224

1408

1222

1244

1271

1803

1800

1612

1964

1906

1718

1532

1616

1730

1659

1658

1892

1841

1655

1979

1793

1722

1536

1350

1524

1608

1642

1448

SFR-22

CRUDE OIL PROGRAME

TOTAL

CRUDE STOCK

M.B.

DATE

VESSEL

KUWAIT

TOTAL STOCK

BARRELS

1st

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

11th

12th

13th

14th

15th

16th

17th

18th

19th

20th

21st

22nd

23rd

24th

25th

26th

27th

28th

29th

30th

31st

OXFORD

E. MUNCHEN

JOHN P.G

BRITISH ENGINEER

CHARIOT

SAN. NICOLA

EXETER.

NEDERLAND

OLYMPIC WIND

RAGNA GORTHEN

HAV KONG

WESTMINSTER.

CHEMAWA

TENACIA

HOEGH SHIELD

HOEGH GRACE

REIN.

810

874

718

1341

1224

1038

852

1036

919

1010

1106

1227

1108

989

870

881

789

725

661

782

718

839

925

943

826

940

807

789

725

661

782

IMPORTS

RUN TO

STILLS

117

186

185

186

117

119

92

64

117

64

186

133

64

204

215

131

240

189

185

150

135

105

115

185

130

220

240

IRAN

IRAQ ARAMCO, BASRAN

TIA JUANA.

RUN TO

STILLS

RUN TO

STILLS

IMPORTS

TOTAL STOCK

BARRELS

TOTAL STOCK

BARRELS

VESSEL

LARGO (ARAMCO)

FERN ROSE (IRAN)

CANTERBURY (IRAN)

WORLD GRANDEUR

GUILD FORD (IRAN)

N.COMMANDER (IRAQ)

MASTER PETER (IRAN)

AARHUS (IRAN)

SALISBORY (IRAQ)

EORLD GRANDEUR (IRAQ)

(TIA JUAN)

IMPORTS

441

372

303

234

165

576

270

210

692

623

1094

1025

929

807

955

948

946

819

967

898

829

1039

986

933

811

689

742

890

SAGUARO (BASRAN)

CRYSANTHY ' L' (ARAMCO)

STEENSMOUNTAIN (IRAN)

646

768

185

270

210

115

175

270

122

53

-

69

122

96

69

-

WORLD INSPIRATION

276

266

256

266

256

246

306

296

286

276

246

236

226

216

206

196

130

TIA JUAN

10

-

FIG. 1.

Appendix 17.1.2. Example of a crude oil inventory schedule.

Distribution

Month of

INTERMEDIATE STOCK SHEET

Refinery

TANKS

335/336

TANKS

450/457

TANK

353

WHITE SPIRIT.

KEROSINE

MAX. 26.5 MR'S

MIN. 1.5

"

MAX. 82 MR'S

MIN. 4

"

MAX. 58 MR'S

MIN. 5

"

MAX. 16 MR'S

MIN. 1

"

T/JET 2486

TANK

332

T/JET 2482

EST

STOCK

DAY

OF

MONTH

PRODN. RUN PRODN. PRODN.RUN RUN PRODN. RUNDIFF.

EST.

STOCKS

DIFF

EST.

STOCKS

DIFF DIFF.

EST.

STOCK

ACT.

STOCKS

ACT.

STOCKS

ACT.

STOCK

1 2.9 2.0 + 0.9

+ 3.1 46.0

49.1

52.2

55.3

57.4

59.5

61.6

55.1

42.1

19.1

6.1

8.2

10.3

12.4

14.7

18.2

21.7

25.2

28.5

31.4

34.5

21.5

8.5

10.6

13.7

16.8

20.1

23.5

27.0

30.5

33.6

+ 3.1

+ 2.1

+ 2.3

+ 3.5

+ 3.1

+ 3.3

+ 3.5

+ 3.1

− 13.0

+ 2.1

− 6.5

− 13.0

9.2 15.1 12

12

13

12

15.1

15.3

15.5

15.1

–

15.1

15.3

15.5

15.1

7.5

–

10.1

11.0

11.9

12.8

13.7

14.6

15.5

16.4

17.3

18.2

19.1

20.0

18.0

16.0

14.0

12.0

10.0

2.9 2.0 + 0.9

– 2.0 + 0.9

– 2.0 + 2.0

– 2.0 − 2.0

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

TOTALS

9.6

6.3 6.9

13.2

19.5

17.8

16.1

14.4

12.7

8.7

1.7

6.3

4.0

9.6

–

8

7

–

8

31.0

23.0

24.0

26.2

27.8

28.4

30.0

31.6

33.2

34.8

26.8

− 8

+ 1.6

+ 6.3

− 1.7

− 7

− 4

+ 1.6

− 8

8

Appendix 17.1.3. Example of a product inventory and schedule.

UNIT

THROUGHPUT

2482 8,000 B/SD

2485 8,000 B/SD

Max. B/SD

Pron.

B/SD

54,800

B/SD

69,000 B/SD

64,000 B/SD

DAYS ON

STREAM

PS-1 31

31

6

10

PS-2

PS-3

HS-2

TCP-1 Crude

TCP-2 Crude

OPERATING SCHEDULE

9FR-816

1 2 3 4 5 6 7 8 91011 1213141516171819 2021222324 25262728293031

KUWAIT

WS

2482

GO

BASRAN

KERO

ARAMCO ARAMCO

IRAQ

KERO

MDO

2486

GO

NAP

GO

MDO

KERO

IRAQ

GO

IRAN

BAS.

HF

2486

GO

KUWAIT

IRAN

ARAMCO

MDO

MAP

HF

GO

S D

KUWAIT

NAP

GO

NAP

GO

HF

NAP

S D

Appendix 17.1.4. An outline operating schedule.

UNIT

THROUGHPUT

54,800 B/SD

10,300 B/SD

B/SD

Pron. 12,000

Reg.

2.82

24.82 8,000

24.86 8,000

H.V.N.

S.R.H.

Hontor.

Pron. 9,600

B/SD

69,000 B/SD

64,000 B/SD

DAYS ON

STREAM

THROUGHPUT

41,000

SEE OPERATING

NOTES

APPROX 8000

15,000

32,000

22,000

2,000

31

17

DAYS ON

STREAM

PS-1

31

16

31

6

10

S/D

S/D S/D

2482

2486

PS-2

PS-3

CB-1

CB-2

TCP-X8fvde

EDELEAMU

CS-4

HS-1

HS-2

UNIT

THROUGHPUT

DAYS ON

STREAM

UNIT

THROUGHPUT

DAYS ON

STREAM

UNIT

H.D.S.R.1 2,000 18

C.S.S.R.2 15,500 31

C.S.S.R.5

L.C.N.S.

Splitter

18

31

2,000

4,000

3,000

5,300

H.D.S.R. 2

H.D.S.R. 3

H.D.S.R. 4

T. C . P. 1

T. C . P. 2

C.N.S.P.

F.C.S.R.

H.P.S.R.

F.H.S.R.

N.S.S.R.

N.F.S.R.

C.S.S.R.I.

Still 13

1234 5 678 9101112131415161718192021222324252627282930

9FR-816

DETAIL OPERATING PROGRAM.

SLOP

RUNNING

1,500 Bbis/DAY WHEN NOT ON 24–82

WS

GO

H.F.

GO

S D

2482

2485

GO

NAP

NF

BASRAN

ARAMCO

KERO

M.D.O.

KUWAIT

BAS

KERO

NAP

IRAQ

M.D.O.

IRAN

KERO

HF

SHUT DOWN

NAP

IRAQ

BASRAN

IRAN

M.D.O.

*

Appendix 17.1.5. A typical detailed operating program and schedule.

UNIT

THROUGHPUT

DAYS ON

STREAM

P. S.-1

P. S.-2

P. S.-3

HS-2

E.P.S.R.

(1)

(2)

MAX

8

48,000

55,000

B/SD

8

67,000

B/SD

8

64,000

B/SD

WED

11

THUR

12

FRI

13

SAT

14

SUN

15

MON

16

TUES

17

WED

18

307

303

313

2482 2486

314 312 315

301 301304 309

307310 311 306

KUWAIT

2482

GO

2486

GOG.O.

GO

MDO MDO

WS

ARAMCO ARAMCOIRAQ

KERO KERO

IRAN IRANKUW

NAP

SHUT DOWN

PREMIUM

KERO

(1) Stop to be run on Nap/Go operations.

(2) Awaiting decision on Prem. Kerosene specification.

If Edeleanu plant runs at only 10,000 BU1/D the

Kero run on Ps-2 willl be curtailed.

9 FR-1086 ISSUE No. 2

WEEKLY OPERATING PROGRAM.

SHIPPING

DEC 11

th "

BR. ENGINEER" (KUW) 306, 312

'' 11

th "

GUILDFORD" (IRAQ) 309, 304, 303

'' 11

th "

WORLD GRANDEUR"(ARAM.) 301, 313, 303

'' 13

th "

SAN NICOLA" (KUW) 307, 312

'' 16

th "

EXETER" (KUW) 310, 311

'' 16

th "

CRYSANTNY ‘L’" (ARAMCO) 303, 304, 314

'' 17

th "

STEENSMOUNTAIN" (IRAN) 312

'' 18

th "

SAGUARO" (BAS) 309

NOTES.

Rev. 1

Appendix 17.1.6. A typical weekly program.

842 CHAPTER 17

Appendix 17.1.7. Typical factors used in capacity

factored estimates

Type of plant Factor (b)

Atmospheric and vacuum distillation 0.6

Catalytic reforming 0.6

Fluid cat cracking 0.7

Naphtha splitter 0.7

Thermal cracker 0.7

Delayed coking 0.6

Fluid coking 0.65

Gas compression—Recip 0.9

Gas compression–Centrif 0.75

Hydrogen plant 0.55

Sulfur production 0.55

Steam generation 0.55

Utilities (general) 0.55

All other type of plants including tankage and off

sites generally may be taken as 0.6.

Appendix 17.1.8. An example of a process speciﬁcation

XYZ Reﬁnery Project

Process speciﬁcation for a thermal cracker

Number of units. One

Capacity. The unit shall have an input capacity of 34,500 barrels per stream day of a

residue from the atmospheric distillation of Kuwait crude oil.

Charge. The normal feedstock will be an atmospheric residuum boiling above 700

◦

F

TBP cut point on Kuwait crude.

Duty. The duty required from this unit will be to thermally crack the feedstock to

produce gas, naphtha distillate, gas oil, and fuel oil.

Yields. The unit shall be designed to make the required products in the following

relative proportions from the feedstock speciﬁed above. The process licensor shall

conﬁrm these proportions by pilot plant tests on samples of the feedstock provided

by the owner.

ECONOMICS 843

wt% on feed

Conversion to 340

◦

F TBP cut point 25.0

Products:

Gas to C

5

9.0

Naphtha distillate to 390

◦

F TBP cut point 20.3

Gas oil 390 to 622

◦

F cut points 24.7

Fuel oil + 622

◦

F cut point 46.0

Products

1.0 The gas shall include C

3

an C

4

’s and shall be routed to the crude unit overhead

distillate drum.

2.0 The overhead naphtha distillate product shall also be routed to the crude unit

overhead naphtha drum. The naphtha product shall have an ASTM distillation

end point of not more than 387

◦

F.

3.0 The gas oil side stream product shall have an ASTM 90 vol% distilled at a

temperature no higher than 645

◦

F.

4.0 The fuel oil as residue from the cracker primary tower shall have a minimum

Pensky Martin ﬂash point of 200

◦

F and shall be thermally stable.

Process conditions

1.0. Thermal cracker furnace

It is required that the furnace and transfer line be capable of effecting a crack of 25

wt% on feed of gas and naphtha to a TBP cut point of 340

◦

F. The transfer line outlet

temperature from the furnace shall not be higher than 920

◦

F at a pressure of 250 psig.

The injection of HP steam into the furnace coils may be considered to increase

turbulence and minimize the lay-down of coke. Should steam be used it’s volume under

the furnace conditions must be accounted for in the design of the furnace coil(s).The

temperature of the feed to the inlet of the furnace soaking section must be control-

lable.

2.0. The main fractionator

The feed to the fractionator from the furnace must be quenched to a suitable tempera-

ture to meet the residue cut point requirement. This temperature must also be sufﬁcient

to produce enough over ﬂash for proper fractionation between the distillate streams.

The column will be operated at a pressure in the overhead distillate drum of 50 psig.

Naphtha distillate stream shall be maximized and steam stripping of the gas oil side

stream should be considered in this respect. Fractionation criteria in terms of gaps

(and overlaps) between the distillate streams shall be:

844 CHAPTER 17

ASTM Dist 95% temp of naphtha and 5% temp of gas oil to be not less than +15

◦

F.

The residue leaving the bottom of the tower shall be steam stripped for ﬂash point

control. It shall also be quenched in the well of the tower to prevent further cracking.

A cold residue stream is recommended for this quench.

Appendix 17.1.9. An example of a process guarantee

XYZ Reﬁnery Project Contract 1234

The process performance guarantees are handled on an individual process unit basis

as set forth in subsequent sections of this exhibit. The utility guarantee covers all of

the process units associated with this contract and is lumped into an aggregate utility

cost as set forth in Section 4.0 of this exhibit.

Where licensed or proprietary processes not owned by contractor are involved or

proprietary catalysts are supplied by others, such as in the case of the thermal

cracker, naphtha hydrotreater, diesel hydro-treater, and catalytic reformer, contractor

offers only the guarantees set forth herein and identiﬁed as the responsibility of the

contractor. Any other guarantees shall be negotiable between Client and Licensors

and are not part of this exhibit.

3.0. Thermal cracker

3.1. Feed

The thermal cracking unit shall be designed to process 34,320 BPSD of Kuwait

reduced crude to produce gas to C

5

, gasoline, gas oil, and fuel oil as residue. The

feedstock shall be material boiling above 700

◦

F TBP cut point from an atmospheric

crude distillation unit. The feedstock shall be substantially in accordance with the

Kuwait assay titled “ASSAY of KUWAIT 31.2

◦

API CRUDE Dated xxxxx”and shall

have the following properties:

Gravity

◦

API 15.8

ASTM D—1,160

◦

F

IBP 650

5% 750

10% 775

20% 800

30% 850

Jones D.S.J., Pujado P.R. Handbook of Petroleum Processing

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