Basis of Design Cooling Water

CONTRACT N°
STAR RAFINERI A.S.

S3ST I UNIT N° U-560
SH/OF
F LU OR® AEGEAN REFINERY
1/25
PROJECT (ARP) STAR SPECIFICATION N°
560-A-PE-0170001
REV I A I 0 I 1 I 2 I
Basis of Design
Cooling Water Unit
U-560
Updated with FEED

2 22/02/13 modifications, Issued for R.M. Fluor
Design
Client Comments
1 05/12/11 RM. l.M. N.J. Fluor
Incorporated
For Client Comments &
0 17/11/11 RM. l.M. N.J. Fluor
Approval
A 24/10/11 Internal Review RM. l.M. N.J. Fluor
STAR RAFINERI A.S. CONTRACT N°
AEGEAN REFINERY PROJECT (ARP) S3ST
SH/OF
Basis of Design 2/25
STAR SPECIFICATION N°
Cooling Water Unit 560-A-PE-0170001
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TABLE OF CONTENTS
1 INTRODUCTION................................................................................................................ 4
1.1 Purpose .............................................................................................................................4
1.2 Objective ............................................................................................................................4
1.3 Brief Process Description ................................................................................................... 4
2 REQUIRED CAPACITY AND TURNDOWN ....................................................................... 5

2.1 Operational Requirements ................................................................................................. 5
2.2 Future Expansion Considerations ...................................................................................... 5
2.3 Design Considerations ....................................................................................................... 5
2.3.1 References.........................................................................................................................7
2.3.2 Cooling Water System ....................................................................................................... 7
2.3.3 Location .............................................................................................................................7
2.3.4 Electrical ............................................................................................................................7
2.3.5 Area Classification..............................................................................................................8
2.3.6 Process Hazard Analysis ................................................................................................... 8
2.3.7 Civil ....................................................................................................................................8
2.3.8 Noise Levels ......................................................................................................................8
2.3.9 Control & Instrumentation................................................................................................... 8
2.3.10 Performance and Guarantees ............................................................................................ 9
2.3.11 Drawing and Documents .................................................................................................... 9
3 FEED STREAMS / PRODUCT STREAMS ....................................................................... 10
4 BATTERY LIMITS ............................................................................................................ 12

4.1 Utilities, Chemicals and Electricity .................................................................................... 12
4.2 Effluents ........................................................................................................................... 12
5 EQUIPMENT .................................................................................................................... 13
5.1 Cooling Water Tower 560E-001, Cooling Water Basin 560CO-001, Cooling Water Drainage
Pit 560UT-001, Cooling Water Drainage Pit Pump 560G-002 .......................................... 13
5.1.1 General requirements ...................................................................................................... 13
5.2 Cooling Water Treatment Package 560PK-001, Cooling Water Sand Filter 560FIL-001 .. 18
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5.3 Cooling Water Pumps 560G-001A/B/C/D/E ...................................................................... 19
6 OPERATIONS PHILOSOPHY.......................................................................................... 20
6.1 Operating Availability and Reliability................................................................................. 20
6.2 Sparing Philosophy .......................................................................................................... 20
6.3 Start-up and Shutdown..................................................................................................... 20
6.4 Modes of Operation.......................................................................................................... 20
6.4.1 Normal operation.............................................................................................................. 20
6.4.2 Turndown Case ................................................................................................................ 20
6.4.3 Cleaning Operation .......................................................................................................... 21
6.5 Material Handling Philosophy ........................................................................................... 21
6.6 Flaring and Draining ......................................................................................................... 21
6.7 Insulation and Tracing ...................................................................................................... 21
6.8 Safety Concept ................................................................................................................ 21
7 REFERENCES ................................................................................................................ 22
8 ATTACHMENTS .............................................................................................................. 23
8.1 Cooling Water Unit sketch ................................................................................................ 23
8.2 Cooling Water Consumers Summary ............................................................................... 24
8.3 Plotplan Cooling Water Unit ...........................................................................................2525
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1 INTRODUCTION
1.1 Purpose
The purpose of this document is to define the requirements and the design criteria for the Cooling
Water Unit for the SOCAR & TURCAS AegeanSTAR Refinery (STAR) Project located in
Aliağa/Izmir in Turkey.
1.2 Objective
The objective of the Cooling Water Unit is to produce and distribute Cooling Water of a quality
level that is required by its specific users.
1.3 Brief Process Description

The following brief description of the Cooling Water Unit should be read in conjunction with the
Cooling Water Unit sketch (560-A-PD-0150001) in Attachment 8.1.
The feed to the Cooling Water Unit is Process Water, which is conditioned by chemicals from the
Cooling Water Treatment Package (560PK-001) and is retained in the Cooling Water Basin
(560CO-001). From here, the Cooling Water is pumped to its users and subsequently, returned to
the Cooling Water Tower 560E-001 where it will be cooled and collected in the Cooling Water
Basin.
The Cooling Water will be monitored on the required pH, and conductivity and on hydrocarbons,
with a continuous blowdown sent to the Oily Water Sewer (OWS) and ultimately to the Waste
Water Treatment Unit U-445 (WWTU)the sea to avoid build up of dirt and salt concentration of the
Cooling Water and. The Cooling Water will also be monitored on hydrocarbons and in case of
detected contamination coming from Cooling Water consumers., the blowdown will be routed to
the Waste Water Treatment Unit U-445.
Sand filters (560FIL-001) with automatic backwashing system are foreseen to filter the circulating
Cooling Water.
A drainage pit (560UT-001), part of the Cooling Water Basin, and drain pump(s) (560G-002)
is(are) foreseen to collect any drains and/or cell compartment contents from the Cooling Water
Tower. The drains will be sent to the sea WWTU via the OWSGeneral Drain System or back into
the Cooling Water Basin.
The Cooling Water Tower is vendor specific and is only described in this document for reference
purpose. The final design shall be by Contractor
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2 REQUIRED CAPACITY AND TURNDOWN
2.1 Operational Requirements

The design capacity is based on the total continuous flow from the “Overall Refinery Utility
Summary Table” [Ref.1] and the maximum flow from “STRAS – PETKIM Battery Limit Conditions”
[Ref.2]. The design capacity includes a design margin of 25%.
The turndown capacity of the Cooling Water Unit will be based on only the skimming units of the
refinery in operations. Refer to the table in Attachment 8.2 for an overview of each individual user.
The Cooling Water Unit capacity is summarized below.
Table 1 – Cooling Water capacity
Cooling Water Capacity( m3/h)

Design 21,000
Normal 16,740
Turndown 9,630
Contractor is responsible for validating the Cooling Water unit capacity based on final refinery
utility balance.
2.2 Future Expansion Considerations

No future expansion is considered.
2.3 Design Considerations

The Cooling Water Unit shall supply Cooling Water to all refinery facilities. The Cooling Water
Tower shall be designed according to the design data given in the following table:
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Table 2 – Design data Cooling Water Tower
Design Data Cooling Water Tower

(2) 3
Flow Rate 21,000 m /hr
º
Wet- bulb temperature 24.6 C
2
Fouling resistance m .h. C/kcal 0.0004
(1) º
Range temperature 12 C
º
Approach 5 C
Prevailing wind direction NNE to SSW
st
Average wind velocity 1 quarter of the year is 3.6 m/sec
nd
2 quarter of the year is 2.9 m/sec
rd
th
Design wind load According DIN 1055
º
Max. recorded temperature 41.8 C
st º
Average Dry bulb temperatures 1 quarter of the year is 9 C
nd º
2 quarter of the year is 19 C
rd º
th º
Elevation above sea level 10 - 40 m
Design seismic load (Turkish Standard) ZONE -1 (Similar to California ZONE 4)
(PGA=0.75 g)
Relative humidity
Summertime average: 67.4% (min.66.3% - max. 69.3%)
Wintertime average: 76.3% (min.75.7% - max.76.7%)
Yearly average: 72.7%
º º º
Temperature @ Unit Battery Limit 30 C normal (70 C design for CW Tower and 120 C design
(1)
(CWS) for CW headers)
º º º
Temperature @ Unit Battery Limit 42 C normal (70 C design for CW Tower and 120 C design
(1)
(CWR) for CW headers)
(2)
Pressure @ Unit Battery Limit (CWS) Contractor to determine pressures based on detailed hydraulic
calculations of the Cooling Water network
(2)
Pressure @ Unit Battery Limit (CWR) Contractor to determine pressures based on detailed hydraulic
calculations of the Cooling Water network
Liquid /Gas Ratio (kg water/kg air) By Contractor
3
Evaporation Loss (m /h) By Contractor (max. 2.4% of circulating flow)
CT heat loading k Cal/h By Contractor
3
Make-up rate (m /h) By Contractor
3
Purge rate (m /h) By Contractor
3
Drift Losses (m /h) By Contractor
(% of total recirculation flow) By Contractor (max. 0.02%)
Suspended solids after filtration Max. 5 ppm
º
(1) The cooling outlet temperature shall not be higher than 30 C or the differential temperature shall not lower than 12
º º º
C when the Cooling Water temperature is higher than 42 C with an ambient wet bulb temperature of 24.6 C and a
3
circulating flow of 21,000 m /h.
(2) The discharge pressure of Cooling Water circulation pumps shall be finalized at detailed engineering & design
stage.
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The Unit shall be designed in accordance with the Project Specification to form an integral part of
the Facility including the following:
2.3.1 References
The following Standards and Specifications apply to this Cooling Water Unit Specification in
addition to Owner’s relevant Standards and Specifications applicable for this Project:
a. BS 4485 [Ref.3]
b. CTI-Code-Tower Standard Specifications [Ref.4]
c. CTI Bulletin ATP-105 – Acceptance Test Procedure for Industrial Cooling Towers [Ref.5]
d. AGMA 420 and 151, Gears [Ref.6]
e. ASTM A 123 (Hot Galvanized), Zinc Coating [Ref.7]
All equipment covered by this specification shall conform generally to the C.T.I. Codes [Ref.4], BS
4485 [Ref.3] and to any applicable local and governmental regulations.
Contractor shall be solely responsible for obtaining and conforming to all necessary local and
governmental regulations.
2.3.2 Cooling Water System

Due to the terraced nature of the refinery site, Contractor shall as a minimum verify the following:
 Required discharge and return pressures based on detailed hydraulic network calculations.
 Correct pressure control facilities shall be implemented in the return line to prevent vacuum
conditions at the higher elevated locations due to the static head in the return line.
 The Cooling Water basin is sized such that the liquid inventory of the Cooling Water network
can drain into the basin. Alternatively safeguarding facilities (for example automatic shut-off
valves) could be implemented to prevent drainage of the network upon power failure.
2.3.3 Location
The Cooling Water Unit shall be located in Aegean Refinery of STRAS the STAR Refinery in
Aliağa, Izmir, Turkey. Refer to Attachment 8.3 for the preliminary plotplan of the Cooling Water
Unit. Refer to BEDD [Ref.102] for site location details.
2.3.4 Electrical
 For utilization voltages of medium and low voltage motors see General Project Design
Specification Electric Power and Lighting STGPS-P1 [Ref.8], section 4.0.
 The medium voltage motors shall be in compliance with STGPS-P1 [Ref.8], section 20.0.
 The low voltage motors shall be in compliance with STGPS-P1 [Ref.8], section 21.0.
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2.3.5 Area Classification

 Classification for areas for electrical and instrumentation installations shall be in accordance
with IEC 60079-10-1 [Ref.9] for flammable gases.
 The appropriate electrical and instrumentation equipment according to ATEX 94 / 9 / EC
[Ref.17] shall be selected inside the hazardous area.
 Ex. Certificates shall be provided by Contractor.
 The preferred Ex-protection of instrumentation installed in hazardous are shall be in
accordance with General Project Specification Instrumentation STGPS-J1 [Ref.18], Section
(I), par. 3.0 General.
2.3.6 Process Hazard Analysis

Contractor to perform all applicable Process Hazard Analysis reviews, classifications and
verifications in accordance with the PHA Framework STGPS-S6 [Ref.20].
2.3.7 Civil
Shelter for the pumps of the Cooling Water Tower shall be equipped with a bridge crane suitable
for the heaviest equipment (electric motor, pump itself etc.) installed.
A dedicated substation shall be designed in accordance with STGPS-R6 [Ref.21].
Small buildings such as for dosing units are preferable pre fabricated and pre dressed.
2.3.8 Noise Levels

The sound pressure level in any area of the unit where personnel may be required to work shall
not exceed the appropriate limit set out in STGPS-S14 [Ref.10].
2.3.9 Control & Instrumentation

Control and Instrumentation shall be in accordance with the project specifications STGPS-J1
[Ref.18] and STGPS-J3 [Ref.14].
Control and Interlocking of the Cooling Water Unit shall be done by a dedicated microprocessor
based PLC, which shall be serially connected to the refinery DCS with a redundant serial
communication link for remote observation from the refinery Main Control Room.
The PLC shall be installed in a Remote Instrument Building (RIB), dedicated to the unit or nearby.
The following instrumentation shall be furnished as minimum:
 Circulating Cooling Water flow rate.
 Make-up and blowdown water flow rates.
 Inlet and outlet temperatures of Cooling Water.
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 Air temperature at fan suction.

 Conductivity of Cooling Water supply
 Residual chlorine of Cooling Water in Cooling Water Basin.
 Residual chlorine low and high alarm.
 pH of Cooling Water (Cooling Water inlet and outlet, pump suction)
 Cooling Water level
 Low level alarm.
 Water pressure (supply at pump discharge).
 Low water pressure alarm.
 Pumps on-off indicators (pumps are autostarted locally).
 Fans on-off indicators (start-stop system local).
 Vibration monitoring system on air-fins.
 Pressure control on return line to accommodate for static head from higher elevations.
 Hydrocarbon content of outlet Cooling Water.
 Remote set-point with position transmitter on the chemical dosing pumps and local on/off.
The following instruments shall be installed locally:

 Cooling Water pump discharge pressure.
 Cooling Water pump discharge temperature.
2.3.10 Performance and Guarantees

Contractor shall prepare the Cooling Water Tower performance curves as follows:
 Curves shall indicate the outlet water temperature with varying ambient wet bulb temperature.
 Curves shall cover capacities of 50%, 90%, 100% and 110% at full speeds.
Contractor shall thermally design and guarantee the Cooling Water Tower in accordance with
C.T.I. ATP-105 [Ref.5].
2.3.11 Drawing and Documents

Contractor shall provide all deliverables as specified in the Project Specification.
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3 FEED STREAMS / PRODUCT STREAMS

The feed stream to the Cooling Water Unit is Process Water from PETKIM. Prior to the usage of
Process Water as Make-up, it is flocculated with Aluminum Sulphate by PETKIM. This will be
done outside the refinery area by PETKIM. The quality of Process Water is summarized in Table
3 below:
Table 3 – Process Water quality
Parameter Units Specification Parameter Units Specification

pH at 20 oC 6.7 – 8.5 Sodium mg/L Max. 12
Conductivity (20 oC) μS/c Max. 315 Potassium mg/L Max. 5
m
Turbidity NTU Max. 1.0 Ammonium mg/L Max. 0.05
Organic Matter mg/L Max. 10 Nitrate mg/L Max. 14
(KMnO4)
Total Solid mg/L Max. 205 Nitrite mg/L Max. 0.5
Total Dissolved Solid mg/L Max. 202 Manganese µg/L Max. 50
Total Suspended Solid mg/L Max. 3 Zinc mg/L Max. 5
Total Hardness mg/L Max. 120 Nickel µg/L Max. 20
(CaCO3)
Ca Hardness (CaCO3) mg/L Max. 80 Arsenic µg/L Max. 10
Mg Hardness (CaCO3) mg/L Max. 40 Cadmium µg/L Max. 3
P Alkalinity (CaCO3) mg/L 0 Cyanide µg/L Max. 10
M Alkalinity (CaCO3) mg/L Max. 85 Fluoride mg/L Max. 1.5
Bicarbonate mg/L Max. 85 Lead µg/L Max. 10
Carbonate mg/L Copper µg/L Max. 40
Chloride mg/L Max. 75 Chrome µg/L Max. 10
Sulfates mg/L Max. 25 Aluminum µg/L Max. 200
Silicium dioxide mg/L Max. 15 Antimon µg/L Max. 5
Total Ferrous mg/L Max. 0.2 Boron mg/L Max. 1
Dissolved Ferrous mg/L Max. 0.1 Mercury µg/L Max. 1
Dissolved Oxygen mg/L 3–9 Selenium µg/L Max. 10
Free Chloride mg/L Max. 0.1 Calcium mg/L Max. 100
Adherent chloride mg/L Max. 0.05 Magnesium mg/L Max. 50
The operating and design conditions of Process Water at the PETKIM Process Water Plant
battery limit are:
 Normal (Pressure; Temperature): 3.7 kg/cm2g; Ambient12 °C.
 Maximum (Pressure; Temperature): 4.1 kg/cm2g; Ambient16 °C.
The conditions at the STAR refinery battery limit shall be verified by Contractor.
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The quality of the Cooling Water Unit shall be according to Table 4 below:
Table 4 – Cooling Water quality:
Parameter Units Specification

pH at 20 ºC 7.9 - 8.4
Total Dissolved Solid mg/L 700 - 800
Total Suspended Solid mg/L 5 - 15
Total Hardness (as CaCO3) mg/L 100 - 580
Calcium (as CaCO3) mg/L 70 - 400
Magnesium (as CaCO3) mg/L 30 - 180
P Alkalinity (as CaCO3) mg/L 0 - 10
M Alkalinity (as CaCO3) mg/L 70 - 390
Chloride (as NaCl) mg/L 40 - 500
The Cycle of Concentration (COC) is 4 for cooling water.

Cooling water shall be treated with chemicals such as Scale and Corrosion inhibitors, Dispersant,
Biocides, Hypochloride and Sulfuric Acid. Side stream filters for 310% of the total flow shall be
provided.
The operating and design conditions of Cooling Water are according to BEDD [Ref.102]. These
conditions shall be verified by Contractor.
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4 BATTERY LIMITS
In section 4.1, the utility and chemical requirements of the Cooling Water Unit are described. In
section 4.2 the effluent streams from the Cooling Water Unit are identified.
4.1 Utilities, Chemicals and Electricity

The following utilities and chemicals are used in the Cooling Water Unit (to be confirmed by
Contractor). For the specific utility conditions, see BEDD [Ref.10].
 Instrument Air
 Plant Air
 High Pressure Steam
 Boiler Feed Water
 Electricity
 Sulfuric Acid
 Sodium Hypochloride
 Corrosion / Scale inhibitor
 Biocide
 Dispersant
The utility / chemical requirements shall be determined by Contractor.
4.2 Effluents
The effluent stream of the Cooling Water Unit is:
 Cooling Water blowdown from the Cooling Water Tower will be sent to the sea. In case of oil
contamination the effluent from Cooling Water Unit will be routed to the OWS and ultimately to
the WWTU (or OWS). Composition and amount to be verified by Contractor.
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5 EQUIPMENT
This paragraph describes the design considerations of individual equipment in the Cooling Water
Unit. Contractor shall perform Basic & Detailed engineering & design in accordance with the
Project Specification.
5.1 Cooling Water Tower 560E-001, Cooling Water Basin 560CO-001, Cooling Water Drainage
Pit 560UT-001, Cooling Water Drainage Pit Pump 560G-002
5.1.1 General requirements

 Fans, manually adjustable pitch type, with gear reducers for single speed motors.
 Drainage lines and drainage pit with pumps that is sufficient for containing the volume of 1 cell
of the Cooling Water Tower.
 Tower frame structure, louvers, casing and water basin shall be of reinforced concrete
construction. Concrete parts of the Tower shall be protected against all corrosive, biological
and chemical environment in the tower by an appropriate cover.
 Contractor to state clearly the Code to which the wind load and snow load calculations have
been based upon.
 The relation between the orientation of the Tower and the direction of the prevailing seasonal
winds shall be considered for any effect on performance.
 Fire protection facilities are required in the design of the Tower. Contractor shall install one
hose reel near each end of the Tower and a hydrant on the Tower deck. Contractor shall
connect the hose reels and hydrant to the existing fire protection and safety facilities of the
refinery as described in STRAS STAR standards STGPS-S4 [Ref.11].
 Each fan shall be fitted with a vibration monitoring and cut-off system to automatically monitor
and cut-off the power supply to fan on detection of high vibration.
 Precautions to be taken to prevent ice formation during winter operation, if necessitated by the
site climatic conditions. Contractor shall provide a winter operation philosophy including
wind/snow load, prevention of ice formation during winter operation.
 Cathodic protection of rebar in the concrete water basin shall be provided.
Structure
 Fan decks and water distribution decks shall be designed for a live load of 500 kg/m2 and shall
be reinforced for any concentrated or distributed load such as fans, drivers, and maintenance
equipment used to service and handle them during operation or maintenance. Design of the
whole structure shall be done according to the load combinations and other conditions given in
STGPS-R1/ R2 [Ref.12], STGPS-R4 [Ref.13] and BEDD Section 5 [Ref.10].
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 The main frame shall form an integral structure, transmitting all load stresses directly to the
Tower foundations.
Pavings
 Pavings shall be designed as per STGPG-S3 [Ref.22] and STGPS-S5 [Ref.23].
Sewers
 Sewer systems shall be designed and installed as per STGPS-S3 [Ref.22].
Foundation Basin
 Each basin division shall be designed so that it can be shut down for maintenance while the
others are operating.
 Each basin division, flumes and suction bay shall be sloped and provided with a sump so that
it may be pumped out for maintenance. Water flume and pump suction bay shall be covered
with galvanized grating.
 The top of the pump casing shall be located at a minimum of 0.30 m below the normal
operating level of the basin. If this is achieved by locating the pumps below grade, they shall
be placed in a concrete pit protected to prevent flooding due to Cooling Water leakage or rain
water run off.
 A pair of screen with a double track shall be provided for each basin division, such that one
may be removed or inserted without removing the other. Slide gate valve shall be provided
ahead of the screens. Stainless steel material shall be provided for screen, track and slide
gate valves.
 A platform shall be provided adjacent to the screens to provide access for maintenance. The
screens shall be designed to be lifted by mobile maintenance equipment.
Louvers & Casing and Partitions

 Air inlet louvers shall be in reinforced concrete designed to give an even air distribution into
the Tower and easily removable for maintenance access.
 Louver assemblies shall be adequately supported to prevent warping and sagging.
 Louver shall extend down to Cooling Water Basin to avoid splashing outside the basin.
 Tower external casing shall be reinforced concrete. The casing may be prefabricated
reinforced concrete panels or cast in place reinforced concrete with steel formwork. In case of
prefabricated reinforced concrete panels sealing strips shall be used between the panels to
provide water tight joints. Joint of prefabricated panels to the main frame of the structure shall
be done by means of cast in place concrete pouring.
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 The Cooling Water Tower shall be divided so that each cell and its basin can be maintained
while the others are in operation.
 Partition walls shall be close boarded watertight, extending from fan deck level to basin cell, to
permit taking any cell out of service without affecting operation of other cells.
 Individual cells serviced with two or more fans shall be provided with transverse partition
walls, centered between fans, to prevent recirculation of air and air by passing through the
filling when one or more fans are not operating.
Steel structures
 Steel structures shall be designed and installed as per STGPS-MR1 [Ref.24] and applicable
standard drawings.
 Stairs ladders and steel platform structures shall be designed and installed as per STGPS-
MR1 [Ref.24] and applicable standard drawings.
 Painting of steel structures shall be as per STGPS-N1 [Ref.25].
Drift Eliminators
 Drift eliminators shall be designed to limit the draft loss under any or all conditions to a
maximum of 0.02 % of the water circulation rate.
 Drift eliminator design shall allow ready access to distribution system headers, laterals and
nozzles.
 The drift eliminators shall be fabricated in removable panel sections. Eliminator sections shall
be arranged to permit easy handling and removal from the Tower. Sections shall be designed
to withstand a minimum live load of 150 kg/m2.
 Drift eliminators material shall be PVC or any other material that Contractor advises.
Fill
 Fill material as grids and supports shall be rigid PVC or polypropylene, fire extinguishing type,
comprising grids arranged in splash back formation.
 The fill shall be built and arranged in modular sections to permit easy handling and removal
from the Tower. Fill shall be properly supported and fastened to prevent warping or buckling
under all expected operating conditions.
Fans
 Fans shall be high efficiency, low speed, propeller type, of proven design with a minimum of 6
(six) blades.
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 Blades shall be fabricated from glass reinforced plastic.

 Blade pitch shall be manually adjustable and blades shall be individually fastened to a hub of
stainless steel or aluminum alloy.
 Fan assemblies shall have hub statically and dynamically balanced and fan blades statically
balanced. The blades shall be balanced with master blade and barycentric weight system in
order to have all blades interchangeable.
 Fans shall be balanced for each tip angle.
 Fan tip speed shall not exceed the speed requirements for confirming to noise limitations.
 Vibration control system referenced in section 2.3.5 shall be of the micro processor controlled
type. In addition, for each fan, a magnetic type, manual reset emergency vibration switch, with
double contacts; one normally open and one normally closed, to suit electrical supply cut-off
shall be specified.
Fan Gears
 Fan gears shall be of the spiral bevel reduction gear for the horsepower requirement at the
maximum required fan pitch angle and design fan speed, with a service factor of 2.0.
 Oil filters with level indicator shall be located outside the fan ring. Lube oil piping to be
stainless steel.
 The design and construction shall be completed by conforming to the AGMA standards
[Ref.6].
 Seals shall be provided to afford protection against moisture leakage at the shaft. Oil filling
and level connections shall extend to the outside of the fan deck.
 The carter of the gear reducer shall be protected by special paint.
Fan Motors
 Fan motors shall be as per electrical General Project Design Specification; STGPS-P1 [Ref.8].
 The motor horsepower shall be sufficient to meet the fan requirement at the maximum
required pitch angle and design speed.
 The fan motors shall be mounted outside the fan ring in a location easily accessible for
maintenance
 Fan motors and electrical connection elements shall be selected in accordance with the area
classification concerned.
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Couplings
 A tubular floating shaft with flexible couplings of approved type shall be provided to connect
each motor and speed reducer assembly. Shaft and coupling shall be stainless steel.
 Shaft and coupling assembly shall be dynamically balanced.
Guards
 Suitable heavy duty guards shall be fitted for personnel protection to cover the exposed
moving parts of the gear, motor and drive shaft.
Fan stacks and Deck

 Fan stacks shall be steel. The fan shall be constructed using steel framework. Glass
reinforced polymer with a protective sheeting inside shall be submitted as an alternative.
 The stack design shall incorporate or provide for a modified venturi throat. Stacks shall have a
height that minimum 5 ºC cooling of Cooling Water can be realized with no fan operation at the
design conditions.
 Reinforced concrete deck structure shall bear any concentrated or distributed dead loads,
such as fan, drivers during operation or maintenance.
 Each fan stack shall be provided with a removable access door.
Fan System Equipment Supports

 Galvanised structural steel shall be supplied to form an integral unit support for fan, gear and
driver.
 The support unit shall be designed to ensure permanent alignment of motor, drive shaft and
reduction gear.
Water Distribution Systems

 The distribution system shall be designed to permit flexible operation of the Tower and to
permit each cell to be taken out of service independently.
 Any piping shall be galvanized steel, plastic or PVC.
 The main inlet connections shall be flanged to ANSI Rating, 150 RF.
 Headers and laterals shall be provided with cleaning access or flush out facilities.
 Spray nozzles shall be self-draining non-clogging type.
 Insulation and/or tracing shall be provided as required for winterization purposes.
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Provision for Access

 Access shall be provided to the drift eliminators, the water distribution system, and fans of
each cell by means of stairs from the fan deck. There shall be one access door for each fan
assembly.
 For extended fan stacks, access to fans, gears and couplings shall be provided by a
removable section or access door in each stack. These sections shall be of sufficient size to
permit removal of the fan hubs and speed reducers.
 The Tower shall be equipped two full stairways at each end for safe access to both interior
and top deck. An escape ladder, with hoop guard, shall be provided at opposite end of Tower.
Stairs and handrails shall be per standard drawings and STGPS-MR1 [Ref.24].
 Handrailing (as per STGPS-MR1 [Ref.24] and adjacent standard drawings) shall be provided
on stairways, platforms and around the fan deck.
Vibration Cut-out Switch

 One monitoring system (explained in section 2.3.5) and one emergency vibration cut-out
switch per fan shall be furnished. Emergency vibration cut-out switch shall be located outside
the fan ring. It shall automatically shut the fan down in case of excessive vibration, and shall
require manual resetting before the driver can be restarted.
 The vibration monitoring system and vibration switch shall:
a. Be suitable for the area classification of its location per specification for Electrical
Equipment Furnished with Package Units (STGPS-J3) [Ref.14].
b. Have an external reset device such that it is not necessary to disassemble the switch for
resetting.
c. Be capable of being set at some known, predetermined increment above the normal
vibration level, and
d. Not trip out due to acceleration of the machinery during starting.
5.2 Cooling Water Treatment Package 560PK-001, Cooling Water Sand Filter 560FIL-001
Cooling Water Treatment Facilities to be installed in a dedicated area close to Cooling Water Unit.
The location of the exact area to be evaluated during Detailed engineering & design stage. The
Treatment Facility shall be properly sheltered and the floor shall be covered with suitable tiles
which are resistive to chemicals. Electric operated hoists with two tons for loading and unloading
chemical containers shall be provided with sufficient quantity.
Cooling Water Treatment shall consist of:
 Sodium hypochloride dosing system.
 Sulfuric acid dosing system.
SH/OF
REV A 0 1 2
 Corrosion/scale inhibitor dosing system (corrosion control and scale prevention).

 Biocide dosing system.
 Dispersant is added to keep particulate matter in suspension
 Filtration of circulating Cooling Water.
Each dosing system shall consist of two dosing pumps, one drum for seven days capacity and
one measuring pot including mixer, if necessary. Drums shall be equipped with level gauge and
level switch for low level alarm.
Sand filters and back wash systems which are capable to filtrate 310% of the Cooling Water
Tower circulating water capacity shall be provided. Each filter unit shall have minimum two
separate filters. A blower shall be provided for each filter unit for air supply.
Filters shall be able to remove 90% of suspended solids of size 10 microns or larger. Total
amount of suspended solids after filter shall be less than 5 ppm.
Automatic backwashing system for the filter units shall be provided. All operations and sequences
are monitored by a PLC including three modes:
a. Automatic mode: all sequences are automatically initiated and checked by the PLC.
b. Semi-automatic mode: backwashing is manually started by the operator but backwashing
operations are sequenced by the PLC. At the end of backwashing, the filters come back to
production sequence.
c. Step by step mode: as semi-automatic mode, but all operations of backwashing are manually
sequenced by the operator.
Backwashing will be actuated by either time or differential pressure across the filter whichever
condition is reached first. Filters are interlocked to allow only one filter to be cleaned at any one
time. Backwash water and pressure will be generated from the filter operation. Washing frequency
shall be maximum two washes per day for each filter.
External and internal surfaces of the filters shall be protected against corrosion with suitable
coating. Type of surface treatment is subject to Owner’s approval.
5.3 Cooling Water Pumps 560G-001A/B/C/D/E

In total 5 Cooling Water pumps (3 back pressure steam turbine driven pumps will be in operation
and 2 electrical driven pumps will be spare) shall be installed in pump station with a shelter and
lifting facilities to be constructed by Contractor. Each pump shall have a capacity of 7,000 m3/h.
The steam turbines shall utilize HP steam and let down to MP steam. The steam shall be
desuperheated to the appropriate header temperature.
Cooling Water circulating pumps shall be horizontal types, in accordance with API 610 [Ref.15].
Vertical pumps shall not be used. Vendor deviations from API 610 will be subject to Owner’s
review and (reasonable) approval.
SH/OF
REV A 0 1 2
6 OPERATIONS PHILOSOPHY
6.1 Operating Availability and Reliability

The Cooling Water Unit must have a high availability and reliability due to the criticality of the
system. This should be ensured in the system design.
Failure of Cooling Water pumps can result in vacuum in the Cooling Water headers. Therefore
either full vacuum specification or vacuum breakers are required for the Cooling Water return
lines. The Contractor shall take this into consideration in the design of the Cooling Water system.
6.2 Sparing Philosophy

The Cooling Water Pump (560G-001A/B/C/D/E) will have two electrical driven spare pumps.
Sparing of the Cooling Water Drainage Pit pump (560G-002) is to be advised and implemented in
the design by the Contractor.
6.3 Start-up and Shutdown

Special requirements for start-up or shutdown of the Cooling Water Unit to be specified by
Contractor.
Maintenance activities that will result in a longer downtime (>24 hrs) should be executed during a
planned total refinery shutdown.
Before startup of the Cooling Water system the system has to be filled and passivated.
Cooling Water failure is usually one of the causes of a large flare load for the refinery. A high
reliability of the Cooling Water system is essential. In certain cases, for process units requiring
Cooling Water during power failure, water cooling could be replaced by air cooling connected to
secure power supply. Assessment and implementation of these critical users shall be done by the
Contractor.
6.4 Modes of Operation

6.4.1 Normal operation
During normal operation the 3 back pressure steam turbine driven Cooling Water pumps feed the
normal consumers in downstream systems and are sufficiently sized to provide additional Cooling
Water to intermittent users.
6.4.2 Turndown Case
The turndown capacity of the Cooling Water Unit will be based on the skimming units of the
refinery in operations, refer to the table in Attachment 8.2:
 U-100 CDV/VDU (Crude / Vacuum Distillation Unit)
 U-110 SGP (Saturated Gas Plant)
 U-120 NHT (Naphtha Hydrotreater Unit)
 U-130 KHT (Kerosene Hydrotreater Unit)
SH/OF
REV A 0 1 2
 U-140 DHT (Diesel Hydrotreater Unit)

 U-160 CCR (Continuous Catalytic Regeneration Reformer)
 U-410 SRCT (Saturated LPG Merox Unit)
 U-420 ARU Train 1 (Amine Regeneration Unit)
 U-430 SRU Train 1 (Sulphur Recovery Unit)
 U-440 SWS Train 1 (Non-Phenolic Sour Water Stripper)
During winter operation it is possible to operate temporarily with a single cooling tower cell for
maintenance (to be confirmed by Contractor).
6.4.3 Cleaning Operation
Cleaning will be carried out during the winter months when one of the cooling tower cells can be
taken out of operation due to cold ambient conditions. The circulation rate will remain at full
capacity (to be confirmed by Contractor).
6.5 Material Handling Philosophy

Materials in the Unit shall be handled as described in section 6.8.
6.6 Flaring and Draining

The Cooling Water Unit will not be connected to the flare system.
Draining shall be in accordance with”Refinery Drainage Philosophy” [Ref.16]. Process drains from
the Cooling Water Tower are routed to the Cooling Water Drainage Pit (560UT-001) first, where it
will be analyzed on pH, before it is send to the General Drain System.
6.7 Insulation and Tracing

Insulation shall be provided to maintain Cooling Water within the operating conditions limit, such
as through exposure to heat sources and/or solar radiation.
Steam tracing shall be provided where Cooling Water lines are exposed to conditions that could
result in freezing of the Cooling Water.
6.8 Safety Concept

As part of the basic and detailed engineering, Contractor shall include in the design special
facilities for safe handling Sulfuric Acid, Sodium Hypochloride, Corrosion / Scale Inhibitor, Biocide
and Dispersant, including provisions for personnel protection.
SH/OF
REV A 0 1 2
7 REFERENCES
1. Overall Refinery Utility Summary Table, BD0506A-PR-000-UB-001 F05.
2. STRAS – PETKIM Battery Limit Conditions, 9 June 2011 Rev.0.Deleted
3. British Standard 4485.
4. CTI-Code-Tower Standard Specifications.
5. CTI Bulletin ATP-105 – Acceptance Test Procedure for Industrial Cooling Towers.
6. AGMA 420 and 151, Gears.
7. ASTM A 123 (Hot Galvanized), Zinc Coating.
8. General Project Design Specification Electric Power and Lighting, STGPS-P1.
9. Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas atmospheres, IEC
60079-10-1.
10. Basic Engineering Design Data, BD0506A-01A1 F03STGPS-A0.
11. Fire Protection and Safety Facilities, STGPS-S4.
12. Specification for foundations and concrete structures, STGPS-R1/ R2.
13. Civil Design Loads, STGPS-R4.
14. Instruments for Packaged Units, STGPS-J3.
15. Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries, API 610.
16. Refinery Drainage Philosophy, BD0506A-PR-0000-BD-002.
17. Equipment and protective systems intended for use in potentially explosive atmospheres,
ATEX 94 / 9 / EC.
18. General Project Specification Instrumentation, STGPS-J1.
19. List of Vendors for Equipment and Materials, attachment 8.8 of ITB.
20. PHA Framework, STGPS-S6.
21. Buildings, STGPS-R6.
22. Sewer and Paving, STGPS-S3.
23. Roads, Fencing and Paved Areas for Vehicles, STGPS-S5.
24. Steel Structures – General, STGPS-MR1.
25. Painting – General, STGPS-N1.
26. Ergonomics and accessibility, STGPS-S14.
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REV A 0 1 2
8 ATTACHMENTS
8.1 Cooling Water Unit sketch

A B C D E F G H I J K L M N O P Q R S T
NOTES
NOTES:
1 1
560G-002 HOLD 560UT-001 560PK-001 560CO-001 560E-001 560FIL-001 560G-001 A/B/C/D/E

1. 5 Pumps in total: 3 steam turbine driven
Cooling Water Drainage Pit Cooling Water Drainage Pit Cooling Water Treatment Cooling Water Basin Cooling Water Tower Cooling Water Sand Cooling Water Pumps
pumps will be in operation, 2 electrical driven
Pump Package Filter
pumps will be spare.
2 2 2. Number of cells and fans per Cooling Water

Tower by Contractor.
3. Each dosing system consist of two dosing

pumps, one drum, and one measuring pot with
3 3 mixer, if necessary.
4. With automatic backwashing system.
Dispersant 5. Number and type of pumps to be determined

4 4 by Contractor.
6. Drainage pit is part of the Cooling Water

Basin. Final design of the drainage system by
Contractor.
5 Sulphuric acid 5
6 6
Sodium hypochloride
pH PC
AI
7 7
pH
Corrosion/scale inhibitor
AI
8
Users 8
Biocide
9 9
Conductivity
AI
560PK-001
NOTE 2
NOTE 3 1
Hydrocarbons
Make-up Water FC
AI
10 10
Process Water (PETKIM) FC
Continuous
560FIL-001 Blowdown
NOTE 4 To WWTU (via OWS)
11
M 1 11
HP steam
pH Chlorine
560G-002 HOLD LC AI AI
12
560E-001 12
NOTE 5
1
560G-001 A/B/C
13 13
NOTE 1 BFW
560UT-001 560CO-001
NOTE 6 TC
14 14
MP steam 1 22/02/13 UPDATED WITH FEED MODIFICATIONS ISSUED FOR DESIGN R.M. Y.M. J.S.
0 14/10/11 FOR CLIENT COMMENTS & APPROVAL R.M. I.M. N.J.
NNF
1 A
REV.
24/10/11
DATE
INTERNAL REVIEW
DESCRIPTION
R.M.
BY CHD.
I.M. N.J.
APPR.
REVISIONS
CONTRACT No.
Drainage 560G-001 D/E JOB No.

S3ST
®
REQ No.
15
To WWTU (via OWS) 1 15
FLUOR DWG. No PLANT LOCATION

560-A-PD-0150001 IZMIR-TURKEY
SOCAR & TURCAS

AEGEAN REFINERY (STAR) PROJECT
SCALE
NONE
16 16 COOLING WATER UNIT SKETCH EQUIPMENT No
PLANT No INDEX REVISION
1
CAD FILE NAME
A B C D E F G H I J K L M N O P Q R S T
SH/OF
REV A 0 1 2
8.2 Cooling Water Consumers Summary

Total
continuous Turndown
3 3
Unit Number Unit Name m /h m /h
U-100 CDV/VDU (Crude / Vacuum Distillation Unit) 3769 3769
U-110 SGP (Saturated Gas Plant) 1670 1670
U-116 UGP (Unsaturated Gas Plant) 33 0
U-120 NHT (Naphtha Hydrotreater Unit) 176 176
U-130 KHT (Kerosene Hydrotreater Unit) 200 200
U-140 DHT (Diesel Hydrotreater Unit) 1205 1205
U-150 HCU (Hydrocracker Unit) 4736 0
U-160 CCR (Continuous Catalytic Regeneration Reformer) 1781 1781
U-190 DCU (Delayed Coker Unit ) 1477 0
U-410 SRCT (Saturated LPG Merox Unit) 4 4
U-415 URCT (Unsaturated LPG Merox Unit) 3 0
U-420/421 ARU (Amine Regeneration Units) 11 6 (1)
U-430 SRU (Sulphur Recovery Unit) 924 462 (2)
U-440/441,U-442 SWS (Non-Phenolic/Phenolic Sour Water Stripper) 368 202 (3)
U-450 HGU 224 0
U-514 Fuel Gas System 0 0
U-518 Natural Gas System 0 0
U-520 Plant Air / Instrument Air System 65 65
U-530 Fire Water System 0 0
U-535 Cold Condensate System 63 63
U-540 Fresh Caustic System 0 0
U-600 Interconnecting 0 0
U-610/640 Sulphur Handling System/Product Storage 0 0
U-620 Crude Storage 0 0
U-630 Intermediate Storage 0 0
U-643 Coke Handling System 0 0
U-655 Spent Caustic System 0 0
U-660/U-661/U-662 Flare System 28 28
Utility Stations
TOTAL 16737 9630
(1) For one ARU train in operation; 50% capacity of normal case is assumed.
(2) For one SRU train in operation; 50% capacity of normal case is assumed.
(3) For only U-440 in operation.
(4) Total continuous flows are based on [Ref.1]
SH/OF
REV A 0 1 2
8.3Plotplan Cooling Water Unit

Basis of Design Cooling Water

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Basis of Design Cooling Water

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CONTRACT N°

STAR RAFINERI A.S.

Cooling Water Unit

Updated with FEED

2 REQUIRED CAPACITY AND TURNDOWN ....................................................................... 5

3 FEED STREAMS / PRODUCT STREAMS ....................................................................... 10

4 BATTERY LIMITS ............................................................................................................ 12

5.3 Cooling Water Pumps 560G-001A/B/C/D/E ...................................................................... 19

1.3 Brief Process Description

2 REQUIRED CAPACITY AND TURNDOWN

2.1 Operational Requirements

Table 1 – Cooling Water capacity

Cooling Water Capacity( m3/h)

2.2 Future Expansion Considerations

2.3 Design Considerations

Table 2 – Design data Cooling Water Tower

Design Data Cooling Water Tower

2.3.2 Cooling Water System

2.3.5 Area Classification

2.3.6 Process Hazard Analysis

2.3.8 Noise Levels

2.3.9 Control & Instrumentation

 Air temperature at fan suction.

The following instruments shall be installed locally:

2.3.10 Performance and Guarantees

2.3.11 Drawing and Documents

3 FEED STREAMS / PRODUCT STREAMS

Table 3 – Process Water quality

Parameter Units Specification Parameter Units Specification

Parameter Units Specification

The Cycle of Concentration (COC) is 4 for cooling water.

4.1 Utilities, Chemicals and Electricity

5.1.1 General requirements

Louvers & Casing and Partitions

 Blades shall be fabricated from glass reinforced plastic.

Fan stacks and Deck

Fan System Equipment Supports

Water Distribution Systems

Provision for Access

Vibration Cut-out Switch

 Corrosion/scale inhibitor dosing system (corrosion control and scale prevention).

5.3 Cooling Water Pumps 560G-001A/B/C/D/E

6.1 Operating Availability and Reliability

6.2 Sparing Philosophy

6.3 Start-up and Shutdown

6.4 Modes of Operation

 U-140 DHT (Diesel Hydrotreater Unit)

6.5 Material Handling Philosophy

6.6 Flaring and Draining

6.7 Insulation and Tracing

6.8 Safety Concept

8.1 Cooling Water Unit sketch

560G-002 HOLD 560UT-001 560PK-001 560CO-001 560E-001 560FIL-001 560G-001 A/B/C/D/E

2 2 2. Number of cells and fans per Cooling Water

3. Each dosing system consist of two dosing

4. With automatic backwashing system.

Dispersant 5. Number and type of pumps to be determined

6. Drainage pit is part of the Cooling Water

Process Water (PETKIM) FC

Drainage 560G-001 D/E JOB No.

FLUOR DWG. No PLANT LOCATION

SOCAR & TURCAS

PLANT No INDEX REVISION

8.2 Cooling Water Consumers Summary