Offsites and Utilities

Conceptual Design

Systems School
2005-2006

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Offsites & Utilities Conceptual Design

Offsites and Utilities scope includes systems such as:

• Instrument / Plant Air System
• Nitrogen / Oxygen / Hydrogen
• Cooling Water System
• Raw / Demineralized / Potable Water System
• Steam / BFW / Condensate System
• Firewater
• Natural Gas / Fuel Gas / Fuel Oil
• Flare System
• Waste Water
• Storage, Loading and Unloading
• etc.

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Offsites & Utilities Conceptual Design

• The Process Systems group does the

conceptual design work for offsites &
utilities.
• These systems need to be up and running
prior to process start up.
• However, utilities and offsites work can not
be completed until the process unit design
is firm.
• Hence there is typically a schedule
challenge.

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Offsites & Utilities Conceptual Design

• Offsites and utilities often constitute 30-60% of the

total plant installed cost.

• Approximately 90% of the project costs have been

fixed once the conceptual design effort has been
completed.

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Offsites & Utilities Conceptual Design

• In 2003, an OSBL offsites initiative was undertaken to

develop cost effective Fit-For-Purpose designs that
will help KBR compete effectively.

• Design manuals were developed with equipment

selection logic diagrams, parametric models, utility
flow diagrams, P&IDs, equipment lists, equipment
load sheets, 3D layout models, and cost estimates.
These are called Modular Reference Designs (MRDs
) and can be found on the myKBR Portal.

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MRD SITE MAP - OVERALL

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MRD SITE MAP - AIR

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MRD SITE MAP – BFW / STEAM / COND

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MRD SITE MAP - CW

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MRD SITE MAP - PWT

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MRD SITE MAP - SWT

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MRD SITE MAP - FLARE

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MRD SITE MAP – LNG JETTY

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AIR SYSTEMS

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Plant and Instrument Air Block Flow Diagram

Instrument Air
Distribution Header

Instrument Air
Dryer Package Instrument Air Receiver

KBR
VENDOR
ATM

Drain

FILTER/ Plant Air Distribution

SILENCER
Header

Plant Air Receiver

Plant and
Instrument Air
Compressors Drain

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Air Systems

Compressed air is used for instruments,

utilities and process users.
The air provided can be:
• Wet or dry
• Continuous or intermittent
• Essential or non-essential
– Essential – Back-up required
– Non-essential – No back-up required

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Air Systems Components

The main components of the air system are

• Compressor
– Centrifugal for high volume
– Screw type for low volume
• Cooler
• Dryer
• Receiver(s)
• Piping network

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Dry Air (Instrument Air)

• -40 ºF or -100 ºF dew point depending on

plant location
• Continuous users
– Control valves (essential, back-up required)
• Intermittent Users
– Pneumatic conveyance
– Instrument panel purges (non-essential)

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Wet Air (Plant Air)

• Continuous users
– Process air for ammonia (essential)
• Intermittent Users
– Pneumatic tools (non-essential)
– Hose stations (non-essential)

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Cooling Water
System

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Typical Cooling Water System

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Cooling Water System

Cooling water is required in most plants to remove

excess heat from all the various processes and
equipment.

The types of cooling systems used are based on

the total amount of heat required to be removed
and the rate at which it should be removed.

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Overview

• Types of Cooling Water Systems

Fresh Water Once Through System

This system includes intake structure/screens, pumps
and drivers.

Fresh Water Open Recirculation System

The system includes cooling tower with support structure,
basin and pump sump with screens, circulation pumps
and drivers, chlorinator, chemical injection system and,
if applicable, make up pumps.

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Overview

• Types of Cooling Water Systems Continued:

Sea Water Once Through System

This system includes intake structure/screens,
pumps and drivers.

Sea Water Once Through System w/ Closed Fresh Sys

This system includes intake structure/screens,
pumps and drivers. Sea/Fresh water exchangers
and fresh water circulation pumps.

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Overview

• Types of Cooling Water Systems Continued:

Sea Water Open Recirculation System

The system includes cooling tower with
support structure, basin and pump sump
with screens, circulation pumps and drivers,
chlorinator, chemical injection system and,
if applicable, make up pumps.

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Design Basis and Criteria

Cooling Tower
• Design wet bulb per ASHRAE recommendations

• Design circulation rate based on the overall plant

max operating duty

• Supply temperature determined by several factors

such as process requirements, plant location, and
economic considerations. (Cooling tower
approach should never be less than 5 deg F)

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Design Basis and Criteria

Cooling Tower (cont’d)

• Return temperature calculated by adiabatic
mixing of all streams returning to the tower at the
design circulation rate.

• Tower type and fill depends on application.

• Typically frames made of douglas fir

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Design Basis and Criteria

Pump Sump & Basin

• Pump sump should be sized using the British
Research Hydraulic Association (BHRA)
guidelines
• Sump low liquid level should meet two
requirements:
– Pump NPSH requirements plus a 5 ft margin for
dissolved air.
– BHRA submergence requirements.

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Design Basis and Criteria

Pump Sump & Basin (cont’d)

• Basin wall height should meet the following
conditions:
– 60 or 20 minutes of retention time at design make up
rate between normal operating level and low liquid
level for fresh and sea water applications respectively.
– 1.5 ft. of solids disengagement space between low
liquid level and the basin floor.
– 0.5 ft of wall height above normal operating level
• Made of reinforced concrete

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Design Basis and Criteria

• Pumps & Drivers

– Pump design capacity is equal to the cooling tower
design circulation rate plus blow down divided by the
number of operating pumps.
– At least one spare pump is required.
– Decision to use 3 X 50%, 4 X 33%, or 5 X 25%
pumps is based on economics and impact on sump
layout.
– Typically one or more of the operating pump(s) is
supplied with a diesel or steam turbine driver is
required to ensure circulation during a power failure.

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Design Basis and Criteria

• Pumps & Drivers (cont’d)

– Spare pump is motor driven with auto start
capabilities.
– Piping design pressure and temperatures typically
150 psig / 150 deg F

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PARAMETRIC MODEL
COOLING TOWER INPUT
Required Circ Rate (gpm) 154,400
•Flexibility Return Temp (F) 113
Supply Temp (F) 95
•Counter/Cross Flow Towers Ambient Wet Bulb Temp (F) 84
•Vertical / Horizontal Pumps Counter/Cross Flow 2 CROSSFLOW
Fill Type 2 SPLASH
•Pump Sparing Configurations Cell Length (ft) 32.1
Cell Width (ft) 79.1
Pump Configuration 5 X 25% Pumps

•Capabilities Vertical / Horizontal Pump 1 Vertical

Cycles of Concentration 1.3
•Performs Cooling Tower Fresh Water / Sea Water 2 SEA WATER
Material Balance
•Determines Number of Cells
•% Utilization
COOLING TOWER OUTPUT
•Estimates Fan Horsepower Target Concentration (gpm/ft2) 15.5
•Sizes Basin and Pump Sump Cell Contact Area (ft2) 1270
•Sizes Pump and Motor Distributor Height (ft) 36
Number of Cells 8
•Sizes Header Required Area/ Actual Area 1.06
Fan Motor HP / (1 per Cell) 150

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Cooling Tower and Basin 3D Model

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Raw Water Systems

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Raw Water Treatment

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Raw Water Treatment

• Raw water that enters the plant facility has

to be treated to remove impurities.
• Treatment steps depend on initial water
quality and final usage requirements.
– For example: River water used for HP boiler
feed water requires more treatment than if
used for a fire water system

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Raw Water Systems

Some users of treated water are as follows:

• Fire Water
• Cooling Tower Make-up
• Potable (Drinking) Water
• Boiler Feed Water
• etc.

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Raw Water Treatment Components

The raw water treatment system may

include the following unit operations:
• Clarifier
• Media Filter
• Clearwell
• Demineralizer
• Reverse Osmosis unit
• Distillation unit

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Raw Water System

Water from open sources (lakes, rivers, ocean) may need to

have suspended solids removed.
The primary equipment is clarifiers and media filters.
• Clarifiers remove the bulk of suspended solids to below
10 ppm.
– Conventional Clarifier
• Used for high flow rate and suspended solid
concentration
• When lime softening is needed
– Lamella Clarifier
• Lower cost and 1/10 the size of conventional clarifier

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Raw Water System

Media filters are located downstream of the clarifier.

• Lowers turbidity
• Acts as a backup to the clarifier
If the majority of the clarified water requires filtration, a
gravity flow filter is the economical choice.
If only a small fraction of the water requires filtration, a
pressurized filter is more economical.
The product stream leaving the clarifier/ gravity filter
flows into a surge tank called a clearwell

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Raw Water System

Some raw water treatment units have both a

clearwell and a clarified water tank down stream.
Clarified water tank is the source water tank for:
– Demineralization
– Fire Water System
– Cooling Tower Makeup
– Potable Water Treatment System
If the clearwell is sized with enough capacity, the
clarified water tank and the pumps used to pump
from the clearwell to the tank can be eliminated.

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Raw Water System

Reverse osmosis and distillation can also

be used for removing dissolved solids
from water. They are used primarily to
make high quality BFW from raw water
with a high dissolved mineral content.

TDS (Total dissolved solids) > 500

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Demineralizer System

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Demineralizer System

Steam generators are the main users of

demineralized water. Pure water is needed to
prevent minerals from depositing as scale on
the boiler.
For example, silicates can convert into gaseous
silica in the boiler drum and carry over with
steam. The silica can then deposit on the
turbine blades and reduce efficiency.

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Demineralizer System

Demineralizer has three distinct components

connected in series:
• Cation Bed
– Exchanges hydrogen ions for cations such as
calcium and magnesium
– Located upstream to remove hardness minerals that
may foul the other beds
• Anion Bed
– Exchanges hydroxide ions for anions (chlorides,
sulfates, silicates, carbonates…)

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Demineralizer System

• Polisher
– Final bed; removes both anions and cations down
to ultra-pure levels.
– Not always necessary if counter current packed
beds are used upstream.

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Steam, BFW and
Condensate Systems

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STEAM, BFW AND CONDENSATE

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Steam, BFW and Condensate System

Steam, BFW and Condensate system

design is the responsibility of Systems
Engineering. Typically an initial steam
balance is done in order to maximize
efficiency of available heat sources. Then
a more detailed steam balance will be
calculated to identify start-up, shutdown,
winter, summer cases, etc.

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Steam, BFW and Condensate System

Systems Engineering is responsible for the following

loadsheets:
• Anion / Cation Exchange and Mixed Bed Polisher
• Demineralized Water Pumps
• Preheat Exchangers (if not utilizing process or waste
heat)
• Deaerator
• Boiler Feed Water (BFW) Pumps
• Chemical Treatment Packages
• Blowdown Drum
• Surface Condenser
• Condensate Return Pumps
• Package Boiler

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Basis of Design

Make-up Water Tank (Demin. or Polished water)

• 8 hours surge using the greater of
– Total Loss of supply water at normal steam production OR
– Maximum steam production with normal supply water flow(s)
• Epoxy coated CS
Make-up Water Pumps
• Primary pump should be steam driven
• Standby should be motor driven
• Design for maximum normal flow at Deaerator
design pressure

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Basis of Design

Deaerator Design
Purpose:
• To prevent corrosion in steam and condensate systems by
removal of dissolved gases (air, O 2, CO2) from water
• To aid in optimal heat transfer of steam by the removal of
inert gases (N2, others dependent on the service)
• To heat BFW to a uniform temperature before pumping to
the steam generator(s)
Method:
• Mechanical deaeration using steam to heat water above
boiling point to release gases
• Addition of Oxygen scavenger to remove residual oxygen
(typically sodium sulfite)

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Basis of Design

Deaerator Design (Cont.)

Sizing Basis:
• Stripping Section is based on flow of make-up water
• Storage section is sized for 8 minutes of maximum
normal BFW rate
• Overflow sized for maximum normal inflow at blocked-in
condition
(ie pump trip)
• Vent sized by Supplier (approximately 1% of steam input)
• Operating Pressure is 10 to 25 psig typically
• Operating temperature is saturated steam at operating
pressure

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Basis of Design

Deaerator Design (Cont.)

• Design for a maximum temperature rise of 50oF in inlet
water temperature for stripping gases
• Design pressure is typically 50 to 75 psig and full vacuum
• Design temperature is typically 300 to 325oF
• Elevation based on NPSHr of BFW pumps with water at
equilibrium
• BFW shall be < 0.007 ppm O2 (before O2 Scavenger)
• CS shell with SS internals in the Stripping section

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Basis of Design

BFW Pumps

• Pump should be designed to meet the following

requirements :
– Maximum Flow @ Boiler Operating Pressure
– 50% of Maximum Flow@ Steam drum relieving
pressure
– Sufficient flow to keep the superheater coils from
overheating
• 7 feet safety factor for NPSH
• 2- 100% Pumps (1 turbine, 1 motor spare with autostart)
• Typically CS with 12 Chrome or 316SS internals

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 Basis of Design
Packaged Boilers
• No spare unless required by client
• Typically designed for 5% above rated capacity for up to 2 hours
• Typically do not specify less than 25% turndown (minimize cost)
• Water Quality per ASME Boiler Water Chemistry (1994)
• Continuous Blowdown of 5-20% for operating pressures <1000 psig
• Continuous Blowdown of 1 - 2% for operating pressures >1000 psig
– Typical, may change based on water analysis
• Minimum of 50oF superheat to prevent condensate buildup in the steam
headers

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Basis of Design

Suspect Condensate (SC)

• Condensate that may be contaminated with hydrocarbons
• Flash to atmosphere, pump to cooler, Activated Carbon
Beds, Mixed Bed Polisher and send to Deaerator
Normally Non-Suspect Condensate (NNSC)
• Condensate that should not contain hydrocarbons
• Flash to LP steam header
• May need to be Polished if soluble iron concentration is high
• Send back to Deaerator (if hydraulics allow)
• Vacuum condensate should be pumped directly to Deaerator

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Water Chemistry Limits

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Water Chemistry Limits

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Water Chemistry Limits

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Waste Water System

The purpose of the system is to convert

plant waste water into an environmentally
harmless stream prior to discharge
Some sources of plant waste water are:
– Process water
– Process Tank/Tower Drains
– Potable Water
– Road Drains and Other Surface Runoff

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Waste Water System

• The Waste Water System can be classified into three

functions: conveyance, retention and treatment.

• Treatment can also be classified into three major

groups primary, secondary and tertiary.

• The environmental group does the conceptual design

for the waste water system. However, the Systems
group is responsible for waste water P&ID
development.

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Waste Water System

• Primary treatment consists of removing visible non soluble

contaminates from the waste water stream.
Example _ API Separator.

• Secondary treatment is the removal of soluble organic

material from the waste water with microbial metabolism.
Example_Biological Treatment Unit

• Tertiary treatment consists of removing non visible

contaminates from the waste water stream.
Example_ Ultra Filtration

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 SEWER
SEGREGATION
6 EXAMPLE
Storage
Loading/Unloading

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Storage, Loading/Unloading

There are many aspects that need to be

considered when planning for storage,
loading and unloading. Some of them are:
• May be high cost due to a large plot space
requirement
• Feed - Product - Intermediate Storage
• Transfer of fluids
• Feed receipt, product metering
• Product shipment - RR, truck, pipeline

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Storage, Loading/Unloading

• Pipeline Design
• Cryogenic Storage
• Pressure Storage
• Atmospheric Pressure Storage
• Environment, Safety, Dikes
• Waste Water, Slops, Offspec Product
• Chemicals
• Product Blending

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Process Unit Offsite Tank Farm

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Above Ground Storage Tanks

Above Ground Storage Tanks

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QUESTIONS ???