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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

BASIS OF DESIGN

SECTION 1.0 PROJECT DESCRIPTION AND DESIGN PHILOSOPHY

Rev.

Date

Description

By

Checked

Approved Disc.

Fluor Daniel

Petrolera Ameriven

3

08-Dec-00

Bid Bulletin /Clarification Comments Incorporated

K. Jain

W. Lawrence

W. Lawrence

M. Castro

2

13 May 99

Approved for Design

C. Kernan

R. Bharvani

J. Mahoney

B. Tomlinson

D. McWilliams D. Meisel

1 0

1 Aug 98

Not Used Issued for Approval

J. Mahoney

R. Bharvani

B. Tomlinson

J. Zilli

D. McWilliams D. Meisel

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Page 1 of 22

Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

TABLE OF CONTENTS 1.0

PROJECT DESCRIPTION AND DESIGN PHILOSOPHY

4

1.1

Purpose

4

1.2

Hamaca Project Overview

4

1.2.1 Petrolera Ameriven Facilities

4

1.2.2 Petrolera Ameriven Upstream Facilities and Functions

4

1.2.3 Upgrader Overview

5

1.2.4

5

1.3

Jose Industrial Complex Condominium

Upgrader Process Description

5

1.3.1 Process Units

5

1.3.1.1 1.3.1.2 1.3.1.3 1.3.1.4

5 6 7 7

1.3.2

1.3.3

Crude Unit Delayed Coking Gas Plant Hydroprocessing

Process Support Units

8

1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5

8 8 8 9 9

Hydrogen Production Amine Regeneration Sour Water Stripping Sulfur Recovery and Tail Gas Treating (SRU & TGTU) Sulfur Prilling

Utilities 1.3.3.1 1.3.3.2 1.3.3.3 1.3.3.4 1.3.3.5 1.3.3.6 1.3.3.7 1.3.3.8

9 Fuel Gas Steam Demineralization Boiler Feed Water and Condensate Recovery Cooling Water Plant and Instrument Air Potable Service and Water Inert Gas

1.3.4 Offsite Facilities

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9 10 10 10 11 11 11 11 11

Page 2 of 22

Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.3.4.1 1.3.4.2 1.3.4.3 1.3.4.4 1.3.4.5 1.3.4.6 1.3.4.7

Tankage Flare Slop Oil System Flushing Oil System Waste Water Treatment Feed & Product Transfer Emergency Power Generation

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

11 12 12 12 12 13 13

1.4

Automation and Control Philosophy

13

1.5

Electrical Systems Design Philosophy

14

1.6

Fire Protection

15

1.7

Communications Philosophy

15

1.7.1

Telephone System

16

1.7.2

Radio System

16

1.7.3 Local Area Network (LAN)

16

1.8

Design Philosophy for Buildings, Shelters and Enclosures

16

1.9

Operating Philosophy

17

1.10

Environmental Considerations

19

1.11

Philosophy for Preinvestment for Expansion

20

1.12

Philosophy for Specifications

21

1.13

Philosophy for Economic Evaluation for Alternatives

21

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.0

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

PROJECT DESCRIPTION AND DESIGN PHILOSOPHY 1.1

Purpose The purpose of this document is to define basic project requirements and design philosophy for the Hamaca Crude Upgrader as a basis for development of individual unit and system designs.

1.2

Hamaca Project Overview 1.2.1 Petrolera Ameriven Facilities Petrolera Ameriven will produce extra heavy crude from the Hamaca Field of the Orinoco Heavy Oil Belt in eastern Venezuela. The project consists of four major components: •

Upstream Production Facilities in the Hamaca Oil Field

•

Pipeline to convey the heavy oil to the Upgrader,

•

Pipeline to convey diluent to the Hamaca Oil Field; and,

•

The Upgrader Facility in Jose

Attachment 1 shows the overall Petrolera Ameriven Hamaca Project. 1.2.2 Petrolera Ameriven Upstream Facilities and Functions The Hamaca Oil Field is located in the Orinoco Oil Belt, approximately 200 kilometers south of the Caribbean coast. The Hamaca Project extra heavy crude oil will be produced from the Tertiary Oficina formation of Block H and the northern portion of Block M. Multiphase pumps will be utilized to pump well output to a single flow station to separate gas from the produced oil and water. The heavy oil must be diluted with lighter hydrocarbons (heavy naphtha) to reduce its density and viscosity to allow pumping to the Upgrader. Gas will be compressed at the production station and sent to a central flow station for desulfurization and drying. Natural gas is sent to PDVSA Gas. The diluted oil mixture is pumped to the central station for dewatering and intermediate storage. The diluted oil will be pumped batchwise through the pipeline system shared with Cerro Negro to the Upgrader. Similarly, diluent naphtha will be pumped batchwise through the pipeline shared with Cerro

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Page 4 of 22

Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Negro back to the field. Two pipelines will be utilized: one for diluted crude and the second for diluent naphtha. Pumping, metering and pigging facilities will be included in the pipeline system. 1.2.3 Upgrader Overview The Hamaca Heavy Crude Upgrader will upgrade 8oAPI heavy crude oil to 25oAPI commercial by removing heavy carbon as coke and removing sulfur and nitrogen contaminants. The Upgrader will process a combined feed of 247,575 Barrels Per Stream Day (BPSD), comprised of 190,000 BPSD of heavy crude oil and 57,575 BPSD of diluent naphtha. Based on the expected “on-stream” factor of 0.93 (339.5 days per year), the Upgrader will process an average of 176,700 Barrels Per Calendar Day (BPCD) of heavy crude and will yield approximately 167,400 BPCD of commercial crude product. Diluent naphtha is recovered and returned to the production field for reuse. Feed and Product properties and specifications are shown in the individual unit Process Design Basis documents. Drawing 421300-00-A00500 Overall Plot Plan (attached) and drawings 421300-XX-AO-0500 (where “XX” is the unit number) Unit Plot Plans show the overall layouts of the upgrader. 1.2.4

Jose Industrial Complex Condominium Several other upgrading projects are being constructed in the same Jose Industrial Complex. Shipment of commercial crude, coke and sulfur will be by others. Petrolera Ameriven will be responsible for signing contracts to supply utilities such as natural gas, raw water and electricity. Drawing 421300-00-A0-5000 (attached) shows the arrangement of the Jose Industrial Complex.

1.3

Upgrader Process Description 1.3.1 Process Units Drawing 421300-00-A1-0001, Block Flow Diagram, shows the basic process configuration for the Upgrader. 1.3.1.1

Crude Unit The diluted crude will be desalted and heated prior to fractionation in atmospheric and vacuum towers. The Crude

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Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Unit (Unit 10) will separate the feed into the following product streams:

1.3.1.2

•

Diluent naphtha, which is routed to tankage and subsequently pumped back to the production field.

•

Combined Distillate (a mixture of atmospheric light and heavy distillates, light vacuum gas oil, and purge naphtha), which will be fed to the Light Oil Hydrotreater (Unit 14).

•

Heavy Vacuum Gas Oil (HVGO), which will be fed to the Gas Oil Hydrocracker (Unit 16).

•

Vacuum Residue, which will be fed to the Delayed Coking (Unit 12).

•

A blend of Vacuum Residue and Medium Vacuum Gas Oil, which will be combined with the Upgrader product Syncrude to produce Commercial Crude.

•

Medium Vacuum Gas Oil (MVGO), which will be routed to the Flushing Oil System. A major portion of the MVGO will be blended directly into commercial crude and the remainder will be utilized for equipment and line flushing.

Delayed Coking The Delayed Coking Unit (DCU, Unit 12) will be designed to process 62,000 BPSD of vacuum residue. The Delayed Coking Unit design will be based on Foster Wheeler’s Selective Yield Delayed Coking process. Feed to the Delayed Coking Unit will be heated and thermally cracked to produce the following product streams:

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•

Light Coker Gas Oil (LCGO) will be fed to the Light Oil Hydrotreater (Unit 14).

•

Heavy Coker Gas Oil (HCGO) will be fed to the Gas Oil Hydrocracker (Unit 16).

•

Naphtha and light ends will be further processed in the Gas Plant (Unit 18).

•

Approximately 4,040 short tons per day of coke will be removed and trucked to the bulk materials terminal (operated by PetroZuata) for sale and export.

Page 6 of 22

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.3.1.3

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Gas Plant The Gas Plant (Unit 18) will be designed to recover butanes and propanes from the net overhead gas and unstabilized naphtha produced in the Delayed Coking Unit (Unit 12). The C3-350oF coker naphtha stream produced in the Gas Plant (Unit 18) will be routed to the Light Oil Hydrotreater (Unit 14). The light ends (C1 – C3) will be amine treated and routed to the refinery fuel gas collection system. The design will include flexibility to control the quantity of C3’s in the C3-350oF Naphtha stream.

1.3.1.4

Hydroprocessing Hydroprocessing will remove sulfur and nitrogen from the naphtha, distillate and gas oil feed streams, and will improve the combustion properties of the distillate. Hydroprocessing will be comprised of three (3) units: Light Oil Hydrotreater (LOH, Unit 14) – The LOH will utilize UOP’s Unionfining hydrotreating process. The LOH will process 55,000 BPSD of combined distillates from the Crude Unit (Unit 10), LCGO from the Delayed Coking Unit (Unit 12), and coker naphtha and coker light ends from the Gas Plant (Unit 18). The objective of the LOH will be to maximize C5-680oF (full range naphtha, kerosene and diesel) production, while minimizing fuel gas production. Gas Oil Hydrocracker (GOH, Unit 16) – The GOH will utilize UOP’s Unicracker process. The GOH will process 60,000 BPSD of straight run heavy vacuum gas oil (HVGO) from the Crude Unit (Unit 10) and heavy coker gas oil (HCGO) from the Delayed Coking Unit (Unit 12). The objective of the GOH will be to maximize C5-680oF (full range naphtha, kerosene and diesel) production. The GOH will be designed for a net conversion of 40% of 680oF feed and will minimize fuel gas production. Hydroprocessing Support Unit (HSU, Unit 15) – The HSU will be a common unit supporting both the LOH and the GOH. It will be designed to process liquid products and flash gas from the relatively cold, low pressure flash drums of the LOH and the GOH. Products from the HSU will include commercial crude and make-up diluent naphtha. A portion of the heavy naphtha

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

produced in the unit will be used as make-up for crude diluent. The remaining naphtha will be blended into the commercial crude. In-line blending will be utilized for blending of vacuum residue and MVGO into commercial crude. Hydrogen for hydroprocessing will be provided from an on-site Hydrogen Production Unit (Unit 22). 1.3.2

Process Support Units 1.3.2.1

Hydrogen Production Hydrogen for hydroprocessing will be produced in a Hydrogen Production Unit (Unit 22), consisting of two parallel 85 MSCFD Steam Methane Reformers (SMR). The hydrogen rich stream from each SMR will be further processed by a Pressure Swing Adsorption (PSA) unit to obtain the required hydrogen purity. The PSA will also recover hydrogen from flash gases produced in the Hydroprocessing Units (Unit 15). In addition to producing hydrogen, the SMR’s will also produce high pressure superheated steam for process and utility use.

1.3.2.2

Amine Regeneration Various operations within the Upgrader produce hydrogen sulfide (H2S), which must be removed to comply with environmental regulations and process requirements. Amine treating will be used to remove the H2S. Amine absorbers will be located in the Hydroprocessing Units, Gas Plant and Tail Gas Treating Unit. The Amine Regeneration (Unit 24) will supply lean amine to all amine absorbers. Rich amine will be returned to the Amine Regeneration Unit for regeneration by stripping of the H2S.

1.3.2.3

Sour Water Stripping Sour water, water containing Hydrogen Sulfide (H2S) and Ammonia (NH3) will be produced in the Upgrader. H2S and NH3 must be stripped from the water to allow the water to be reused. Sour water will be segregated into two streams, phenolic and non-phenolic water (i.e. with or without phenols and cyanides) and processed in segregated stripping trains.

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Page 8 of 22

Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

The H2S/NH3 rich offgas will be fed to the Sulfur Recovery and Tail Gas Treating Unit. 1.3.2.4

Sulfur Recovery and Tail Gas Treating (SRU & TGTU) The Sulfur Recovery Unit (Unit 28) will be designed to process acid gas streams from the Amine Regeneration Unit (Unit 24) and the Sour Water Stripper (Unit 26). The Sulfur Recovery Unit utilizes a Claus Process provided by Stork Engineers & Contractors, with sulfur degassing technology licensed from SIOP. The Tail Gas Treating Unit (Unit 30) utilizes Shell’s SCOT process. Together, the SRU and TGTU will recover 99.9 wt% sulfur from the acid gas feed streams, incinerate all ammonia and oxidize any remaining sulfur compounds to sulfur dioxide before venting to atmosphere. The TGTU effluent SO2 will be a maximum 250 ppmv. The Sulfur Recovery Unit will utilize three parallel Claus reaction trains to recover 600 Long Tons Per Day (LTPD) of elemental sulfur. The TGTU will consist of one 100% capacity SCOT unit.

1.3.2.5

Sulfur Prilling Liquid Sulfur will be fed to a dry process Sulfur Prilling Unit (Unit 32), based on the Sandvik Rotoform Process or equivalent, to produce pastilles of solid sulfur. Sulfur will be solidified and trucked to the bulk materials terminal (operated by PetroZuata) for sale and export.

1.3.3 Utilities 1.3.3.1

Fuel Gas The Fuel Gas System will consist of the following subsystems: •

Refinery Gas collection and Fuel Gas distribution

•

Low Pressure Natural Gas distribution to the Sulfur Recovery Unit and for use as pilot gas for furnaces and flares

Refinery gas is produced in the Delayed Coking Unit (Unit 12) and the Hydroprocessing Units (Units 14/15/16). This gas will be amine-treated to reduce sulfur (H2S) content to below

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Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

160 ppmv. This refinery gas is blended with imported natural gas and is supplied to users within the Upgrader as fuel gas. Natural Gas will be supplied by Sevigas via high pressure pipeline. 1.3.3.2

Steam Steam will be produced for Upgrader process and utility use by process heat transfer and utility boilers. Three levels of steam will be produced for use in the Upgrader: •

Superheated High Pressure Steam (600 psig)

•

Saturated Medium Pressure Steam (150 psig)

•

Saturated Low Pressure Steam (50 psig)

The Utility Steam Generation and Distribution System (Unit 41) will be composed of two high pressure utility boilers and medium pressure and low pressure letdown stations. During normal operation, steam production will be mainly from the Hydrogen Production Unit (Unit 22), the Delayed Coking Unit (Unit 12), and the Sulfur Recovery Unit (Unit 28). The utility boilers will operate in hot standby mode. 1.3.3.3

Demineralization The Reverse Osmosis System (Unit 42) will be utilized to produce demineralized quality water as makeup for steam generation. The Reverse Osmosis (RO) System will be based on sodium zeolite softeners followed by RO membrance system.

1.3.3.4

Boiler Feed Water and Condensate Recovery The Condensate Recovery System will include collection of condensate and treatment of the recovered condensate for re-use in the Boiler Feed Water system. The recovered condensate will be combined with demineralized water and treated in a deaerator to produce Boiler Feed Water (BFW). The BFW System supplies boiler water to the process waste heat boilers. Both systems are contained in the Boiler Feed Water Deaeration and Condensate Recovery System (Unit 43).

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Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.3.3.5

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Cooling Water The Cooling Water System (Unit 47) will be a closed loop, recirculating water system designed to meet the cooling water requirements of all users. The system will consist of a counterflow, multi-cell cooling tower with an at-grade basin, multiple pumps, chemical addition systems, filters and distribution piping.

1.3.3.6

Plant and Instrument Air Plant and Instrument Air (Unit 46) will be used for maintenance operations, and for control signals and control valve actuation, respectively. Instrument air will be oil free and dried to dew point of -40 oF.

1.3.3.7

Potable Service and Water The Potable and Service Water System (Unit 44) will receive clarified raw water from the condominium. Clarified raw water will be filtered, chlorinated and stored for use as makeup water supply. Potable water will be supplied for use in sanitary facilities, safety showers and eyewash stations.

1.3.3.8

Inert Gas The Inert Gas System (Unit 48) will be leased to supply 99+% purity nitrogen. The system will store liquid nitrogen in an onsite cryogenic storage tank and will vaporize and distribute nitrogen to plant users.

1.3.4 Offsite Facilities 1.3.4.1

Tankage The Tank Farm (Unit 61) will provide tankage for Diluted Crude Feed, Intermediate Products and Commercial Crude Product. Tankage will support start-up, normal operations, and turneddown operation of the Upstream Facilities during Upgrader maintenance periods of up to 30 days.

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Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.3.4.2

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Flare In the Flare System (Unit 57), three separate flare systems will be utilized: two Hydrocarbon Flares (HP & LP flares) and one Acid Gas Flare. The Hydrocarbon Flares will be designed to handle the maximum flare relief load from the process high pressure and low pressure systems. The hydrocarbon flare will incorporate steam assist to produce smokeless operation. The LP and HP flare headers will have a crossover line to allow for upgrader operation at reduced throughput when one flare tip is undergoing maintenance. The Acid Gas Flare will be designed to dispose of acid gas relief from the Amine Regeneration Unit (Unit 24), Sour Water Stripper (Unit 26), Sulfur Recovery Unit (Unit 28), and Tail Gas Treating Unit (Unit 30).

1.3.4.3

Slop Oil System A Slop Oil System (Unit 63) will be provided to collect offgrade material and/or equipment and piping flushes. Two grades of Slop Oil will be considered: •

Light Slop Oil

•

Heavy Slop Oil

Oil and Water collected in the Slop Oil System will be separated and reprocessed separately. Oil will be transferred to either the Crude Unit (Unit 10) or the Delayed Coking Unit (Unit 12). Separated water will be treated in the Sour Water Stripper (Unit 26). 1.3.4.4

Flushing Oil System A Flushing Oil System (Unit 51) will provide flushing oil to high pour point hydrocarbons for piping, instruments and equipment. Medium Vacuum Gas Oil (MVGO) from tankage will be the source of Flushing Oil.

1.3.4.5

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Waste Water Treatment

Page 12 of 22

Basis of Design Section 1.0 Project Description and Design Philosophy

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Waste water will include process water as well as rainwater runoff that falls within the boundaries of the facility since it may accidentally become contaminated. A Waste Water Treatment System (Unit 65) will be designed to treat three classifications of waste water:

1.3.4.6

•

Accidentally Oily Sewer (AOS) System

•

Oily Water Sewer (OWS) System

•

High Biochemical Oxygen Demand System

Feed & Product Transfer All process and utility materials entering or leaving the Upgrader whose custody is transferred to or from an entity outside the Upgrader, either the Condominium or Petrolera Ameriven Upstream, will be metered in the Feed and Product Transfer (Unit 90). If the value of a material depends on its composition or quality, then the composition/quality will also be measured. Examples of products to be measured are diluted crude from Upstream, returned naphtha to Upstream, Commercial Crude, utilities (natural gas, water, electricity, etc) from the Condominium. Coke and sulfur products will be weighed.

1.3.4.7

Emergency Power Generation An Emergency Power Generation System (Unit 62) will provide emergency electrical power to critical loads throughout the Upgrader.

1.4

Automation and Control Philosophy The operation of the Hamaca Crude Upgrader shall be automated to the maximum economic extent possible. A Distributed Control System (DCS) shall be provided to automate unit operations. This DCS shall be the central point of monitoring and controlling the plant operation. The DCS may be augmented by other systems such as Programmable Logic Controllers (PLC). All process variables significant for safe, stable and efficient operation of the plant shall be controlled and monitored. For efficient monitoring and controls, the DCS System is divided into Operating Blocks, as follows: •

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Crude Unit/Shipping and Receiving

Page 13 of 22

PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

•

Delayed Coking/Gas Plant

•

Hydroprocessing

•

Sulfur Block

•

Utilities

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

For each Operating Block, at least one operator will be stationed in the Central Control Room (CCR) at all times and at least one operator will be stationed in the operating area (field). The CCR operator(s) and the field operator(s) will constantly communicate with each other through radio. The CCR operator(s) will be key personnel. The CCR operator(s) will direct the field operator(s) to check field equipment and instruments on an as needed basis. The field operator(s) will have access to a DCS screen in the Field Information Centers (FIC) located in the operating unit. The field operators may be involved in non-control related activities as well. During normal operation, the process units will be monitored and controlled from the CCR. Operator intervention shall be planned only where a discretionary decision is required, or where operator action is designed as part of a safe operating procedure. During start-up, shutdown and major transitions, the process units will be monitored and controlled jointly from the field and the CCR. Unit start-ups and shut-downs need not be fully automated. Generally, “state-of-the-art” control technologies shall be used. “State-of-the-art” technologies include technologies that have been in commercial operation for at least one (1) year. “State-of-the-art” technologies with less commercial operating experience must be approved by Petrolera Ameriven. 1.5

Electrical Systems Design Philosophy The Upgrader will receive electrical power from a reliable source through the JIC Condominium. The primary source of electrical power shall consist of two (2) 115kV circuits derived from the EDELCA Jose substation and routed to the site 115kV substation located in the Upgrader. Two (2) 100% rated transformers will step the voltage down to 34.5kV, which is the primary power distribution voltage for the major plant substations. Major substations shall be located optimally to serve designated area loads via substation transformers (34.5kV / 13.8kV) and 13.8kV feeders. The 13.8kV feeders will supply power to the process and non-process electrical substations, which shall contain suitably rated switchgear. The switchgear shall be secondary selective, with appropriate system protection.

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Generally, power distribution systems shall be by means of underground cables installed in conduits, or buried directly. Motor Control Centers (MCC’s) shall be the secondary power distribution centers for most plant motors and static electrical loads. MCC architecture shall be standardized and the operation of each MCC will be on-line supervised. The electrical design of switchgear, MCC’s, substations and distribution systems shall be supported by short circuit studies, load flow studies, voltage drop calculations, and motor start-up studies. Plant electrical system components such as transformers, cables, MCC, etc, will be sized based on plant load assessment and electricity consumption (load) list. Total electrical loads for each distribution center will be prepared. Lightning protection shall be provided by means of appropriate lightning arrestors grounded to the plant grounding system. See SP-421300-60-1 for additional guidelines. 1.6

Fire Protection The Fire Protection System (Unit 67) will minimize the likelihood, spread and duration of a fire, minimize damage to equipment and facilities, and minimize injury or death of personnel in the event of a fire. The fire protection system will consist primarily of the following systems:

1.7

•

Fire Detection and Alarm

•

Flammable Gas Detection and Alarm

•

Toxic Gas Detection and Alarm

•

Passive Fire Protection

•

Emergency Control

•

Firewater Reservoir, Pumps and Distribution System

•

Fire fighting foam, spray systems and other miscellaneous items such as steam, dry chemical, CO2 and mobile fire fighting equipment.

•

Fire Protection for Buildings

•

Fire Station Equipment

•

Fire Fighting Training Ground

Communications Philosophy

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.7.1

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Telephone System The Upgrader shall be equipped with a complete telephone system to support facility operations. The telephone system shall be compatible with Venezuelan and international standards.

1.7.2 Radio System The Upgrader shall be equipped with a radio system with twelve (12) frequencies to support all operations and maintenance functions. 1.7.3 Local Area Network (LAN) Offices within the Upgrader will have personal computers connected through a Local Area Network (LAN). 1.8

Design Philosophy for Buildings, Shelters and Enclosures The Hamaca Crude Upgrader will include the following major buildings to meet the requirements of the complex and Venezuelan laws, regulations and customs: •

Laboratory

•

Warehouse

•

Administration Building

•

Change House Building

•

Workshop

•

Fire Station

•

Guard Station

•

Plant Entrance and Security Station

•

Truck Staging & Automotive Shop

•

Wash Station & Fueling Station

•

Cafeteria

•

Catalyst Storage Building

•

Electrical Main Sub-Station

•

Electrical Sub-Station 10B/12/13/13B

•

Electrical Sub-Station 10C/11/12B/12C/14

•

Central Control Building

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

•

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Field Information Centers

All buildings, shelters and enclosures shall be one or two story structures provided with utilities such as air conditioning, ventilation, chilled water, sanitary water collection, electrical systems, telecommunications, potable water, etc, based on the specific needs of each building. Air filtration and pressurization systems shall be provided for occupied buildings in classified areas. Fire alarm, fire detection and fire fighting equipment shall also be provided where required. Buildings will be designed keeping locally available construction materials and techniques in mind. 1.9

Operating Philosophy The Petrolera Ameriven Upgrader will be designed to process a single feed (Naphtha Diluted Hamaca Crude) and will produce a single product (Commercial Crude) and two byproducts: coke and sulfur. The facility will be operated in a safe, environmentally responsible, and reliable manner under established conditions. An extended shutdown of the Crude Unit or Delayed Coker will generally result in unacceptable product quality, precipitating a total plant shutdown or result in internal unit circulation. The loss of either the Light Oil Hydrotreater or the Gas Oil Hydrocracker will result in a 50% turndown. The overall Upgrader design considers the scheduled and unscheduled loss or maximum turndown rate of any single operating unit. The Hydroprocessing Units will be designed for a catalyst run length of two years. The Delayed Coking Unit heaters will practice on-line spalling quarterly, and steam/air decoking, as appropriate, annually. The Upgrader design will include biannual shutdown for inspection, maintenance and test. On-stream design factor will be set at 93%, including scheduled, each four years, a total plant shutdown (30 days) and unscheduled outages (11 days annually). Daily maintenance activities will be based on a “Reliability Based Maintenance” philosophy, which is focused on prevention of failure, rather than correction. This maintenance philosophy is a combination of Predictive Maintenance and Preventive Maintenance techniques. To avoid major rotating equipment failures, the Technical and Operating Groups will co-develop startup, shutdown and equipment monitored procedures. On-line vibration monitoring devices will automatically shutdown equipment if a fault is detected. On-line hydrocarbon leak detection and heat sensitive detectors will automatically activate deluge systems to prevent fires. A comprehensive, on-line, corrosion monitoring system will be developed by the Technical Services Department, which will determine the points to be monitored, and supervise the monitoring of critical points in the process to predict failure and replacement, avoiding failure.

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

The Upgrader shall be designed to operate for four-year intervals between the total plant turnarounds. The shutdown, maintenance and startup activities will be accomplished in thirty days and will involve equipment cleaning, catalyst replacement and other maintenance work that cannot be accomplished with the units operating. The annual plant capacity allows for up to eleven (11) days per year of unscheduled shutdowns. Significant maintenance activities will be accomplished while the units are in operation. This work will be maximized to insure the scope of the biannual shutdown is minimized. Biannual scheduled down periods for maintenance on some equipment (Hydroprocessing) is anticipated. Facilities shall be designed to support a maximum thirty (30) day turnaround time (stream to stream) with the following unit outage duration and frequency: Crude Unit •

Inspection, maintenance and testing – thirty (30) days stream to stream at four-year intervals during the total plant shutdown period.

Coker •

On-line Spalling six (6) days at 87.5% design capacity quarterly.

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Heater Decoking ten (10) days at 60% design capacity annually.

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Inspection, maintenance and testing – thirty (30) days stream to stream at four-year intervals during the total plant shutdown period.

Light Oil Hydrotreater •

Biannual 15 day outage for catalyst change and cleanup.

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Inspection, maintenance and testing – twenty (20) days stream to stream at four-year intervals. To reduce the level of activity during the major four-year outage, inspection, maintenance and testing will be performed outside of the total plant turnaround period; the fifteen (15) day catalyst change will be included in this down period.

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Gas Oil Hydrocracker •

Biannual twenty-two (22) day outage for catalyst change and cleanup.

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Inspection, maintenance and testing – thirty (30) days stream to stream at four-year intervals; during the total plant shutdown period, the twenty-two (22) day catalyst change will be included in this down period.

Sulfur Recovery Units, Utility Boilers, and Sour Water Strippers •

To reduce the level of activity during the major four-year outage, inspection, maintenance and testing will be performed outside of the total plant turnaround period. These will generally coincide with an LOH or GOH catalyst change, coker heater spalling, and SRU turnaround.

Hydrogen Production Unit •

The two trains comprising this unit will undergo inspection, maintenance and testing outside of the total plant turnaround period whenever possible (on a scheduled basis, more extensive work for furnace tube replacement will be scheduled during the total plant shutdown). This turnaround will coincide with an LOH or GOH turnaround.

The design shall seek to achieve a plant with a minimum of 93% availability; i.e., on-stream factor of 0.93 (minimum) in the initial phase of operation. 1.10

Environmental Considerations The Hamaca Crude Upgrader will incorporate an environmentally responsible design, and must be able to be build with minimal environmental impacts and in such a manner that preserves the natural characteristics and environmental features of the Jose area. The Upgrader will comply with all applicable Venezuelan federal and local environmental, health and safety regulations. The Upgrader will minimize emissions and discharges. The project will incorporate any additional environmental controls identified as necessary and required during the project environmental permitting process. The Upgrader will incorporate the following environmental control features: •

Fired heaters and boilers shall utilize refinery fuel gas containing less than 160 ppmv sulfur compounds; no fuel oil firing will be employed.

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Sulfur Recovery Units with Tail Gas Treating shall be installed to treat acid gas and minimize sulfur emissions.

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.11

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

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Low Nox burners will be utilized to minimize emission of nitrogen oxides.

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Wet Systems will be employed to handle petroleum coke and thereby minimize fugitive particulate emissions.

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Hydrocarbon storage tanks will be equipped with vacuum/pressure conservation vents, floating roofs or carbon canister to control emissions of volatile organic compounds (VOC’s).

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On-Site waste water treating consisting of CPI separators, dissolved air flotation, and biological treatment will be used to produce an effluent stream meeting applicable standards for ocean discharge.

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Rainfall runoff will be drained to a segregated waste water collection system for treatment prior to discharge.

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Sour water streams will be stripped and reused to the maximum extent possible.

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Recyclable / reclaimable catalysts will be used where practical.

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Equipment noise abatement and attenuation systems will be utilized as required to comply with occupational noise exposure limits.

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Flares will use steam for “smokeless” operation.

Philosophy for Preinvestment for Expansion The Hamaca Crude Upgrader will be designed to process 190,000 BPSD. Ultimately, however, Petrolera Ameriven intends to expand the facility to process 210,000 BPSD. In general, the design of the Upgrader will allow only for the processing of 190,000 BPSD. The design of certain systems or components, where the cost of debottlenecking or replacement is prohibitive, will be based on the ultimate 210,000 BPSD capacity. Systems or components designed for the expanded 210,000 BPSD include: •

Delayed Coking Unit - Coke drum will be designed for 29 ft. diameter.

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Hydrogen Production - Natural Gas Compressor will be designed to handle 125% of required capacity.

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Cooling Water System - The Cooling Tower Basin will be sized to handle 125% of required capacity.

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Interconnecting - Most process and utility lines on the Interconnecting Piperack will be sized for 110% of required capacity.

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General - Steam, condensate, BFW, and cooling water subheaders within the unit/area will be sized for 110% of required capacity.

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PETROLERA AMERIVEN S.A. Hamaca Crude Upgrader Project, Downstream Jose, Venezuela

1.12

Basis of Design Section 1.0 Project Description and Design Philosophy

Grupo Alvica Contract No. 04477000 Rev. 3, 08 Dec 00

Philosophy for Specifications During basic engineering the Texaco General Equipment and Material Specifications (GEMS) were selected as the basis for Upgrader (and Upstream) specifications. Those general specifications have been modified by Petrolera Ameriven and its contractors as deemed appropriate to incorporate site-specific requirements, recent industry developments, and potential value enhancements.

1.13

Philosophy for Economic Evaluation for Alternatives •

Economic evaluations shall consider life cycle costs.

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Changes to original scope will be considered if (1) they have a simple payout of two years or less, or (2) they have at least a return on investment of at least 15% considering a 10% discount rate and 34% taxes.

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