Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-101-1222-0001S
Limited Liability Company
Nghi Son, Vietnam Rev. 1 Page 1 of 17

Employer Contract No.: , Contractor JOB Code: 0-6495-20 Date: 02/FEB/16

Design Basis for Service Water / Potable Water

Unit No.: 101

Unit Abbreviation.: SPW

Document Class: X

Issue Purpose For Construction

Rev Date Page Description Prep'd Chk'd App'd

1 02/FEB/16 ALL Revised IFC J.H.H H.S.K M.J.K

0 29/NOV/13 ALL Issued for Construction J.H.H H.S.K M.J.K
A 04/SEP/13 ALL Issued for Review J.H.H H.S.K M.J.K

Operation Centre JOB Code: 11102D Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
SK J.H.Han H.S.Kim M.J.Kim

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CONTENTS

1 INTRODUCTION.............................................................................................................................. 3
1.1 Unit Processing Objectives ........................................................................................................... 3
1.2 Use of Document............................................................................................................................ 3
2 UNIT DEPENDENCE ....................................................................................................................... 3
3 BASIS OF DESIGN.......................................................................................................................... 3
3.1 Design Objective ............................................................................................................................ 3
3.2 Design Capacity ............................................................................................................................. 4
3.3 Feedstock Properties ..................................................................................................................... 4
3.3.1 Raw Water Quality .................................................................................................................. 4
3.4 Product Specification..................................................................................................................... 4
3.4.1 Service Water Quality ............................................................................................................. 4
3.4.2 Potable Water Quality ............................................................................................................. 4
3.5 Service Water/ Potable Water Demand.......................................................................................... 5
3.5.1 Service Water Demand ........................................................................................................... 5
3.5.2 Potable Water Demand ........................................................................................................... 5
3.6 SYSTEM DESCRIPTION ................................................................................................................. 6
3.6.1 Service Water Storage and Distribution ................................................................................ 6
3.6.2 Potable Water Storage and Distribution ................................................................................ 6
3.7 Utilities............................................................................................................................................ 7
3.8 Other Raw Material Requirements................................................................................................. 7
4 BATTERY LIMIT CONDITIONS ....................................................................................................... 7
5 PROCESS SCHEMATICS ............................................................................................................... 8
6 APPENDICES NOTES..................................................................................................................... 9
6.1 Appendix 1 – Raw Water Demand ................................................................................................. 9
6.1.1 Appendix 1.1 - Overall Water Balance Diagram..................................................................... 9
6.1.2 Appendix 1.2 –Summary of Equipment Design Capacity ................................................... 10
6.2 Appendix 2 – Raw Water Quality ................................................................................................. 11
6.3 Appendix 3 – Service Water Demand .......................................................................................... 12
6.4 Appendix 4 – Potable Water Demand .......................................................................................... 14
6.5 Appendix 5 – Service Water Pump Design Capacity .................................................................. 15
6.6 Appendix 6 – Users Battery Limit Conditions............................................................................. 17

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1 INTRODUCTION

1.1 Unit Processing Objectives

This unit is designed to receive Raw water import supply for storage and distribution as
Service water and Potable water for various process units in the refinery and to utility and
offsite systems.

1.2 Use of Document

This document defines the design basis of Service Water and Potable Water System.

For supporting information, please refer to the latest issued revision of the following
documents:

· Basic Engineering Design Data (S-000-1220-0001V)

· Fire & Gas Detection & Protection Specification (S-000-1241-0001V)

· Demineralised Water System Design Basis (S-102-1222-0001S)

2 UNIT DEPENDENCE

The Service Water and Potable Water Unit shall be capable of operating as an independent
unit subject to the availability of

· Raw water import

· Chemicals for Chlorination

· Utilities

· Disposal of effluent waste stream

· Emergency Power

3 BASIS OF DESIGN

3.1 Design Objective

An import supply of Raw water is received by pipeline from NSEZ and is metered at the
Service and Potable Water System Unit battery limit and supply is provided to Service
water Storage Tanks, Potable water Storage Tanks and Fire water Storage Tank.

Based on the Raw water quality parameters provided, no further treatment is required for
use as Service water by Refinery users. Thus, Service water is supplied from a Storage
Tanks (101-TK-001 A/B) filled from the Raw water supply.

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Additionally, a separate connection from the Service water Storage Tanks to Fire water
pump suction line shall be provided for use in emergency.

The Raw water supply is of Drinking water quality and is suitable for use without any
treatment as Potable water. Therefore, Raw water is supplied to the Potable water Storage
Tanks (101-TK-002 A/B), with a facility to filter and chlorinate all the supply water upstream
of the Potable water Storage Tanks to ensure that the water quality is maintained in
storage.

The Raw water available quantity is limited to 30000 m³/day.

3.2 Design Capacity

Raw water daily demand is estimated to be 1165.5 m³/h (i.e.1151.5+14 m³/h). The Raw
water requirement of the various process units in the refinery and utility & offsite systems is
tabulated in Appendix -1.

The Service water daily demand is estimated at 1151.5 m³/hr. The supply system should be
designed for variation in demand from process units. Refer Appendix-3.

Daily average demand of Service and Potable water are

· Service water : 27636 m³/day Refer Appendix-1

· Potable water : 336 m³/day Refer Appendix-1

For Equipment design capacity refer Section-6.1.2, Appendix-1.2.

3.3 Feedstock Properties

3.3.1 Raw Water Quality

Raw water quality is tabulated in Appendix 2.

3.4 Product Specification

3.4.1 Service Water Quality

The Service water quality is same as Raw water quality. Raw water will be used as Service
water without any treatment. Quality of Service water is same as defined in 3.3.1.

3.4.2 Potable Water Quality

Potable water supplied from the Potable water Storage Tank shall meet the Raw water
quality defined in 3.3.1, plus the following additional parameters (all values as maxima
unless otherwise indicated).

· Free Chlorine: 0.3 mg/l – 0.5 mg/l

· Total Coliforms: 0 Bacterium/100ml

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· Thermotolerant Coliforms 0 MPN/100ml

3.5 Service Water/ Potable Water Demand

3.5.1 Service Water Demand

The Service Water requirement of the various process units in the refinery and utility &
offsite systems is tabulated in Appendix 3.

3.5.2 Potable Water Demand

a) Design Basis

The Potable Water System consists of storage tanks, Potable water filters, Chlorination
Package, Auto backwash Sand Filter, Potable Water Supply Pumps, and above ground
insulated distribution pipework. The Potable water distribution is a pressurised distribution
system.

The Potable water supply shall provide the needs of the personnel working in the NSRP
organisation and the site contractors, details of which are given below.

· 450 Shift Workers (3 shifts / 24 hours)

o 150 Shift workers (1 Shift / 8 hours)

· 524 Day Workers

· 120 Day Contractors

This gives a maximum of 794 workers on site simultaneously during the day and a total of
1094 individual workers on site in a 24 hour period.

The above number of workers is based on preliminary information provided on NSRP

Organization Structure after plant start up in 2016. These will be confirmed once actual
NSRP Organizational Structure is firmed up later.

For the purpose of estimating the Potable water demand, the following assumptions are
considered.

· Water consumption: 300 litres per man-day

· A Peaking Factor of 6 is applied to the average water demand to give peak Potable
water requirement for pump sizing.

b) Potable Water Demands

The Potable water requirement for the entire NSRP complex is tabulated in Appendix 4.

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3.6 SYSTEM DESCRIPTION

3.6.1 Service Water Storage and Distribution

a) Service Water Tanks

The Raw water is received and stored in Service water Storage Tanks (101-TK-001 A/B).
Service water storage is 27636 m³ for one day at daily average flow rate (including design
margin) identified in Appendix 3, plus an additional 17220 m³ capacity (referred from
document S-000-1241-0001V) as back up source to provide Fire water. Total working
volume of Service water Storage Tanks is 44856 m³. The Tanks are 2X50% capacity. Each
Tank working volume is 22428 m³. Provision will be made to connect this Fire water
supply to the suction of Fire water Pumps. The Tanks are constructed of carbon steel with a
phenolic epoxy lining to prevent corrosion.

b) Service Water Pumps

Service water Pumps are provided to supply service water to users at the conditions
identified in Section 4. The Service water Pumps (101-P-001A/B/C) are 3 X 50 % duty to
meet the design capacity defined in Appendix 5. These Pumps are electric motor driven
and shall be connected to the emergency power supply to be able service water supply into
the independent CW system in Unit 110&121 during GPF.

Service water Pumps (101-P-001 A/B/C) are sized at a capacity of 230 m³/h per pump.

One Pump runs for normal demand, two Pumps are required for peak demand.

c) DM Plant Supply Pumps

Separate set of Service water Pumps are provided to supply Service water to Demin Plant
at required supply pressures. To meet this requirement, Demin Plant Supply Pumps
(101-P-003 A/B) are provided to supply Service water to Demineralization Unit at the
condition identified in Section 4. The DM Plant Supply Pumps are 2 x 100% duty to meet
the design capacity defined with considered the product design capacity of RO / IX unit
(650 m³/h which includes design margin) and 20% of RO reject / 10% of IX regeneration
loss. These pumps are electric motor driven.

DM Plant Supply Pumps (101-P-003 A/B) are sized at a capacity of 902.8 m³/h per pump.
One pump operating and second pump is stand-by.

3.6.2 Potable Water Storage and Distribution

a) Potable Water Tanks

The Potable water is stored in Potable water Storage Tanks (101-TK-002 A/B). The Potable
water storage is for two days at design flow rate identified in Appendix 4. Total storage
capacity of Potable water Tanks is estimated to be of a working volume of 1440 m³. The
Potable water storage is 2 X 50% capacity. Each Tank working volume is 720 m³. The
Tanks are constructed of carbon steel with a phenolic epoxy lining to prevent corrosion.

b) Chlorination Package

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Chlorination Package (101-A-001) is provided at upstream of the Potable water Storage

Tanks (101-TK-002 A/B) to maintain the free chlorine concentration at 0.3 mg/l in the
Potable water supply to users. Also, shock dosing of Hypochlorite is done once in 3-5
weeks (To be confirmed) to disinfect the water to protect against Legionella. It is envisaged
that sodium hypochlorite solution is supplied to the site in drums as a 10~12% solution.

Further, an Auto Backwash Sand Filter Package (1X100%) is provided in the pump
minimum flow recycle line for algae removal. A continuous flow of about 14 m³/h is ensured
through this filter.

c) Potable Water Supply Pumps

Potable water Supply Pumps are provided to supply Potable water to users at the condition
identified in Section 4. The Potable water Supply Pumps (101-P-002A/B/C/D) are 4 X 33%
duty to meet the peak capacity defined in Appendix 4 plus continuous recycle (i.e.107+14
m³/h). The Pumps are electric motor driven and shall be connected to the emergency
power supply to ensure that safety showers can operate at any time. The Potable water
distribution is above ground and is a pressurized distribution system.

Potable water Supply Pumps (101-P-002 A/B/C/D) are sized to have a capacity of 40.3
m³/h per pump. This requires one Pump running for normal demand (including continuous
recycle) and three Pumps for peak demand.

d) Potable water Filters

Two 100% Cartridge Filters are provided in the feed line to Potable water Tanks
(101-TK-002 A/B) upstream of Chlorine injection point to remove suspended solids in the
incoming Raw water.

3.7 Utilities

The Service water and Potable water system requires the following utilities. Refer to BEDD
for supply conditions.

· Electric power

· Instrument air

· Emergency Power

3.8 Other Raw Material Requirements

· Sodium hypochlorite

4 BATTERY LIMIT CONDITIONS

The Service water & Potable water operating and design conditions at Users are listed in
Appendix 6.

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SYSTEM SKETCH-SERVICE AND POTABLE WATER PLANT

A
Raw Water Import
from NSEZ

Chlorination
Package
101-A-001

Potable Water Drinking Water/EW/SS

NSRP Complex Project

Tanks

101-TK-002 A/B 101-P-002A/B/C/D

PROCESS SCHEMATICS

101-F-001 A/B
Potable Water
Supply Pumps

CDU
Service Water
Title: Design Basis for Service Water / Potable Water

Tanks RFCC

Utility Boilers
101-TK-001A/B 101-P-001A/B/C
Service Water Plant Air/
Pumps Instrument Air

Flare System

Sewage and Effluent

101-P-003 A/B
DM Plant Treatment
Supply Pumps Miscellaneous Users
Employer Doc. No.

Contractor Doc. No.

Demineralised
W ater
S-101-1222-0001S

Fire W ater Pump

Unit-170

Fire Water Tank

Unit-170
KEY Unit-101 Interfaces
Rev. 1

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S-101-1222-0001S

6 APPENDICES NOTES

6.1 Appendix 1 –Raw Water Demand

Normal
Demand Peak Daily Demand
Sl. No Description
Demand (m³/h) (m³/day)
(m³/h)

1. Make-up to Service Water Tanks 966.3 1151.5 27636 (Note 2)

2. Make-up to Potable Water Tanks 14 (Note 1) 53.5 (Note 3) 336

3. Feed to Fire Water System(Note 4) 0 1560 0

Total Demand 980.3 1205 27972

Notes:

1. Normal Potable water flow is flow average over 24 hour period.

2. Flow rate is derived from Appendix 3 Total daily average with design margin over 24
hour period (i.e. 1151.5 X 24).

3. Peak make up to Potable Water Tanks assumed 50% of Peak Potable Water
consumption (i.e. 107/2). This peak is supplied from storage.

4. Peak flow to Firewater tank is same as peak design inlet Raw water flow of 1560 m³/h
and it is not a regular demand.

6.1.1 Appendix 1.1 - Overall Water Balance Diagram

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Notes:

It includes design margin.

Peak flow to Firewater tank is same as peak design inlet Raw water flow of 1560 m³/h.

6.1.2 Appendix 1.2 –Summary of Equipment Design Capacity

S.No Equipment Design Capacity Reference

Service Water Storage

22428 m³
1 Tanks Section 3.6.1, a
(Note 1)
(101-TK-001 A/B)
Potable Water Storage
720 m³
2 Tanks Section 3.6.2, a
(Note 1)
(101-TK-002 A/B)
Service Water Supply
230 m³/h
3 Pumps Section 3.6.1, b
(Note 2)
(101-P-001 A/B/C)
Potable Water Supply
4 40.3 m³/h
Pumps Section 3.6.2, c
(Note 2)
(101-P-002 A/B/C/D)
DM Plant Supply Pumps 902.8 m³/h
5 Section 3.6.1, c
(101-P-003 A/B) (Note 2)

Notes:

1. Design capacity refers to one tank working capacity

2. Design capacity refers to one pump design capacity

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6.2 Appendix 2 – Raw Water Quality

The Raw water is received from a third party supplier and shall meet the requirements
below.

Quality Units Max Value

Turbidity NTU 2
pH - 6.5-8.5
Total Dissolved Solids mg/l 1000
Hardness mg/l (as CaCO3) 300
+
Ammonia mg/l (as NH4 ) 3.0
Zinc mg/l 3.0
Copper mg/l 1.0
Aluminium mg/l 0.2
Total Iron mg/l 0.3
Manganese mg/l 0.3
Chrome mg/l 0.05
Sulphide mg/l 0.05
Arsenic mg/l 0.01
Lead mg/l 0.01
Antimony mg/l 0.005
Mercury mg/l 0.001
Chloride mg/l 300
Nitrate mg/l 50
Nitrite mg/l 3
Fluoride mg/l 1.5
Cyanide mg/l 0.07
Chlorine Residue mg/l 0.3 – 0.5

The Raw water quality is defined in BEDD (S-000-1220-0001V)

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6.3 Appendix 3 – Service Water Demand

Normal Peak Daily Average

Unit No Units
(m³/h) (m³/h) (m³/h)

010 Crude Distillation Unit 0 93.4 (Note-6) 0

Saturated LPG Treater Merox

012 0.1 1 0.1
Unit (Note-7)
022 RFCC (Note-8) 106.8 106.8 106.8
RFCC LPG Treater Merox Unit
024 2.8 2.8 2.8
(Note-9)
041 PENEX (Note-10) 0 8.3 0

102 Demineralised Water (Note-4) 722.7 826.4 826.4

103 Cooling Water (Note-11) 0 3 0

104 Sea Water (Note-12) 19.2 23.4 19.2

110 Utility Boilers (Note-1) 55.7 55.7 55.7

Flue Gas Desulphurisation
111 16.8 37.9 16.8
(Note-13)
Plant Air / Instrument Air
121 13.4 13.4 13.4
(Note-2)
130 Chemicals Storage (Note-14) 0.6 0.6 0.6
Intermediate Product Storage
153 2.1 2.1 2.1
(Note-15)
170 Fire Water System 0 2870 0

180 Flare System (Note-16) 10 10 10

190 Sewage and Effluent Treatment 14 14 (Note-5) 14

Ship Loading System / Product
200 2.1 2.1 2.1
Jetty (Note-17)
Miscellaneous Users (Note-3) 0 66 33

Total 966.3 1103.0

Total with margin 1151.5(Note-18)

Notes:

1. The users are dedicated cooling water system for 110 unit and Ammonia tank vent
scrubber.

2. The user is dedicated cooling water system for 121 unit.

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3. Miscellaneous users of utility hose stations are Normally No Flows. Daily average
demand assumes 6 hoses in operation while in peak 12 hoses are in operation.

4. Since RO/IX plant in Demin Water System is sized for peak flow, peak Service
water requirement is taken same as peak for the Demin Water System Unit. Flow
rate is referred from Demineralised Water System Design Basis document
(S-102-1222-0001S).

5. The Users are 190-A-201/204/205/206/208/214/215/216/218.

6. Peak consumption is infrequent and is excluded from Daily average. It will be

catered from storage.

7. The user is 012-P-201A.

8. The users are Flue Gas Scrubber System and pumps.

9. The users are 024-P-101A/102A/108/202A and 024-E-201.

10. The user is 041-E-204.

11. The user is Oil Removal Package.

12. The users are 104-P-001A/B/C/D, 104-P-006A/B and 104-A-001,

Electro-Chlorination System.

13. The users are 111-P-101A/B, 111-P-001A/B/C and 111-TK-101, Quench Water
Tank.

14. The users are 130-P-001A/B, 130-P-002, and 130-P-003A/B.

15. The user is 153-A-001, Vapour Recovery Package.

16. The users are 180-A-001-03, HC flare seal drum and 180-A-001-05, HC purge
flare seal drum

17. The user is 200-A-010, Common Vapour Recovery System.

18. Design margin has been included.

19. Figures in the table are based on Overall Utility Summary data.

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6.4 Appendix 4 – Potable Water Demand

Normal Design Peak

Remarks
m³/h m³/h m³/h

14 30 84
Potable Water
Note 1 Note 2 Note 3

23 No normal
EW/SS 0 0
Note 4 usage

Total 14 30 107
Notes:

1. Normal flow is flow average over 24 hour period (i.e.1094 X 0.3 / 24).

2. Design flow is average flow for the maximum number of workers on site in an 8
hour period (i.e.794 X 0.3 / 8).

3. Peak flow takes into account Peaking Factor of 6 X average normal rate for Pump
sizing (i.e. 14 X 6).

4. Peak flow is 110% of the flow to four Eye Wash/ Safety Showers Units.

5. The figures mentioned in the above tables have been estimated from preliminary
NSRP Organizational Structure after plant start up in 2016. These will be
confirmed once actual NSRP Organizational Structure is firmed up later.

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6.5 Appendix 5 – Service Water Pump Design Capacity

Normal Peak Simultaneous

Unit No Units
(m³/h) (m³/h) Peak (m³/h)

010 Crude Distillation Unit 0 93.4 93.4

012 Saturated LPG Treater Merox Unit 0.1 1 1

022 RFCC 106.8 106.8 106.8

024 RFCC LPG Treater Merox Unit 2.8 2.8 2.8

041 PENEX 0 8.3 8.3

103 Cooling Water 0 3 3

104 Sea Water 19.2 23.4 23.4

110 Utility Boilers 55.7 55.7 55.7

111 Flue Gas Desulphurisation 16.8 37.9 37.9

121 Plant Air / Instrument Air 13.4 13.4 13.4

130 Chemicals Storage 0.6 0.6 0.6

153 Intermediate Product Storage 2.1 2.1 2.1

180 Flare System 10 10 10

190 Sewage and Effluent Treatment 14 14 14

200 Ship Loading System / Product Jetty 2.1 2.1 2.1

Miscellaneous Users (Note-3) 0 66 33

Total 243.6(Note-2) 407.5

Total with margin 448.25(Note-5)

Notes:

1. Selected Pump (101-P-001 A/B/C) capacity 230 m³/h. One Pump runs for normal
demand, two Pumps are required for peak demand.

2. Normal service water demand has been finally confirmed from process units,
respectively during overall utility summary. Selected service water pumps rated
capacity (253 m3/h) can cover normal service water demand (243.6 m 3/h).

3. Miscellaneous users of utility hose stations are Normally No Flows. Simultaneous

peak demand assumes 6 hoses in operation while in peak 12 hoses are in
operation.

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4. Flow rates correspond to respective Units are referred from Appendix-3.

5. Design margin has been included.

6. Figures in the table are based on Overall Utility Summary data.

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6.6 Appendix 6 – Users Battery Limit Conditions

Service Water
Service Water Potable Water
to Demin Unit

Pressure, kPa(g)
Minimum 240 - 615
Normal 321 576 873
Maximum 476 - 875
Design 813 800 1213
Temperature, °C
Minimum 15 15 15
Normal 30 30 30
Maximum 35 35 35
Design 60 60 60

Notes

1. Pressures are at Battery Limit and defined relative to grade elevation and referred
from BEDD document, S-000-1220-0001V.

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