MINISTRY OF EDUCATION AND TRAINING

HANOI UNIVERSITY OF MINING AND GEOLOGY

NGUYEN VAN KHAI

THESIS
Laern about the water
treatment process of the
unit 31 Dung Quat oil
refinery
HANOI - 04/2019
 ACKNOWLEDGMENT
I sincerely thank Dr. Cong Ngoc Thang who has dedicated guidance and help me.
Thanks to the teacher's guidance, I understood the necessary issues and completed
this thesis in due time.

However, with the large of workload and in a limited time, so during the process
of compeleted this thesis I can not avoid mistakes and shortcomings. I hope all of
our beloved teachers would review and help me perfect my project.

Once again, I would like to express my deep gratitude to Dr. Cong Ngoc Thang
and all the teachers of Oil and Gas Faculty - major in Oil refining and
Petrochemistry - (Hanoi University of Mining and Geology) have helped me
during 5 years of studying and finishing this thesis.

Thank you sincerely!

Hanoi, 4-2019

Student

Nguyen Van Khai

 TABLE OF CONTENT
ACKNOWLEDGMENT
TABLE OF CONTENT
LIST OF SYMBOLS, ABBREVIATIONS
LIST OF TABLES
LIST OF DRAWINGS, GRAPHS
INTRODUCTION

CHAPTER 1 : An overview of Dung Quat refinery

1.1 Geographical location of Dung Quat refinery

1.1.1 Natural Conditions
1.1.2 The importance of Dung Quat refinery
1.1.3 Technical features
1.1.4 History of Dung Quat refinery
1.1.5 Organization chart of Binh Son refinery and petrochemical plant
1.1.6 Raw materials for Dung Quat refinery

CHAPTER 2: Introduction of WATER SUPPLY SYSTEM

2.1.2 Water treatment unit

2.2 Raw materials and products

CHAPTER 3: Control and operate system

of water system of Dung Quat oil refinery

3.1 Normal Startup

3.1.1 A brief introduction
3.2 Normal Shutdown
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3.3 Emergency shutdown

CHAPTER 4 : SAFEGUARDING DEVICE

4.1 Alarms & Trips .......................................................................................................................

4.1.1 Service water pumps and back wash pumps protection (031-US-102) ......................
4.1.2 Demineralised water storage tanks overfilling protection (031-US-104) ...................
4.1.3 Demineralised water pumps and regeneration pumps protection (031-US-105)
4.1.4 Potable water storage tank overfilling protection (031-US-108)
4.1.5 Potable water pumps protection (031-US-109) ..........................................................
4.1.6 ADP Alarms ................................................................................................................
4.2 Safeguarding Description........................................................................................................
4.2.1 Fresh Water Storage Tanks TK-3101A/B ...................................................................
4.2.2 Service Water Pumps P-3101A/B/C ...........................................................................
4.2.3 Potable Water Storage Tank TK-3102 ........................................................................
4.2.4 Potable Water Pumps P-3102A/B ...............................................................................
4.2.5 Demineralised Water Storage Tanks TK-3103A/B ....................................................
4.2.6 Demineralised Water Pumps P-3103A/B ...................................................................
4.2.7 Sulphuric Acid Support Facilities ...............................................................................
4.2.8 Caustic Support Facilities ...........................................................................................
4.3 Safeguarding Equipment .............................................................................................
4.3.1 LO Valve at TK-3102 Inlet .........................................................................................
4.3.2 Check Valve at A-3102 Outlet Line to TK-3103A/B .................................................
4.3.3 Service Water Tanks, TK-3101A/B Top Inlet ............................................................

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 LIST OF SYMBOLS, ABBREVIATIONS
No. Abbreviation Meaning of symbol, abbreviation Page
1 BSR Binh Son Refining 3
2 DQR Dung Quat Refinery 5
3 TK TANK 7
4 CCC Central Control Complex 9

5 20

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 LIST OF TABLES
No. Name of table Content of table Page

1 Table 1.1 Process units and Offsites of Dung Quat 3

refinery

2 Table 1.2 Product’s Capacity 5

3 Table 2.21 : data the quality of clean water 7

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 LIST OF DRAWINGS, GRAPHS
No. Name of graph Content of drawing, graph Page
1 Figure 1.1 Process units and Offsites of Dung Quat 3
refinery

2 Figure 1.2 Organization chart of Binh Son refinery and 5

petrochemical plant
3 Figure 2.1 Organization chart of BSR 7
4 Figure 2.2 Dung Quat refinery’s Process Unit 9

5 Figure 3 PFD U 31 Water system 24

INTRODUCTION

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Page 53 of 79
CHAPTER 1 : An overview of Dung Quat refinery

1 Geographical location and orbit of Dung Quat refinery

Dung Quat or Binh Son oil refinery, the first oil refinery of Vietnam is located at Dung Quat economic zone,
Quang Ngai province, which has the Northwest borders Chu Lai Airport, the West borders national highway
1A, East and Northeastern East border the East Sea. And Quang Ngai city is at the Southwest. Distance from
Dung Quat refinery to:
- To Quang Ngai city: 25-40 km
- To Da Nang city: 100 km
- To Hanoi: 880 km
- To Ho Chi Minh City: 870 km
- To Chu Lai airport: 13km
Geographical coordinates: 1080.47 degrees East, 150.23 degrees North latitude

Figure 1.1: Geographical of Dung Quat refinery in the map

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1.1.1Natural Conditions
>Topographic:
- Dung Quat Economic Zone or Binh Son Refining is located in the flat terrain of Quang Ngai Province,
between the coast are low mountain range and sand dunes.
+ Highest altitude: + 20m.
+ Medium altitude: 4 ÷ 10m.
+ Lowest alitude: 0.1 ÷ + 3.0m.
- The terrain has the shape of sloping from West to East and from South to North with an average slope
of 0.4 ÷ 8%.
> Climate:
- Dung Quat refinery is in the South Central climate region. So there are two separated seasons.
+ Winter: Not so cold, the average winter temperature is 19 oC and absolute minimum temperature does
not fall below than 12 oC.
+ Summer: Temperature are fairly high in about 4 months which have the average temperature of 28 oC.
Other elements:
+ Sunshine: Quang Ngai Province has the avarage sunny hours of 1,800 ÷ 2,000 hours per year.
+ Wind: Quang Ngai province has a hot dry West wind in the summer, but not as powerful as the North
Central Region. It has long-lasting hot season, sometimes accompanied with the strong southwest winds
causes drought in the area. Northeast Monsoon: Often causes gusts, whirlwinds and often causes heavy
rain, while temperatures drop sharply.
+ Average wind speed : 2.9 m / s.
+ Maximum wind speed : 40m / s.
+ Typhoons: Quang Ngai as well as all the other central region which are sea coastal provinces are
affected by tropical storms. On average per year, storms directly affects Quang Ngai province, caused
heavy rain and very strong winds of level 6 or higher. There are also three to four tornados along with
heavy rain and strong winds, sometimes accompanied by sea level rise.
1.1.2 The importance of Dung Quat refinery
Over the years the world has witnessed major fluctuations and needs in the oil and refined oil markets.
Unstable situation in the major oil-supplying regions and the rise in demand of oil-supply have helped the
price of oil and gasoline increased to the record levels. Especially, in the year 2008, the world crude oil
market was constantly fluctuating unnormally. It was the reason pushing the crude oil price to the record
of $150/barrel, and then fell down magnificently to below $45/barrel.
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 Fluctuations in crude oil prices have had a negative impact on many economies, leading to many
consequences, affecting the growth rate of many countries, including our country Vietnam. To reduce the
negative impact of oil price fluctuations and ensure our national energy security, Vietnam needs to be
proactive in satisfying domestic demand of oil-supplying. Building refineries will create a precondition
for the chemical industry to develop. Refined products are the main raw material for polymerization
production, lubricant additives and some cosmetic products . Nowaday, more than 99% of the oil exports,
50% of the imported oil products are due to Foreign transport. The production and consumption of oil in
the country make the domestic transporting service increase, especially the shipbuilding industry grow
rapidly. These are two important sectors that are capable of generating great added value and a lot of
potential for development. So after all, Vietnam has decided to invest in building the first oil refinery in
Dung Quat - Quang Ngai called Dung Quat the first oil refinery . Dung Quat is located in Quang Ngai
province, in central region of Vietnam where has the lowest economic growth in the country. The refinery
plant located here do not directly create jobs or contribute to local budgets. But with the development of
infrastructure including deep-water ports, roads, electricity, telecommunication networks ... serving
refineries (without those factories) Open policies will attract domestic and foreign investment projects in
Dung Quat economic zone in particular and in the central region. Dung Quat has attractive comparative
advantages: located in the midst of Vietnam and the region; There is Chu Lai International Airport, deep
sea port; Has a new city with a full range of high quality amenities and services; To enjoy the highest
privileges in Vietnam and to apply the regime and mechanism of open management in line with
international practices and adaptation to the nature of economic globalization today.

1.1.3 Technical features

Dung Quat refinery has a designed capacity of 6.5 million tons of crude oil annually, or 140 thousand
barrels per day (22×103 m3/d). The capacity would be expanded to 10 million tons per year by 2013–2014. In
addition to fuels, the refinery will also produce petro-chemical products. The refinery complex area comprises:

 overall refinery Process, Utility and Offsites Facilities: about 110 ha;
 Crude Tank Farm and Flare Area: about 42 ha;
 Product Tank Farm: about 36 ha;
 Seawater intake, Waste Water and Crude Oil Pipelines: about 4 ha;
 Interconnecting Pipelines, road and right of Way: about 40 ha;

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 Product Harbor Service Area: about 135 ha.

Main contractors of the refinery were Technip, JGC Corporation, and Técnicas Reunidas. The refinery cost
US$3 billion, up from $2.5 billion previously and more than double an original cost estimate of about
$1.4 billion in 1994. It may need another $1 billion to build a desulphurising unit targeted for 2013.

1.1.4 History of Dung Quat refinery

The Dung Quat refinery story began in 1995 with the withdrawal of Total from the project (Total
claimed the site of the refinery made no sense and would involve increased costs of more than $500m).

A consortium of foreign firms stepped in (LG Group, Petronas, Conoco, Stone and Webster and PRC -
Chinese Petroleum Company and China Development) but withdrew two years later for the same reasons.

In 1999, Prime Minister Phan Van Khai took steps to speed up construction of the country's first oil
refinery. The rekindled project was a joint venture between Vietsovpetro (a Vietnam-Russia joint venture
responsible for the bulk of Vietnam's oil exports) and Russia's External Economic Federation (Zarubeznheft).

The joint venture was dissolved in December 2002 by the Russians who claimed the refinery was not
economically viable at the intended site. In February 2003 Vietnam decided to go it alone and continue with
the refinery construction. Phase I operations began in February 2009.

The Dung Quat refinery has cost an estimated at $3bn for construction and equipment. The original
front-end engineering and design contractor for the project was Foster Wheeler Energy of the UK (this was
superseded by a FEED agreement signed with Technip in 2004). The refinery was built on a site consisting of
338ha of land and 473ha of sea in the Dung Quat Economic Zone.

Vietnam has awarded contracts to a group of construction companies including Technip-Coflexip of

France, JGC Corp of Japan and Technicas Reunidas of Spain, for technology and equipment supply. Stone
and Webster provided project management consultancy services as per their October 2003 contract.

One of the consortia, TPC Complex, which consists of Technip, Technip Geoproduction and Technicas
Reunidas, was awarded the engineering, procurement and construction turnkey contracts No.1 and No.4 for
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the refinery in May 2005. In June 2006 the refinery selected the SmartPlant Enterprise as its standard software
for management of plant design, maintenance and operations of the plant.

The refinery complex area consists of the following components:

- Refinery processing, utility and offsite facilities (110ha) Crude oil tank farm and gas flare-off area
(42ha)
- Product tank farm (36ha)
- Seawater intake, waste water processing and crude oil pipelines (4ha) Interconnecting
pipelines and road access (40ha);
- Harbour product export area (135ha);
Crude Supply:

The refinery is designed to process crudel from Bach Ho crude oil field, which is expected to run out before
2020. Petrovietnam has a preliminary agreement with BP for supplies of similar quality to use exclusively
until 2011.

Ownership:

The refinery is owned and operated by Petrovietnam. Petrovietnam negotiates with foreign oil companies,
including Royal Dutch Shell, Essar Group and SK Energy, toupgrade and sell part of the refinery.

1.1.5 Organization chart of Binh Son refinery and petrochemical plant

To run any kind of plants, how the organization chart is will somehow reflect the effective or the
feasibility of the project. Unlike many other companies, BSR has built up its own organization chart to run their
specific refinery configuration

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Figure 1.2 : Organization chart of Binh Son refinery and petrochemical plant

Page 59 of 79
 Figure 1.3: Organization chart of BSR

1.1.6 Raw materials for Dung Quat refinery

Crude oil used as raw material for the plant is crude oil from Bach Ho field and from Dubai oil field.
Bach Ho crude oilfield is located in the Southeast Vietnam, about 145km from the coast of Vung Tau. This is
the main oil field for many refining factory of VietNam. From Bach Ho crude oilfield, there is a long-way gas
pipeline along the shore to supply Dinh Co liquefied gas plant, Ba Ria power plant and Phu My electricity
center. Nowaday, we are using the lastest technology for mining, Bach Ho crude oilfield is currently exploited
by self-spraying technology, contributing to the economy of the country. Crude oil which extracted from the
Bach Ho crude oilfield has very good quality, which is sweet, light oil and have the low percentage of impurities.
Bach Ho crude oildfield has a reserve of about 300 mil. tons and has been commercially exploited since the
middle of 1986. It is the largest oil field in Vietnam and now has the maximum exploitation capacity. Each day
this oildfield could be exploited about 38000 tons of crude oil accounted for 80% of Vietnam crude oil output.
Accoring to the plan, Dung Quat oil refinery will use 100% of crude oil from Bach Ho field in phase 1 and in
phase 2, the factory will process crude oil mixture (85% Bach Ho crude and 15% Dubai sour crude).

1.1.7 Process units:

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 Figure 2.2 : Dung Quat refinery’s Process Unit

The project site is comprised of four main areas: process units and utilities, product tank farm, cargo
terminals and wharf oil refueling and marine plateharge and plateharge systems. These areas are connected by
pipeline systems with adjacent roads.

Total area of the project is approximately 338 hectares, including the following:

- All technology workshops, auxiliaries and peripherals: about 110 hectares

- Sea area: 471 hectares
- Flare and Crude oil storage tank: about 42 hectares
- Product storage tank: about 44 hectares.
In addition, the port area of the product will occupy about 35 hectares

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The main process units and utilities of Dung Quat refinery is shown in the table below:

Table 1.1: Process units and Offsites of Dung Quat refinery

Area Process Unit

Unit 012: Naphtha Hydrotreating Unit (NHT)
Section 1A Unit 013: Continuous Catalytic Reforming Unit (CCR)
Unit 023: (ISOMER)
Unit 011: Crude Distillation Unit (CDU)
Section 1B Unit 014: Kerosene Treating Unit (KTU)
Unit 037: Fuel-gas
Unit 015: Residue Fluid Catalytic Cracking (RFCC)
Unit 016: LPG Treating Unit(LTU)
Section 2 Unit 017: RFCC Naphtha Treating Unit (NTU)
Unit 021: Propylene Revovery Unit (PRU)
Unit 018: Sour Water Stripper (SWS)
Unit 019: Amine Regenaration Unit (ARU)
Unit 020: Caustic Neutralization Unit (CNU)
Section 3 Unit 022: Sulfur Recovery Unit (SRU)
Unit 024: (LCO-HDT): diezel Hydrotreating
Unit 058: Effulent Treatment Plant (ETP)
Unit 031: Process Water
Unit 033: Cooling water.
Unit 034: Sea cooling water
Unit 035: Instrument/Plant air
Section Cold Unit 036: Nitrogent plant
Utility
Unit 037: Fuel gas
Unit 039: Caustic supply
Unit 057: Flare
Unit 059: Fire water

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 Unit 100: RO Silica Seperating
Unit 032: Steam
- LPS (Low Pressure Steam): 3–6 kg/cm2
Section Hot - MPS(Medium Pressure Steam): 14-16 kg/cm2
Utility - HPS(High Pressure Steam): 40-42 kg/cm2
Unit 040: Power Station
- There are four transmitters.While 3 of those generators run at 50%,
50%, 100%, and the remaining machines are redundant
Unit 038: Fuel oil
Unit 051: Intermediate tankge
Unit 054: Blending Unit
Unit 055: Flushing oil
Offsite P1 - Using LGO from CDU to clean pipes system.
Unit 056: Slops oil
- Collect oil from units, provide for CDU, RFCC unit.
Unit 060: Crude oil tankge
- Included 8 tanks, each tank has the capacity of 65.000 m3, 22.4 m
height, diameter 69m

Unit 052: Product tank farm

- 22 product tanks including 5 petrol tanks, 3 propylene
tanks, 5 LPG tanks, 1 slops oil

Unit 053: Truck loading

- Each truck has 13m3 loading
Offsite Unit 081: Jetty Topside
P3/Jetty
- There are 6 berths: 4 berths, each carrying 1000-5000 m3, 2 berths
each carrying 15000-30000 m3
Unit 082: SinglePoint Mooring (SPM)
- d=12m, 5m height (3,75m under the sea)

Unit 071: Interconnecting Pipleline (P1 P3)

- 12 pipelines: 8 product pipelines and 4 auxiliary pipelines, total 7km
long.

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 Unit 072: Interconnecting Pipleline ( P3 Jetty)
- 15 pipelines: 10 product pipelines, 5 waste oil extraction
lines and ballast water, 3km long.

Products of Dung Quat refinery:

- Types of products:
+ PropyleneLiquefied;
+ Petroleum Gas (LPG);
+ Gasoline Mogas(A-90/92/95 RON gasoline);
+ Kerosene;
+ Automotive diesel fuel (DO);
+ Fuel oil (FO);

- Product’s Capacity:

Products name x106 tons/year

Propylene 110 - 150

LPG 280 - 300

Gasoline Mogas 90/92/95 2000 - 2500

kerosene /Jet Fuel A1 400 - 410

Diesel 2500 - 3000

Fuel Oil (FO) 300 - 350

Fuel for the plant/jet 470 - 490

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 Table 1.2 Product’s Capacity

Product quality:
For products consumed domestically in accordance with product quality standards of Vietnam. For
export products must reach the requirements of export quality.
When reached the maximum capacity, Dung Quat refinery will produce 150,000 tons of petrol, 240,000
tons of diesel, about 23,000 tons of LPG and other products such as propylene over 8,000 tons, Jet-A1
gasoline (about 30,000 tons) and FO (about 25,000 tons). Dung Quat refinery will meet about 30% of
petroleum demand in the country, step by step ensure the number one spot of national energy providing

CHAPTER 2: Introduction of WATER SUPPLY SYSTEM

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 Figure 3 : PFD U 31 Water system

2.1 The purpose of the workshop

The water system receives clean water from a water treatment plant outside the refinery after the production
and distribution of three different types of water to the premises used in the plant and storage area of the
product:
-Clean water
- Demineralized water
-Water

+Clean water tank TK-3101A / B : A clean water tank with a capacity of 7849 m3 per tank and can provide
approximately 3 days in normal factory operation. Storage tanks are designed when each tank can drain water
for maintenance but does not affect the operation

+Living water tank TK-3102: Daily water tank with a capacity of 100 m3 corresponding to 24 hours in normal
operation.

+Demineralized water tank TK-3103A / B: Demineralized water tank with capacity of 5472 m3 each tank and
each tank can provide 2 days of normal consumption. Storage tanks are designed as each tank can be drained
for maintenance as not affecting the operation

2.1.1 system equipment

Plumbing includes the following: • TK-3101A / B Clean Water Tank

• Water tank TK-3102

• Demineralized water tank TK-3103A / B

• Clean water pump P-3101A / B / C

• Domestic water pump P-3102A / B

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• Demineralized water pump P-3103A / B

• Cartridge filter F-3101A / B

• Water Treatment Unit A-3101

• A-3102 demineralized water treatment unit

• Add sodium bisulphite A-3103

2.1.2 Water treatment unit

*Water Treatment Unit A-3101

The water treatment pool includes:

Sodium hypochlorite storage tank capacity of 0.5 m3 to contain diluted chemicals.
The chlorination dosage pump has a capacity of 2.9 l / hr to bring chemicals into clean water
This group is responsible for maintaining the residual chlorine content of 0.2 ppm at the outlet of the domestic
water tank. Pump pumping chlorine excess excess 5ppm into the fresh water at the inlet of the water tank
every few hours.

* A-3102 demineralized water treatment unit

The demineralised water treatment unit consists of 2 lines, each with a designed capacity of 175 m3 / hr. Two
demineralized conveyors can be operated at the same time to provide the required capacity of the plant. Two
perfect lines can supply up to 350m3 / h of demineralized water. Running each line at 50% capacity is the
recommended operating condition in the design. While the plant operates normally, each demineralized water
line produces approximately 110 m3 / h

In order to produce 175 m3 / hr of demineralized water, the required amount of clean water is 205 m3 / h.
This is because during the 14 hours of operation, A-3102 takes two hours to regenerate. In the regeneration
mode of 63 m3 of demineralized water for the regeneration of cations, anions and mixed beds .

Therefore, when more than 14hrs, the A-3102 needs to produce demineralized water equivalent to 16hrs to
use

We have capacity:
16hr 63 3
A  3102 net production  175 m3 /hr   m /hr
14hr 14
 205 m3 /hr

* Sodium bisulphite supply group A-3103:

Sodium bisulphite A-3103 supply chain includes:

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-Sodium bisulphite tank with a capacity of 0.05 m3 for soluble chemical storage
-Two metering pumps with a maximum capacity of 5.5 l / hr each, at 4.6 kg / cm2.g, will be added to the
drinking water system at the injection site.

-In a sodium bisulphite tank a stirrer is used to dissolve sodium bisulphite in powder form.

-Chlorine is provided to reduce excess chlorine in drinking water

2.2 Raw materials and products

2.2.1 Material standards

The quality of clean water from the foreign station fence factory supply to the refinery water system:

Tables 2.21 : data the quality of clean water

Examination qualities unit Dry season Wet season

ph 6,85 6,7
Suspended solids content mg/l 2,95 15
Insoluble solids content mg/l 115 40
Total Solids mg/l 118 83
Total Hardness of Water CaCO3 (Ca2+ mg/l 37,66 33,4
Mg2+)

mg/l 0,03 0,22

Total amount of Fe2 + ion

Na + content mg/l 12,32 10,65
The SO42- mg/l 16,89 16,2
Total alkaline CaCO3 (HCO3-) mg/l 18,3 18,3
The content of NO3- mg/l 0,1 0,27
The content of NO2- mg/l ND 0
The content of Cl- mg/l 20,21 15,3
SiO2 content mg/l 6,48 6,94
Normal Cl2 content mg/l ND 0,3
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  Conditions provided
 Minimum pressure of 3.1 kg / cm²g
 Normal temperature is 30 °C
 Lowest 15 °C
 Highest 35 °C

2.2.2 Product quality

+Clean water

The quality of clean water is the same as the quality of water supplied from the fodder plant (see above).

+ Water for domestic use

The opacity of the filter is no more than 1.5 (mg / l)

Insoluble solids content not more than 10 (mg / l)
The chlorine content of TK-3102 is 0.2 ppm

3. Demineralizes water:

Basic Quality Requirements

Maximum TDS 0.05 ppm
Maximum silica (as SiO2) 0.02 ppm
Maximum conductivity 0.2 microsiemens/cm at 25°C
Additional Quality Requirements
Hardness non detectable
pH 7.0 to 8.0
Iron, Fe max 0.02 ppm
TOC < 1.0 ppm
BOD non traceable
COD < 2.0ppm
Free chlorine 0 ppm
TSS 1ppm

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We have Battery limit condition of U-31:

Pressure, kg/cm²g Temperature, °C

Description
Nor Max Min Design Nor Max Min Design
Feed
Fresh Water 3.1 14.2 (1) 30 35 15 60
Product
Service Water 5.0 9.5 1.5 14.2 30 35 15 60
Potable Water 2.0 4.0 0.5 5.5 30 35 15 60
Demineralised Water 5.0 7.5 1.5 11.0 30 35 15 60

2.2.3 design point

System activity

In too process processing for water, active operation is set 031-AIC-001 in Manual manual and install the
first value is 100% to the maximum speed speed for the Cloidity at the start into the tank contains water
activities

Analyzer 039-AL-002 is used for the observation:

• The concentration of chlorine in the water before distribution

• Reducing the concentration of chlorine in drinking water while reducing chlorine

Water bypass road

Road bypass the valve manually from the network water network running water so that in case there
is no water in the tank and the pump, the road will open and provide a sufficient amount of water
required for the throat washing for a while short time. In this case, no chemical processing.

To improve user safety, this bypass road design characteristics are as follows:

• Road bypass will always play to isolate between the two systems. It will open only when a part of
the water system are in the processing stage. Isolated bypass valves are equipped with 'Lock
Closed'de ensure that it not be opened when there is no work permit

• The tap-off is set to the output of water purification equipment F-3101A / B to optimize water
quality standards normal drinking water.
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Therefore,

• Work Permit will be required when opening the bypass road

• The households using clean water (the administrative building, control room, home guards) will be
told not to allow to drink during chemical management.

Regeneration needs demineralized water clusters A-3102

Clean water tank TK-3101A / B and demineralized water tank TK-3103A / B is used for regeneration
of demineralized water clusters A-3102

Operation clean water tank

Clean water tank TK-3101A / B can be arranged in two different positions:

TK-3101B

TK-3101A

TK-3101A tanks and installed TK3101B related to water supply and receiving clean water. This
approach avoids deposits in both pools.

TK-3101B

TK-3101A

TK-3101A tanks and special TK3101B fitted to receive and provide clean water in the same
time. This choice improve water supply when this request.

Installation of pump: The pump and motor, are designed for open valve condition at startup

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2.2.4 Oil and liquid contamination.

Water from the tank to neutralize and wastewater during backwashing of cluster
demineralized water and water from workshops provide alkaline discharged workshop
sewage treatment (ETP) via the degradation of oil (OWS) .

3 Describes the processing system

 Clean water system :

The water system receives clean water from outside the fence of the plant into the tank TK3101A or
TK3101B through the tank control valve. The P-3101A / B / C pumps provide water to households used in
the plant including demineralized A-3102, domestic water system (F-3101A / B) and distribution to sub-
stations and technology workshops in the plant and product containment area. A minimum flow is extracted
to maintain the network pressure and prevent leakage.

 Water supply system

P-3101A / B / C clean water supply to domestic water system. Filter F-3101A / B filters solids that are
insoluble in water to 10mg / l and produce at least 1.5mg / l after filtration. Simultaneously spray sodium
hypochlorite after filter F-3101A / B, the chlorine content in clump A-3101 is controlled by Cl analyzer is

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 placed at the input water tank TK-3102 and test set Cl is located at the outlet of domestic water tank TK-
3102 so that Cl content reaches 0.2 ppm

The P-3102A / B will distribute domestic water in tank TK-3102 to households in the plant and have a
minimum flow of extracted water to maintain the network pressure and prevent the pump from operating.
OK. Bypass from clean water to the distribution network of the domestic water is connected to the
domestic water purifier to provide water in the shortest time to the safety equipment in the case of pumps
and water tanks are not. Provided when handling chemicals

 Demineralized water systems

A-3102 demineralized water is supplied by the P-3101A / B / C pump. There are two ways of operating
in the demineralised water: The filling (tank TK-3101A or TK-3101B from the start), clean water flow to the
passage of the demineralisation A-3102 is controlled on the flow controller at the input of A -3102.

Supplementation (based on the balance between consumption and production in normal operation), the
proportion of demineralized water produced is based on normal consumption requirements. The tank level
TK-3103A or TK-3103B is controlled by the corresponding controller when installed. When selecting a tank
for level control, set the tank level and adjust the level controller.
The P-3103A / B pumps distribute demineralized water to the consumers in the plant and have a minimum
flow of water extracted to maintain the network pressure and prevent pump failure.
The demineral water has 2 lines, each designed to have a clean water capacity of 205 m3 / hr and produce 175
m3 / hr, reducing the regeneration and backwashing operation of the reducing water minerals

CHAPTER 3: Control and operate system

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of water system of Dung Quat oil refinery

3 target item

The description descriptor and shutdown is applied for transport for system

3.1 Normal startup

• 3.1.1 A brief introduction

 The main steps for starting a water system are as follows:
Start fresh water system (TK-3101A / B, P-3101A / B / C)
Start up domestic water system (F-3101A / B, TK-3102A / B, P-3102A / B, A-3102, A-3103)
Launch of demineralized water system (TK-3103A / B, P-3103A / B, A-3103A / B)
Plumbing will be started before other systems start. Desalinated water and domestic water can be started with
other systems and separated

 Final preparation

+Clean water system:


 Open the inlet valve of the tank
 Insert fresh water into either tank TK-3101A / B or both from outside the factory fence
 Select operating mode from tank to suction of pump
 Make sure the smallest pump controller of the pump will install a pump and a pump in ready mode
 Make sure that the backup pump is automatically started in standby mode
 When the LAL is low in the tank, we start the pump P-3101A or B or C.
 Automatically start up the pump


+ Water supply system :

 Choose one of the two filters F-3301A / B

 Ensure that the valve on the supply network is closed and the bypass line is removed
 Adding chemicals to the A-3101 water solution with a chlorine content of 12.4% wt
 Add a suitable amount of water to dilute the chlorine required
 Open the inlet valve of the tank

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  Open control valve LV-009 when tank TK-3102 is filled with water
 Make sure that the backup pump is automatically started in standby mode
 When the LAL is low in the tank, we start the pump P-3101A or B
 Start the A-3101 water treatment set and make sure the AIC-001 is in online mode
 Observation of chlorine concentration with analyzer AL-002
 When the level of TK-3102 at 50%, the value of chlorine concentration is 0.02 ppm (seen by AL-
002), and the valve
 Set the automatic mode to control the level in the tank
 Backup pumps will start automatically

+ Demineralized water systems

 Open the inlet valve of the tank

 Launch a demineralized water line
 Turn the water inlet valve to fit (FV-009/012)
 Arrange the tanks to the suction head of the pump
 Make sure that the lowest flow control of the pump will work
 Make sure that the backup pump starts automatically in standby mode
 When the LAL is low in the tank, we start the pump P-3101A or B

 Set the automatic mode to control the level in the tank

 Backup pumps will start automatically

Note :

N2 is not required when starting tank TK-3101A / B

3.2 Normal shutdown

+ Clean water system :

Stop TK-3101A or TK-3101B when filling in water Isolation of backup pumps Stop running pumps P-3101A
/ B / C Isolation of tank TK-3101A / B Drain the tank and bomb if necessary

+ • Demineralized water systems :

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Stop the production of demineralized water from the A-3102 and TK-3103A or TK-3103B water tanks.
Isolate the backup pumps Stop the pump running P3103A / B Isolation of water tank TK-3103A / B Drain the
tank and pump if necessary Isolate and stop A-3102 demineralized water according to equipment supplier

+ Water supply system :

Stop TK-3102 is filling the water Isolate the backup pumps Stop the pumps running Closure of chlorine into
water treatment cluster A-3101 Isolation tank TK-3102 Drain the tank and pump if necessary

+ Desalination system in domestic water tank :

Initial conditions
The bypass will be granted with a work permit
Households that use domestic water (administrative buildings, control rooms, security gates) will know that
drinking water can not be mixed with dechlorinated water at the time of operation.
- Isolation tank TK-3102 by valve LV-009 and header block valve. Pump P3102A / B will operate on its
circulation.
- Increase the setting value of AIC-001 up to 5ppm
- Observation of the increase in chlorine concentration in the tank via analyzer AL-002
- When the chlorine analyzer reaches 5ppm, stop chlorine spraying into the tank
- Keep the pump running with the isolated tank at least 24hr
- Start the dechlorination system
- Bring the analyzer to chlorine content AL-002 into the tank
- When chlorine analyzer AL-002 reaches 0.02 ppm, dechlorination is stopped
- Stop pumping
- Drain the tank out of the drain valve
- Continue to stop under the shutdown section of the water system

3.3 Emergency Shutdown :

 Loss of energy
In case of energy loss, clean water system, demineralized water and drinking water will not be provided to the
users because the supply pump will shut down.
• Loss of breath
The water system continues to operate
• Loss of control

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Clean water, demineralized water and drinking water continue to operate Additional clean water from outside
the fence will be interrupted when the control valve is closed due to lack of control air The production of
demineralized water will stop when the controlled gas permits the demineralization of the A-3102
demineralized water Replenishment of drinking water from the water network will be interrupted when the
control valve is closed due to lack of control air

• Loss of cooling water The water system continues to operate

• Loss of gas The water system continues to operate
• Nitrogen depletion The water system continues to operate, however it does not seal the demineralized water
tank TK-3103A / B, which can allow for operation.
• Mechanical breakdown
• Clean water pump P-3101A / B / C In the case of mechanical failure of the running pump, 31-US-101 will
automatically start the pump on the basis of low pressure reading from 31-PI-001. And the water system will
continue to operate.
• Domestic water pump P-3102A / B In the case of mechanical failure of the running pump, 31-US-107 will
automatically start the backup pump based on low pressure readings from 31-PI-022. And the domestic water
system will continue to operate. .
• Demineralized water pump P-3102A / B In case of mechanical failure of the running pump, 31-US-103 will
automatically start the backup pump based on low pressure readings from 31-PI-005. And the demineralized
water system will continue to operate.

CHAPTER 4 : SAFEGUARDING DEVICES

4.1 Alarms & Trips

4.1.1 Service water pumps and back wash pumps protection (031-US-102)

In the event of 031-LALL-003 (low low level) in the tank TK-3101A, then service water pumps
P-3101A/B/C and backwash pumps A-3102-P-01A/B are shut down. Backwash pumps A-
3102-P-01A/B are part of A-3102 package (demineralised water package).

In the event of 031-LALL-004 (low low level) in the tank TK-3101B, then service water pumps
P-3101A/B/C and backwash pumps A-3102-P-01A/B are shut down.

4.1.2 Demineralised water storage tanks overfilling protection (031-US-104)

In the event of 031-LAHH-007 (high high level) in the tank TK-3103A, then valves 031-FV-
009 / 031-FV-012 are closed.

In the event of 031-LAHH-008 (high high level) in the tank TK-3103B, then valves 031-FV-
009 / 031-FV-012 are closed.
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 4.1.3 Demineralised water pumps and regeneration pumps protection (031-US-105)

When TK-3103A is selected by 031-LHS-005, in the event of 031-LALL-007 (low low level) in
the tank TK-3103A, then demineralised water pumps P-3103A/B and regeneration pumps A-
3102-P-02A/B are shut down.

When TK-3103B is selected by 031-LHS-005, in the event of 031-LALL-008 (low low level) in
the tank TK-3103B, then demineralised water pumps P-3103A/B and regeneration pumps A-
3102-P-02A/B are shut down.

4.1.4 Potable water storage tank overfilling protection (031-US-108)

In the event of 031-LAHH-010 (high high level) in TK-3102, then valve 031-LV-009 is closed.

4.1.5 Potable water pumps protection (031-US-109)

In the event of 031-LALL-010 (low low level) in TK-3102, then potable water pumps P-
3102A/B are shut down.

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 4.1.6 ADP Alarms

The following alarms to be initiated on the anunciator display panel (ADP) if the respective
DCS alarms remain active for a variable duration of approximately fifteen seconds (time to
be adjusted if necessary).

Designation DCS alarm ADP alarm

Service water pressure low 031-PAL-001A 031-PAL-001B
Demineralised water pressure low 031-PAL-005A 031-PAL-005B
Potable water pressure low 031-PAL-022A 031-PAL-022B
Potable water chlorine content 031-AAH-002A 031-AAH-002B
high
Demineralised water tanks level 031-USA-110A 031-USA-110B
low low 031-LALL-005 / 031-LALL-
006

4.2 Safeguarding Description

4.2.1 Fresh Water Storage Tanks TK-3101A/B

Overflow line to protect against liquid overpressure. Vent line to prevent against
overpressure/vacuum. High level alarms 031-LAH-001/002 will warn the operator that a
manual action is required to stop fresh water filling.

4.2.2 Service Water Pumps P-3101A/B/C

Low low level in TK-3101A/B will trip the pumps via DCS logic 031-US-102.

4.2.3 Potable Water Storage Tank TK-3102

Overflow line to protect against liquid overpressure. Vent line to prevent against
overpressure/vacuum. High high level in TK-3102 will close the inlet valve 031-LV-009 via
DCS logic 031-US-108 to prevent over flowing.

4.2.4 Potable Water Pumps P-3102A/B

Low low level in TK-3103A/B will trip the pumps via DCS logic 031-US-108.

4.2.5 Demineralised Water Storage Tanks TK-3103A/B

Overflow line to protect against liquid overpressure. Vent line to prevent against
overpressure/vacuum. High high level in TK-3103A/B will close inlet valve 031-FV-009/012
via DCS logic 031-US-104 to prevent overflowing.

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4.2.6 Demineralised Water Pumps P-3103A/B

Low low level in TK-3102A/B will trip the pumps via DCS logic, 031-US-105.

4.2.7 Sulphuric Acid Support Facilities

A level transmitter, LIT 751 with four set points is mounted to level gauge, LG751 for level
control.

A high level alarm is an indication of liquid high level and at high high level, the acid
unloading pump shall stop immediately.

A low level warning is an indication of liquid low level and at low-low level the acid dosing
pumps shall stop immediately and annunciate.

Instrument Tag No: LIT-751

Location: Acid Storage Tank, A-3102-TK-01
Event: Action in AUTO Mode and Alarm Mode
Level HH (95%): Alarm on, manually stop acid unloading pumps, A-3102-P-03A/B
Level H (50%): Alarm on
Level L (10%): Warning: Operator to arrange for acid tanker
Level LL: PLC to stop acid dosing pumps, A-3102-P-05A/B

4.2.8 Caustic Support Facilities

Two level transmitters, LIT 762 for level control are provided. A high level alarm is an
indication of liquid high level.

A low level warning is an indication of liquid low level and at low-low level the acid dosing
pumps shall stop immediately and annunciate.

High high level indicating of overflowing & alarm shall be annunciated.

Instrument Tag No: LIT-762

Location: Caustic Day Tank, A-3102-TK-02

Event: Action in AUTO Mode and Alarm Mode
Level H: Alarm on, close Valve UV-761
Level L: Warning: caustic filling required.
Level LL: PLC to stop Caustic dosing pumps, A-3102-P-04A/B

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4.3 Safeguarding Equipment

PSV Tag No. Control Valve Tag Remarks

No.
031-PSV-042 031-PCV-041 In the case of control valve fails open, PSV
protects Potable Water System (design
pressure = 5.5 kg/cm²g) against
overpressure from the service water system
(design pressure = 14.2 kg/cm²g).
031-PVV-008 031-PCV-010 In the case of control valve fails open, PVV
protects Demineralised Water Tank TK-
3101A (design pressure = 0.02 kg/cm²g)
against overpressure from the Nitrogen
system (design pressure = 11.7 kg/cm²g).

031-PVV-009 031-PCV-017 In the case of control valve fails open, PVV

protects Demineralised Water Tank TK-
3101B (design pressure = 0.02 kg/cm²g)
against overpressure from the Nitrogen
system (design pressure = 11.7 kg/cm²g).

4.3.1 LO Valve at TK-3102 Inlet

It is provided to allow line from downstream of TK-3102 level control valve 031-LV-009
manifold to be designed for 3.5 kg/cm²g, compatible with design of Potable Water Treatment
Package A 3101.

4.3.2 Check Valve at A-3102 Outlet Line to TK-3103A/B

It is provided to avoid back flow from Demineralised Water Tanks TK-3103A/B to the
Demineralised Water Package trains in case of their depressurisation.

4.3.3 Service Water Tanks, TK-3101A/B Top Inlet

It is provided to avoid back flow from Service Water Tanks TK-3103A/B to the fresh water
supply network outside of the Refinery fence.

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4.3.4 Demineralised Water Package A-3102

Page 52 of 79
Page 53 of 79
 CONCLUSIONS AND RECOMMENDATIONS
1. Conclusions : Process Water and Cooling water are two important plants in
the petrochemical refinery used to provide water for domestic use and to cool
the plant.

2. Recommendations:

Regular maintenance of water pipes and the pump tank water pump
controller. Regular inspection of pumping equipment Stabilizers

1
 REFERENCES
1. ARAMIS Development Ltd
2.

2
ATTACHMENTS AND APPENDICES

1. ACKNOWLEDGMENT
2. CHAPTER
3. CONCLUSIONS AND RECOMMENDATIONS

Thank you !