River Water Intake Unit Operating Manual - Karbala Refinery Project - PDF

OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT...

OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 1/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 PMC response to transmittal KRP-T- CH-EH-12211-PR OPERATING MANUAL FOR UNIT 60 – RIVER WATER INTAKE UNIT PMC REVIEW STATUS CODE CODE 1 : REJECTED CODE 2 : REVIEWED WITH COMMENTS CODE 3 : NO COMMENTS / APPROVED PROJECT : KARBALA REFINERY PROJECT Refer to: IONE-AA00-PE-PM-0005 for code LOCATION : KARBALA, IRAQ description EMPLOYER : STATE COMPANY FOR OIL PROJECTS (SCOP) Sharad Patil 2016.08.01 10:00:33 +01'00' A 15 JUL 16 ISSUE FOR REVIEW S.J.Kim S.J.Seong K.D.Ko J.B.Kim REV. DATE DESCRIPTION PRPD CHKD REVD APPRD CONFD Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering & Construction Co., Ltd., and Hyundai Engineering Co., Ltd., Note : a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 2/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 REVISION HISTORY Rev Date Description Page A 15 JUL 16 Initial issue. ALL General comment: 1. JV's checker and reviewer to review the document thoroughly before release for Employer review, since there are many typo errors in this document. 2. Please provide complete tag numbers including unit number for instruments like 60-LI-0003 not LI-0003. 3. English is very poor in this document and in places difficult to understand. Some sentences are not complete, use proper punctuations marks in the sentences. 4. Instructions provided in section 5,6, & 7,8 (Start-up, Normal operation and shutdown, emergency shutdown) are inadequate or not clearly written. Please revisit these sections 5,6 and 7. Since this is an operating manual meant for instructing operators for safe operation of unit. 5. Add section on 'Plant Safety' same as FEED operating manual section 6.0. 6. JV to include all agreed items from CRS of table of contents in operating manual like trouble shooting, operating adjustments, draining procedures, etc. 7. JV to attach all the reference documents latest revisions stated in section 10 of operating manual in next issue of this document. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 3/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 TABLE OF CONTENTS 1. INTRODUCTION................................................................................................................................................ 9 1.1. ACRONYMS AND ABBREVIATION............................................................................................................................................. 9 1.2. typo error PLANT DESCRIPTION............................................................................................................................................................... 11 1.3. UNIT DECRIPTION..................................................................................................................................................................... 13 2. PROCESS PRINCIPLES................................................................................................................................. 15 2.1. BASIS OF DESIGN..................................................................................................................................................................... 15 2.1.1. River Water..................................................................................................................................................................... 15 2.1.2. River Water Analysis................................................................................................................................................... 15 2.1.3. River Water Intake Package (60-PK-001)......................................................................................................... 15 2.1.4. River Water Basin (60-BA-001)............................................................................................................................. 15 2.1.5. River Water Lift Pumps.............................................................................................................................................. 16 2.1.6. Coarse Strainer Package (60-PK-002)............................................................................................................... 16 2.1.7. Hydrocyclone Package (60-PK-003)................................................................................................................... 16 2.1.8. Break Tanks.................................................................................................................................................................... 17 2.1.9. Raw Water Transfer Pumps.................................................................................................................................... 17 2.1.10. Sludge Basin (60-BA-002)....................................................................................................................................... 17 2.1.11. Sludge Pumps............................................................................................................................................................... 18 2.1.12. Sludge Thickener Package (60-PK-006 A/B)................................................................................................... 18 2.1.13. Thickened Sludge Pumps........................................................................................................................................ 18 2.1.14. Sludge Filterpress (60-PK-007)............................................................................................................................. 18 2.1.15. Sludge Storage System Package (60-PK-008)............................................................................................... 19 2.1.16. Recycled Water Basin (60-BA-003)..................................................................................................................... 19 2.1.17. Recycled Water Pumps............................................................................................................................................. 19 2.1.18. Air Compressors........................................................................................................................................................... 19 2.1.19. Plant Air Receiver........................................................................................................................................................ 19 2.1.20. Air Dryer Package........................................................................................................................................................ 20 2.1.21. Instrument Air Receiver............................................................................................................................................. 20 2.1.22. Sodium Hypochlorite Dosing Package (60-PK-009)..................................................................................... 20 2.1.23. Diesel Truck Unloading Pump................................................................................................................................ 20 2.1.24. Diesel Storage Vessel................................................................................................................................................ 20 2.1.25. Emergency Diesel Generation Package............................................................................................................ 21 2.1.26. Potable Water Tank..................................................................................................................................................... 21 2.1.27. Potable Water Pumps................................................................................................................................................ 21 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 4/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.2. FEEDSTOCK AND PRODUCT SPECIFICATIONS................................................................................................................... 21 2.2.1. Feedstock........................................................................................................................................................................ specification 21 2.2.2. Product............................................................................................................................................................................. 25 2.3. PROCESS T HEORY AND CHEMISTRY.................................................................................................................................... 25 2.4. BATTERY LIMIT CONDITIONS................................................................................................................................................. 25 2.5. SPECIFICATION OF CHEMICAL AND CATALYSTS............................................................................................................... 26 2.6. UTILITIES CONDITIONS............................................................................................................................................................ 26 2.7. EFFLUENT SUMMARY............................................................................................................................................................... 26 2.7.1. Gaseous effluent.......................................................................................................................................................... 27 2.7.2. Liquid effluent................................................................................................................................................................ 27 2.7.3. Solid effluent.................................................................................................................................................................. 27 3. PROCESS DESCRIPTION............................................................................................................................. 28 3.1. DESCRIPTION OF FLOW SEQUENCE.................................................................................................................................... 28 3.1.1. River Water Intake & Pre-treatment..................................................................................................................... 28 3.1.1.1. River Water Intake.................................................................................................................................................. 28 3.1.1.2. River Water Pre-treatment.................................................................................................................................. 28 3.1.2. Raw Water Storage and Distribution................................................................................................................... 29 3.1.3. Biocide Dosing System.............................................................................................................................................. 29 3.1.4. Sludge Treatment......................................................................................................................................................... 29 3.1.4.1. Sludge Thickening.................................................................................................................................................. 29 3.1.4.2. Filterpress.................................................................................................................................................................. 30 3.1.4.3. Sludge Storage and disposal............................................................................................................................. 30 3.1.5. Utilities.............................................................................................................................................................................. 30 3.1.5.1. Plant Air & Instrument Air..................................................................................................................................... 30 3.1.5.2. Potable Water (Drinking Water)........................................................................................................................ 31 3.1.5.3. Power........................................................................................................................................................................... 31 3.2. CONTROL PHILOSOPHY.......................................................................................................................................................... 31 3.2.1. River Water Storage and Distribution.................................................................................................................. 31 3.2.2. River Water filtration................................................................................................................................................... 32 3.2.3. Pump auto start philosophy..................................................................................................................................... 33 3.2.3.1. One duty (operating) and one stand-by pump........................................................................................... 33 3.3. PROCESS VARIABLES.............................................................................................................................................................. 34 4. COMMISSIONING........................................................................................................................................... 35 4.1. GENERAL..................................................................................................................................................................................... 35 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 5/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 4.2. EQUIPMENT AND UNIT INSPECTION...................................................................................................................................... 36 4.3. COMMISSIONING OF UTILITIES.............................................................................................................................................. 36 4.3.1. Air Compressor (60-K-001 A/B)............................................................................................................................. 36 4.3.2. Air Dryers Package (60-PK-005 A/B).................................................................................................................. 37 4.4. FLUSHING, BLOWING, AND CHEMICAL CLEANING OF PIPING...................................................................................... 37 4.4.1. Water Flushing.............................................................................................................................................................. 37 4.4.1.1. Cleaning River Water Basin (60-BA-001)..................................................................................................... 37 4.4.1.2. Flushing for potable water header................................................................................................................... 38 4.4.1.3. Flushing between 60-PK-006 (60-BA-004 A/B) and 60-PK-007......................................................... 38 4.4.2. Air Blowing...................................................................................................................................................................... 39 4.4.3. Chemical Cleaning...................................................................................................................................................... 39 4.4.4. Steam Blowing.............................................................................................................................................................. 39 4.5. T IGHTNESS T EST AND VACUUM T EST................................................................................................................................. 39 4.6. AIR FREEING.............................................................................................................................................................................. 39 4.7. DRY-OUT...................................................................................................................................................................................... 39 4.8. CATALYST & CHEMICAL LOADING........................................................................................................................................ 39 4.8.1. Packing............................................................................................................................................................................. 39 4.8.2. Catalyst Filling............................................................................................................................................................... 39 4.8.3. Loading of Chemicals................................................................................................................................................. 40 4.8.3.1. Loading of Hypocholorite (60-PK-009).......................................................................................................... 40 4.9. LOW PRESSURE LEAK T EST AND PURGING...................................................................................................................... 40 4.10. EMERGENCY DIESEL GENERATOR....................................................................................................................................... 40 5. START UP........................................................................................................................................................ 41 5.1. START-UP PREPARATION........................................................................................................................................................ 41 5.1.1. Preparatory inspection............................................................................................................................................... 41 5.1.2. P&ID check..................................................................................................................................................................... 42 5.1.3. Mechanical check........................................................................................................................................................ 42 5.1.3.1. Vessel.......................................................................................................................................................................... 42 5.1.3.2. Pumps.......................................................................................................................................................................... 44 5.1.3.3. Piping........................................................................................................................................................................... 44 5.1.4. Instrumentation check................................................................................................................................................ 45 5.1.5. Electrical installation check...................................................................................................................................... 48 5.1.6. Catalyst & Chemical inventory check.................................................................................................................. 48 5.1.6.1. Catalyst....................................................................................................................................................................... 48 5.1.6.2. Chemicals.................................................................................................................................................................. 49 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 6/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 5.1.7. Operability Check......................................................................................................................................................... 49 5.1.8. Establishing of Utility Services............................................................................................................................... 49 5.1.8.1. UTA (Utility Air)......................................................................................................................................................... 49 5.1.8.2. INA (Instrument Air)................................................................................................................................................ 49 5.1.8.3. PWA (Drinking Water)........................................................................................................................................... 49 5.2. START-UP SEQUENCE............................................................................................................................................................. 50 5.2.1. Initial Start-Up............................................................................................................................................................... 50 5.2.1.1. River Water Basin (60-BA-001)........................................................................................................................ 50 5.2.1.2. River Water Lift Pumps (60-P-001 A/B/C).................................................................................................... 50 5.2.1.3. Coarse Stariner Package (60-PK-002) & Hydrocyclone Package (60-PK-003).......................... 51 5.2.1.4. Break Tank (60-TK-001 A/B) & Raw Water Transfer Pumps (60-P-003 A/B/C)........................... 52 5.2.1.5. Sludge Basin (60-BA-002), Sludge Thickener Package (60-PK-006) & Sludge Pumps.......... 52 (60-P-005 A/B).............................................................................................................................................................................. 52 5.2.1.6. Recycled Water Basin (60-BA-003) & Recycled Water Pumps (60-P-007 A/B).......................... 53 5.2.1.7. Sludge Filterpress Package (60-PK-007)..................................................................................................... 53 5.2.1.8. Sludge Storage Package (60-PK-008).......................................................................................................... 54 5.2.1.9. Sodium Hypochlorite Dosing Package (60-PK-009)................................................................................ 54 5.2.2. Normal Start-Up........................................................................................................................................................... 54 The sequence of the normal start-up is as follows......................................................................................................... 54 5.3. ESTABLISH NORMAL CONDITION.......................................................................................................................................... 55 5.3.1. Break Tank (60-TK-001 A/B)................................................................................................................................... 55 5.3.2. Sludge Storage Package (60-PK-008)................................................................................................................ 55 5.3.3. Pig Launcher (60-Z-005).......................................................................................................................................... 55 6. NORMAL OPERATION................................................................................................................................... 58 6.1. OPERATING CONDITIONS........................................................................................................................................................ 58 6.2. ANALYTICAL............................................................................................................................................................................... 60 6.3. SAMPLING PROCEDURE.......................................................................................................................................................... 61 6.3.1. General............................................................................................................................................................................. 61 6.3.2. Reference drawings.................................................................................................................................................... 61 6.3.3. Sampling facility details........................................................................................................................................... 61 6.3.4. General precautions................................................................................................................................................... 62 6.3.5. Sampling procedures for various types............................................................................................................ 62 6.3.5.1. Sampling procedure for type 1....................................................................................................................... 62 6.3.5.2. Sampling procedure for type 6....................................................................................................................... 63 6.4. EQUIPMENT DATA..................................................................................................................................................................... 64 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 7/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 6.5. T ROUBLESHOOTING AND O PERATING ADJUSTMENT...................................................................................................... 66 6.5.1. Air Compressor (60-K-001 A/B)............................................................................................................................ 66 6.5.2. Coarse Strainer Package (60-PK-002) & Hydrocyclone Package (60-PK-003)................................ 67 6.5.3. Air Dryer Package (60-PK-005 A/B).................................................................................................................... 67 7. NORMAL SHUTDOWN................................................................................................................................... 68 7.1. NORMAL SHUTDOWN PROCEDURE...................................................................................................................................... 68 7.1.1. Sodium Hypochlorite Dosing Package (60-PK-009)..................................................................................... 68 7.1.2. River Water Lift Pumps (60-P-001 A/B/C)......................................................................................................... 68 7.1.3. Coarse Strainer Package (60-PK-002) & Hydrocyclone Package (60-PK-003)............................... 68 7.1.4. Sludge Pumps (60-P-005 A/B) & Sludge Basin (60-BA-002).................................................................... 68 7.1.5. Sludge Thickener Package (60-PK-006 A/B) & Thickened Sludge pumps (60-P-006 A/B)......... 68 7.1.6. Sludge Filterpress Package (60-PK-007) & Sludge Storage Package (60-PK-008)....................... 68 7.1.7. Break Tanks (60-TK-001A/B) & Raw Water Transfer Pumps (60-P-003A/B/C)................................ 69 7.1.8. Air Compressor (60-K-001 A/B)............................................................................................................................. 69 7.2. EQUIPMENT ISOLATION............................................................................................................................................................ 69 7.2.1. Safe guidelines for isolating equipment for inspection or repair.............................................................. 69 7.2.2. Lockout/Tagout.............................................................................................................................................................. 70 7.2.3. Blind list............................................................................................................................................................................ 70 7.2.4. Safe practices for entering and working in confined spaces..................................................................... 71 7.2.4.1. Standby attendant................................................................................................................................................. 71 7.2.4.2. Hazard assessment................................................................................................................................................ 72 7.2.4.3. Closing equipment................................................................................................................................................ 72 8. EMERGENCY SHUTDOWN........................................................................................................................... 73 8.1. EMERGENCY SHUTDOWN PHILOSOPHY.............................................................................................................................. 73 8.1.1. Unit emergency shutdown (Level-1).................................................................................................................... 73 8.1.2. Unit section emergency shutdown (Level-2).................................................................................................... 74 8.1.3. Equipment emergency shutdown (Level-3)...................................................................................................... 75 8.2. UTILITY FAILURE....................................................................................................................................................................... 76 8.2.1. Cooling water failure................................................................................................................................................... 76 8.2.2. Power failure.................................................................................................................................................................. 76 8.2.3. Instrument air failure................................................................................................................................................... 76 8.2.4. Fuel gas failure............................................................................................................................................................. 77 8.2.5. Steam failure.................................................................................................................................................................. 77 8.3. PROCESS FAILURE................................................................................................................................................................... 77 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 8/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 8.4. OTHER FAILURES...................................................................................................................................................................... 77 8.4.1. External fire.................................................................................................................................................................... 77 8.4.2. Hydrocarbon release.................................................................................................................................................. 79 9. SPECIAL PROCEDURE................................................................................................................................. 83 10. REFERENCE DOCUMENTS...................................................................................................................... 84 10.1. PROCESS FLOW DIAGRAMS.................................................................................................................................................. List all the drawings 84 10.2. PROCESS HEAT AND MATERIAL BALANCE........................................................................................................................ in one section like 85 10.3. '10.1 Drawings' and P&IDS.......................................................................................................................................................................................... 86 subsection for 10.4. MSDS.......................................................................................................................................................................................... 88 10.1.1 for PFD 10.5. UTILITY CONSUMPTION SUMMARY....................................................................................................................................... 10.1.2 p&id 89 10.6. EQUIPMENT LIST....................................................................................................................................................................... 10.1.3 MSD and so 90 10.7. CATALYST AND CHEMICALS CONSUMPTION SUMMARY................................................................................................. on 91 10.8. EFFLUENT SUMMARY............................................................................................................................................................... 92 10.9. LABORATORY T EST SCHEDULE............................................................................................................................................ 93 10.10. CAUSE AND EFFECTS DIAGRAMS................................................................................................................................... 94 10.11. RELIEF LOAD SUMMARY.................................................................................................................................................... 95 10.12. DCS GRAPHIC...................................................................................................................................................................... 96 10.13. VENDOR O PERATION MANUAL........................................................................................................................................ 97 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 9/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 1. INTRODUCTION This Operating Manual is meant only as guide and reference for the Personnel involved in the operation and maintenance of the Unit, which it is issued for. As such, this manual does not cover each and every step to be taken in the ordinary operation of the Unit. At it would not be really practical to cover all possible contingencies or emergencies in a document which only provides basic information, this manual can be no substitute for the Operator judgment. Some of the procedures and operating conditions given herein may require modifications to meet unusual or emergency conditions. It is, therefore, recommended that all Operating Personnel become intimately familiar with all details or Unit operation and with the functions of all operating equipment in order to be in a position to be able to operate the Unit safely and efficiently. List all the abbreviation used 1.1. Acronyms and Abbreviation in this document, BL Battery Limit their are many abbreviation BDV Depressurizing Valve (Blowdown Valve) missed in this list BPSD Barrel per Standard Day which are used in DCS Distributed Control System the document. DP Design Pressure P Differential Pressure DIH Deisohexanizer DT Design Temperature EDP Emergency Depressurization EIV Emergency Isolation Valve ESD Emergency Shutdown EOR End of Run HC Hydrocarbon HFO Heavy Fuel Oil HHLL High High Liquid Level HILL High Interface Liquid Level HLL High Liquid Level HP High Pressure HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 10/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 HS Hand Switch HVGO Heavy Vacuum Gas Oil IBP Initial Boiling Point L Low LG Level Gauge LL Liquid Level LLL Low Liquid Level LLLL Low Low Liquid Level LP Low Pressure LPG Liquified Petroleum Gas LVGO Light Vacuum Gas Oil MOV Motor Operated Valve NG Natural Gas NHT Naphtha Hydrotreating OP Operating Pressure OT Operating Temperature PFD Process Flow Diagram P&ID Piping & Instrument Diagram PG Pressure Gauge PLC Programmable Logic Controller PPM Parts Per Million PSV Pressure Safety Valve PVSV Pressure Vacuum Safety Valve ROV Remote Operated Valve TG Temperature Gauge TRV Thermal Relief Valve TSO Tight Shut-off HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 General for section 1.2. This section is mostly verbatim from the DOC. NO. : IONE-7A60-DO-PR-0001 ITB document. JV to ensure that the KARBALA REFINERY PROJECT Rev. A Page 11/97 information presented is up-to-date and Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 reflects the latest project information. 1.2. Plant Description Karbala Refinery is to design and build a grass root refinery that shall process 140,000 BPSD of crude. Crude slate comprises two Iraqi Crudes as Basrah regular crude oil and Mishrif crude oil. of Refinery production target is mainly transportation fuels for the Iraqi market. The production of heavy fuel oil is also foreseen and its primary outlet is the fuel oil pipeline to “Al-Khairat” power station. Other refinery products are paving and industrial bitumen and solid sulphur. The Karbala refinery configuration is comparable to a medium conversion scheme, based on VGO treatment and Fluid Catalytic Cracking (i.e. FCC) technologies with the objective to obtain a significant conversion of heavy materials into desulphurized gasoline and secondarily distillates. Refinery will foresee one single integrated distillation train for Crude & Vacuum able to process 140,000 BPSD with the flexibility to run the topping at reduced capacity even in case of Vacuum unit maintenance. The unstabilized naphtha is sent to the naphtha hydrotreater and subsequently to the naphtha stabilizer and naphtha splitter for separation into light-ends and light and heavy naphtha. Light-ends are sent to LPG and gas sweetening unit for LPG stabilization and separation into C3 and C4 fractions. Fuel gas and LPG sulphur specifications are achieved by amine treating. Gasoline octane level is obtained by the use of Continuous Catalytic Reforming and Isomerization with DIH. Olefinic LPG produced in the FCC gas concentration unit is sent to Polynaphtha unit for olefins polymerization into an Olefinic gasoline stream, partially hydrogenated. Thanks to the deep desulfurization achieved in the VGO HDT unit, the gasoline which exit from the FCC unit is at lower than 10 ppm sulphur, thus not requiring further treatments. Kerosene and middle distillates are sent separately in dedicated hydrodesulphurization unit to achieve the final product specifications. Vacuum Residue is partially used for bitumen production while the remainder portion is sent to fuel oil production by blending with LCO, Slurry and VGO diesel. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 12/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 Refinery will produce the following products: LPG - This list is not Regular Gasoline (RONC 90) complete. JV to Premium Gasoline (RONC 95) complete products list. Aviation Turbine Kerosene (ATK) - JV to confirm Kerosene sulphur wt% values Diesel (Sulphur 10 ppmwt) are accurate as per latest project Heavy Diesel (Sulphur 2.5 wt%) information Refinery Fuel Oil (Sulphur 0.2 wt%) - Products only Heavy Fuel Oil (Sulphur 5.5 wt%) produced in specific operating modes Sulphur should be identified also. Include The Refinery consists of the following main facilities: definition of modes. The Refinery facilities, comprising the crude processing facilities and the entire utility and off site system supporting Refinery operation; The Refinery Distribution Depot, which purpose is to receive Refinery products and dispatch them to pipeline system and truck loading facilities; Raw Water Intake Station at the river banks of the Euphrates River; Following main linear structures’ corridors comprising: - A raw water pipeline to supply the Refinery with its water demand extending around 33 km from the Euphrates River (at the Raw Water Intake Point); and - A treated water pipeline from Karbala Refinery to Euphrates River extending in parallel to the raw water pipeline. - A fuel oil pipeline to convey the heavy fuel oil to the Al-Khairat power station located east of the refinery and extending around 23 km. The Refinery facilities consist of the following units: Consider adding Crude and Vacuum Distillation Unit (CDU, VDU) Unit numbers against the listed Naphtha Hydrotreating Unit (NHT) items. Isomerization Unit (ISO) Continuous Catalytic Reforming Unit (CCR) Kerosene Hydrodesulphurization Unit (KHT) Diesel Hydrodesulphurization Unit (DHT) HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 13/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 VGO Hydrotreating Unit (VGO HDT) Fluid Catalytic Cracking Unit (FCC) Polynaphtha Unit (PNU) Asphalt Blowing Unit (ABU) LPG Production Unit (LPG) See general Hydrogen Production Unit (HPU) comment for Gas Sweetening and Amine Regeneration Unit (ARU) section 1.2 above. Sour Water Stripper Unit (SWS) JV must update this section to Sulphur Recovery Unit (SRU) and Tail Gas Treatment Unit (TGTU) reflect latest Utility systems, including Fire Water, Service Water, Drinking project Water, information Condensate Collection & Treatment, BFW & Steam Generation, Instrument & Plant Air, Nitrogen Generation, Caustic Soda & Sulphuric Acid, Refinery Fuels, Natural Gas Receiving & Metering Facilities, Raw Water Treatment, Power Generation Unit, Cooling Water Off Site systems, including crude, intermediate, component & final product storage and related pumping station and Blending facilities, Asphalt Loading, Sulphur Solidification and Bagging, Flare, Waste Water Treatment, Buildings, Main S/S Heavy Fuel Oil Pipeline to Al-Khairat power station Refinery Interconnecting Unit Distribution Depot Where is Unit 60? typo error ' 1.3. Unit Decription Description' The Purpose of the River Water Intake Unit (RWI) is to provide the Euphrates River Water to Karbala Refinery plant. The River Water Intake Unit (RWI) is located at approximately 33 km far from Karbala Refinery Plant. Unit 60 is composed of the following sections: River Water Intake and Pre-treatment. Sodium Hypochlorite Dosing System (for Biocide). Raw Water Storage and Distribution. Sludge Treatment. Utilities. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 14/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 Equipment of Unit 60 is as below: Equipment No. Equipment Description 60-BA-001 River Water Basin 60-BA-002 Sludge Basin 60-BA-003 Recycled Water Basin 60-BA-004 A/B Thickening Basins 60-K-001 A/B Air Compressors 60-P-001 A/B/C River Water Lift Pumps 60-P-003 A/B/C Raw Water Transfer Pumps 60-P-005 A/B Sludge Pumps 60-P-006 A/B Thickened Sludge Pumps 60-P-007 A/B Recycled Water Pumps 60-P-008 Diesel Truck Unloading Pump 60-P-010 A/B Potable Water Pumps 60-PK-001 River Water Intake Package 60-PK-002 Coarse Strainer Package 60-PK-003 Hydrocyclone Package 60-PK-005 A/B Air Dryers Package 60-PK-006 A/B Sludge Thickener Package 60-PK-007 Sludge Filterpress Package 60-PK-008 Sludge Storage Package 60-PK-009 Sodium Hypochlorite Dosing Package 60-PK-011 Emergency Diesel Generator Package 60-TK-001 A/B Break Tanks 60-TK-002 Potable Water Tank 60-V-001 Plant Air Receiver 60-V-002 Instrument Air Receiver 60-V-003 Diesel Storage Vessel 60-Z-003 A/B Sluice Gates 60-Z-004 A/B Sluice Gates 60-Z-005 Raw Water Pig Launcher HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 15/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2. PROCESS PRINCIPLES Provide reference 2.1. Basis of Design here for process design basis This design basis covers all the design concepts to be adopted for the River Water Intake document number Unit serving the Karbala Refinery. River water intake prepared is located during at Euphrates River at about 33 km far from Karbala Refinery. EPC stage. The River Water Intake Unit will be designed to supply all water required for the Refinery from Euphrates River. 2.1.1. River Water The design water demand from Euphrates River is 1,200 m3/hr. 2.1.2. River Water Analysis Euphrates River Water has the composition indicated in the following table Basic Design Data [IONE-AA00-SP-PR-0001]. 2.1.3. River Water Intake Package (60-PK-001) Four (4) intake screens, passive type, are provided. Three (3) are in normal operation, one is spare. Each intake screen is designed for 33% of river water basin design flow rate. 2.1.4. River Water Basin (60-BA-001) The sedimentation section is sized to insure 10 minutes hold-up to allow the settling of sand. The distance between the suction bay floor and the lowest point of pump suction is at least 300 mm. Minimum pumps submergence is no less than 1,500 mm above the bottom of suction pumps bay floor. The margin between minimum pumps submergence and the minimum water level in the suction bay is assumed equal to 1,900 mm. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A confirm Page 16/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 The centre line of the suction pipe at the inlet of the basin is assumed to be 700 mm above the minimum water level in the basin due to the pressure drop through the suction screen and pipe. The suction screens must be located at minimum distance of 800 mm from minimum Euphrates River level to the intake pipe centerline. The difference between the minimum and the maximum Euphrates River level is equal to 6,600 mm. The walls of the basin reach a height of 900 mm above the maximum level in the basin. 2.1.5. River Water Lift Pumps 3 X 50% vertical centrifugal pumps (60-P-001 A/B/C) are provided. Two (2) are in normal operation one is spare. Each pump is rated at 670 m3/hr. All pumps are electric motor driven. Two electric pumps motor will be supplied by emergency power back-up of Emergency Diesel Generator (60-PK-011). 2.1.6. Coarse Strainer Package (60-PK-002) 3 X 50% Coarse Strainers are provided. Two (2) are in normal operation one is spare. Each coarse strainer is rated at 670 m3/hr. Back-wash water flow rate is estimated as 6.0% of each coarse strainer capacity. Filtration degree: 350 microns Solid retention efficiency: 95%. Assumed back-wash water TSS concentration equal to 1,000 ppm. 2.1.7. Hydrocyclone Package (60-PK-003) 3 X 50% Hydrocyclone sets are provided. Two (2) are in normal operation one is spare. Each Hydrocyclone set is rated at 630 m3/hr. Underflow from each hydrocyclone set is estimated as 4.5% of each hydrocyclone capacity. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 17/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 Filtration degree: 15 microns. Solid retention efficiency for particles above 15 µm: 95%. Assumed underflow TSS concentration equal to 17,997 ppm. 80% reduction in suspended solids concentration in water inlet is expected. 2.1.8. Break Tanks Two (2) tanks (60-TK-001 A/B) operating in parallel in normal operation are provided. Each tank working volume is sized for 2 hours hold up at design feed rate of 1,200 m3/hr. Overall storage capacity is 4 hours. 2.1.9. Raw Water Transfer Pumps 3 X 50% horizontal centrifugal pumps (60-P-003 A/B/C) are provided. Two (2) are in normal operation one is spare. Each pump is rated at 600 m3/hr. All pumps are electric motor driven. Two electric pumps motor will be supplied by emergency power back-up of Emergency Diesel Generator (60-PK-011). 2.1.10. Sludge Basin (60-BA-002) The distance between the basin floor and the lowest point of pump suction is at least 300 mm. Minimum pumps submergence is no less than 800 mm above the bottom of basin floor. The basin will have the base sloping of 2% away from the pump compartment. The distance between LALL and LAL and between LAH and LAHH is equivalent to 10 minutes of sludge liquid flow rate at design rate (140 m3/hr). The walls of the basin reach a height of 800 mm above the maximum level. TSS concentration assumed in the liquid sludge is 8,020 ppm. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 18/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.1.11. Sludge Pumps 2 X 100% vertical centrifugal pumps (60-P-005 A/B) are provided. One (1) is in normal operation one is spare. Each pump is rated at 155 m3/hr (included 10% overdesign). Both pumps are electric motor driven. One electric pump motor will be supplied by emergency power back-up of Emergency Diesel Generator (60-PK-011). 2.1.12. Sludge Thickener Package (60-PK-006 A/B) 2 X 75% thickening basins (60-BA-004 A/B), circular type, are provided. Both basins are in normal operation. Each basin is rated at 105 m3/hr. TSS concentration assumed at inlet each basin is 8,020 ppm. TSS concentration expected after thickening is not lower than 50,000 ppm. Solid detention time assumed in each thickening basin is equal to 24 hrs. 2.1.13. Thickened Sludge Pumps 2 X 100% rotary pumps (60-P-006 A/B) are provided. One (1) is in normal operation one is spare. Each pump is rated at 120 m3/hr. Both pumps are electric motor driven. One electric pump motor will be supplied by emergency power back-up of Emergency Diesel Generator (60-PK-011). 2.1.14. Sludge Filterpress (60-PK-007) 2 X 75% filterpresses are provided. Both filterpresses are in normal operation. TSS concentration assumed at inlet each basin is 50,000 ppm. TSS concentration expected after thickening is not lower than 320,000 ppm. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 19/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.1.15. Sludge Storage System Package (60-PK-008) Two (2) storage silos are provided. One (1) is in normal operation one is spare. Each silo will have two days hold up capacity at design sludge cake rate of 70 m3/hr. 2.1.16. Recycled Water Basin (60-BA-003) The distance between the basin floor and the lowest point of pump suction is at least 300 mm. Minimum pumps submergence is no less than 800 mm above the bottom of basin floor. The basin will have the base sloping of 2% away from the pump compartment. The distance between LALL and LAL and between LAH and LAHH is equivalent to 10 minutes of sludge liquid flow rate at design rate (140 m3/hr). The walls of the basin reach a height of 800 mm above the maximum level. 2.1.17. Recycled Water Pumps 2 X 100% vertical centrifugal pumps (60-P-007 A/B) provided. One (1) is in normal operation one is spare. Each pump is rated at 155 m3/hr (included 10% overdesign). Both pumps are electric motor driven. One electric pump motor will be supplied with emergency power back-up an emergency diesel generator. (60-PK-011) 2.1.18. Air Compressors 2 X 100% reciprocating compressors (60-K-001 A/B) are provided. One (1) is in normal operation one is stand-by. Each compressor is rated at 225 Nm3/hr. Both compressors are electric motor driven. 2.1.19. Plant Air Receiver Plant air receiver (60-V-001) is sized for 5 minutes hold up at compressor design rate and at pressure decay from 8.8 to 5.3 kg/cm2 (g). HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 20/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.1.20. Air Dryer Package 2 X 100% air dryers (60-PK-005 A/B) are provided. One (1) is in normal operation one is stand-by. Each air dryer is rated at 125 Nm3/hr. 2.1.21. Instrument Air Receiver Instrument air receiver (60-V-002) is sized for 10 minute hold up at compressor normal rate of 100 Nm3/hr and at pressure decay from 8.2 to 4.7 kg/cm2 (g). 2.1.22. Sodium Hypochlorite Dosing Package (60-PK-009) Sodium Hypochlorite solution will be injected in the River Water Basin (60-BA-001) and in the Break Tanks (60-TK-001 A/B). Dosage rates are the following: SHOCK OR SHOT? - Normal continuous dosage: 3 ppm. - Shot peak dosage: 6 ppm for one hour. Sodium Hypochlorite solution concentration is 12 wt% minimum. Sodium hypochlorite solution daily normal consumption is about 1587.5 kg/day. Overall net storage capacity of dosing system shall be at least 7 days of continuous operation (9.5 m3 working volume). Sodium Hypochlorite solution is supposed to be supplied by truck. 2.1.23. Diesel Truck Unloading Pump One (1) rotary pump (60-P-008) is provided. Pump is rated at 17 m3/hr and is electric motor driven. 2.1.24. Diesel Storage Vessel One (1) tank (60-V-003) is provided. Two (2) days storage are provided. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 21/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.1.25. Emergency Diesel Generation Package Emergency Diesel Generation Package (60-PK-011) is provided to allow operation of River Water Intake Unit in case of power failure. The Emergency Diesel Generation Package will have the estimated capacity of 2,900 kVA. 2.1.26. Potable Water Tank One (1) tank (60-TK-002) is provided. Its working volume is sized for 40 m3. correct the tag number in design 2.1.27. Potable Water Pumps basis document IONE-7A60-SP- 2 X 100% horizontal centrifugal pumps (60-P-010 A/B) PR-001 page 9/13. are provided. One (1) is in normal operation one is stand-by. Each pump is rated at 6.8 m3/hr. All pumps are electric motor driven. One electric pump motor will be supplied by emergency power back-up of Emergency Diesel Generator (60-PK-011). 2.2. Feedstock and Product Specifications 2.2.1. Feedstock specification River Water. River Water Intake is located at Euphrates River at about 33 km far from Karbala Refinery. The water quality of the Euphrates River is indicated in section 3 of Basic Design Data [IONE-AA00-SP-PR-0001]. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 22/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 23/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 24/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 25/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.2.2. Product specification delete pre Raw Water. The screened river water is going to River Water Pre-treatment (Unit 30, located in Karbala Refinery), in which various particles (alluvial silt and organic extraction, etc.) are screened. 80% reduction in suspended solids concentration in water is expected. 2.3. Process Theory and Chemistry provide product specification in Not applicable for this unit. table same as stream 4 (raw water to unit 30)from the 2.4. Battery Limit Conditions HMB. Battery limit conditions for unit feeds and products are provided in following table. Opeating Operating Design Design Stream description Pressure Temperature Pressure Temperature kg/cm2g kg/cm2g Incoming Streams River Water (intake ATM AMB ATM AMB from Euphrates River) Outgoing Streams Screened River Water 12.2 35 16 80 to Refinery Describe about the list these in hypochlorite abbreviation list addition and its application, similar to section 2.3 operating manual of unit 34. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 26/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.5. Specification of Chemical and Catalysts The chemical specifications relevant to River Water Intake Unit are indicated in following table. For details, refer to attached document, Catalyst and Chemical Consumption Summary [IONE-7A60-CN-PR-0004]. Initial Consumption Item No. Service Chemical Type Remarks Charge Amount /yr 60-PK-009 Sodium Sodium 11.1 m3 524 ton/yr Hypochlorite Hypochlorite Dosing 12% solution Package in remarks, provide the dosage rates 2.6. Utilities Conditions normal and shot. Below table provides utility design information for the Karbala Project. For further information refer to Basic Design Data [IONE-AA00-SP-PR-0001]. Operating Condition Design Condition Service Pressure Temperature Pressure Temperature kg/cm2g kg/cm2g (min/nor/max) (min/nor/max) Instrument Air 8.2 (2) (3) AMB 12 93 Plant Air 8.8 (2) AMB 12 93 Potable Water 5 AMB 8 80 (1) (Drinking Water) Notes: (1) 65 for underground lines. (2) At users. 9 kg/cm2g at Source. (3) 4 kg/cm2g for actuator sizing. 2.7. Effluent Summary The effluent summary relevant to River Water Intake Unit is indicated in following tables. For details, refer to attached document, Effluent Summary for Unit 60 [IONE-7A60-CN-PR-0005]. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 27/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 2.7.1. Gaseous effluent Not applicable for this unit. 2.7.2. Liquid effluent Not applicable for this unit. 2.7.3. Solid effluent Equipment Disposal Service Fluid Remark No. Amount, /yr 60-PK-008 Sludge Storage Biological 25,550 m3/yr Intermittent. Package Sludge 70m3/day 60-PK-005 Air Dryers Package Dryer 40 kg/ 2yrs - Adsrobents HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 28/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 3. PROCESS DESCRIPTION provide reference document number 3.1. Description of Flow Sequence of process description document 3.1.1. River Water Intake & Pre-treatment prepared during 3.1.1.1. River Water Intake EPC stage. The river water is routed to River Water Basin by means of 4 independent suction screens as parts of 60-PK-001 and suction pipes. The suction pipes and their screens are located in the Euphrates River below the minimum river level. The river water flows by gravity to the River Water Basin (60-BA-001). The River Water Basin is divided into three sections: inlet section, sedimentation section Please update the and suction bay. process description as per FEED In the inlet section four intake pipes (two intake pipes per each channel) feeding the river operating manual 2342-AA60- water to the basin are installed. The Sedimentation section is sized to optimize settling of coarse TSS under river water MS-0000-50 section 2. Some useful design flow rate condition and be divided in two parallel channels. information is Four removable Sluice Gates (60-Z-003 A/B, 60-Z-004 A/B), two for each channel, isolate missing in this section,which isone channel in case of maintenance while the other one is working. provided in FEEDAir back flushing of each intake screen by means of compressed air is provided to remove operating manual. heavy built-up of silt and debris. River Water Lift Pumps (60-P-001 A/B/C) installed in a dedicated compartment of suction bay transfer river water to the pre-treatment packages. 3.1.1.2. River Water Pre-treatment Euphrates River is composed of very fine particles, of alluvial silt and organic extraction. The majority of solid particles that could potentially cause blockages within the hydrocyclone system are removed by Coarse Strainer Package (60-PK-002). Backwash is normally initiated on a timer basis but could be initiated by high differential pressure indicating a dirty element. River Water Lift Pumps (60-P-001 A/B/C) will continuously supply the river water to strainers for backwashing mode. The backwash is water will be continuously discharged to the Sludge Basin (60-BA-002). The very fine solid particles are removed by Hydrocyclone Package (60-PK-003). HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 29/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 The treated water is sent to Break Tanks (60-TK-001 A/B), and the separated and concentrated suspended solid is accumulated in the bottom conical chamber of 60-PK-003 and continuously discharged to the Sludge Basin (60-BA-002). 3.1.2. Raw Water Storage and Distribution The treated water coming from Hydrocyclones (60-PK-003) is stored in two Break Tanks (60-TK-001 A/B). Raw Water Transfer Pumps (60-P-003 A/B/C) pump the water through distribution pipeline to the River Water Storage Tanks (30-TK-009 A/B). In order to clear the built-up of solids settled in the pipeline, regular cleaning with soft pigging will be provided. For this purpose a Pig Launcher (60-Z-005) at River Water Intake Unit (Unit 60) and a Pig Receiver (30-Z-001) at Raw Water Treatment Unit (Unit 30) will be installed. is provide reference of vendor 3.1.3. Biocide Dosing System document section of process Continuous injection and batch dosing of biocide will be provideddescription for intake to in the river water more details. prevent and control the growth of bacterial slime which could plug both lines and equipment of the plant. The sodium hypochlorite solution from Sodium Hypochlorite Dosing Package (60-PK-009) will be injected to the River Water Basin (60-BA-001) and the Break Tanks (60-TK-001A/B). is 3.1.4. Sludge Treatment The sludge liquid from River water pre-treatment packages is de-watered to obtain a solid cake of desired proprieties for its handling, transport and disposal. typo error 3.1.4.1. Sludge Thickening The liquid sludge leaving the Coarse Strainer (60-PK-002) and Hydrocyclone package (60- PK-003) flows by free draining to the Sludge Basin (60-BA-002) and then is pumped to the sludge treatment section for its dewatering. The expected suspended solid concentration in the liquid sludge is 8,020 ppm. From the Sludge Basin (60-BA-002) the sludge is sent by the Sludge Pumps (60-P-005A/B) to the Sludge Thickener Package (60-PK-006 A/B) to obtain a suspended solid content not lower than 50,000 ppm. HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 30/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 The clarified water from Thickening Basin top is discharged in the Recycled Water Basin (60-BA-003) and recycled to the River Water Basin (60-BA-001) through the Recycled Water Pumps (60-P-007 A/B). 3.1.4.2. Filterpress The thickened sludge is extracted from the bottom of Sludge Thickening Basin (60-BA-004 A/B) by means of the Thickened Sludge Pumps (60-P-006 A/B) and sent to the Sludge Filterpress (60-PK-007) for further dewatering from 5% by wt. of TSS concentration to 32% by wt. minimum. The clarified water leaving the Filterpress (60-PK-007) is collected in the Recycled Water Basin (60-BA-003) and recycled to the River Water Basin (60-BA-001) through the Recycled Water Pumps (60-P-007 A/B). The clarified water flows by free draining to the Recycled Water Basin (60-BA-003). 3.1.4.3. Sludge Storage and disposal The dewatered sludge cake coming from Sludge Filterpress Package (60-PK-007) is sent to the Sludge Storage Package (60-PK-008). A sludge elevator and a sludge conveyor (included in the 60-PK-008) will route the sludge cake in the Sludge Storage Silos (included in the 60-PK-008). Two sludge storage silos will be installed and the stored sludge cake will be sent by truck to the final disposal. 3.1.5. Utilities The following separate utility facilities will be installed for River Water Intake Unit. 3.1.5.1. Plant Air & Instrument Air Instrument air necessary for River Water Intake facilities will be provided by Air Compressors (60-K-001 A/B). The compressed air will be cooled and sent to the Plant Air Receiver (60-V-001) which ensures moisture droplets separation and provided hold-up to the plant air network. The instrument air is produced by Air Dryers Package (60-PK-005 A/B) which is installed at HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 31/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50 the outlet of the Plant Air Receiver (60-V-001) and sent to the Instrument Air Receiver (60- V-002). From Instrument Air Receiver (60-V-002), it will be distributed to the instrument air network. 3.1.5.2. Potable Water (Drinking Water) Potable water will be imported from external suppliers by truck (i.e. Karbala Refinery or other sources). Potable water will be stored in a Potable Water Tank (60-TK-002) and distributed to buildings and to eye washer and safety shower if any, by means of Potable Water Pumps (60-P-010 A/B) Karbala Refinery is not fed by National Grid. Contractor to confirm specification of National Grid and if 3.1.5.3. Power not required delete it. River Water Intake facilities is normally fed from Karbala Refinery Network and National Grid. Emergency Diesel Generator Package (60-PK-011) will be provided to ensure availability of Raw Water to Karbala Refinery for commissioning / start-up operations and in case of power failure. A diesel oil is unloaded from the truck into the Diesel Storage Vessel (60-V-003) via Diesel Truck Unloading Pump (60-P-008), and then is sent by gravity to the day tank (included in the 60-PK-011) to generate the electric power for River Water Intake Unit. 3.2. Control Philosophy JV to update this Please provide section with the P&IDs numbers as latest information 3.2.1. River Water Storage andtoDistribution reference ease from the control reading. narrative document Level of Break Tanks (60-TK-001A/B) is controlled byincluding cascade level-flow employercontrol. Taking into comment, Slave Controller (60-FI-0004) is cascaded with Master Controlleropen (60-LIC-0004 or 60-LIC- consideration of CRS comments. control valve FO. 0013). And 60-HS-0005 is provided to select which level signal will be used for master this should be controller between 60-LIC-0004 and 60-LIC-0013. direct action. In case the Break Tanks (60-TK-001 A/B) level decreases thus process variable is under the set point of tanks level, 60-LIC-0004 or 60-LIC-0013 that are reverse action controllers will send LIC output signal to 60-FIC-0004 and it will be the remote set point of 60-FIC-0004. to reset the HDGSK JV Gran Seoul Tower 1, 33, Jong-ro, Jongno-gu, Seoul, Korea  OPERATING MANUAL OPERATING MANUAL FOR UNIT 60 DOC. NO. : IONE-7A60-DO-PR-0001 KARBALA REFINERY PROJECT Rev. A Page 32/97 Ref. FEED DOC. No. : 2342-AA60-MS-0000-50