cooling water demand calc
DESCRIPTION
cooling waterTRANSCRIPT
CLIENT : CONTRACTOR :
COOLING WATER CONSUMPTION CALCULATION
[A] SUMMARY
Plant Equipment Tag Number DescriptionHeat duty Water Demand
RemarkskW kg/hr
CFU 5000 BPD
E-170 MS Cooler 198.00 17036 (Note-2)
P-160 A/B Feed Pump - 3000 (Note-4) Used as water sealing
P-100 A/B Fractionation Reflux Pump - 3000 (Note-4) Used as water sealing
P-140 A/B Kerosene Pump - 0 (Note-4) Used as water sealing
P-150 A/B Diesel Pump - 0 (Note-4) Used as water sealing
Total water demand = 23036
NHT 2500 BPD
P-201 A/B NHT Feed Pump - 3000 (Note-4) Used as water sealing
P-203 A/B Stripper Bottom Pump - 3000 (Note-4) Used as water sealing
P-202 A/B Stripper Reflux Pump - 3000 (Note-4) Used as water sealing
P-206 NHT Wash Water Pump - 30 (Note-4) Used as washing water
Total water demand = 9030.00
CRU 2500 BPD
P-302 Caustic Recycle Pump - 0 (Note-4) Used as water sealing
E-302 HP Absorber Feed Cooler 210.00 18069 (Note-4) (Note-3)
P-301 A/B Separator Bottom Pump - 3000 (Note-4) Used as water sealing
P-303 A/B LPG absorber Bottom Pumps - 3000 (Note-4) Used as water sealing
E-305 Reformate Trim Cooler 512.00 44054 (Note-4) (Note-3)
E-304 Stabilizer Overhead Cooler 350.00 30115 (Note-4) (Note-3)
P-304 A/B Stabilizer Reflux and Distillate Pump - 3000 (Note-4) Used as water sealing
P-305 A/B Stabilizer Reboiler Pump - 3000 (Note-4) Used as water sealing
E-309 LPG Product Trim Cooler 12.00 1033 (Note-4) (Note-3)
E-307 Deethanizer Condenser 128.00 11013 (Note-4) (Note-3)
Total water demand = 116282.98
UTILITY
P-402 Heavy Napfta Pump - 0 (Note-4) Used as water sealing
P-404 Low Octane Pump - 0 (Note-4) Used as water sealing
P-401 A/B Truck Loading Pump - Light Product - 0 (Note-4) Used as water sealing
P-401 C/D Truck Loading Pump - Heavy Product - 0 (Note-4) Used as water sealing
P-415 Truck Fillling Shed Pump - 0 (Note-4) Used as water sealing
P-413 Make up Water Pump - 0 (Note-4) Used as water sealing
P-405 Cooling Water Circulation Pump - 3000 (Note-4) Used as water sealing
P-407 Booster Pump - 0 (Note-4) Used as water sealing
P-410/420 Electric/Diesel Fire Pump - 3000 (Note-4) Used as water sealing
P-460 Jockey Pump - 3000 (Note-4) Used as water sealing
P-400 Flare KO Drum Pump - 0 (Note-4) Used as water sealing
Total water demand = 9000
Total (with 20% margin) 188819 kg/hr 189 m3/hr
Total sealing water (with 20% margin) 43236 kg/hr 43 m3/hr
Notes :
1
2 The off-spec cooler is intermittent basis, use during commissioning/ start-up Fractionation Unit.
During commissioning of fractionation there is no requirement of cooling water on the CRU.
3 The cooling water demand for CRU is calculated based on heat duty requirement from Axens (for NHT & CRU Capacity 2500 BOPD)
4 Cooling water consumption for pump is given as per Vendor information and be summarised as below and used for mechanical sealing :
Assume that for pump with power more than 5 bkW will utilize sealing water
Pump Tag No. Cooling Water Demand Power
RemarksbkW
CFU 5000 BPD Area
P-160 A/B 3 5.20 During normal operation
P-100 A/B 3 8.20 During normal operation
P-140 A/B 0 3.00 During normal operation
P-150 A/B 0 4.10 During normal operation
NHT 2500 BPD Area
P-201 A/B 3 48.00 During normal operation
P-203 A/B 3 71.00 During normal operation
P-202 A/B 3 7.00 During normal operation
P-206 0.03 2.20 Intermittent
CRU 2500 BPD Area
P-302 0 4.20 During normal operation
P-301 A/B 3 26.00 During normal operation
P-303 A/B 3 20.00 During normal operation
P-304 A/B 3 27.00 During normal operation
P-305 A/B 3 43.00 During normal operation
UTILITY
P-402 0 4.30 During normal operation
P-404 0 4.30 During normal operation
P-401 A/B 0 4.80 During normal operation
P-401 C/D 0 4.80 During normal operation
P-415 0 3.50 During normal operation
P-413 0 1.00 During normal operation
P-405 3 51.00 During normal operation
P-407 0 0.07 During normal operation
P-410/420 3 132.00 Intermittent
P-460 3 13.00 During normal operation
P-400 0 2.13 During normal operation
ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR 5,000 BPD CAPACITY CONDENSATE FRACTIONATION PLANT
The calculation of cooling water demand is based on differential temperature of 10oC across the exchanger.
Assumption temperature differential of 10 oC across exchanger.
m3/h
FANKAM REFINERY LTD
P.T. ISTANA KARANG LAUT
CLIENT : CONTRACTOR :
COOLING WATER CONSUMPTION CALCULATION
[A] CALCULATION FOR EACH COOLER
1 CFU 5000 BPD
E-170 (MS Cooler) Conversion Factor :
Duty = 198 kW 1.0 kW = 1.0 kW = 3600.0 kJ/hr
712800 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 17036 kg/hr
So, the cooling water flowrate of E-170 is = 17036 kg/hr
2 CRU 2500 BPD
E-302 (HP Absorber Feed Cooler)
Duty = 210 kW
756000 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 18069 kg/hr
So, the cooling water flowrate of E-302 is = 18069 kg/hr
3 E-304 (HP Stabilizer Overhead Cooler)
Duty = 350 kW
1260000 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 30115 kg/hr
So, the cooling water flowrate of E-304 is = 30115 kg/hr
4 E-305 (Reformate Trim Cooler)
Duty = 512 kW
1843200 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 44054 kg/hr
So, the cooling water flowrate of E-305 is: 44054 kg/hr
5 E-307 (Deethanizer Condenser)
Duty = 128 kW
460800 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 11013 kg/hr
So, the cooling water flowrate of E-307 is = 11013 kg/hr
6 E-309 (LPG Product Trim Cooler)
Duty = 12 kW
43200 kJ/hr
Cp of water = 4.184
ΔT = 10
m = Q
Cp x ΔT
m = 1033 kg/hr
So, the cooling water flowrate of E-309 is = 1033 kg/hr
ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR 5,000 BPD CAPACITY
CONDENSATE FRACTIONATION PLANT
kJ/kgoC
oC
kJ/kgoC
oC
kJ/kgoC
oC
kJ/kgoC
oC
kJ/kgoC
oC
kJ/kgoC
oC
P.T. ISTANA KARANG LAUT
FANKAM REFINERY LTD
Refer to Axen Document for 2500 BPD NHT & CRU will have typical man power as below :
Field operator per shift : 1
Board/DCS operator per shift : 1/2
Supervisor per shift : 1/4
Then, here is summary of man power demand operating the plant
[A] NHT area
Field operator per shift : 4 employee
Board/DCS operator per shift : 2 employee
Supervisor per shift : 1 employee
Total : 7 employee (assumed)
[B] CRU area
Field operator per shift : 4 employee
Board/DCS operator per shift : 2 employee
Supervisor per shift : 1 employee
Total : 7 employee (assumed)
[C] CFU + UTILITY area
Field operator per shift : 4 employee
Board/DCS operator per shift : 2 employee
Supervisor per shift : 1 employee
Plant Mng : 1 employee
Total : 8 employee (assumed)
[D] E & I Department
Technician per shift : 2 employee
Supervisor per shift : 1 employee
Total : 3 employee (assumed)
[E] MECHANICAL Department
Technician per shift : 4 employee
Supervisor per shift : 1 employee
Total : 5 employee (assumed)
[F] HSE Department
HSE staff per shift : 1 employee
Supervisor per shift : 1 employee
Total : 2 employee (assumed)
[G] FACILITY ENGINEERING Department
Process Engineer : 1 employee
Instrumentation Engineer : 1 employee
Mechanical Engineer : 1 employee
Electrical Engineer : 1 employee
Engineering Spt : 1 employee
Engineering Mng : 1 employee
Total : 6 employee (assumed)
[I] SUMMARY
Total of employee : 38 employee (assumed)
[J] PLANT AREA
CFU & SRU Area : 3000 refer to plant layout
NHT & CRU Area : 3750 refer to plant layout
Total of plant area : 6750
PURPOSERECOMMENDED MINIMUM RANGE
liter/person/day liter/person/day
Drinking water 38 employee - 5 2~5
Sanitation services 38 employee - 20 0~75
Bathing 38 employee - 15 5~70
- - - -
Total =
Cleaning process area 6750 m2 50 - -
Total =
Recirculation Cooling Water Flow : 188.8
831.3 gpm
Hot Water Temperature : 45
113
Cold Water Temperature : 30
m2
m2
m2
NUMBER OF PEOPLE OR PLANT
SURFACE AREA
employee or m2 liter/m2/day
Emergency shower/eye wash/face wash
m3/hr
oC
oF
oC
86
Temperature Difference : 15
27
Evaporation Rate : 16.8 gpm
3.8
2.0 %
Cycle of Concentration : 10
Blow Down Rate : 0.4
1.9 gpm
Drift + Other Loss Rate : 0.0
0.0 gpm
Cooling Tower Water Make Up Rate : 4.2
18.7 gpm
Water Treatment Package Capacity : 4.3
4.8 (if using branckish water)
8.6 (if using sea water)
oF
oC
oF
m3/hr
m3/hr
m3/hr
m3/hr
m3/hr as permeate
m3/hr as raw water
m3/hr as raw water
PERMEATE
REJECT
RAW WATERREVERSE OSMOSIS
RAW WATER
CLEAN WATER
KATION EXCHANGE
R
ANION EXCHANGE
R
Water Treatment Package Capacity : 4.3
19.0 gpm
Duty : 1 x 100%
Raw Water Tank Capacity : 4.8 residence time is 1 hr
2.1 m as ID
1.4 m as H
Balance Volume : 1.00
Raw Water Tank Capacity : 8.7 residence time is 1 hr
2.5 m as ID
1.7 m as H
Balance Volume : 1.00
Raw Water Tank Capacity : 4.4 residence time is 1 hr
2.0 m as ID
1.4 m as H
Balance Volume : 1.00
Raw Water Pump Capacity : 19.3 15 minutes filling time for raw water tank
Raw Water Pump Capacity : 34.7 15 minutes filling time for raw water tank
Raw Water Pump Capacity : 17.4 15 minutes filling time for raw water tank
Duty : 2 x 100%
m3/hr
m3
m3
m3
m3/hr
m3/hr
m3/hr
CLEAN WATER
RAW WATER TANK
RAW WATER PUMP
Product Water Tank Capacity : 8.6 residence time is 2 hr (Note-1)
2.5 m as ID
1.7 m as H
Balance Volume : 1.00
Cleaning Pump Capacity : 0.05 10 % tolerance
Duty : 2 x 100%
Distribution Pump Capacity : 0.07 10 % tolerance
Duty : 2 x 100%
Distribution Pump Capacity : 5.00 10 % tolerance
Duty : 1 x 100%
m3
Note-1 : residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration time during regeneration of water treatment package
m3/hr
m3/hr
m3/hr
PRODUCT WATER TANK
CLEANING PUMP
DISTRIBUTION PUMP
EMERGENCY SHOWER PUMP
Cooling Tower Capacity : 188.82 20 % tolerance
Duty : 1 x 100%
Recirculating Water Pump Capacity : 188.82 20 % tolerance
Duty : 2 x 100%
Sealing Pit Pump Capacity : 43.24 20 % tolerance
Duty : 2 x 100%
Sealing Water Collection Pit Capacity : 43.2 residence time is 1 hr
5.3 m as L
1.5 m as H
5.4 m as W
m3/hr
m3/hr
m3/hr
m3
COOLING TOWER
RECIRCULATING WATER PUMP
SEALING PIT PUMP
AG
UG
SEALING WATER COLLECTION PIT
WATER DEMAND
TYPE OF WATERContinuous Intermittent
liter/day
190 - Treated water
760 - Treated water
570 - Treated water
- 4.5 Treated water
0.06 m3/hr Treated (clean) water
1000 - Un - treated water
0.04 m3/hr Un - treated (raw) water
m3/hr
(assumed that cleaning is conducted daily but partially which density is 1000 liter for 20 m2 area per day)
15 minutes filling time for raw water tank
15 minutes filling time for raw water tank
15 minutes filling time for raw water tank
residence time for product water tank capacity is longer than at raw water tank capacity refer to longer duration time during
which density is 1000 liter for 20 m2 area per day)
Raw Water Pump
Recirculating Water Pump
River
Oily Water from NHT 2500 BPD - Continuously
Oily Water from Tank Area - during hard rain - Intermittent
Oily Water - if any - Intermittent
[1] To Condensate-Column Overhead Vapor Heat Exchanger [2] To Flare System[1] Vapor-Liquid from Air
Cooled Overhead Condenser[2] From Fuel Gas System
Water from Deep Well
Reverse Osmosis/Demineralized
[assumed]
[1] Reductor[2] Antiscalant[3] Disinfectant
Permeate as CT Make Up Water - Continuosly
Reject - Continuously
Cooling Tower[assumed : wet type]
CT Blow Down - Continuously
[1] Antiscalant[2] Microbiologycal Treatment[3] pH Adjusment
Reflux AccumulatorReflux back to top of CFU
Oily Water Collection Pit
Oily Water from CRU
2500 BPD - Continuously
API Separator
Equalizing Pond
Slop HC Tank
Oil back to Condensate Feed
Tank
Effluent Treatment Package
Water from Slop HC Tank - Intermittent
Water from API Separator - Continuously
Used chemical after regeneration - Intermittent
Raw Water Tank
Water as cleaning of plant area - Continuosly
Heat Exchangers in Plant
Cold Water
Hot Water
Sealing Water Collection Pit
Pumps in Process Plant Area
Evaporation + Drift
Water purpose for drinking, sanitation, bathing
Cleaning Pump
Product Water Tank
Distribution Pump
Emergency Shower PumpWater purpose for emergency shower during accident
Sealing Pit Pump
Reduce to 390 ppm TDS CW from 400 ppm
Evap = 75 L/s
TDS = 0 mg/L
CW = 5000 L/s
TDS = 400 mg/L
2,000,000 mg/s
Maintain 400 ppm TDS CW
Evap = 75 L/s
TDS = 0 mg/L
CW = 5000 L/s
TDS = 400 mg/L
2,000,000 mg/s
FILL/SPLASH BAROF
COOLING TOWER
FILL/SPLASH BAROF
COOLING TOWER
BD = 125 L/s
TDS = 406 mg/L
50,761 mg/s
RCW = 4925 L/s
TDS = 406 mg/L
2,000,000 mg/s
MU = 200 L/s
TDS = 10 mg/L
2000 mg/s
BD = 11 L/s
TDS = 406 mg/L
4,277 mg/s
RCW = 4925 L/s
TDS = 406 mg/L
2,000,000 mg/s
BASINOF
COOLING TOWER
BASINOF
COOLING TOWER
MU = 86 L/s
TDS = 50 mg/L
4277 mg/s
With blowdown :CW = 5000 L/s
TDS = 1,951,239 mg/s
390 mg/L
Without Blow Down :CW = 4925 L/s
TDS = 2,000,000 mg/s
MU = 75 L/s
TDS = 2000 mg/s
TDS = 400.4 mg/L
With Blow Down :CW = 5000 L/s
TDS = 2,000,000 mg/s
400 mg/L
Without Blow Down :CW = 4925 L/s
TDS = 2,000,000 mg/s
MU = 75 L/s
TDS = 4277 mg/s
TDS = 400.86 mg/L