96326047 process-description-og-lpg-train-4

PROCESS DESIGN BASIS
Doc No. : S090768.231-3.00-005-A-E
Job No. : 090768
Rev. B Page 1 of 42
LPG Train-4 Project at MAA Refinery
Contract CA/CSPD/0009
LPG Train-4 Project
at
MAA Refinery
Contract CA/CSPD/0009
(S090768.231-3.00-004-A-E)
B 26-Oct-11 Revised as Marked J.M.Jung J.M.Mun G.P.Moon S.K.KIM
A 16-Aug-10 Issue For Approval G.P.Moon S.M.Choi B.J.Yi S.K.KIM
REV. DATE DESCRIPTION ORIGINAL/
REVISED BY
CHECKED
BY
CHECKED
BY
APPROVED
BY

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
Rev. B Page 2 of 42
INDEX
1. GENERAL............................................................................................................................................6
1.1 Plant Facilities ..........................................................................................................................7
2. OVERALL DESIGN BASIS...................................................................................................................9
2.1 Design Throughput...................................................................................................................9
2.2 Feed Stream Condition and Composition ...............................................................................9
2.2.1 Feed Gas Condition and Composition .........................................................................9
2.2.2 Condensate Feed Condition and Composition.......................................................... 11
2.2.3 LPG Feed Compositions .............................................................................................13
2.2.4 Exceptional Operation.................................................................................................15
2.3 Product Specifications...........................................................................................................15
2.3.1 Ethane / Propane / Butane Recovery..........................................................................15
2.3.2 Residue Gas Specification..........................................................................................15
2.3.3 Ethane Product Specification .....................................................................................16
2.3.4 Propane Product Specification...................................................................................17
2.3.5 Butane Product Specification .....................................................................................18
2.3.6 Kuwait Natural Gasoline Product Specification.........................................................18
2.3.7 Fuel Gas Specification ................................................................................................18
2.4 Battery Limit Conditions ........................................................................................................19
2.4.1 Battery Limits Conditions for Feed Gas .....................................................................19
2.4.2 Battery Limits Conditions for Condensate Feed........................................................19
2.4.3 Battery Limits Conditions for LPG Feed.....................................................................20
2.4.4 Battery Limit Condition for Product ...........................................................................20
2.4.5 Battery Limits Conditions for Propane Refrigerant System ......................................21
2.4.6 Battery Limits Conditions for Deep Refrigerant System ...........................................21
2.5 Design Consideration.............................................................................................................22
2.5.1 Plant Design Life .........................................................................................................22
2.5.2 Plant Availability..........................................................................................................22
2.5.3 Effluent Treatment.......................................................................................................22
2.5.4 Physical Properties .....................................................................................................22
2.5.5 Remote/Emergency Depressurization........................................................................22

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2.5.6 Pressure Relief System and HIPPS ............................................................................22
2.5.7 Source and Compressing of Regeneration Gas.........................................................23
3. DESIGN BASIS FOR FEED PRETREATMENT UNIT(UNIT 231)........................................................24
3.1 DESIGN BASIS FOR FEED GAS COMPRESSION..................................................................24
3.1.1 Feed Gas Compressor ................................................................................................24
3.1.2 Product specifications ................................................................................................24
3.1.3 Water Content..............................................................................................................24
3.1.4 Feed Gas Specification for Mercury Guard Bed.........................................................24
3.1.5 Product specifications for Mercury Guard Bed..........................................................25
3.2 SPECIFICATION FOR CONDENSATE AND LPG DEHYDRATION ..........................................25
3.2.1 Product specifications for condensate dehydration..................................................25
3.2.2 Product Specifications for LPG dehydration .............................................................25
3.3 GDESIGN BASIS FOR HP FUEL GAS CONDITION ..............................................................25
3.3.1 System Capacity..........................................................................................................25
3.3.2 HP Fuel Gas Specification .........................................................................................26
3.4 GENERAL DESIGN CONSIDERATION....................................................................................25
3.4.1 Feed Gas Compressor ................................................................................................25
3.4.2 Feed Gas Dehydrator, Condensate and LPG Dehydrator..........................................26
3.4.3 Feed Gas Compressor Discharge Air Cooler .............................................................26
3.4.4 Gas Filters....................................................................................................................27
3.4.5 Mercury guard bed ......................................................................................................27
3.4.6 Regeneration Gas Heater............................................................................................27
3.4.7 Dryer Regeneration Compressor................................................................................27
3.4.8 Feed Gas Compressor Suction Drum .......................................................................28
3.4.9 HP Fuel Gas / Gas Exchanger.....................................................................................28
3.4.10 HP Fuel Gas Chiller .....................................................................................................28
3.4.11 HP Fuel Gas KO Drum.................................................................................................28
3.4.12 HP Fuel Gas KO Drum Pump .....................................................................................28
4. DESIGN BASIS FOR NGL RECOVERY AND CONDENSATE STRIPPING UNIT(UNIT 232) .............29
4.1 DESIGN BASIS FOR NGL RECOVERY SECTION...................................................................29
4.1.2 Equipment Design Consideration...............................................................................29

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4.2 DESIGN BASIS FOR CONDENSATE STRIPPING SECTION ..................................................31
5. DESIGN BASIS FOR NGL FRACTIONATION UNIT(UNIT 233)..........................................................32
5.1 DESIGN BASIS........................................................................................................................32
5.1.2 Recovery and purity ....................................................................................................32
5.1.3 Battery limits conditions.............................................................................................32
5.1.4 Equipment design consideration................................................................................32
6. DESIGN BASIS FOR PRODUCT TREATING (UNIT 234)...................................................................34
6.1 C3 TREATING..........................................................................................................................34
6.1.1 Feed Specification.......................................................................................................34
6.1.2 Product Specification..................................................................................................34
6.2 C4 TREATING..........................................................................................................................34
6.2.1 Feed Specification.......................................................................................................34
6.3.1 Equipment design requirements ................................................................................34
7. DESIGN BASIS FOR REFRIGERATION UNIT(UNIT 235)..................................................................36
7.1 DESIGN BASIS FOR PROPANE REFRIGERANT FACILITY...................................................36
7.1.1 Feedstock Characteristics and Capacity....................................................................36
7.1.2 Equipment Design Requirements...............................................................................36
7.1.4 Propane and Deep Refrigerant Accumulator Pressure..............................................38
7.2 DESIGN BASIS FOR DEEP REFRIGERANT FACILITY ..........................................................38
7.2.1 Feedstock Characteristics and Capacity....................................................................38
7.2.2 Equipment Design Requirements...............................................................................38
7.2.4 Deep Refrigerant Accumulator Pressure....................................................................39

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8. DESIGN BASIS FOR SOUR WATER STRIPPER (UNIT 236).............................................................40
8.1 DESIGN BASIS........................................................................................................................40
8.1.1 Design capacity...........................................................................................................40
8.1.2 Feed Condition and Compositions.............................................................................40
8.1.4 Battery Limits Conditions for Sour Water Stripping Unit ..........................................41
8.2.1 Equipment design requirements ................................................................................41

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1. GENERAL
Feed Gas supplied to LPG Train-4 (LPG 4) facilities consist of mixture of Associated Gas
and Condensate from the KOC Gathering Centers Southeast Kuwait (SEK) and North
Kuwait (NK) oilfields. In addition, existing KNPC Refinery Gases from the Shuaiba (SHU)
AGRP and the Mina Al-Ahmadi (MAA) AGRP are supplied to the Fourth Gas Plant facilities.
Future Non-associated Gas from the Dorra Gas field is considered in the design cases.
The range of the Feed Gas composition is covered by the six defined design cases, which
govern the design of Liquefaction and Fractionation Sections. And JT valve operation case
of Winter Without Dorra feed is also considered in design. These cases are presented in the
Design Basis and summarized below:
1. Summer Case Without Dorra
2. Summer Case With Dorra
3. Winter Case Without Dorra
4. Winter Case With Dorra
5. Rich Case
6. Lean Case
7. JT Valve Operation Case
A separate design Feed quality has been defined to represent the maximum content of 2.5
mol% CO2 and 2000 ppm H2S (2400 ppm for metallurgical purpose).
To support the operations of the LPG Train-4, C3 Refrigeration and general Utility Facilities
are provided. These facilities consist of Fuel Gas System, Heat Recovery Steam Generation
System, Sea Water System, Closed Cooling Water System, Nitrogen Generation System,
Instrument and Plant Air Systems, Water Treatment and Distribution Systems, Pressure
Relief and Flare, Liquid Disposal Systems, Fire Fighting System, Effluent Treating, and HP
Fuel Gas Conditioning etc.
The design of the NGL section is based on the GSP (Gas Sub-cooled Process), which is a
Turbo Expander, based cryogenic technology. The GSP (Gas Sub-cooled Process) was
selected among 4 candidate processes, which are two open-art and two licensed processes,
i.e. GSP (Gas Sub-cooled Process, Open Art), OHR (Over Head Recycle, Open Art), SFR

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(Split Flow Reflux, Licensed by Ortloff), and the CRR (Cold Residue Recycle, Licensed by
Ortloff) during the development of the Feasibility Study by Fluor Daniel.
This plant capacity is designed to process 805 MMSCFD of Feed Gas and 106.3 MBPD of
external Condensate in addition to the Condensate produced in the NGL Recovery Section
of the process. Product Recoveries of at least 75% C2, 97% C3 and 99% C4 are expected.
The Percent Recovery varies based on the Feed composition. Among the 6 different Feed
Cases, the Lean Case will have the highest Percent Recovery
1.1 Plant Facilities
The Plant facilities are provided as follows to allow operations for 6 different cases:
Feed Pretreatment Unit (Unit 231)
Two gas turbine driven compressor trains to get driving force of ethane
recovery.
Feed Gas, Condensate and LPG Dehydration to prevent ice and hydrate
formation in the down stream NGL Recovery Unit (Unit 232) which would cause
blockage of lines and equipment.
Mercury Guard Bed is provided downstream of the Feed Gas Dehydrator. The
purpose of Mercury Guard Bed is to remove trace quantities of mercury that
could be present in the feed to the NGL Recovery Unit (Unit 232) to protect the
brazed aluminum plate heat exchanger against rapid corrosion of aluminum.
Mercury, even in trace quantities, has been found to corrode aluminum rapidly
under certain conditions.
NGL Recovery Unit (Unit 232)
The purpose of the NGL Recovery Unit (Unit 232) is to produce and recover the
C2 heavier component. The selected process is GSP process which is using
Turbo Expander and C3 Refrigeration System as a cooling medium.
Condensate Stripping System is to separate stripped condensate from the feed
condensate and to inject separated light ends into the Demethaniser
(V-232-001).
NGL Fractionation Unit (Unit 233)
Single NGL fractionation facilities including Deethaniser, Depropaniser,

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Debutaniser system.
The objectives of a fractionation unit are to produce ethane, propane, butane,
pentane and KNG for using as a fuel gas or storage.
Product Treating Unit (Unit 234)
Propane sweetening and drying
Butane sweetening and drying
Purpose of Propane and Butane Treatment Facilities are to remove the residual
mercaptan and sulphur compounds (H2S, COS) in order to meet commercial
grade specifications.
Propane Refrigeration & Deep Refrigeration System (Unit 235)
The purpose of C3 Refrigeration System is to provide main cooling duty to
liquefying the C2 heavier component.
The purpose of Deep Refrigeration System is to provide cooling duty for
propane product cooling down to -49 (-45 )
Sour Water Stripping Unit (Unit 236)
Sour water stripping unit are provided with inlet feed drums, stripping tower and
associated equipment, etc. The purpose of sour water stripping unit is to strip
out H2S in sour water. The H2S gas is sent to existing SRU.

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2. OVERALL DESIGN BASIS
2.1 Design Throughput
The throughput or flow rate to the LPG 4 is shown in Table 2-1. Depending on the
design case, the LPG 4 can be broken down into two parts:
Gas feed for NGL Recovery Unit
Condensate and LPG Feed for Fractionation Unit
The facilities pertaining to Dorra Gas/Condensate sweetening and glycol Dehydration
facilities have been excluded from the scope of work of LPG 4 Project.
Table 2-1 Feed Case Overview for the new Gas Train
Gas Feed Liquid Feed
805 MMSCFD 106.3 MBPD
2.2 Feed Stream Condition and Composition
2.2.1 Feed Gas Condition and Composition
The operating window for CO2 and H2S in sour gas will be as follows.
CO2: Max. 2.5 mol% (normal average is 2 mol%)
H2S: Max. 2400 ppm(Max quantity to be considered for metallurgical purpose
only) (normal average is 1000 ppm)
The following tables 2-2 though 2-4 show the condition and compositions of the
feed stream:
Table 2-2 The feed gas condition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Temperature ( ) 96.9
(36.1)
103.1
(39.5)
96.8
(36.0)
102.9
(39.4)
105.1
(40.6)
103.7
(39.8)
Pressure
psig
(barg)
508.9
(35.1)
508.9
(35.1)
509.1
(35.1)
508.9
(35.1)
550.4
(38.0)
529.4
(36.5)
Flow
MMSCFD 805 805 805 805 805 805
kgmol/h 40172 40170 40172 40167 40488 40170

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Table 2-3 The feed gas composition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Unit Mol% Mol% Mol% Mol% Mol% Mol%
Hydrogen H2 0.00 0.00 0.00 0.00 0.21 0.00
Nitrogen N2 0.57 0.38 0.45 0.30 0.16 0.11
Oxygen O2 0.01 0.01 0.01 0.01 0.00 0.00
H2S H2S 0.20 0.20 0.20 0.20 0.20 0.20
CO2 CO2 2.30 2.50 2.30 2.50 2.10 1.38
Methane C1 73.12 78.15 71.03 76.84 63.21 80.42
Ethane C2 14.71 10.99 15.22 11.31 17.18 10.41
Propane C3 6.56 4.93 8.33 6.05 10.73 4.57
i-Butane IC4 0.67 0.75 0.60 0.70 1.30 0.56
n-Butane NC4 1.37 0.99 1.31 0.95 3.13 1.29
i-Pentane IC5 0.16 0.24 0.24 0.29 0.56 0.31
n-Pentane NC5 0.18 0.20 0.17 0.20 0.68 0.38
n-Hexane NC6 0.03 0.57 0.03 0.56 0.41 0.38
n-Heptane NC7 0.01 0.01 0.01 0.01 0.05 0.00
n-Octane NC8 0.00 0.00 0.00 0.00 0.01 0.00
Water H2O 0.10 0.07 0.10 0.07 0.05 0.00
Impurities
Note1
ppmw
111 114 108 112 92 117
Total 100 100 100 100 100 100
Note 1 : Refer to Table 2-4 for the components and quantities of impurities.

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Table 2-4 The feed gas impurities are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Unit ppmw ppmw ppmw ppmw ppmw ppmw
Carbon Disulphide 0.48 0.50 0.47 0.49 0.40 0.52
Carbonyl Sulphide 20.63 21.22 20.14 20.89 17.89 21.77
Methyl Mercaptan 24.58 25.28 23.99 24.89 21.08 25.94
Ethyl Mercaptan 48.47 49.86 47.32 49.09 40.53 51.14
Dimethyl Mercaptan 0.07 0.07 0.07 0.07 0.05 0.06
i-Propyl Mercaptan 11.83 12.17 11.54 12.00 9.15 12.47
n-Propyl Mercaptan 1.80 1.85 1.76 1.82 1.28 1.88
Methyl Ethyl Sulphide 0.47 0.48 0.46 0.48 0.35 0.48
Methyl Propyl Sulphide 1.52 1.57 1.49 1.54 0.91 1.62
n-Butyl Mercaptan 0.06 0.06 0.06 0.06 0.03 0.04
Tert Bytyl Mercaptan 0.27 0.28 0.27 0.28 0.20 0.31
Dimethyl Disulphide 0.28 0.28 0.28 0.29 0.16 0.32
Diethyl Disulphide 0.04 0.04 0.04 0.04 0.01 0.06
2-Methyl Thiophene 0.15 0.16 0.14 0.15 0.08 0.14
2.2.2 Condensate Feed Condition and Composition
The following tables 2-5 and 2-7 show the condition and compositions of the case
1for Condensate:
Table 2-5 The Condensate condition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Temperature
( )
102.0
(38.9)
106.4
(41.3)
102.1
(38.9)
106.4
(41.3)
106.1
(41.2)
106.4
(41.3)
Pressure
psig
(barg)
565.6
(39.0)
565.6
(39.0)
565.6
(39.0)
565.6
(39.0)
536.6
(37.0)
565.6
(39.0)
Flow MBPD 59.4 66.3 59.4 66.3 55.1 66.3

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Table 2-6 The Condensate composition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Hydrogen H2 0.00 0.00 0.00 0.00 0.00 0.00
Nirtrogen N2 0.09 0.07 0.09 0.07 0.09 0.07
Oxygen O2 0.00 0.00 0.00 0.00 0.00 0.00
H2S H2S 0.09 0.07 0.09 0.07 0.09 0.07
CO2 CO2 0.28 0.44 0.54 0.65 0.27 0.65
Methane C1 9.11 10.46 9.08 10.44 9.01 10.44
Ethane C2 15.49 13.10 13.46 11.48 15.44 11.48
Propane C3 30.15 25.04 28.54 23.73 30.17 23.73
i-Butane IC4 8.05 7.26 8.41 7.53 8.06 7.53
n-Butane NC4 21.54 17.61 24.07 19.59 21.58 19.59
i-Pentane IC5 5.03 5.00 4.95 4.94 5.04 4.94
n-Pentane NC5 6.12 5.68 5.81 5.43 6.15 5.43
n-Hexane NC6 3.07 14.47 3.24 14.69 3.08 14.69
n-Heptane + NC7 0.89 0.71 1.60 1.27 0.89 1.27
Propylene 0.00 0.00 0.00 0.00 0.00 0.00
H20 H2O 0.08 0.06 0.08 0.06 0.09 0.06
Impurities
Note1
ppmw
341 315 334 310 325 339
Total 100 100 100 100 100 100

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Table 2-7 The Condensate impurities are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Ethyl Mercaptan 119.52 110.58 117.01 108.81 119.41 108.79
Dimethyl Mercaptan 0.31 0.29 0.30 0.28 0.31 0.28
i-Propyl Mercaptan 105.01 97.20 102.81 95.6 89.17 124.24
n-Propyl Mercaptan 11.11 10.28 10.88 10.11 11.42 10.40
Methyl Ethyl Sulphide 4.79 4.44 4.70 4.36 4.78 4.36
Methyl Propyl Sulphide 28.50 26.38 27.90 25.94 28.46 25.93
n-Butyl Mercaptan 1.50 1.39 1.47 1.36 1.51 1.37
Tert Bytyl Mercaptan 2.74 2.55 2.70 2.51 2.74 2.49
Dimethyl Disulphide 7.11 6.59 6.97 6.48 7.10 6.47
Diethyl Disulphide 5.05 4.68 4.95 4.59 5.05 4.60
2-Methyl Thiophene 4.22 3.89 4.12 3.83 4.22 3.84
2.2.3 LPG Feed Compositions
The following tables 2-8 and 2-10 show the condition and compositions of the 1
for LPG:
Table 2-8 The LPG condition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Temperature
( )
100.4
(38.0)
100.4
(38.0)
100.4
(38.0)
100.4
(38.0)
100.4
(38.0)
100.4
(38.0)
Pressure
psig
(barg)
580.2
(40.0)
580.2
(40.0)
580.2
(40.0)
580.2
(40.0)
580.2
(40.0)
580.2
(40.0)
Flow MBPD 47.1 40.2 47.1 40.2 47.1 40.2

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Table 2-9 The LPG composition are :
Case Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Hydrogen H2 0.00 0.00 0.00 0.00 0.00 0.00
Nirtrogen N2 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen O2 0.00 0.00 0.00 0.00 0.00 0.00
H2S H2S 0.00 0.00 0.00 0.00 0.00 0.00
CO2 CO2 0.00 0.00 0.00 0.00 0.00 0.00
Methane C1 0.41 0.41 0.41 0.41 0.41 0.41
Ethane C2 6.02 6.02 6.02 6.02 6.02 6.02
Propane C3 44.50 44.51 44.50 44.51 44.50 44.51
i-Butane IC4 16.66 16.65 16.66 16.65 16.66 16.65
n-Butane NC4 28.39 28.39 28.39 28.39 28.39 28.39
i-Pentane IC5 2.57 2.56 2.57 2.56 2.57 2.56
n-Pentane NC5 1.44 1.44 1.44 1.44 1.44 1.44
n-Hexane NC6 0.00 0.00 0.00 0.00 0.00 0.00
n-Heptane + NC7 0.00 0.00 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00 0.00 0.00
H20 H2O 0.00 0.00 0.00 0.00 0.00 0.00
Impurities
Note1
ppmw
86 86 86 86 86 86
Total 100 100 100 100 100 100
Table 2-10 The LPG impurities are :
Case
Without
Dorra
Summer
With
Dorra
Summer
Without
Dorra
Winter
With
Dorra
Winter
Rich Lean
Ethyl Mercaptan 54.20 54.19 54.20 54.19 54.20 54.19

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2.2.4 Exceptional Operation
JT Valve Operation Case
During transient operation – i.e. start-up or shutdown operation – or while
expander is under shutdown, expander could not be operated due to turn
down operation ( < 30%), high pressure gas letdown is performed through
pressure control valve installed as a by-pass of the Feed Gas Expander. In
this case, Residue Gas Compressor is not anymore mechanically driven and
shall be by-passed. During this operation mode, Demethaniser columns shall
be operated at higher pressures than normal.
2.3 Product Specifications
2.3.1 Ethane / Propane / Butane Recovery
The calculated Ethane recovery is to be 76.9 mol%. The calculated propane
recovery is to be 97 mol%. The calculated butane recovery is to be 99.7 mol%.
The Guaranteed Recovery based on the exhibit D for “PROCESS
PERFORMANCE AND CONSUMPTION GUARANTEES” are given below :
Recovery is applicable for all cases except Rich and J-T case.
Compositions Guaranteed Recovery
Ethane 75.4% of Feed
Propane 96.75% of Feed
Butane 99.45% of Feed
2.3.2 Residue Gas Specification
After the removal of ethane and heavier components, residue gas from the
Recovery Unit (Unit 232) will be sent to the new ERP Unit downstream of the
existing trains 1,2, and 3. The maximum H2S concentration in the residue gas is
800 ppmv. The LPG 4 will be sent to the Ethane Recovery Plant (ERP), CO2
content in the residue gas should not exceed 2 mole percent.
HP Fuel gas from Ethane Recovery Plant residue gas shall be supplied to Gas
Turbine as a fuel and to Dryer Regeneration Heater and Treater Regeneration
Heater as a regeneration gas and to letdown facility of LP Fuel gas Knock-out
Drum in which LP fuel gas will be supplied for the process heaters and boiler. The
residue gas from LPG 4 will be used for back-up for fuel of above consumption
facilities.

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2.3.3 Ethane Product Specification
The Ethane Product gas shall meet the specifications listed Table 2-11.
Table 2-11 Ethane Product Specification
Product Specification (vol.%)
Min. Max.
Methane 7.1
(1)
11.5
(1)
Ethane 85.6 90.8
Propane 0.1
(1)
2.5
C4 0 0.1
CO2 2.3
(1)
11
H2S 0.4
(1,2)
0.6
(1) Value is allowed to be lower than shown in table.
(2) H2S content in FEED gas shall be limited 700 ppm to meet product
specifications.

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2.3.4 Propane Product Specification
The Propane Product shall meet the specifications listed below.
Table 2-12 Propane Product Specification
Test
Method
Unit
Limits
Min Max
Composition
C2 and Lighter D 2163 mol% 2.0
C3 (Propane) “ “ 96.0
C4 and Heavier “ “ 2.5
Hydrogen Sulphide (H2S) D2420 Negative
Moisture Content D2713 Pass
Olefins D2163 mg/L Report
Residual Matter D2158
‘R’ Number “ 10
‘O’ Number “ 33
Residue on Evaporation D2158 mass% Report
Sulphur, Total D2784/3246 mg/kg 20
Corrosion
Corrosion, Copper Strip 1h @
37.8 °C
D1838 No.1
Volatility
Density @ 15 °C D1657/2598 lb/ft
3
(Kg/L) Report
Volatile Residue
95% vol. Evaporated @ D1837 (°C) Report
(760 mm Hg)
Vapor Pressure @ 37.8 °C D1267 kPa
(psia)
1380
(200)
Note: Confirm to Gas Processor Association (GPA) Standard

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2.3.5 Butane Product Specification
The Butane Product shall meet the specifications listed below.
Table 2-13 Butane Product Specification
Test Method Unit
Limits
Min Max
Composition
C4(Butane) D 2163 mol% 95.0
C5 and Heavier “ “ 2.0
Hydrogen Sulphide(H2S) D2420 Negative
Free Water Content (Note 2) Visual None
Olefins D2163 mol% Report
Residue on Evaporation D2158 mass% Report
Sulphur, Total D2784/3246 mg/kg 20
Corrosion
Corrosion, Copper Strip 1h @
37.8 °C
D1838 No.1
Volatility
Density @ 15 °C D1657/2598 lb/ft3
(Kg/L) Report
Volatile Residue
95% vol. evaporated @ D1837 °F (°C) Report
(760 mm Hg)
Vapor Pressure @ 37.8 °C D1267 kPa
(psia)
483
(70)
Note: 1. Confirm to Gas Processor Association (GPA)
2. Water shall be determined by visual inspection of the samples used for
the density determination
2.3.6 Kuwait Natural Gasoline Product Specification
For Kuwait Natural Gasoline (KNG), the RVP should not exceed 10.5 psia.
There are no other specific requirements of the KNG product.
2.3.7 Fuel Gas Specification
The H2S content is to be not more than 2,400 ppmv.

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2.4 Battery Limit Conditions
2.4.1 Battery Limits Conditions for Feed Gas
The conditions of the main streams to the Feed gas compression are listed
hereafter :
Table 2-14 Feed Gas battery limit conditions
Feed Gas Operating Condition(1)
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
From NK
542.3 (37.4) 100.4 (38)
1209.6
(83.4)
141.8 (61)
From SEK
563.3 (38.8) 100.4 (38)
1055.9
(72.8)
170.6 (77)
From AGRP MAA
557.5 (38.4) 118.4 (48)
764,4
(52.7)
199.4 (93)
From AGRP SHU
550.5 (38.0) 118.4 (48)
638.2
(44.0)
167 (75)
Battery Limit pressure is referenced to grade at the LPG 4 IBL battery limit.
2.4.2 Battery Limits Conditions for Condensate Feed
The operating conditions of the main streams to Dehydration Facilities are listed
hereafter.
Table 2-15 Condensate Feed battery limit
Condensate Feed Operating Condition(1)
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
From SEK
591.8 (40.8) 100.4 (38)
1375.0
(94.8)
181.4 (83)
From NK
590.7 (40.7) 100.4 (38)
1375.0
(94.8)
156.2 (69)
From AGRP MAA
596.1 (41.1) 100.4 (38)
1215.4
(83.8)
199.4 (93)
From Slug Catcher
589.7 (40.7) 100.4 (38)
1026.9
(70.8)
167 (75)
From ERP
Condensate
591.9 (40.8) 100.4 (38)
1348.9
(93.0)
167 (75)
Battery Limit pressure is referenced to the LPG 4 IBL battery limit.

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2.4.3 Battery Limits Conditions for LPG Feed
The operating conditions of the main streams to Dehydration Facilities are listed
hereafter.
Table 2-16 LPG Feed battery limit
LPG Feed
Operating Condition(1)
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
From MAB & SHU
607.4 (41.9) 100.4 (38)
799.2
(55.1)
167 (75)
From MAA
592.3 (40.8) 100.4 (38)
1375.0
(94.8)
181.4 (83)
2.4.4 Battery Limit Condition for Product
The battery limit conditions are below shown in Table 2.17.
Table 2.17 Product Battery limit conditions
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
Residue Gas 438
(30.2)
100.4
(38)
520
(35.9)
180
(82.2)
LP Fuel Gas 72.5
(5)
100.4
(38)
126.2
(8.7)
284
(140)
Ethane 325
(22.4)
100.0
(37.8)
460
(31.7)
280 / -57.3
(138/-49.6)
Propane 202.9
(15.0)
-49
(-45
(1)
)
554.5
(38.2)
-59.8
(-51)
Butane 94.3
(6.5)
14
(-10
(1)
)
300.3
(20.7)
-20
(-29)
Pentane 91.4
(6.3)
100
(37.8)
206.6
(14.3)
150.8
(66)
KNG 69.6
(4.8)
100
(37.8)
237.1
(16.4)
140
(60)
(1) Propane, butane, pentane and KNG product rundown to be cooled below the
boiling point and at a temperature suitable for storage at atmospheric level.
(2) Battery limit pressure is referenced to the LPG 4 IBL battery limit.

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2.4.5 Battery Limits Conditions for Propane Refrigerant System
Propane make-up is performed from propane product at normal operation. For
initial charge during start-up, propane is provided from existing gas plant. The
following Table 2-18 shows the condition of the case specific feed streams:
Propane blow down, in case of unit 235 emptying, is sent to the existing propane
tank.
The conditions at the battery limit of propane for make-up and empting are shown
blow table 2-18:
Table 2-18 Battery limit for propane make up.
Propane
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
From Existing Gas
Plant
243.7
(16.8)
-49
(-45)
488.8
(33.7)
-58
(-50)
To Existing Propane
Tank ()
-49
(-45)
554.5
(38.2)
-59.8
(-51)
2.4.6 Battery Limits Conditions for Deep Refrigerant System
Deep refrigerant is ethane and propylene mixture. Propylene make-up is
performed from existing gas plant or . Ethane make-up is performed from ethane
product line.
Deep refrigerant blow down, in case of Deep Refrigerant System (Unit 235)
emptying, is sent to the flare stack.
Table 2-19 Battery limit for propylene and ethane make up
Propylene / Ethane Operating Condition(1)
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
Propylene From
Existing Gas Plant
() 77 (25)
1299.5
(89.6)
180 / -70.6
(82.2) / (-57)
Ethane From ERP
(Ethane Recovery
Plant)
290
(20.0)
101
(38.3)
460
(31.7)
280 / -57.3
(138 /-49.6)
Battery Limit pressure is referenced at the LPG 4 IBL battery limit.
Ethane shall be provided above the 99.9 mol% purity to prevent corrosion.
2.5 Design Consideration

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2.5.1 Plant Design Life
Industry Standard design approaches will be used in equipment design. Plant
design life is 20 years for economic evaluation.
2.5.2 Plant Availability
The plant availability is defined at 8,000 hours per year for the economic.
2.5.3 Effluent Treatment
Effluents will be collected and treated in accordance with common industry
practices, maximizing use of existing MAA Refinery facilities, such to meet the
Kuwait EPA standards.
2.5.4 Physical Properties
The physical properties of the streams will be determined from a process
simulation in the software package HYSYS Version 7.1.
"Normal" vapour conditions (e.g. for volume in Nm3):
P = 14.7 psia (1 Atm), T=60 °F (15.6 °C)
2.5.5 Remote/Emergency Depressurization
It should be designed to include for remote/emergency depressurization facilities.
The minimum design temperatures shall comply with DEP 30.10.02.31– Metallic
Materials – Prevention of Brittle Fracture and API 521.
2.5.6 Pressure Relief System and HIPPS
All pressure safety vents route via common header to the Flare K.O Drum.
Cooling water thermal relief vents located at exchangers route safely to
atmospheric location. For control valve discharging to Flare K.O Drum, the control
valve is used tight shut designation in order to mitigate inadvertent product losses
to flare system. The HIPPS system has also been identified to limit flaring rate to
flare system.
2.5.7 Source and Compressing of Regeneration Gas
The high pressure fuel gas from Ethane Recovery Plant (ERP) should be used as
the primary source of the regeneration gas for all the system. The H2S and water

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contents of this gas would be provided with 40 ppmv and trace respectively.
The regeneration gas from the three driers (Feed Gas Dryer, Condensate Dryer,
LPG Dryer) will be excessive and should be routed to the high pressure fuel gas
and installed a common centrifugal compressor, (to boost spent regeneration gas
to the high-pressure Fuel Gas pressure), Air Cooler and Discharge Drum at the
discharge of the Compressor.

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3. DESIGN BASIS FOR FEED PRETREATMENT UNIT(UNIT 231)
3.1 DESIGN BASIS FOR FEED GAS COMPRESSION
3.1.1 Feed Gas Compressor
Two (2) Feed Gas Compressor trains have been provided (2 x 50%). Each train is
driven by a dedicated gas turbine. Gas turbine is heavy-duty industrial type and
capable of dual firing (fuel gas & gas oil). Fuel gas is normally used for turbine
operation and when fuel gas is not available, then gas oil will be used to run the
turbines. The exhaust gas from each gas turbine will be directed to the respective
Heat Recovery Steam Generator (one HRSG per gas turbine train) to recover
heat and produce high pressure steam.
The discharge pressure is controlled by Gas Turbine Speed Control Device. An
anti-surge system is provided down stream of the Feed Gas Compressor
Discharge Water Cooler to ensure stable Compressor operations. The Feed Gas
is compressed to a pressure so that when it is cooled and expanded through the
Turbo-Expander.
3.1.2 Product specifications
The maximum concentration of water in the dry gas at the outlet of the
Dehydration Facilities shall be 0.1 ppmv (free water dew point lower than -148 °F
(-100°C) at 440.9 psia (30.4 bara)).
This value is defined considering hydrate formation temperature in the
downstream units as hydrates are likely to form in the downstream NGL Recovery
unit (unit 232) where temperatures can be reached to -148 °F (-100 °C) @ 440.9
psia (30.4bara)(Feed to Demethaniser V-232-001).
3.1.3 Water Content
All Feed vapor streams have water contents of 803 ppmv for the Rich Case
except Dorra Gas. All liquid streams in the feed are water saturated. The LPG 4
will be designed for an upset condition where all vapor streams are water
saturatedat 86 °F (30 °C) in accordance with MOM-FGTP-SKE-001.
3.1.4 Feed Gas Specification for Mercury Guard Bed
The dry gas coming from feed gas dehydrator, which will have mercury

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concentration design value of 100 ng/Nm³.
3.1.5 Product specifications for Mercury Guard Bed
The maximum concentration of mercury in the treated gas at the outlet of the
shall be 10 ng/Nm³.
3.2 SPECIFICATION FOR CONDENSATE AND LPG DEHYDRATION
3.2.1 Product specifications for condensate dehydration
The saturated water content at the feed temperature 113 °F (45 °C) with 5.4 °F
(3 °C) margin in water content will be applied with design case.
The maximum concentration of water in the dry condensate at the outlet of the
Dehydration Facilities shall be 1.0 ppmw.
3.2.2 Product Specifications for LPG dehydration
The saturated water content at the feed temperature 102 °F (38.9 °C) in water
content will be applied with design case.
The maximum concentration of water in the dry LPG at the outlet of the
Dehydration Facilities shall be 1.0 ppmw.
3.3 DESIGN BASIS FOR HP FUEL GAS CONDITIONING
3.3.1 System Capacity
Inlet Design Flow : Max. 403.3 MMSCFD , 50% of Feed Gas in case 2,
Without DORRA Summer plus inclusion of 10% design margin.
Outlet Design Flow : Max. 384.2 MMSCFD plus inclusion of 10% design
margin.
3.3.2 HP Fuel Gas Specification
LHV(Low Heating Value) of conditioned HP Fuel Gas shall be 1088 BTU/SCF.
The outlet temperature of conditioned HP Fuel Gas is 50.1
3.4 GENERAL DESIGN CONSIDERATION
3.4.1 Feed Gas Compressor
For centrifugal or axial compressor, the design pressure of upstream

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equipment should be set at a safe margin above the settle-out pressure.
Downstream equipment design pressure will be set at blocked in condition.
However, to prevent excess over design, the design pressure can be lowered
with proper protection system such as HIPPS or PSV.
Centrifugal Compressor
The choking capacity shall be not less than 115 percent of the rated
capacity while the surge capacity shall be less than 75 percent of the
rated capacity at the rated speed.
Unless otherwise specified, compressors will be started on full recycle
with the system at specified "Settling-Out Conditions". The recycle piping
will be designed to handle a minimum 110 percent of surge flow at
maximum continuous speed.
A dedicated anti-surge controller is to be provided protection of the Feed Gas
Compressor.
3.4.2 Feed Gas Dehydrator, Condensate and LPG Dehydrator
The Dryers are designed to accommodate the molecular sieve inventory as
proposed by the main suppliers.
The adsorbent material is supported on a fixed grid, with layers of ceramic balls at
the top and bottom of the bed. The Dryers are externally insulated (heat and cold
conservation)..
As the Dryers will be cycling through the adsorption and regeneration sequences,
mechanical design of the Dryers shall take into account the effects of thermal
fatigue.
The water content of the dry liquid shall be guaranteed, the molecular sieve
lifetime shall be guaranteed to be at least three years, the pressure drop across
the drier during adsorption step shall be guaranteed to be a maximum of psi (0.
bar).
3.4.3 Feed Gas Compressor Discharge Air Cooler
Outlet temperature of air cooler should be designed as 140 °F (60 ) and
controlled by motor on/off or louver opening.

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3.4.4 Gas Filters
Mercury guard filter
Treated gas outlet filter will be installed downstream the mercury guard bed.
There are two 100% cartridge filters designed to remove fines 5 m and
larger. The pressure drop through the fouled filter shall not exceed 7.3 psi (0.5
bar).
Feed gas compressor suction drum
Feed gas compressor suction drum includes the function of filtering.
Refer to item 3.4.8.
3.4.5 Mercury guard bed
Mercury guard shall be alumina impregnated catalyst or equivalent process. The
catalyst will not be regenerated on site, but will be removed and disposed off. The
maximum available pressure drop across the mercury guard adsorber shall be 7.3
psi (0.5 bar).
The Mercury(Hg) content is to be more than 10 ng/Nm3.
3.4.6 Regeneration Gas Heater
One regeneration gas heater for the three dryers (Feed Gas Dehydrator,
Condensate Dehydrator, LPG Dehydrator) would be required for regeneration
system design.
The heater is provided by a cylindrical fired heater.
As there is no regeneration gas flow in furnace during cooling and bed switching
steps, two alternatives may be foreseen by the supplier:
Pilots operating continuously and burners maintained to the minimum
sustainable flame (preferred option).
Pilots operating continuously and burners stopped (automatic restart
provided).
The relevant flame detection devices shall be provided (UV detection for burners
and pilots).
3.4.7 Dryer Regeneration Compressor
The Dryer Regeneration Compressor(C-231-002) is a centrifugal type, driven

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by steam turbine and is provided with anti-surge devices.
Regeneration Compressor Discharge Air Cooler(E-231-007) is designed to
cool compressor discharge down and uses air as a cooling media.
Regeneration Compressor Discharge Drum (V-231-007) is to separate gas
and potential liquid. This vertical drum is equipped with a mesh to avoid any
liquid carry-over to residue gas header.
3.4.8 Feed Gas Compressor Suction Drum
The Feed gas compressor suction drums are designed to remove fines
5 m and larger that is contained in the feed gas. This drum is equipped
with the lower sump to collect bulk contaminants and Cyclotube with
independent second stage sump to remove and collect entrained
contaminants. The pressure drop through the Feed gas compressor
suction drum shall not exceed 2 psi (0.14 bar).
3.4.9 HP Fuel Gas/Gas Exchanger (E-231-031)
The conditioned HP fuel gas is heated by Feed Gas and thus the Feed Gas is
pre-cooled in the process
3.4.10 HP Fuel Gas Chiller (E-231-032)
The pre-cooled Feed Gas is cooled by C3 Refrigerant to 10.4 in order to
achieve 1088 BTU/SCF of Fuel gas LHV and heavy component is liquefied
3.4.11 HP Fuel Gas KO Drum (V-231-031)
The purpose of HP Fuel Gas KO Drum is to separate the liquid and gas
formed after the chilling of Feed Gas .
3.4.12 HP Fuel Gas KO Drum Pump
The separated liquid is pumped to Feed Condensate Drum (V-231-011)

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4. DESIGN BASIS FOR NGL RECOVERY AND CONDENSATE STRIPPING UNIT(UNIT 232)
4.1 DESIGN BASIS FOR NGL RECOVERY SECTION
Products of NGL Recovery Unit (Unit 232) are:
Residue Gas to Ethane recovery Unit or High pressure fuel gas header,
NGL to the Deethaniser of Fractionation Unit (Unit 233),
The residue gas is normally routed to new Ethane Recovery Plant (ERP).
However in case of excess quantity, it shall be diverted to HP fuel gas header.
The specifications of the residue gas from the unit 232 shall comply with the
following specifications:
H2S max. 800 ppmv
CO2 max. 2 mol%
At the outlet of the Deethaniser bottom, the NGL shall meet the ethane and the
propane product specification of NGL fractionation unit (233) in terms of
hydrocarbons contents.
The Ethane and Propane product specification shall meet the specification
specified on para.2.3.3 and 2.3.4 of this document.
4.1.2 Equipment Design Consideration
Column
V-232-001 Demethaniser
The operating pressure of the Demethaniser is set to ensure residue gas and
ethane recovery at an optimum pressure without any recycle compressor.
There are packing in the top section and trays for the bottom. The two
sections are defined by a different column diameter.
The below special devices are provided:
Two nozzle on the mixed feed from Feed Gas Expander to ensure a
proper distribution at the column inlet,
One demister on column top to avoid any liquid carry-over.

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Compressor
C-232-001 Residue Gas Compressor
The Residue Gas Compressor is driven by the Feed Gas Expander,
L-232-001. Recovered energy from the Feed Gas Expander is used to
increase the pressure of the Residue Gas to the design conditions based on
the Lean Case.
Drums
V-232-003 Chilled Feed Gas K.O Drum
This horizontal drum purpose is to separate the liquids and gases formed
after the chilling of the Feed Gas to the Demethaniser. It is equipped with a
symmetrical, dual-entry inlet distributor and an outlet vapor mesh pad to avoid
any liquid carry-over to the Feed Gas Expander.
Exchangers
V-232-E001/002/003 Cold Box
In the Cold Box, one stream is cooled down :
Warm dried gas.
Simultaneously, cold streams are reheated :
Demethaniser overhead gas,
Demethaniser side withdrawals.
E-232-003 Demethaniser Reflux Subcooler
This plate fin heat exchanger purpose is to cool down stream used as
Demethaniser reflux while heating up residue gas. This exchanger is part of
the cold box.
E-232-006 Demethaniser Trim Reboiler
This is a vertical thermosyphon type reboiler using low pressure steam as
heating medium. It will be used during start-up and JT valve operation case.
E-232-004 Dry Feed Gas Chiller
This kettle type shell and tube heat exchanger uses propane as cooling
medium for chilling of feed gas.

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Expander
L-232-001 Turbo Expander
This Expander allows for drop both temperature and pressure by an isentropic
letdown. Energy is recovered in the associated Residue Gas Compressor.
By-pass valve of the Expander is provided for start-up, transient and
shutdown operations.
4.2 DESIGN BASIS FOR CONDENSATE STRIPPING SECTION
Products of unit 232 condensate stripping section are :
Condensates from condensate stripper sent to Deethaniser,
C1 : Max. 2 mol%
Column
V-232-002 Condensate Stripper
Raw condensate from Condensate Dehydrators is treated in the Condensate
Stripper V-232-002. Lighter components are removed as vapor overhead
product and supplied to the demethanizer V-233-001.
The column is equipped with :
Reboiler E-232-008, heated by low pressure steam,
Side reboiler E-232-007, in which liquid coming out from column is heated
and sent back to column after exchanging heat with column bottom
The E-232-008 is fed with low pressure steam under flow control reset by
bottom trays temperature.
The condensate stripper bottom temperature is about 221 °F (105 °C).
The condensate flow rate is controlled by the level of V-232-002. which
changes the flow to the Deethaniser V-233-001
Exchangers
E-232-008 Condensate Stripper Reboiler
This is a kettle type reboiler using low pressure steam as heating medium.

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5. DESIGN BASIS FOR NGL FRACTIONATION UNIT(UNIT 233)
5.1 DESIGN BASIS
The product from NGL fractionation unit shall meet the specification specified on
para.2.3.3, 2.3.4, 2.3.5 and 2.3.6.
5.1.2 Recovery and purity
The recovery and purities from NGL fractionation unit shall meet the specifications
listed below. Guaranteed product quality is applicable for all cases except J-T
case.
Product Recovery, mol% Purity, mol%
Ethane(C2) 75 ~ 76 (Calculated) Min. 85.6
Propane(C3) 97 (Calculated) Min. 96.0
Butane(C4) 99 (Calculated) Min. 95.0
5.1.3 Battery limits conditions
The Battery limit conditions of the main streams are listed on para. 2.4.4
5.1.4 Equipment design consideration
V-233-001:Deethaniser
The operating condition of the Deethaniser is set to ensure Ethane recovery
at an optimum pressure. High Integrated Pressure Protection System (HIPPS)
will be considered at the column overhead line to mitigate flare load.
V-233-002: Depropaniser
The operating condition of the Depropaniser is set to ensure the condensation
of the propane . High Integrated Pressure Protection System (HIPPS) will be
considered at the column overhead line to mitigate flare load.
V-233-003: Debutaniser
The operating condition of the Debutaniser is set to ensure the condensation
of the butane Debutaniser Overhead Condenser. High Integrated Pressure
Protection System (HIPPS) will be considered at the column overhead line to

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mitigate flare load.
LP steam flow rate and quantity to reboilers :
The LP steam flow rate to the Reboiler of the column is indirectly controlled by
condensate level controller in condensate pot which is reset by the
temperature of the sensitive tray of the corresponding column of which the
temperature is to be controlled. The quantity of reboiler shall be limited two (2)
to install symmetrically.

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6. DESIGN BASIS FOR PRODUCT TREATING (UNIT 234)
6.1 C3 TREATING
6.1.1 Feed Specification
The feed specifications listed below (specified for the existing trains) will be
adopted and applied to the design of the LPG 4..
H2S 100 ppmw
MeSH 100 ppmw
COS 93 ppmw
6.1.2 Product Specification
The maximum concentration of total sulphur, H2S and COS in the treated Propane
Product at the outlet of the Propane Treater will be 20 ppmw, NIL for H2S and 3.0
ppmw for COS, respectively.
6.2 C4 TREATING
6.2.1 Feed Specification
The feed specifications listed below (specified for the existing trains) will be
adopted and applied to the design of the LPG 4..
MeSH 108 ppmw
EtSH 363 ppmw
The maximum concentration of total sulphur and COS in the treated butane at the
outlet of the treater facilities shall be 20 ppmw and 3.0 ppmw respectively.
6.3.1 Equipment design requirements
Heaters
Regeneration Heater
One regeneration gas heater for the two treaters (C3 / C4 treaters) would be
required for regeneration system design.
The heater is designed to heat and vaporize the regeneration flow stream.
The heater is to be a natural gas fired cylindrical type heater. The outlet

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temperature of the heater shall be 68 °F (20 °C) above the required
regeneration temperature.
Regeneration of the product treaters involves a hot regeneration stage and
finally a cooling stage. The regeneration uses ERP HP fuel gas. Fuel gas is
heated to regeneration temperature in the fired heater H-234-001 before it is
passed over the molecular sieves for regeneration
Exchangers
E-234-005/009/012/013: Regeneration Air Cooler
Outlet temperature of air cooler should be designed as 140 °F (60 ) and
controlled by pitch or louver opening. However, air cooler outlet temperature
of E-234-009 is 150 °F (65.5 ) to prevent a partial condensing in the air fin
cooler and balance heat load to sea water cooler, E-234-010A/B.
E-234-006/010: Regeneration Water Cooler
The shell and tube exchanger is designed to subcool the propane/butane to
minimize the duty of the downstream refrigeration system.
E-234-001/002/003, E-234-007 Propane Product Refrigerant Cooler / Chiller
The shell and tube exchanger is designed to meet the B/L temperature of
-49 °F (-45 °C) for C3 and 14 °F (-10 °C) for C4.
E-234-011: Treater Regeneration Gas Preheater
The Preheater is designed to exchange heat of ERP high pressure fuel gas
with hot regeneration gas and sent into regeneration gas heater. The outlet
temperature of the preheater is designed to ensure a vapour phase into
H-234-001.
Filters
F-234-001/003: Treater Outlet Filters
The filter is designed to remove any molecular sieve material 99% down to a
size of 5 µm from the propane and butane product. The fouled filter pressure
drop should be limited to 7.0 psi (0.48 bar).
F-234-002/004/005/006: Regeneration Gas Filter
The regeneration gas filter is designed to remove particle from regeneration
gas coming out of treaters. The filter will be sized to remove 99% of 5µm size
particles and larger particles. The fouled pressure drop should be limited to
maximum of 7.0 psi (0.48 bar).

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
7. DESIGN BASIS FOR REFRIGERATION UNIT(UNIT 235)
7.1 DESIGN BASIS FOR PROPANE REFRIGERANT FACILITY
7.1.1 Feedstock Characteristics and Capacity
The composition and properties of the propane refrigerant used in this facility, are
as below:
Ethane: maximum 0.5 mol%
Propane: minimum 99.0 mol%
C4 and heavier: maximum 0.5 mol%
The Propane Refrigeration Unit consists of a closed loop in which the propane is
flashed, vaporized, recompressed and condensed.
Compressor shall be capable of restart-up from settle-out condition
The settle out condition is determined from bubble pressure at maximum ambient
temperature 140°F (60 °C). When the temperature of system is over 140°F
(60 °C), the propane will be vented to the Low Pressure Fuel Gas system.
7.1.2 Equipment Design Requirements
All equipment and lines in the Propane Refrigeration Unit will be designed to
accommodate the required flow rates to supply the cooling duties of the LPG
Train-4 Plant.
As the Feed Gas compositions provided by KNPC are very wide for the design
cases, the Rich Feed case will not have any design margins applied to the sizing
of the equipment. For the other cases, the design margins will be included in the
Equipment Data Sheets as 20 percent. In case of compressor suction vessel, the
design margins will be applied in Equipment Data Sheets as 25 percent.
Compressor
C-235-001A/B Propane Refrigerant Compressor
Two (2) Propane Refrigerant Compressors have been provided (2 x 50%).
Each compressor is driven by a dedicated gas turbine. Gas turbine is heavy-
duty industrial type and capable of dual firing (fuel gas & gas oil). Fuel gas is

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Job No. : 090768
normally used for turbine operation and when fuel gas is not available, then
gas oil will be used to run the turbines. The exhaust gas from each gas
turbine will be directed to the respective Heat Recovery Steam Generator
(one HRSG per gas turbine train) to recover heat and produce high pressure
steam.
Heat Exchangers
E-235-001 Propane Refrigerant Condenser
Propane Refrigerant Condensers (E-235-001) are designed to cool
compressor discharge down to condensing temperature and uses sea water
as a cooling media.
E-235-002 Propane Refrigerant Subcooler
Propane Refrigerant Subcooler (E-235-002) is designed to cool down liquid
propane refrigerant coming out from V-235-001 and uses cold heat of ethane
product.
Drums
V-235-001 Propane Refrigerant Accumulator
This horizontal drum purpose is to provide a liquid propane refrigerant buffer
(Surge) to overcome any process or propane refrigerant system upsets.
V-235-002 Propane Refrigerant Compressor LP Suction Drum
This vertical drum separates Propane vapor and liquid from the vapor to the
suction of the Propane Refrigerant Compressor. It is equipped with a mesh
pad in the vapor outlet to avoid any liquid carry-over to the Low pressure
suction of the Propane Refrigerant Compressor. This drum also serves as the
inventory of LP Propane Refrigerant used to cool the Propane Product in E-
235-003, the Propane Product LP Refrigerant Cooler. It is also provided with
a special diffuser pipe to cool down the hot anti-surge stream, by vaporizing
the liquid Propane Refrigerant contained in the bottom section.
V-235-003 Propane Refrigerant Compressor MP Suction Drum
This vertical drum separates Medium Pressure Propane vapor and liquids. It
is equipped with a mesh pad to avoid any liquid carry-over to the second-
stage, Propane Refrigerant Compressor suction. It is equipped with a special
diffuser pipe to cool down the hot anti-surge stream, by vaporizing the liquid

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
Propane Refrigerant contained in the bottom section.
V-235-004 Propane Refrigerant Compressor HP Suction Drum
This vertical drum separates High Pressure Propane vapor and liquids. It is
equipped with a mesh pad to avoid any liquid carry-over to the third-stage
Propane Refrigerant Compressor suction. It is equipped with a special diffuser
pipe to cool down the hot anti-surge stream, by vaporizing liquid Propane
Refrigerant contained in the bottom section.
7.1.4 Propane Accumulator Pressure
The pressure in Propane Refrigerant Accumulator, V-235-001 is maintained by
means of hot gas by-pass around the Propane Refrigerant Condenser, E-235-001.
A differential pressure controller (PDC) maintains a constant pressure drop
through the Propane Refrigerant Condenser, E-235-001, to keep the hot gas by
pass valve under control whatever the flow through the E-235-001.
7.2 DESIGN BASIS FOR DEEP REFRIGERANT FACILITY
7.2.1 Feedstock Characteristics and Capacity
The composition of the deep refrigerant which has been considered:
Ethane: 30 mol% or Ethane: 37 mol%
Propylene: 70 mol% Propane: 63 mol%
The Deep Refrigeration Unit consists in a closed loop in which the deep
refrigerant (ethane and propylene mixture) is flashed, vaporized, recompressed
and condensed.
Compressor shall be capable of restart-up from settle-out condition
The settle out condition is determined from bubble pressure at maximum ambient
temperature 140°F (60 °C). When the temperature of system become over 140°F
(60 °C), the will be vented to flare system. De-ethaniser ovhd will be used as
make up for ethane.
7.2.2 Equipment Design Requirements
All equipment and lines in the Deep Refrigeration Unit will be designed to
accommodate the flow rate required to supply the cooling duty of the Propane
Product Deep Refrigerant Chiller, E-234-003.
As the Feed Gas compositions provided by KNPC are very wide for the design

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
cases, the Rich Feed case will not have any design margins applied to the sizing
of the equipment. For the other cases, the design margins will be included in the
Equipment Data Sheets as 20 percent. In case of compressor suction vessel, the
design margins will be applied in Equipment Data Sheets as 25 percent.
Compressor
C-235-011 Deep Refrigerant Compressor
The Deep Refrigerant Compressor(C-235-011) is a centrifugal type, driven by
steam turbine with load controller and is provided with anti-surge devices.
Heat Exchangers
E-235-011 Deep Refrigerant Condenser
Deep Refrigerant Condenser (E-235-011) is designed to cool compressor
discharge down to condensing temperature and uses sea water as a cooling
media.
E-235-012 Deep Refrigerant Subcooler
Deep Refrigerant Subcooler(E-235-012) is designed to cool down liquid deep
refrigerant coming out from V-235-011 to sub-cooled condition and uses cold
heat of propane refrigerant.
Drums
V-235-011 Deep Refrigerant Accumulator
This horizontal drum purpose is to provide a liquid deep refrigerant buffer to
overcome any process or deep refrigerant system upsets.
V-235-012 Deep Refrigerant Compressor Suction Drum
This vertical drum is to separate gas and potential liquid. It is equipped with a
mesh to avoid any liquid carry-over to Deep Refrigerant Compressor suction.
7.2.4 Deep Refrigerant Accumulator Pressure
Pressure in Deep Refrigerant Accumulator, V-235-011 is maintained by means of
pressure control valve to .

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
8. DESIGN BASIS FOR SOUR WATER STRIPPER (UNIT 236)
8.1 DESIGN BASIS
8.1.1 Design capacity
Design capacity of 40 Sm3/h is composed of existing gas plant, slug catcher and
LPG 4 and its composition is based on LPG 4.
Table 8-1 Sour Water Feed Flow Rate
Source Definition Existing gas plant Slug catcher LPG 4 Total feed
Flow rate ,Sm3/h 20 10 10 40
8.1.2 Feed Condition and Compositions
The following tables 8-2 and 8-3 show the condition and compositions of the case
specific feed streams for Condensate:
Table 8-2 The sour water condition are :
Pressure psig (barg) 21.8 (1.5)
Temperature °F ( ) 104 (40.0)
Total Flow Rate kg.mol/hr 2,249
Table 8-3 The sour water composition are :
Component Composition, mol%
H2S 500 ppm
H2O 99.87
CO2 800 ppm
The Treated Water from the Sour Water Stripper shall have the following
specification.
H2S: Not more than 10 ppmw
Acid Gas from New Sour Water Stripper
The composition and amount of Acid Gas from OVHD of Sour Water Stripper are
estimated as below.

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
Table 8-4 The sour gas composition are :
Component Composition, mol%
H2S 34.63
H2O 9.95
CO2 55.41
8.1.4 Battery Limits Conditions for Sour Water Stripping Unit
Incoming:
Sour water to new Sour Water Stripper from existing gas plant:
Outgoing:
Treated water to existing WWT from new Sour Water Stripper:
Acid gas to existing SRU from new Sour Water Stripper:
Table 8-5 Battery limit for sour water and gas treating
Commodity Operating Condition(1)
Design Condition
Pressure
psig (barg)
Temperature
°F ( )
Pressure
psig (barg)
Temperature
°F ( )
Sour Water 29 (2.0) 104 (40) 50.8 (3.5) 248 (120)
Treated Water 240.7 (16.6) 100.4 (38) 435.1 (30.0) 167 (75)
Sour Gas 18.9 (1.3) 190.4 (88) 50.8 (3.5) 248 (120)
8.2.1 Equipment design requirements
Column
V-236-001: Sour Water Stripper
The Sour Water Stripper column is designed to strip H2S out of the Sour
Water feed, down to a concentration of 10 ppmw or less. The column is
equipped with one-pass, valve trays.
Drum
V-236-002: Sour Water Feed Separator
The separator is sized for minimum storage to accommodate any surge in
sour water feed to the Sour Water Stripper and for removing slop from feed

Doc No. : S090768.231-3.00-004-A-E
Job No. : 090768
water.
V-236-003: SWS Reflux Separator
The SWS Reflux Separator is sized for a liquid residence to support the SWS
reflux Pump. In addition, the vapor space above the feed nozzle is designed
to minimize entrainment of liquid into the Sour Gas stream. A mesh Pad is
also included in the top of the vessel to minimize entrainment carry-over.
Exchanger
E-236-001: SWS Overhead Condenser
This Air Cooler/Condenser is designed to partially condense the Sour Water
Stripper overhead stream, producing a concentrated Sour gas stream to be
routed to the existing Sulfur Plant and a sour liquid reflux stream.
E-236-003A/B: Feed/Bottoms Exchanger
This exchanger is designed to recover heat from the Stripped Water bottoms
product and transfer it to the Sour Water Feed stream, thereby reducing the
Reboiler requirements during normal operations.
E-236-004A/B: Stripped Water Trim Cooler
This exchanger is designed to cool the Stripped Water exiting the
Feed/Bottoms Exchanger to a temperature of 100 o
F (37.8 o
C). Seawater is
used as the cooling medium.
E-236-002: SWS Reboiler
This is a kettle-type exchanger using Low-pressure steam as the heating
medium. The Reboiler will generate the required stripping steam to achieve a
bottoms product composition of 10 ppmw or less of H2S.

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