diesel production unit brochure2 (1)

Copyright© 2009, Ventech Engineers International Corp. All Rights Reserved 1

VENTECH ENGINEERS INTERNATIONAL CORP.VENTECH ENGINEERS INTERNATIONAL CORP.VENTECH ENGINEERS INTERNATIONAL CORP.VENTECH ENGINEERS INTERNATIONAL CORP.

1149 ELLSWORTH

PASADENA, TEXAS, USA 77506

TEL: (713) 477-0201 FAX: (713) 477-2420

E-MAIL: [email protected]

WEBSITE: www.ventech-eng.com

The Solution for Remote and Offshore Production Sites


Produce Specification Diesel

World’s Fastest Construction Schedule

Modularized for Fast Assembly at Site

Simple To Operate

Fully Warranted

Installation, Training & Start-Up Supervision

Completely Operational in Six Weeks

Built to ASME & API Specifications

For More Information Contact:

Kevin Stanley, Sales Manager

International Headquarters

Ventech Engineers International Corp.

1149 Ellsworth, P.O. Box 4261

Pasadena, Texas 77502

Tel: (713) 477-0201 Fax: (713) 477-2420

E-mail: [email protected]

Website: www.Ventech-eng.com


VENTECH's Diesel Production Units (DPU) are complete, modularized units ready for immediate

installation, and are designed to be fully erected and operational within two weeks from arrival at a

prepared project site. All equipment is fully warranted for one full year after commissioning or 18

months after delivery. Ventech can have your DPU designed, manufactured and ready for export

shipment from our Pasadena, Texas fabrication facility in as little as five to six months from the

funding of an executed contract.

PRODUCTION FROM EACH DIESEL PRODUCTION UNIT

• NAPHTHA - Naphtha's boiling end point is typically between 150°C (302°F) to

193°C (380°F). This rough-cut hydrocarbon will generally be blended back with the

residuum and re-injected into the crude pipeline.

• DIESEL (DISTILLATE) - This product's typical boiling range is from about 185°C

(365°F) to about 351°C (665°F), and can be used as a heating oil and fuel. The unit

will produce arctic, winter and summer grades of diesel, depending upon the quality

of the crude.

• RESIDUUM - The remaining crude, which is heavier than diesel, typically begins to

boil at about 287°C (550°F). This product is generally blended back with the

naphtha and re-injected into the crude pipeline.

Based on a typical .865 gravity (32° API) crude oil, the Ventech DPU will process the rated capacity

and produce by volume approximately 25% Naphtha, 30% Distillate, and 45% Residuum. Actual

processing capacities, product percentages and boiling points will vary depending on the special

characteristics of your crude. Upon receipt of your crude composition, Ventech will furnish the

yields that can be produced and, at your request, make modifications to your DPU to meet your

special product and design requirements.

Ventech can also furnish any optional equipment needed for further processing of your product

streams such as Distillate Hydrotreaters, Catalytic Reformers, Vacuum Units and Naphtha

Stabilizers.


VENTECH DIESEL PRODUCTION UNIT

EQUIPMENT, SPECIAL DESIGNS, OPTIONS & SERVICES

TYPICAL COMPONENTS

SPECIAL DESIGNS:

•••• Non-Steam Design • Product Trim Cooling

•••• High Sulfur Crude Metallurgy (1-3%) • Computer Control

•••• Winterized Design

•••• Fuel Gas or Distillate Firing Of Crude Heater

OPTIONS & SERVICES:

•••• DPU Spare Parts – Start-up

• DPU Spare Parts - Two (2) Years

• DPU Spare Parts - Three (3) Years

• Construction Advisor - 1 Man For 60 Days

• Training and Start Up Advisor - 1 Man For 30 Days

• Modular Mounted Cooling Tower

• Modular Mounted Boiler

• Modular Mounted Desalter

• Modular Mounted Metering System – Additives and Chemical Injection

• Loading Pumps

• Loading Platform

• Crude Tanks:

• 5,000 BBL • 10,000 BBL • 15,000 BBL • 20,000 BBL or as specified

• Product Tanks:

• 1,000 BBL • 3,000 BBL • 2,000 BBL • 4,000 BBL or as specified

• Security Packaging for Shipment

• Freight to Foreign Port


DPU CAPACITIES

Each DPU is custom designed to satisfy the user’s unique requirements. The yield of diesel varies

in accordance with the unique characteristics of the crude oil feedstocks. The units can generally be

operated with a minimum turndown of fifty percent (50%) of maximum throughput.


TYPICAL COMPONENTS

■ Ventech provides completely assembled process modules containing all the necessary

equipment, piping, electrical and instrumentation components. On-Module equipment

includes:

• Heat Exchangers

• Pumps (100% Spared)

• Crude Tower

• Diesel Side Stripper (if necessary)

• Air Coolers

• Accumulator Vessel

• Instrument Air Compressor

• Chemical Injection

• Product Sample Cooling

The crude charge heater is supplied loose for block-mounted installation.

■ The Process Control System, Safety Interlock System, and Motor Control Center is

Prefabricated and installed on module. The unit can be controlled locally and/or from a

remote control room.

■ Loose items, ready for field installation include:

•••• Interconnecting Piping Between Modules

•••• Computer for communication with the module mounted control system

•••• Ladders, Platforms, and Insulation for the Crude Tower, and Strippers

■ Additional Features:

• Fire Detection System on the Modules

• All Piping and Instrumentation Diagrams, Electrical One-Line Diagrams, Typical

Foundation Loading Diagrams, and Assembly Instructions necessary for complete

assembly of the DPU.

• Operating Manuals

• Electronic and Printed Sets of Job Data Books


TYPICAL DIESEL PRODUCTION UNIT EQUIPMENT LIST

Equipment Number Equipment Description

T-101 Crude Column

T-102 Diesel Stripper (if required)

H-101 Crude Feed Heater

V-101 Crude Reflux Accumulator

E-101 A/B Crude/Residuum Exchanger

E-103 Diesel Side Stripper Reboiler (if necessary)

AE-101 Crude Condenser

AE-102 Naphtha/Reside Air cooler

AE-103 Diesel Product Cooler

P-101 A/B Crude Charge Pumps

P-102 A/B Residuum Pumps

P-103 A/B Crude Column Reflux Pumps

P-104 A/B Diesel Product Pumps


SPECIAL DESIGNS

► Steam Design - For applications where the owner prefers to utilize steam for the DPU

operations. An optional design can be utilized to furnish a process system that requires

steam for stripping or heating.

► Winterized Design - For applications in severe winter conditions. A special design is

available for operating in environments colder than -20°F (-29°C). This design utilizes

special metallurgy, arctic grade electrical, recirculating air coolers, electric heat tracing and

flushing systems. The process skid is enclosed, insulated, heated and ventilated. The sides

are removable for summer operation and serve as security packaging during shipment to the

site.

► Product Trim Cooling - Air-cooling is utilized to cool products prior to flowing to storage.

If additional cooling is required during the hottest part of the summer, water-cooled trim heat

exchangers can be added

after the air coolers to

operate during the peak

temperature periods.

► Distillate Firing -

Applicable where fuel gas

is not available. The crude

heater will be modified to

burn distillate from the

DPU.

► High Sulfur Metallurgy -

The typical unit is designed

to process crudes with

sulfur less than 1% by

weight. If higher sulfur

crudes are to be used, a high sulfur design is used to increase the alloy content in the heater,

piping, and some of the equipment.

► High Salt Crude Oils - An electrostatic desalter and special metallurgies can be

incorporated in the process design if the crude oil contains high quantities of salt.


MODULAR DIESEL PRODUCTION UNIT DESIGN

GENERAL

The DPU is designed to produce a quality diesel product. The unit is constructed to meet or

exceed American codes. It is instrumented to allow minimal supervision during operation

and the modular equipment is arranged to allow for easy access during maintenance. The

units are designed to be energy efficient and produce properly cooled products for storage.

The components of each unit are tested before they are shipped to ensure trouble-free

operation. The process equipment and piping systems are fully hydro tested and pumps and

motors are test run to check for proper operation. Instrumentation and electrical systems

undergo a complete systems check.

CODES AND STANDARDS

All equipment and materials provided meet or exceed the applicable American standards and

codes. Listed below are some of the typical standards and specifications that are the basis for

our unit's design:

• ASME, Code Section I, Boiler and Pressure Vessel

• ASME, Code Section VIII, Div. 1, Pressure Vessels

• ASME-B31.1, American Typical Code for Power Piping

• ASME-B31.3, Petroleum Refinery Piping

• TEMA, Requirements of Tubular Exchanger Manufacturer's Association

• NFPA, Requirements for Burner Controls

• API-RP520, Parts I and II, Design and Installation of Pressure Relieving

Systems in Refineries.

• NEC, National Electrical Code


CIVIL DESIGN

Ventech provides foundation-loading diagrams with typical spread footing foundation

designs after receipt of the Client's soil analysis.

STRUCTURAL DESIGN

Ventech is providing pre-fabricated Modularized structures. These structures are designed

with sufficient strength to support the Heat Exchangers, Pumps, Crude Tower, Stripper,

associated piping,

instrumentation, and

electrical gear during

shipping and operation.

These structures also

provide support in the

field for the

accumulator and air

cooler, which will be

placed on top of the

Process Module.

The modules are

floored with steel

checkered plate with

acts as a catch basis to

contain spills.

Ladders and platforms are provided for the Crude Tower, Strippers, Module and Air Cooler.

Some ladders and platforms are shipped loose for field erection.

The modular structures are fitted with lifting lugs for crane handling.


MECHANICAL DESIGN

Ventech provides all the equipment as listed in the typical DPU Equipment List.

All pumps and double pipe heat exchangers are mounted on the module.

The Crude Tower and Stripper are supplied mounted in the modules in their respective

shipping orientation. The Crude Tower and Stripper will have to be rotated to their vertical

positions at the site by the client.

The Air Cooler and Accumulator Drum are supplied on a pre-piped module that will be set

on top of the process module by the client at the project site.

The materials used in the construction of the unit are suitable for low sulfur crude and are

mainly carbon steel with the exceptions of alloy trim in control valves, 5% chrome heater

tubes. Additional metallurgy upgrades are available for processing high sulfur crudes.

A special winterized design is available for ambient environmental conditions lower than -

20°F (-29°C).

PIPING DESIGN

Ventech provides all the interconnecting process piping between the Modules. All of the

interconnecting piping is prefabricated and furnished for easy installation. These piping

materials are provided loose for field

assembly.

Ventech designs, fabricates, and

installs on the module, all the

interconnecting piping between the

heat exchangers and pumps.

All pipe, fittings and valves are of a

carbon steel or 5% chrome metallurgy,

as required.

All piping on the module is

hydrostatically tested prior to shipping.


ELECTRICAL DESIGN

An electrical Motor Starter Rack is provided on the process module for the control of the

pump motors and air cooler motors.

Ventech installs the cable tray electrical conduits, fittings and wiring on the module between

the module mounted

pump motors and the

control center or a

junction box for a remote

control center.

A lighting system is

installed on the process

module(s), and is also

provided on the Crude

Tower and

Accumulator/Air Cooler

module.

INSTRUMENTATION DESIGN

Ventech provides all the instrumentation specified on the Piping and Instrument Diagrams.

All the control loops located on the modules are mounted and tested by Ventech.

All instrumentation is pneumatic or electric at the client's option. All control valves are

pneumatic.

The computer control system is locally mounted or supplied loose for installation by the

client in the client's control room.

Ventech also provides a Crude Charge Heater burner management Control Panel for safe and

efficient operation of the heater.


PROTECTIVE COATINGS DESIGN

All pipe and equipment on the modules is primed and insulated as specified on the Piping

and Instrument Diagrams.

All pipe and equipment on the modules that is not insulated is primed and painted.

SCHEDULE

Ventech has expedited the engineering, procurement, assembly, testing and preparation for

shipment in as little as five (5) months from the funding of an executed contract.

INSTALLATION

The DPU has been designed to allow for a quick and easy installation. Ventech’s DPU can

generally be completely installed and operating, producing specification diesel, in as little as

two (2) weeks from arrival at a prepared project site. The three (3) modules containing the

process equipment, Crude Tower and Stripper are designed to be adjacent to one another and

bolted together. All of the interconnecting pipe between the modules is prefabricated and

flanged for expedient installation.


ENGINEERING DOCUMENTATION

Ventech provides the following documentation:

◊ Two (2) sets of job books that contain all vendor information. Information included

consists of the original equipment manufacturer's drawings, data, spare parts lists,

and equipment operating manuals.

◊ Two (2) sets of plant operating manuals. These manuals will supply detailed start-up

and operating procedures.

◊ Two (2) sets of drawings will be supplied of the process flow diagrams, piping and

instrument diagrams, electrical one-lines, general arrangement drawings, and all

Civil/Structural, Piping, Mechanical, Electrical and Instrumentation drawings

required for maintenance and operation of the unit.


TECHNICAL SUPPORT

Ventech maintains a full service engineering group in Houston, Texas that provides

construction advice and/or training and start up assistance. This group is also available for

technical service and warranty assistance.

EXCLUSIONS

The following items are not included as part of the typical Diesel Production Unit, and,

unless requested by the Client, are excluded from the responsibility of Ventech:

♦♦♦♦ DPU Spare Parts

♦♦♦♦ Land, buildings, and foundations for the unit, including site preparation

♦♦♦♦ Utilities necessary to operate the unit

♦♦♦♦ Tanks, towers, boilers, and any other equipment not included in the typical Diesel

Production Unit's description

♦♦♦♦ All interconnecting piping and wiring between the typical Unit and aforementioned

equipment

♦♦♦♦ Fire fighting equipment

♦♦♦♦ All field installation, erection, start-up operating services or personnel

♦♦♦♦ Plant effluent facilities for environmental compliance by the Unit with any federal,

state or local laws or regulations or administrative decisions

♦♦♦♦ All costs, fees, duties, and licenses required by any law, order, rule or regulation

relative to inspection of the material or labor

♦♦♦♦ All traveling, living and other expenses for client's representatives

♦♦♦♦ Flare system

♦♦♦♦ Any freight, licenses, taxes, or other fees necessary to ship the Unit from the Port of

Houston, Texas

♦♦♦♦ Engineering design of foundations and plot plan

♦♦♦♦ Engineering design of piping support structures for off-module connecting pipe


SOME OF THE MANY OTHER SERVICES AVAILABLE FROM VENTECH

● Site Engineering

● Further Process Engineering Design and Procurement for Offsites and Support

Facilities

● Civil/Structural Engineering and Design

● Piping Engineering and Design

● Electrical and Instrumentation Engineering and Design

● Construction Management and Start-Up Services

OTHER MODULARIZED PROCESSES

● Vacuum Units

● Naphtha Hydrotreaters/Catalytic Reformers

● Desulfurizers

● Gas Processing Plants

FOR MORE INFORMATION

We would like to discuss with you further details of how our Company can help solve your

processing needs. Please contact our Sales Department at:

Ventech Engineers International Corp.

1149 Ellsworth, P.O. Box 4261

Pasadena, Texas 77502

Tel: (713) 477-0201 Fax: (713) 477-2420

E-mail: [email protected]

Website: Ventech-eng.com

diesel production unit brochure2 (1)

Documents

prepared project site

heat exchangers

air cooler

carbon steel

crude oil

instrument diagrams

control valves

crude tower