Volume 1 - General_v1-ch03-basis Of Design

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PROJECT PROCEDURE BASIS OF DESIGN

VOLUME 1

CHAPTER 3

BASIS OF DESIGN

0

05-NOV-12

ISSUE FOR PDP

M. GUEYE

F. BETTON

F. BETTON

REV.

DATE DD-MMM-YY

STATUS – REVISION MEMO

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

Document revisions. © INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

CONTENTS 1.

PLANT DEFINITION 1.1

2.

PLANT CAPACITY, OPERATING FACTOR AND PRODUCT MIX 2.1 2.2

3.

TEMPERATURE AND PRESSURE FLOW

UTILITIES & RAW MATERIAL SPECIFICATIONS 4.1 4.2

5.

PLANT CAPACITY AND OPERATING FACTOR DESIGN GRADE SLATE

DEFINITION OF TERMS 3.1 3.2

4.

FUNCTIONS OF UNITS

UTILITIES & RAW MATERIAL ELECTRICITY

SPECIFICATION OF CHEMICALS 5.1 5.2 5.3 5.4 5.5 5.6

GENERAL TEAL LIQUID ADDITIVE PRODUCT ADDITIVES CATALYSTS MISCELLANEOUS CHEMICALS

6.

PRODUCT CHARACTERISTICS

7.

ENVIRONMENTAL CONDITIONS 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11

CLIMATIC CHARACTERISTICS TEMPERATURE HUMIDITY WIND DIRECTION AND VELOCITY AIR PRESSURE SEISMIC DESIGN RAINFALL SNOWFALL FROZEN SOIL DEPTH WINTERISATION PERSONNEL PROTECTION

8.

SPACING OF EQUIPMENT

9.

ENVIRONMENT REQUIREMENT

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

ATTACHMENTS

ATTACHMENT A

RAW MATERIAL CONDITIONS AT LLPDE BATTERY LIMIT

ATTACHMENT B

RAW MATERIAL COMPOSITIONS AT LLPDE BATTERY LIMIT AND CORE PLANT

ATTACHMENT C

UTILITY CONDITIONS AT LLPDE BATTERY LIMIT & AT USERS

ATTACHMENT D

UTILITY COMPOSITIONS AT LLPDE LIMIT

ATTACHMENT E

PLOT LAYOUT SPACING OF EQUIPMENT RP44-7

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BASIS OF DESIGN

1.

PLANT DEFINITION

1.1

FUNCTIONS OF UNITS Feedstock Preparation Unit The raw materials, ethylene, butene-1, hexene-1, octene-1, pentane and hydrogen are metered, treated in order to achieve required reaction quality and transferred to the polymerisation unit. All feeds are fed to the core plant by pipeline. Nitrogen is treated to generate the various required quality levels. Catalyst Feeding The Ziegler catalyst or the Metallocene catalyst (one transfer and one injection system per catalyst type) is transferred batchwise via tote bins to the injection system. Continuous Catalyst Injection process is used. Polymerisation Ethylene, comonomer (butene-1, hexene-1, octene-1), hydrogen, pentane, TEAl, liquid additives and catalyst are introduced into the fluidised bed reactor where the continuous polymerisation reaction takes place. The fluidising process gas is circulated in a reaction loop where entrained powder is removed by cyclones, the gas cooled, condensate separated and the gas compressed and recycled to the reactor. The condensate is pumped back to the reactor through injection nozzles. Reagents (TEAI and liquid additives S1 and B1) are directly injected into reactor from dedicated containers. Powder degassing and Powder conveying Polymer product (powder) is removed by lateral withdrawal systems. Residual hydrocarbons are stripped from the powder in multistage degassing process and residual catalyst is deactivated before the powder is directed to the Extrusion feeding and Pelletisation unit. Pentane and comonomer extracted from the powder are recovered and recycled to the reaction loop. Nitrogen from degasser outlet gas is separated from heavy hydrocarbons and recycled to the degasser. The capacity of the purge column provides up to 4h storage at powder design rate to accommodate stoppages in the upstream or downstream sections of the plant.

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BASIS OF DESIGN

Extrusion feeding and Pelletisation Powder from the Polymerisation and pure powder additives, supplied from Flexible Intermediate Bulk Containers (FIBCs 1 and 2 m3), are fed into the extruder via an extruder feed screw. A facility for addition of powder from 25 kgs bags is also provided with each FIBC unloading station. The product pellets are carried away and cooled by a pellet water circuit, dried, screened, metered and conveyed via a pneumatic air system to the Pellet conveying and Blending unit. Pellet conveying and Blending Pellets from the Extrusion feeding and Pelletisation are transferred to one of 2 continuous pellet blenders. Under level control the pellets are simultaneously transferred to OSBL via an elutriation system to ensure pellet quality in the final storage bins. In normal operation, only one pellet blender is required with a second blender being used for transitions. One additional pellet blender is installed for flexibility. Liquid recovery Unit Liquid purges during normal and transition operation with Ziegler grades are distilled in the LRU column in order to remove traces of TEAL prior sending the purge stream to OSBL. TEAL and heavy components are recycled to the main loop. The LRU may be bypassed if necessary. Utilities Vents & Flare It consists of the facilities for primary gaseous effluent treatment, including the flare drum. Utilities battery limits It consists of metering and distribution of steam, steam condensate recovery, cooling water, other waters (demineralised and service), instrument air and standard quality nitrogen. Utilities required for common Ethylene and Hydrogen treatment are segregated from LLDPE networks. Nitrogen Nitrogen is purified and letdown to generate the various required pressure levels of nitrogen. Primary aqueous treatment facilities The water effluents, potentially containing powder, pellets and extruder start-up materials are recovered and treated if required, before being sent OSBL to oily water or contaminated rain water system.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

1.2

SCOPE OF THE PROCESS DESIGN PACKAGE

The Process Block Diagram, in chapter 4 of this volume, shows the scope of the LLDPE plant and indicates the ISBL and OSBL facilities which are necessary to support it. This PDP defines the units of the Gas Phase LLDPE Plant, which are described in general terms in Section 1.1 above. The Units for the Plant are: Feedstock Preparation Unit (200) Catalyst Injection Unit (300) Polymerisation Unit (400) Degassing and recycle Unit (600) Vent Recovery Unit (600) Liquid Recovery Unit (700) Additive and Pelletising Unit (800) Pellet Blending Unit (800) Reagents and Utilities Unit, including: • Utilities distribution, including (100): o

Nitrogen letdown and distribution,

o

Steam distribution,

o

Steam condensate recovery,

o

Cooling water distribution,

o

Other waters distribution (demineralised, service, potable),

o

Instrument air distribution,

o

Plant air distribution,

o

Fuel gas distribution.

• Flare KO Drum and Flare Header (100) • Process vents (100) • Nitrogen treatment (200), • Waste water treatment (100).

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

2.

PLANT CAPACITY, OPERATING FACTOR AND PRODUCT MIX

2.1

PLANT CAPACITY AND OPERATING FACTOR The gas phase polyethylene plant will be designed to produce 350 KTPA of low and high density polyethylene using Ziegler or Metallocene catalysts with C6 or C8 comonomers. The plant will also have the capability to produce LL and HD polyethylene using Ziegler catalyst with butene comonomer.

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BASIS OF DESIGN

2.2

DESIGN GRADE SLATE The design grades for the Polymerisation loop are: Innovene PEG Grade Name

Segment

Comonomer

Catalyst

Rate (t/h)

kT/a (1)

LL6209AA

Film LL C6

Hexene-1

Ziegler

44

88

LL6409AA

Film LL C6

Hexene-1

Ziegler

44

26

LL6608AA

Film LL C6

Hexene-1

Ziegler

44

26

LL6130AA

Film LL C6

Hexene-1

Ziegler

44

35

PF6212AA

Film mLL C6

Hexene-1

Metallocene

44

70

PF6612AA

Film mLL C6

Hexene-1

Metallocene

44

35

PF6130AA

Film mLL C6

Hexene-1

Metallocene

44

53

HD3850UA

Rotomolding

Hexene-1

Ziegler

44

17

LL8409AA

Film LL C8

Octene-1

Ziegler

44

-

LL8608AA

Film LL C8

Octene-1

Ziegler

44

-

LL8130AA

Film LL C8

Octene-1

Ziegler

38

-

PF8212AA

Film mLL C8

Octene-1

Metallocene

40

-

PF8612AA

Film mLL C8

Octene-1

Metallocene

44

-

PF8130AA

Film mLL C8

Octene-1

Metallocene

40

-

HD8850UA

Rotomolding

Octene-1

Ziegler

44

-

TOTAL

350

Note 1: Used for additive storage sizing only.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

The plant shall have the capability of producing the following Butene-1 grades. Innovene PEG Grade Name

Segment

Comonomer

Catalyst

Rate (t/h)

LL0209KJ

Film LL C4

Butene-1

Ziegler

44

LL0220AA

Film LL C4

Butene-1

Ziegler

44

LL0230AA

Film LL C4

Butene-1

Ziegler

44

LL0410AA

Film LL C4

Butene-1

Ziegler

44

LL0640AA

Film LL C4

Butene-1

Ziegler

44

HD3840UA

Rotomolding

Butene-1

Ziegler

44

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

3.

DEFINITION OF TERMS

3.1

TEMPERATURE AND PRESSURE

3.1.1 Design Temperature or Pressure The maximum temperature or pressure that the system could be subjected to reach under any emergency condition. This forms the basis for the mechanical design (e.g. relief valve setting). 3.1.2 Maximum Temperature or Pressure The maximum temperature or pressure that the system could attain under normal operating conditions (used to determine limits of instrument operation and equipment sizing where appropriate). 3.1.3 Normal Temperature and Pressure The normal temperature or pressure at which the system operates under steady state conditions. 3.1.4 Minimum Temperature and Pressure The minimum temperature or pressure that the system might attain under any conditions. This is also used as a basis for the mechanical design where applicable (e.g. vacuum conditions, or Joule-Thomson temperature effects).

3.2

FLOW

3.2.1 Maximum Flow The maximum available flow on either a short term or continuous basis. If the former is entered the acceptable duration should be indicated. 3.2.2 Normal Flow The normal process flow corresponding to the grade with the highest continuous requirements. 3.2.3 Minimum Flow The minimum flow required on a continuous basis (used for process design).

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BASIS OF DESIGN

4.

UTILITIES & RAW MATERIAL SPECIFICATIONS

4.1

UTILITIES & RAW MATERIAL This section contains information defining the raw materials required by the process which are available to the Plant from the Licensee’s facilities and is the basis upon which the PDP is prepared. Refer to: Attachment A:

Raw material conditions at LLDPE battery limit

Attachment B:

Raw material compositions at LLDPE battery limit and core plant

Attachment C:

Utility conditions at LLDPE battery limit & at users.

Attachment D:

Utility compositions at LLDPE battery limit

NB: LLDPE battery limit = PDP Scope

4.2

ELECTRICITY The power supply conditions at battery limits are assumed as follows: Nominal voltage

Motor size range

Phase

Frequency

11 or 33 kV

Medium Voltage Motors

3

50 Hz

6.6 kV

P > 185 kW

3

50 Hz

400 V

P ≤ 185 kW

3

50 Hz

230 V AC

Lighting, plugs and others

1+N

50 Hz

The requirement for a high integrity electrical supply, with “voltage dip” protection should be noted. A DC back-up electrical supply is not required for the plant. An uninterruptible power supply of 30 minutes duration must be specified for the DCS. Monitoring, control and safety instrumented systems and field instrument equipment must be powered via an uninterrupted power source (UPS) continuously operating in on-line mode. The UPS must provide the battery back-up over a period of time sufficient for accident-free shutdown of a facility. There is no requirement for battery power back-up of motors.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

5.

SPECIFICATION OF CHEMICALS

5.1

GENERAL The catalyst reagents required by the Innovene G process are shown below. Name

Chemical Name

Generic Description

TEAl

Tri-Ethyl-Aluminium

Cocatalyst

Liquid additive B1 (n-BuCl)

Butylchloride

Catalyst activity booster

Liquid additive S1 (Stadis)

5.2

Antistatic agent

TEAl INEOS Technologies uses and recommends Tri-Ethyl-Aluminium that meets the following specification: Al content greater than 22 % wt. N-butyl group content less than 7.0 % wt. Hydride content less than 0.6 % wt. TEAl used in the design is undiluted.

5.3

LIQUID ADDITIVE

5.3.1 Liquid additive : B1 n-BuCl (B1): ButylChloride (pure liquid) 5.3.2 Liquid additive : S1 Stadis (S1): INNOSPEC additive type STATSAFE 6000 or equivalent.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

5.4

PRODUCT ADDITIVES The basis of design of the powder additive system results from the formulation of commercial Innovene grades as given in Table 3.1 in chapter 10 of this volume. Properties of the additives are given in datasheet Typical 3, in Volume 2, chapter 2.

5.5

CATALYSTS Catalyst will be supplied in a ready-to-use form, under nitrogen, by INEOS.

5.5.1 Ziegler SDx Catalyst Physical Properties: Bulk Density Average Particle Size

310 - 340 kg/m3 33 - 47 µm

Typical Specifications: Titanium Content Hydrocarbons Content

3.1 - 3.7 % wt < 5 % wt

5.5.2 Ziegler NOVACAT T Catalyst Physical Properties: Bulk Density Average Particle Size

400 - 430 kg/m3 38 - 50 µm

Typical Specifications: Titanium Content Hydrocarbons Content

0.38 – 0.52 % wt < 2 % wt

5.5.3 Metallocene Catalyst Physical Properties: Bulk Density Average Particle Size

370 - 390 kg/m3 35 - 45 µm

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BASIS OF DESIGN

Typical Specifications: Titanium Content Hydrocarbons Content

5.6

0.20 – 0.30 % wt < 1 % wt

MISCELLANEOUS CHEMICALS The following chemicals are also required: 1. Bottled carbon monoxide for use in termination of the polymerisation reaction in the event of an emergency. 2. The extruder pellet water circuit and the Recycle Gas Compressor cooling water circuit may require chemicals, depending on the water quality and operating temperature. The details are to be developed during detailed engineering. 3. TEAl deactivating agents e.g. carbon dioxide. 4. Seal pot mineral oil e.g. ISOPAR.

6.

PRODUCT CHARACTERISTICS Typical powder, pellet and extrusion additives physical properties for the design grades are given in data sheets, Typical 1, Typical 2 and Typical 3 included in Volume 2 Chapter 2.

7.

ENVIRONMENTAL CONDITIONS

7.1

CLIMATIC CHARACTERISTICS The Plant will be located in a new complex at Johor Baru in Malaysia.

7.2

TEMPERATURE

7.2.1 Average Temperature Coastal environment with tropical/monsoon location.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

Maximum recorded ambient temperature

36 °C

Minimum recorded ambient temperature

20.2 °C

7.2.2 High and Low Ambient Design Temperatures

7.3

7.4

7.5

7.6

Maximum air temperature for design

36.5 °C

Annual average air temperature.

27.5 °C

Minimum air temperature for design (used as MDMT)

20 °C

Design Web bulb for cooling tower design

30 °C

HUMIDITY Average relative humidity

83.4

%

Maximum relative humidity

98.9 %

WIND DIRECTION AND VELOCITY Prevailing wind direction

From NNE (13%) and from S (10%)

Design wind velocity

32.5 m/s

AIR PRESSURE Min Atmospheric Pressure

1002 mbar abs.

Average Atmospheric Pressure

1010 mbar abs.

SEISMIC DESIGN The effects of earthquake shall be taken into account. The design shall be based on design conditions indicated below, and be in full accordance with the latest revision of Uniform Building Code (UBC 1997). For load and design factors reference is made to the UBC section 1624 through 1633. Design Condition One: “Operating Basis Earthquake” (OBE).

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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BASIS OF DESIGN

All equipment, structures and buildings shall be designed for OBE. The OBE shall be based on the following factors: a) Seismic Zone 1 shall be applied for all equipment (Z= 0.075). b) Importance factor 1 shall be applied for all equipment (I = 1). c) Site Amplification factor 1.5 shall be applied (S3 =1.5). d) For vertical ground acceleration a factor of 0.05 g shall be applied. Tsunami may occur.

7.7

RAINFALL Maximum 24-hour rainfall

240 mm (10mm/h during 24h)

Maximum hourly rainfall

45 mm (180mm/h during 15min)

Design must consider occasional lightning and thunderstorm.

7.8

SNOWFALL Not applicable.

7.9

FROZEN SOIL DEPTH Not applicable.

7.10

WINTERISATION Not applicable.

7.11

PERSONNEL PROTECTION Personnel protection will be applied on all lines and equipment with Operating temperature ≥ 70°C or Minimum temperature to avoid ice.

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JSD

-

002

Serial n°

0001 Page

0

17

BASIS OF DESIGN

8.

SPACING OF EQUIPMENT Equipment Spacings used for the development of the layout drawings of this PDP follow the most constraining rule between the “Plot Layout Spacing of Equipment” table from INEOS standard: RP 44-7 (extract in attachment E) and GAP, for inter-unit spacing.

9.

ENVIRONMENT REQUIREMENT Emission levels; Licensor standard will be applied: -

Allowable hydrocarbons to atmosphere (deliberate discharge only) : 15 mg/Nm3 (*)

-

Powder to atmosphere (maximum after filtration or treatment)

: 10 mg/Nm3 (*)

(*) Standard value to be confirmed by Client.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

JSD

-

002

Serial n°

0001 Page

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18

BASIS OF DESIGN

ATTACHMENT A RAW MATERIAL CONDITIONS AT LLDPE BATTERY LIMIT TABLE 61070F-3200-JSD-0000-02A

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

BASIS OF DESIGN - ATTACHMENT A

CLIENT

Project N° - Unit

Code

Type doc.

Serial N°

Rev. Index

61070F-3200

JSD

-

02A

0

Chk by FBN FBN

Page

PETRONAS PROJECT RAPID

LOCATION JOHOR, MALAYSIA UNIT

RAW MATERIAL CONDITIONS SUMMARY TABLE

Rev. XA 0

Date JUN 12 NOV 12

Made by BGO MGU

Technologies

1/1

350 KTA LLDPE PLANT

FLOWING FLUID

PRESSURE AT LLDPE BL

TEMPERATURE AT LLDPE BL

bar g - REF. TO GRADE

°C

REMARKS

CODE

NAME OF FLUID

G OR L

MINI

NORMAL

MAXI

DESIGN

MINI

NORMAL

MAXI

DESIGN

ET

Ethylene Import

G

32.0

32.0

34.0

42.0

10

20

AMB (36)

80/-45

1BTN

Butene-1

L

6.0

7.0

8.0

12.0

AMB (20)

AMB (27)

AMB (36)

80/ -7

iPENT

Pentane

L

6.0

7.0

8.0

12.0

AMB (20)

AMB (27)

AMB (36)

80

1HEX

Hexene-1

L

6.0

7.0

8.0

12.0

AMB (20)

AMB (27)

AMB (36)

80

1OCT

Octene-1

L

6.0

7.0

8.0

12.0

AMB (20)

AMB (27)

AMB (36)

80

HG

Hydrogen Import

G

23.0

25.0

26.0

30.0

AMB (20)

AMB (27)

45

80

OWNER REFERENCE

Technologies

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0

BASIS OF DESIGN

ATTACHMENT B RAW MATERIAL COMPOSITIONS AT LLDPE BATTERY LIMIT AND CORE PLANT Please note that the Innovene Specification = Reactor Requirement ETHYLENE Component Ethylene Methane + Ethane (Ethane)

Units vol % min. vol ppm max

SCU Specification at B.L Note 1 99.95 min 500 max (450 max)

Innovene™G Specification 99.95 550 max

N2

vol ppm max

5

-

Total Hydrocarbons C3 and higher

vol ppm max

10

20

Acetylene

vol ppm max

2 (Note 1)

1

Sulfur as H2S, Total

vol ppm max

1

1

Water

vol ppm max

5 (Note 1)

0.1

Oxygen

vol ppm max

1 (Note 1)

0.1

CO

vol ppm max

1 (Note 1)

0.1

CO2

vol ppm max

5 (Note 1)

0.1

H2

vol ppm max

5

5

Alcohol as Methanol

vol ppm max

4 (Notes1)

0.5

Nitrogen compound (NO+NO2)

vol ppm max

0.2

0.2

Oxygenated compounds (as ketone)

vol ppm max

1

1

Ammonia

vol ppm max

0.2

0.2

Chloride(as Cl or Cl²)

vol ppm max

1

0.8

N2O

Vol ppm max

0.2

Note 1: It is assumed the feed quality available at battery limit will match the Innovene™ G except for the following impurities for which treatment is required: • O2, CO and C2H2 removal (copper oxide/zinc oxide based catalyst) • CO2, water,alcohol (Molecular sieve for water, and activated alumina beds) • Layout and PIDs to allow for future installation of Chloride guard.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

Discipline

Doc. Type

Unit n°

PRO

DES

3200

INE

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

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-

002

Serial n°

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20

BASIS OF DESIGN

HYDROGEN

Component

Units

Specification at B.L (TBC)

Innovene™G Specification

Hydrogen

vol. % min.

99.7

98

N2

vol. % max.

0.3 (*)

2

Methane

vol. % max.

(*)

0.1

Acetylene

vol. ppm max.

-

10

Other hydrocarbons

vol. ppm max.

20 (NOTE1)

20

Carbon Monoxide

vol. ppm max.

1 (NOTE1)

1

Carbon Dioxide

vol. ppm max.

20 (NOTE1)

0.5

Oxygen

vol. ppm max.

0.1

1

Water

vol. ppm max.

2 (NOTE1)

0.5

Total Sulfur

wt ppm max.

1

5

Total combined Nitrogen

wt ppm max.

0.5 (NH3)

1

He

vol ppm max.

150 (tbc)

Total chlorine

Wt ppm max.

1

(*) Total CH4 + N2 at B.L : 0.3% vol max. Note 1: It is assumed the feed quality available at battery limit will match the Innovene™ G except for the following impurities for which treatment is required: •

CO2 and water removal (activated alumina beds)

•

Treatment for C2H2 and CO is not required.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

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DES

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BASIS OF DESIGN

HEXENE-1 Specification at B.L Note 1

Component

Hexene-1

99% wt min

Innovene ™ G specification 99% wt min

Lighter than C6

0.5% wt max

0.5% wt max

Heavier than C6

0.5% wt max

0.5% wt max

Other C6

0.5% wt max

0.5% wt max

Olefins (Internal & Branched)

2% wt max

2.0% wt max(with paraffin)

Carbon monoxide

1 ppm wt max

1 ppm wt max

Carbon dioxide

1 ppm wt max

1 ppm wt max

Carbonyls (as =O)

10 ppm wt max

0.5 ppm wt max

Alcohols (as -OH)

5 ppm wt max

1 ppm wt max

Benzene

1 ppm wt max

1 ppm wt max

THF

5 ppm wt max

5 ppm wt max

Oxygen (liquid phase)

1 ppm wt max

1 ppm wt max

Water 1,3 Hexadiene

25 ppm wt max 10 ppm wt max as total diene

0.6 ppm wt max 10 ppm wt max as total diene

Total Combined Sulphur

1 ppm wt max

1 ppm wt max

Peroxide(as active O)

2 ppm wt max

0.5 ppm wt max

Note 1: Data based on INEOS experience. INEOS will add treatment facilities in anticipation of commercial available specifications, based on their experience. Guard treatment is typically provided for water and oxygenated compounds removal. Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

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Rev.

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BASIS OF DESIGN

OCTENE-1

Component

Units

Spec at BL Note 1

Innovene™ G Specification

C8 hydrocarbons

wt. % min.

99

99

Lighter than C8

wt. % max.

0.5

0.5

Heavier than C8

wt. % max.

0.5

0.5

Octene-1

wt. % min.

99

99

Olefins (Internal & Branched)

wt. % max.

1

1

Paraffins

wt ppm max.

0.5

0.5

Carbon monoxide

wt ppm max.

1.0

1.0

Carbon dioxide

wt ppm max.

1.0

1.0

Carbonyls (as MEK)

wt ppm max.

10

0.5

Alcohols (as -OH)

wt ppm max.

3

1.0

Benzene

wt ppm max.

1.0

1.0

Oxygen (liquid phase)

wt ppm max.

1.0

1.0

Water

wt ppm max.

50

0.6

Total Combined Sulphur

wt ppm max.

1

1

Peroxide(as active O)

wt ppm max.

2

1

Note 1: Data based on INEOS experience. INEOS will add treatment facilities in anticipation of commercial available specifications, based on their experience. Guard treatments are typically provided for water and oxygenated compounds removal. Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

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BASIS OF DESIGN

BUTENE-1

COMPONENT

Battery Limit Specification Note (2)

Innovene G Specification to Reactor

99% wt min

99% wt min

Butene-1 Butene-2 (cis and trans isomer)

1% wt max

Other butenes and butane

1% wt max

Acetylene

10 ppm wt max

Propyne (methyl acetylene)

1% wt max

10 ppm wt max

5 ppm wt max

1,3 Butadiene (including propadiene)

50 ppm wt max

1,2 Butadiene

5 ppm wt max

C5 and heavier

500 ppm wt

Carbonyls (as MEK)

5 ppm wt max

Alcohols (as methanol)

5 ppm wt max

MTBE

5 ppm wt max

Carbon Monoxide

2 ppm wt max

Carbon Dioxide

2 ppm wt max No spec. (not normally present)

Ammonia Nitrogen compounds (NO+NO2)

1% wt max

No spec. (normally not present) (1)

Oxygen (liquid phase) Water Total combined Sulphur (as H2S) Peroxides (as active O2) Total Chloride

1 ppm wt max 20 ppm wt max 3 ppm wt max 3 ppm wt max 1 ppm wt max

50 ppm wt max 5 ppm wt max 500 ppm wt 0.5 ppm wt max 1 ppm wt max 5 ppm wt max 2 ppm wt max 2 ppm wt max No spec. (not normally present) No spec. (normally not present) (1) 1 ppm wt max 0.6 ppm wt max 3 ppm wt max 0.5 ppm wt max 1 ppm wt max

Note 1: Excludes dissolved nitrogen Note 2: Data based on INEOS experience

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

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PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

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3200

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BASIS OF DESIGN

INEOS will add treatment facilities in anticipation of commercial available specifications, based on their experience. Guard treatments are typically provided for water and oxygenated compounds removal. Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

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PRO

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BASIS OF DESIGN

PENTANE Battery Limit Specification COMPONENT

INNOVENE™ G SPECIFICATION Note 1

n-pentane

50% wt (min) (2)

i-pentane

50% wt (max) (2)

C5 Content

No specific requirement. Licensee to advise (NOTE1)

99% wt min

99

% wt min

Carbon Monoxide

1 ppm wt max

1

ppm wt max

Carbon Dioxide

1 ppm wt max

1

ppm wt max

Water (to reactor)

50 ppm wt max

1 ppm wt max

Oxygen (in liquid phase)

0.5 ppm wt max

1 ppm wt max

Total oxygenated compounds (as C=O)

5 ppm wt max

0.5 ppm wt max

Total aromatics as Benzene Total Combined Sulphur

20 ppm wt max

20

ppm wt max

2 ppm wt max

2

ppm wt max

50 mg Br/100g

50

mg Br/100g

Bromine Index

Compounds not shown may not be present. Supply of pentane needs to meet the Innovene™ G specification. However, guard treatment is typically provided ISBL for water removal. Activated alumina is recommended to remove also oxygenated compounds, regardless of supply specification. Note 1: Data based on INEOS experience Note 2: Other supplies acceptable in the range of 60-80% n-pentane and balance i-pentane. INEOS will add treatment facilities in anticipation of commercial available specifications, based on their experience. Guard treatments are typically provided for water and oxygenated compounds removal. Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

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Serial n°

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BASIS OF DESIGN

ATTACHMENT C UTILITY CONDITIONS AT LLDPE BATTERY LIMIT & AT USERS TABLE 61070F-3200-JSD-0000-02B

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

BASIS OF DESIGN - ATTACHMENT C

Technologies CLIENT

PETRONAS

LOCATION

PROJECT RAPID JOHOR, MALAYSIA

UNIT

350 KTA LLDPE PLANT

Project Nr - Unit

Code

Type doc

61070F-3200

JSD

-

Rev XA XB 0

UTILITIES AND EFFLUENTS CONDITIONS SUMMARY TABLE

PRESSURE AT BL

PRESSURE AT USERS

TEMPERATURE AT BL

TEMPERATURE AT USERS

bar g - REF. TO GRADE

bar g - REF. TO GRADE

°C

°C

Date JUN 12 SEP 12 NOV 12

FLOWING FLUID NAME OF FLUID

G OR L

MINI

NORMAL

MAXI

DESIGN

MINI

NORMAL

MAXI

DESIGN

MINI

NORMAL

MAXI

DESIGN

MINI

NORMAL

MAXI

DESIGN

SH

High Pressure Steam

G

52.5

53.0

53.5

62 / FV

48.7

49.2

52.5

62 / FV

430

435

440

455

265

425

440

455

SL

Low Pressure Steam

G

6.5

7.0

7.5

9.0 / FV

4.7

5.2

6.0

9.0 / FV

180

185

190

295

160

170

190

295

SCL

Low Pressure Condensate

0.0

1.0

2.0

9.0/FV

100

120

133

295

PCC

Low Pressure Condensate (to OSBL)

L/G

9.0

9.0

9.0

15.0

IA

Instrument air

G

6.0 (7)

7.0

9.0

12.0

6.0 (7)

6.7

9.0

PA

Plant air

G

6.0

8.0

9.0

12.0

5.7

7.7

LLN

Very Low Pressure Nitrogen

G

generated ISBL

0.05

LN

Low Pressure Nitrogen

G

generated ISBL

LNP

High Purity LP Nitrogen

G

LNS

Standard LP Nitrogen

MN

NO USERS

not returned OSBL

02B

0

Chk by FBN FBN FBN

Page

REMARKS

CODE

not returned OSBL

Made by BGO MGU MGU

Serial Nr Rev index

NO USERS

Amb (20)

100

105

150

12.0

25

Amb (27)

45

75

Amb (20) Amb (27)

45

80

Dew point: -40°C

9.0

12.0

25

Amb (27)

45

75

Amb (20) Amb (27)

45

80

Dew point: -40°C

0.06

0.07

0.10

generated ISBL

Amb (20) Amb (27)

45

80

OSBL quality.

3.0

3.0

3.4

4.4

generated ISBL

Amb (20) Amb (27)

40

80

Normal quality.

generated ISBL

2.0

2.2

2.4

2.8

generated ISBL

Amb (20) Amb (40)

40

80

High purity

G

generated ISBL

3.0

3.0

3.4

4.4

generated ISBL

Amb (20) Amb (40)

45

80

OSBL quality.

Medium Pressure Nitrogen

G

generated ISBL

7.0

7.5

8.0

10.5

generated ISBL

Amb (20) Amb (40)

40

80

Normal quality.

MNP

High Purity MP Nitrogen

G

generated ISBL

7.0

7.5

8.0

10.5

generated ISBL

Amb (20) Amb (40)

40

80

High purity.

LPN

Raw LP Nitrogen

G

MPN

MP Nitrogen

G

HPN

Raw High Pressure Nitrogen

G

HN

High Pressure Nitrogen

G

generated ISBL

28.7

31.4

34.0

40.0

generated ISBL

Amb (20)

40

40

80

Normal quality.

PHN

Priority HN

G

generated ISBL

29.2

31.4

34.0

40.0

generated ISBL

Amb (20)

40

40

80

Normal quality / High priority.

HNP

High Purity HN

G

generated ISBL

28.7

31.4

34.0

40.0

generated ISBL

Amb (20)

40

40

80

High purity.

PHNP

Priority HNP

G

generated ISBL

29.2

31.4

34.0

40.0

generated ISBL

Amb (20)

40

40

80

High purity / High priority.

CWS

Cooling Water Supply

L

6.0

6.0

7.0

13 (6)

5.5

5.5

7.0

13 (6)

30

34

34

80

CWR

Cooling Water Return

L

3.0

3.0

4.0

13.0 (6)

3.0

3.5

4.5

13.0 (6)

44

44

80

DMW

Demineralised Water

L

7.0

7.0

8.0

13.0

6.5

6.5

8.0

13.0

Amb (27)

35

80

RFH

High Pressure Flare

G

-

0.2 (2)

1.6 (3)

3.5

-

0.2 (2)

2.5 (4)

3.5

PRV

Powder Relief Vent

G

not returned OSBL

0.0

0.2 (5)

2.5 (4)

3.5

not returned OSBL

Amb (20) Amb (27) Amb (36)

200 (5)

PV

Powder Vent operational

G

not returned OSBL

0.1

0.2

0.5

4.4

not returned OSBL

Amb (20) Amb (27) Amb (36)

130

To flare via purge column

CRV

Catalyst Relief Vent

G

not returned OSBL

0.0

0.0

1.0 (4)

1.0

not returned OSBL

Amb (20) Amb (27) Amb (36)

80

Atmospheric system.

CV

Catalyst Vent operational

G

not returned OSBL

0.05

0.05

0.2

3.1

not returned OSBL

Amb (20) Amb (27) Amb (36)

80

Atmospheric system with oil guard.

FG

Fuel Gas

G

4.0

DC

Clean hydrocarbon liquid drain

L

6.0

HCD

Hydrocarbon Liquid Drain

L

not returned OSBL

TD

TEAL drain

L

not returned OSBL

OWS

Oily water

L

Atm

STW

Storm water

L

Atm

PWS

Polymer water

(1) (2) (3) (4) (5)

L

7.0

7.0

9.0

generated ISBL 32.0

32.0

34.0

NO USERS

12.0 6.8

7.0

9.0

Amb (20) Amb (27)

Amb (20) Amb (27)

30

25

5.0

7.0

3.2

3.7

4.5

7.0

35

tbc

6.6

12.0

0.2

1.0

2.0

3.5

tbc

1.0

2.0

Amb (20) Amb (27)

34

80

44

44

80

Amb (27)

35

80

80

NO USERS

80

34

45

OSBL quality.

25

OSBL quality.

40

50

80

35

40

50

80

45

45

80

-24

45

45

80 / -29

3.5

not returned OSBL

-24

45

45

80 / -29

-24

45

45

80 / -29

0.2

1.0

2.0

3.5

not returned OSBL

Atm

Atm

Atm

Atm

Atm

Atm

Atm

Amb (20) Amb (27) Amb (36)

80

Amb (20) Amb (27) Amb (36)

80

Atm

Atm

Atm

Atm

Atm

Atm

Atm

Amb (20) Amb (27) Amb (36)

80

Amb (20) Amb (27) Amb (36)

80

Atm

not returned OSBL

Amb (20) Amb (27)

100

not returned OSBL

NOTES: Available ΔP at BL: 2 bar min. Available ΔP for design: 1 bar for all users. Superimposed backpressure Maximum BL Main Header Backpressure 1.6 barg. Maximum allowable backpressure at safety valve discharge. To be confirmed during D.E. For main header. May be locally higher as specified in PDP.

Atm (6) (7)

Atm

Atm

OSBL quality.

Note 1.

Amb (20) Amb (27) Amb (36) 200 / -29 Amb (20) Amb (27) Amb (36) 200 / -29 (5)

4.5

0.2

45

NO USERS

80

generated ISBL

12.0

NO USERS

40.0

45

FV to be specified on elevated equipment and piping (above 5 meters) 4 barg for pneumatic actuators design

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

60

To flare

Export to OSBL

1/1

OWNER REFERENCE

Technologies

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

JSD

-

002

Serial n°

0001 Page

0

27

BASIS OF DESIGN

ATTACHMENT D UTILITY COMPOSITIONS AT LLDPE LIMIT

NITROGEN

COMPONENT Purity

Two qualities are required. In addition, raw OSBL nitrogen (“standard quality”) is suitable for treater regeneration and use in the finishing area. Normal and high purity nitrogen are generated ISBL from OSBL nitrogen.

UNITS

B.L specifications

INNOVENE™ G SPECIFICATION High purity

Normal purity

% mol (min)

99.99

99.99

99.99

Oxygen

ppm mol (max)

5

0.1

1

Carbon dioxide

ppm mol (max)

20

0.1

1

Carbon monoxide

ppm mol (max)

20

0.1

1

Water

ppm mol (max)

5

0.1

1

-

-

HC Chlorine

ppm mol (max) ppm mol (max)

5 1

DEMINERALISED WATER: From OSBL.

Parameters Silica

Value < 0.02 mg/L (max)

Iron

< 0.01 mg/L (max)

Copper Na Oil and grease Conductivity

< 0.003 mg/L (max) < 0.01 mg/L < 0.2 mg/L < 0.2 μs/cm (max) @ 25°C

pH

6 to 7.5

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

JSD

-

002

Serial n°

0001 Page

0

28

BASIS OF DESIGN

HP & LP STEAM

:

From OSBL. Fouling factor: 0.00017 m2.°C / W

INSTRUMENT AIR

:

From OSBL. Quality: dust free, oil free and free from other contaminants. Dew point -40°C at operating pressure From OSBL. Quality: Oil free.

PLANT AIR COOLING WATER.

:

From OSBL Atmospheric Cooling Tower system Fouling factor: 0.00029 m2.°C / W

CW CHARACTERISTICS

UNITS

VALUE

Total Hardness (TA) as CaCO3

mg eq/l

TBD

Total Alkalinity

mg/l

TBD

Calcium Hardness

mg/l

TBD

Conductivity

μS/cm

TBD

Chlorides (as Cl)

Ppm wt

250 (as preliminary figure)

Sulphates

mg/l

TBD

Dissolved Solids

mg/l

TBD

-

TBD

Total Fe

mg/l

TBD

Total Al

mg/l

TBD

pH

Cooling water treatment will include anti-corrosion agent, scale inhibition and biocide as appropriate. It will be suitable to be used for CS or SS heat exchangers.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

JSD

-

002

Serial n°

0001 Page

0

29

BASIS OF DESIGN

FUEL GAS: from OSBL Fuel Gas is only used for flare purging. Molecular weight from 16 to 58 kg/kmol.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

JSD

-

002

Serial n°

0001 Page

0

30

BASIS OF DESIGN

ATTACHMENT E PLOT LAYOUT SPACING OF EQUIPMENT RP44-7

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.