1/39

REQUEST FOR PROPOSAL PART 4.1 SCOPE OF WORK and DESIGN BASIS 4.1.1 SCOPE OF WORK – GENERAL

4.1.1.1 Overall Responsibilities

CONTRACTOR shall have overall responsibility for the EPC Work, which includes Pre-commissioning, Commissioning and Performance Test-Run, of Cilacap RFCC PROJECT (PROJECT), which consists of Process Units, Utility Units and Offsite Facilities (collectively, “PLANT”), on the Fixed Lump-sum and Turnkey Basis. The EPC includes the design and engineering of the PLANT, procurement of all equipment and materials including two years operation spare parts, preparation of the SITE for construction, construction and installation of the PLANT at the proper SITE locations, which leads to Completion of Erection.

After the Completion of Erection, CONTRACTOR shall conduct Pre-commissioning Works such as mechanical checking, pressure testing and other cold testing. The Pre commissioning Works also include preparatory works for starting operation of the PLANT and normally includes drying-out of the system, loading of catalysts, chemicals and lubricants, and systems airtight tests, etc. Upon completion of these Pre-commissioning activities, the PLANT attain MECHANICAL COMPLETION, or in other words “Ready For Feed-In”. During this period, catalysts/ chemicals, fuels and utilities shall be provided by CONTRACTOR. Where some of them are supplied by OWNER, it will be at CONTRACTOR’s account.

CONTRACTOR shall be responsible for conducting the start-up activities after MECHANICAL COMPLETION and for providing catalyst/chemicals and items other than those supplied by CONTRACTOR to start and to operate the PLANT. Operators and feedstock (atmospheric residue and vacuum distillate) shall be supplied by OWNER. CONTRACTOR shall also be responsible for providing supervisors, labors, materials, equipment/tools and consumables.

CONTRACTOR’s responsibility for the time for Completion is the time of OPERATIONAL ACCEPTANCE of the PLANT. At the OPERATIONAL ACCEPTANCE, the risk of loss and the responsibility for custody/control of the PLANT shall be transferred from CONTRACTOR to OWNER.

CONTRACTOR shall also be responsible for any defects of the WORKs until FINAL ACCEPTANCE of the PLANT (expiration of the Warranties Period).

The Scope of WORK is detailed in PARTs 4.1.2, 4.2, 4.3, 4.4 and 4.5 of this RFP. CONTRACTOR shall coordinate its activities and the activities of suppliers, manufacturers, sub-contractors and others under its control in order to achieve OPERATIONAL ACCEPTANCE and its obligations thereafter with the standard of care and performance set forth in this RFP.

2/39

4.1.1.2 Design and Engineering

CONTRACTOR, using the engineering design specifications stipulated in PART 4 hereof, shall perform all engineering and design services, prepare and deliver the complete engineering (including process, mechanical, instrument, electrical and civil /architect engineering), covering those portions not expressly provided in PART 4 but inferred as necessary for safe and stable commercial operation of the PLANT.

The PLANT shall be engineered and designed to enable it to meet the performance guarantees specified in PART 3A EPC Contract Form and its relevant EXHIBIT. Engineering and design shall include without limitation the preparation of studies and calculations, general assembly and construction drawings, equipment and technical specifications, field construction specifications, definitive specification lists, equipment and materials lists and revisions thereof pertaining to all systems, general arrangements of equipment of the PLANT, all other required drawings, surveys, soil reports, maps, specifications required for the procurement of all equipment and materials, the performance of all construction and installation services, and any other works required up to OPERATIONAL ACCEPTANCE of the PLANT, and all relevant technical data, including, without limitation, layouts, flow diagrams and material balances.

CONTRACTOR shall be familiar with the International Code and Standards, UOP Schedule-A, Axens’ design packages, Indonesian National Standards and Government Regulations which are related to this PROJECT. Wherever those standards for equipment and installations have duplication or contradiction, CONTRACTOR shall use the optimum technical standards for OWNER’s advantage.

4.1.1.3 Procurement

CONTRACTOR shall supply all equipment and materials, construction equipment, temporary facilities, services, catalysts, chemicals and other supplies, construction consumables, utilities, power and fuel required for the construction and commissioning of PLANT, commissioning and achievement of the performance guarantees of the PLANT. CONTRACTOR shall be responsible for the procurement of all construction, and commissioning spare parts and special tools required up to OPERATIONAL ACCEPTANCE.

CONTRACTOR shall ensure that all Equipment and Materials which become the property of OWNER shall be new and of the most suitable grade. CONTRACTOR shall procure all Equipment and Materials, component and part of the Facilities in a manner to ensure that each of such system, component and parts will comply with Refinery International Code and Standard.

CONTRACTOR shall also prepare and recommend, for OWNER's review and approval, lists of two years’ operation spare parts in consultation with vendors/suppliers. These lists shall be prepared and submitted on the vendors’ proposal. After approval by OWNER of these lists, CONTRACTOR shall be responsible for procurement of these operation spare parts. The price for two years’ operation spares will be treated as a provisional sum, apart from the Fixed Lump Sum, at the time of the EPC Contract conclusion.

All procurement shall be accomplished in accordance with the Project Procedure as prescribed in PART 3A and 3B hereof. CONTRACTOR shall obtain and deliver to OWNER all vendor manuals not later than 12 (twelve) months prior to MECHANICAL COMPLETION.

3/39

CONTRACTOR's procurement obligations shall include,

i) preparation and issuance of CONTRACTOR’s tendering documents (i.e. bid invitations, instructions for tendering, forms of contract, general conditions, special conditions, specifications and terms of payment), obtaining bids and analysis of bids, including vendors’ offer of recommended two years operation spares, awarding contracts or purchase orders. Where vendors are specified for equipment and materials by OWNER/ Licensor in PART 3A and 3B or PAR 4 of this RPF, CONTRACTOR is not allowed to purchase those items from other venders without prior approval of OWNER.

ii) negotiating and adjusting prices for changes in contracts and purchase orders, and

preparation of the change order procedure, and

iii) administration and follow-up of purchase orders or contracts and coordination thereof to ensure deliveries from vendors to meet the Project Schedule

4.1.1.4 Logistics

CONTRACTOR shall be responsible for arranging the complete handling and protection of all equipment and materials, all construction equipment, all temporary facilities, all other materials and supplies and all fuel used in the performance of the WORK including shipping, forwarding, transporting, storage in transit, expediting, unloading, receiving and storage thereof at SITE, subject to the provisions of this RFP.

CONTRACTOR's obligations for materials handling shall include:

i) Provision of all necessary documentation for obtaining import licenses for all shipments arriving in Indonesia;

ii) Obtaining customs clearance of all such shipments upon arrival at the Indonesian port of entry;

iii) Inspection of all shipments at the time of off-loading, at the SITE or at any other

appropriate time, with timely notice to OWNER so that OWNER may participate in any such inspection if it so requires, provided that CONTRACTOR shall not be required to unpack, uncrate or unseal shipments, where, by the judgment of CONTRACTOR, the proper procedure is to leave the particular item in its closed condition unless Governmental Authorities otherwise require; and

iv) Developing procedures for the uniform crating and marking of shipments, for the

procurement of insurance (according to the provisions of the EPC Contract Form) and for processing claims for losses and damages arising under all insurances. It will be advised to TENDERERS in due course which party, OWNER or CONTRACTOR, shall procure the cargo insurance.

CONTRACTOR shall establish with OWNER, within one (1) month after the Effective Date, the details of all customs documentation required and the procedures and time schedule for processing such documentation in order to obtain customs release. CONTRACTOR shall be responsible for all financial guarantees and bonds required for the temporary importation of equipment, materials and tools. OWNER will provide assistance to obtain such permits and documentations.

4/39

4.1.1.5 Construction

CONTRACTOR shall, in the shortest practicable time, provide the services, staffs and labors (skilled and unskilled), materials, tools, machineries, equipments, facilities (including temporary facilities and construction utilities) and supplies not furnished by OWNER, and do all things necessary to construct the PLANT, all in accordance with PART 3 and 4.

CONTRACTOR's obligations for construction shall include;

i) Warehousing and protection of all materials, machineries, equipment, and spare parts, the erection of all machineries, equipment, and tankages and materials, the arranging for suppliers and manufacturers of equipment and machineries to provide supervision of the erection and installation thereof, construction of all interconnected piping, the installation of electrical wirings and instrumentations, all civil works, all pressure/mechanical tests, electrical and instrumental tests for the PROJECT, the loading/ filling/ preparing/ checking/ testing of catalysts and chemicals, lubricants and sealing fluids. In addition, all other works and services necessary to achieve MECHANICAL COMPLETION and OPERATIONAL ACCEPTANCE of the PLANT in accordance with the provisions of this RFP,

ii) Provision of all materials, engineering and quality assurance, field material control

and testing, arranging survey services for layout of the PLANT at the SITE and provision of all necessary Site grading and paving, except as actually provided by OWNER,

iii) Preparation and coordination of construction and manning schedules, developing

and maintaining uniform Project labor practices ; developing and maintaining proper standards for safety and housekeeping at the SITE, for conduct on the SITE , for security of the SITE and for other related protective services, and

iv) Provision of and administration of construction shelters, camps, and offices,

developing and administering on-the-job training programs for construction workers retained on the SITE, procurement of all insurances in accordance with the requirements of the EPC Contract Form. In addition, administration of insurance programs for CONTRACTOR and its sub-contractors (in coordination with OWNER), administration and resolution of labor matters, provision of field office services and administration and maintenance of field vehicles and equipment.

It will be advised to TENDERERS in due course which party, OWNER or CONTRACTOR, shall procure the CAR and CGL insurances.

4.1.1.6 QUALITY ASSURANCE / QUALITY CONTROL

(1) QA/QC PLAN AND PROCEDURES

Contractor shall be responsible for the inspection and testing of Equipment and Material, machinery, spare parts, tools and appliances to be furnished for the Facilities, or used in connection with the Work, throughout all phases of design, procurement, field construction and start-up/ commissioning. Contractor shall operate a quality management system that meets the intent of ISO 9000 families or other equal and approved quality management system, covering all aspects of the Work and shall impose a commensurate level of quality on all Sub-Contractors and Vendors. The system shall ensure that quality management of

5/39

the Work is applied from inception to completion of the Work.

During procurement and field construction, Contractor shall implement additional procedures that may benefit to the quality control of the Work, provided that Contractor obtains Owner’s Approval before implementing any such additional procedures. Inspection, Testing and Quality Control personnel shall be dedicated to the Project and not involved in the expediting of the goods.

All QA/QC procedures shall be subject to Owner's prior approval.

Contractor shall make or cause to be made all necessary or prudent field and laboratory tests of Equipment and Materials either at site or at any time or place as may be necessary or appropriate or as Owner after consultation with CONTRACTOR may require. CONTRACTOR shall report to Owner’s in writing as to the conformity or non-conformity to specifications of the Workmanship and materials of items tested. All test equipment, materials and consumable are to be supplied by CONTRACTOR. Inspection Agencies used by CONTRACTOR shall be informed to Owner’s.

(2) THIRD PARTY INSPECTION

Owner may place a SUBCONTRACT with a Third Party Inspector(s).

CONTRACTOR shall enable the Third Party Inspector to perform, in an independent manner, any inspection on CONTRACTOR QA/QC program and operations to ensure that all related requirements specified in the CONTRACT are met. CONTRACTOR shall deal with the WORK, shall provide information and access to the Third Party Inspector, and shall process QA/QC related matters in a manner that will enable the Third Party Inspector to perform inspections of WORK and witness tests in a timely manner in accordance with the WORK TIME SCHEDULE. CONTRACTOR shall not be entitled to a CHANGE ORDER in respect of requirements as may be specified by the Third Party Inspector within the inspection Scope of WORK outlined herein or elsewhere in the CONTRACTS. Inspection performed by the Third Party Inspector on behalf of Owner’s and/or the Certifying Authority shall not be construed as releasing the CONTRACTOR from performing its inspection program.

(3) MIGAS INSPECTION

All Equipment and Material (such as heat exchangers, columns, pressure vessels, tanks, rotating equipments, lifting equipments, electrical equipments, relief valves, etc. ) shall be subject to inspection by MIGAS and all other required Indonesian Government agencies. CONTRACTOR'S scope of Work is arranging for and obtaining all inspections and documentation as required by MIGAS and all other required Indonesian Government agencies. All cost incurred (allowance and transportation) for MIGAS inspector or third party inspector on behalf MIGAS will be paid by Owner’s and all cost for arranging and obtaining all inspections and documentation as required by MIGAS and all other required Indonesian Government agencies shall be born by CONTRACTOR..

(4) DEPNAKER CERTIFICATES

CONTRACTOR shall obtain from DEPNAKER relevant certificates and Operating Permit for the Boilers and other equipment as required by the regulation. All cost incurred (allowance and transportation) for DEPNAKER inspector or third party

6/39

inspector on behalf DEPNAKER will be paid by Owner’s and all cost for arranging and obtaining all inspections and documentation as required by DEPNAKER and all other required Indonesian Government agencies shall be born by CONTRACTOR.

(5) DIMET CERTIFICATES

CONTRACTOR shall obtain DIMET relevant certificates and Operating Permits for the custody Metering and Tanks as required by regulation. All cost incurred (allowance and transportation) for DIMET inspector or third party inspector on behalf DIMET will be paid by Owner’s and all cost for arranging and obtaining all inspections and documentation as required by DIMET and all other required Indonesian Government agencies shall be born by CONTRACTOR.

4.1.1.7 Estimates, Schedules, Lists and Reports.

CONTRACTOR shall prepare and deliver to OWNER all estimates, schedules, lists and reports necessary or appropriate for the most diligently and orderly performance of the PLANT. These shall be prepared in accordance with the Project Procedures under PART 3 and shall include, but not limited to:

i) Estimates of,

- manpower requirements, by category, for all phases of the WORK, including field staff labor and personnel.

- quantities of equipment and materials and construction equipment.

- cost of modifications, and changes in the WORK.

ii) Schedules of,

- proposed sequence of the works, with dates of anticipated commencement and completion of the various phases of the WORKs and the portions or units thereof.

- Work schedules and manpower build-up charts for all phases of the WORKs - both general and detailed and showing, by category, the labor (skilled and unskilled) and personnel to be used.

- procurement schedules showing dates for requisitions, required approvals, release of purchase orders, anticipated delivery and dates required at SITE.

iii) Lists of:

- all equipment and materials, including spare parts and special tools.

- critical items of equipment and materials. - construction spare parts through MECHANICAL COMPLETION, up to

OPERATIONAL ACCEPTANCE.

- two years operation spare parts.

iv) Reports of,

- progress reports - general and specific - with respect to all phases of the WORK and all portions of the PLANT.

- deliveries of equipment and materials.

- modifications, change orders and changes in the Scope of WORK.

7/39

4.1.1.8 Project Scheduling.

CONTRACTOR shall perform the planning and scheduling in accordance with the requirements as provided in PART 3.

4.1.1.9 Operation and Maintenance Manuals and Data Books.

CONTRACTOR shall furnish OWNER with definitive operation and maintenance manuals , mechanical catalogues, and data and design calculation books for the PLANT, including all systems and parts thereof. Such manuals, catalogues and books will be prepared in accordance with, and delivered at the times required by the Project Procedures and in the quantities stated therein. The definitive operation and maintenance manuals are to be delivered 12 (twelve)months before MECHANICAL COMPLETION.

CONTRACTOR shall periodically supply, free of charge, to OWNER information generally made available to its customers to reflect technical development and operating experience gained from other similar installations by CONTRACTOR.

4.1.1.10 CONTRACTOR’s Responsibility after MECHANICAL COMPLETION CONTRACTOR shall be responsible for conducting the start-up activities after MECHANICAL COMPLETION and for providing catalyst/chemicals and items other than those supplied by CONTRACTOR to start and to operate the PLANT. CONTRACTOR shall also be responsible for providing supervisors, labours, materials, equipment/tools and consumables. Operators and feedstock (atmospheric residue and vacuum distillate) shall be supplied by OWNER.

4.1.1.11 Responsibilities Following OPERATIONAL ACCEPTANCE

CONTRACTOR shall also be responsible for any defects of the WORKs until FINAL ACCEPTANCE of the PLANT (expiration of the Warranties Period).

4.1.1.12 Support Services.

Except for items provided or arranged for by OWNER, CONTRACTOR shall provide all services required for the support of its obligations unless otherwise expressly described in PART 3 and 4 of the RFP. CONTRACTOR's obligations for such support services shall include:

i) The provision of liaison facilities in Indonesia and at the SITE for the

administration of personnel and for the performing of the procurement services required of CONTRACTOR under this RFP,

ii) The provision of all appropriate home office services necessary or appropriate

to enable CONTRACTOR to perform its obligations under this RFP, and iii) The provision of assistance to OWNER, as it may request, in connection with

8/39

press releases, public statements or other public relations activities undertaken in connection with the PROJECT.

4.1.1.13 Miscellaneous Final Clean-up.

Prior to FINAL ACCEPTANCE of the WORK:

i) CONTRACTOR shall remove, as requested by OWNER, all temporary structures, debris, wastage, spoil and utilities furnished by it and its sub-contractors, relocate excess equipment and materials at locations designated by OWNER and leave all building interiors and the SITE in a clean and orderly condition.

ii) CONTRACTOR shall turn over to OWNER or sell, at OWNER’s option, all

surplus items including salable scrap, and remit or credit the proceeds of such sales to OWNER. Unless otherwise directed by OWNER, the purchases and sales prices of such surplus items shall be subject to approval by OWNER.

iii) CONTRACTOR shall prepare and furnish in accordance with the Project

Procedures record drawings and specifications to show construction "as built" of the PLANT as provided in PART 3 hereof. These record drawings shall be prepared by correcting drawings (including OWNER’s drawings) prepared for construction purposes or, where construction drawings cannot be satisfactorily revised for record purposes by preparation of appropriate new drawings. These drawings are also to include those supplied by vendors and suppliers of equipment and materials.

iv) CONTRACTOR shall prepare final fixed asset records and inventory lists of

surplus materials and spare parts in accordance with PART 3 of the RFP.

4.1.2 DESIGN BASIS

4.1.2.1 PLANT Description

OWNER briefly presents the outline of the PLANT hereinafter to help a TENDERER understand OWNER’s PLANT philosophy. PLANT construction work includes the pre-FEED stage, FEED stage, EPC stage and commissioning stage which could be ready for commercial operation by OWNER. PLANT shall be stand-alone basis which means independent facility from Pertamina existing refineries. OWNER desires PLANT shall be operable in the manner of minimum interaction from and to PERTAMINA existing refineries. In line with the above OWNER’s PLANT operation philosophy TENDER shall be required to strictly comply with OWNER’s requirements which will be stipulated in this RFP. Further to the above, OWNER has intended to construct PLANT with 62,000 BPSD capacity at the initial operation period and to expand its capacity up to 70,000 BPSD in future. For the design capacity of 62,000 BPSD, the design crudes are the atmospheric residue of 57,980 BPSD, and the vacuum distillate of 4,020 BPSD to be supplied from the existing Pertamina’s Refinery.

The products produced in PLANT shall be transferred back to Pertamina through the storage facility in PLANT.

9/39

In this regard, PLANT shall have the interconnection and interfaces with Pertamina’s existing refinery facilities including common utilization of certain facilities, such as fire station and fire cars, and some tanks from capital expenditure minimization point of views. In general a bidder shall take into consideration the operation philosophy, maintenance philosophy and safety philosophy which OWNER will describe and require in the RFP. The design philosophy shall be established in line with the above three philosophies in the manner of the Life Cycle Cost (LCC) minimization concept. The following description represents the general information of PLANT and its products for the purpose of bid preparation. In addition to general information, TENDERER shall refer to technical documents enclosed in this RFP

Major units and facilities

• RFCC Unit • Gasoline Hydro-treating Unit • Amine Treating Unit • LPG Extraction Unit • Propylene Extraction Unit • Hydrogen Purification Unit • Sour Water Stripping Unit • Spent Caustic Treatment Unit • Waste Water Treatment Unit • Offsite and Utility Facilities

Products

• Treated Fuel Gas • Mixed LPG • Propylene • Gasoline • Light Cycle Oil ( LCO) • Decant Oil (DCO)

Process Licensors

The following License Agreements have been concluded between OWNER and selected Licensors: • UOP LLC (USA) for “Fluid catalytic Cracking Process for Resid” • UOP LLC (USA) for “Caustic MEROX Extraction Process for LPG” • AXENS ( France) for “ PRIME G+ Gasoline Hydrotreating Process”

4.1.2.2 Plant Design Basis

(1) Design Concept

The PLANT shall be designed and constructed for a design capacity of 62,000

10/39

BPSD of Feed-1 (see (2) Design Feedstock below). The Feed-1 is the design feedstock. However it is expected that, in future, PLANT capacity will be increased to 70,000 BPSD when processing Feed-1 or Feed-2 to get gasoline to meet Euro III.

The future modifications required to debottleneck PLANT shall be minimum, the basic design of the licensed units (UOP and AXENS) has considered a 15% over design capacity as design margins in order to enable to accommodate the future capacity of 70,000 BPSD. The performance tests will be carried out based on 62,000 BPSD of Feed-1 and related performance guarantees refer to this design capacity.

(2) Design Feedstock

The design feedstock Feed-1 is an atmospheric residue originating from domestic Indonesian crudes and vacuum distillate originating from Middle East crudes. Feed-1 quality is described in the following table, also the quality of Feed-2 is described.

11/39

TABLE 1: FEED STOCKS FOR RFCC

(3)

Products Specifications

PLANT is designed to produce the following products, listed below:

• Fuel Gas • Mixed LPG • Propylene • Gasoline • Light Cycle Oil (LCO) • Decant Oil (DCO).

(4) Turn-down capacity PLANT shall be designed to be capable of operating continuously at between 60% and 100% of design capacity when processing the design feedstock.

Component Feed-1 ( DESIGN

CASE)

Feed-2

Blend % 100 100 Type of feed Atm. Residue

based on Blended Domestic Crude + Vacuum Distillate

Atm.Residue based on mixture of Blended Domestic Crude and

Imported Sour Crude + Vacuum Distillate

API or specific gravity 20.81 20.32 ASTM distillat. (D 1160) °C

IBP 10% (LV%) 389 388

30% 50% 527 521 70% 90% 723 718 EP

UOP K 12.0 11.93 ~ 11.60 Sulfur, wt % 0.34 1.95

Nitrogen, wt -PPM 3000 3000 Conradson Carbon ,wt % 6.2 6.2

Hydrogen, wt % Metals :

• Nickel , wt ppm

• Vanadium wt ppm • Sodium wt ppm • Iron, wt ppm

13 0.6 6 20

13 17 6 20

Viscosity @ 210° F (99°C) , cSt 29 27

12/39

(5) Continuous operation period

The PLANT shall be designed and constructed to be capable of operating continuously for at least 36 consecutive months without “unplanned “shut down.

(6) Operation Mode

The gasoline max.operation mode shall be considered in designing the PLANT for each feedstock.

(7) Service life

The equipment service life to be considered for materials selection and applied corrosion allowances shall be as follows: • Columns & reactors ( excluding internals)` : 30 years • Pressure Vessels ( excluding internals) : 20 “ • Tanks : 30 “ • Air-cooled exchangers ( including tubes) : 20 “ • Shell & Tube Heat Exch. ( excluding tubes) : 20 “ • Fired Heaters Tubes : 100,000 hr • Pumps : 20 years • Centrifugal Compressor : 30 “ • Steam Turbines : 30 “

(8) Offsite and Utilities Facilities

The PLANT shall be designed and constructed as a “self standing” facility, basically able for operation independently from operation of the existing Pertamina’s Cilacap Refinery. However the PLANT shall be interconnected to existing Refinery because of:

• Acid Gas is to be fed to existing SRU • Feedstocks are fed from existing refinery • Hydrogen which is purified in PSA unit in PLANT required for Gasoline

Hydrotreating Unit is imported as hydrogen rich gas from existing refinery • Some utilities , including MP Steam Heavy Gas Oil (HGO), naphtha, demin

water, and LPG will be imported from existing Refinery for start-up requirements

• Potable water is imported from existing refinery • Fire & Gas detecting system protecting new facilities shall be

interconnected for safety reasons Furthermore following existing facilities are to be available also for PLANT:

• Main access gate and internal roads up to PLANT area. • Fire fighting building • First Aid building

Modification and extension of existing facilities : • Modification of existing Marine (jetty) facilities (Jetty # 64 & # 68).

- Jetty # 64 : Construct a small annex platform for MLA, 2 BD and 4 MP - Jetty # 68 : Refurbished Jetty existing and Install 1 MLA on existing

13/39

loading platform. Refurbishment shall be proposed to Pertamina for approval.

• Extension of existing maintenance shop. • Modification of existing tank for feedstock (35T-4). • DCS modification in Existing SRU (at Reaction Furnace).

New offsite and utilities facilities shall include:

• Pumps and flow meter system for existing feedstocks storage tanks • Final products storage tanks. • Marine loading facilities for LPG and Propylene export. • Fuel system • Flare system • Flushing oil system • Slop facilities • Power generation and distribution system • Steam generation and distribution system • Condensate collection and treatment system • Cooling Water system • Demin-water system • BFW System • Service water system • Drinking/potable water system • Compressed air system • Nitrogen system • Fire fighting and Fire & Gas detection system • Spare parts & Catalyst Warehouse • Administrative building • MCR building • New substations / LAR • UPS system • Catalyst handling system • Cathodic protection • Telecommunication • CCTV system • Sewer and waste waters collection • Effluent treatment system ( including spent caustic and chemicals waters) • Segregated closed drain system for amine, sour water, Light Hydrocarbon,

and Heavy Hydrocarbon. • Emergency System including Emergency Diesel Generator System • Interconnecting system • Laboratory building ( equipment included) • Chemical storage building • Chemical storage shed • Fire shelter • Field operator houses • Roads, paving, sewers • Lightings system • Grounding & Lightning protection system

(9) Overall Plot Plan

14/39

An overall plot plan of PLANT and the existing Cilacap Refinery facilities area is shown in attachment A. These plans have been developed based on the following conditions: • The new PLANT is planned to be located adjacent to the existing Refinery

on West side. • The new tanks for LPG and Propylene products will be located in an area

adjacent to existing Jetty Units 67 & 68, separately from main PLANT facilities.

• Some existing tanks to be used for PLANT feed-stocks storage are located in the existing tank yard.

4.1.2.3 PROCESS UNITS DESCRIPTION

The following description represents the proposed scope of facilities for the process units. The process design of the units represented by these process descriptions, process flow diagram, equipment lists, etc. will be subject to review and further development by EPC CONTRACTOR. In particular, the unit process design and hence unit configuration, yield, material balances, etc. will refer to the LICENSOR’s BED and FEED Engineering documentation which all of those requirement has been included.

(1) RFCC Unit

(a) Objective

The RFCC Unit consists of a reactor, a regenerator, a main fractionators section, and a gas concentration section. The reactor section is designed to convert the residue feed to maximize gasoline while minimizing the coke, gas and fuel oil. The main fractionators section is designed to separate efficiently the cracked products to gas, gasoline, LCO and DCO. The gas concentration is designed to separate efficiently gas and gasoline to off gas, LPG and gasoline. Block flow diagram of the RFCC Unit is described in the Attachment B.

(b) Feed

The RFCC Unit is designed to process the feedstock as described in the Table-1 in previous page.

(c) Effluent from RFCC Unit

The RFCC Unit exhausts the regenerator flue gas from the RFCC regenerator, and sour water drained from overhead separators, and produces intermediate products, cracked naphtha, cracked LPG and sour gas, and also produces final products, LCO and DCO.

Regenerator flue gas

Regenerator flue gas is designed to make a maximum energy recovery. Since flue gas contains CO, the gas shall be burned in the CO boiler provided in the ISBL.

Sour water

Sour water is sent to the Sour Water Stripping Unit to remove H2S, NH3 and other volatile materials.

15/39

Intermediate products

Cracked Naphtha is sent to the Gasoline Hydrotreating Unit for desulphurization. Cracked LPG is sent to the Amine Treating Unit to remove H2S. Cracked sour gas is sent to the Amine Treating Unit to remove H2S.

Products

LCO is sent to LCO tank as RFCC product. DCO is sent to DCO Tank as RFCC product. LCO from the RFCC Unit meets the LCO product specifications described in the Attachment C. DCO from the RFCC Unit meets the DCO product specifications described in the Attachment C.

(d) Capacity and Turndown Capacity The RFCC Unit is designed to process 62,000 BPSD of feedstock. The unit is capable of operating at between 60% and 100% of design capacity. The unit is capable of operating of cycles for at least 36 consecutive months.

(2) Gasoline Hydrotreating Unit

The Gasoline Hydrotreating Unit is designed to process total naphtha from the RFCC Unit.

(a) Turndown Capacity

The unit shall be capable of operating at between 60% and 100% of design capacity when processing the design feedstock. The unit is designed to be capable of operating for cycles of at least 36 consecutive months.

(b) Product Properties

The gasoline from the unit meets the specifications for gasoline product in the Attachment C.

(3) Hydrogen Purification Unit

(a) Hydrogen feedstock

The hydrogen used in Gasoline Hydrotreating Unit is produced by the Hydrogen Purifiction (“HP”) Unit with purifying the H2 rich gas to 99v% Hydrogen. The composition of typical H2 rich gas fed from the existing refinery is described below.

mol%

Pressur

e Temperatur

e Max. flow

rate H2 73.6

16.5 kg/cm2g 37°C 6,977 Nm3/h

C1 7.8 C2 9.0 C3 5.5 iC4 1.5

16/39

hC4 1.2 iC5 0.5 nC5 0.3 C6

+ 0.6

Refer to FEED package in detail.

(b) Hydrogen purity

Product hydrogen is produced with more than 99v% cont. of hydrogen.

(c) Raffinate gas

Raffinate gas from the HP Unit is sent to the fuel gas system in the PLANT. Make-up gas compressor and Raffinate gas compressor shall be included in HP Unit. The HP Unit is capable of operating for cycles of at least 36 consecutive months.

(4) Gasoline Oxidation Stability Chemical Injection System

The Gasoline Oxidation Stability Chemical Injection System is designed to improve oxidation stability of RFCC gasoline product from Gasoline Hydrotreating Unit.

(5) Amine Treating Unit The Amine Treating Unit is designed to process untreated off gas and mixed LPG from the RFCC Unitand untreated off gas from the PRIME G+ Unit.

(a) Objective

The Amine Treating Unit is designed to remove H2S in untreated off gas from the RFCC and PRIME G+ Unit and mixed LPG derived from the RFCC Unit to meet treated off gas and LPG product specification described in the Attachment C.

(b) Effluent

• The gas scrubbed in the Amine Treating Unit is sent to the fuel gas system in the PLANT and/or existing refinery. • The mixed LPG scrubbed in the Amine Treating Unit is sent to the LPG • Extraction Unit. • Acid gas from the Amine Treating Unit is sent to the existing sulfur recovery unit.

(c) Capacity and Turndown Capacity

The unit is designed to process the total gas and mixed LPG derived from RFCC Unit. The unit is capable of operating at between 60% and 100% of design capacity. The unit is capable of operating of cycles for at least 36 consecutive months.

(d) Product Property

17/39

The treated gas from the unit meets refinery fuel gas specifications set forth in the Attachment C. The concentration of H2S in mixed LPG outgoing from the Amine Treating Unit is removed to a low level to prevent caustic soda in the next LPG Extraction Unit from the damage from such H2S.

(6) LPG Extraction Unit

The LPG Extraction Unit is designed to process total Mixed LPG product from the Amine Treating Unit.

(a) Feed Definition

The feedstock for the LPG Extraction Unit is LPG derived from the Amine Treating Unit. The product LPG Extraction Unit can be processed as the Propylene Recovery from feedstock for Unit or can be used as LPG finished product.

(b) Product Properties

The LPG from the unit meets the Propylene Recovery Unit feed specifications or Mixed LPG for domestic market product specifications described in the Attachment C.

(c) Turndown Capacity

The unit is capable of operating continuously at between 60% and 100% of the design capacity when processing the design feedstock. The unit is capable of operating continuously for at least 36 consecutive months.

(7) Propylene Recovery Unit The Propylene Recovery Unit is designed to process the LPG product (C3/C4 stream) from the LPG Extraction Unit.

(a) Feed Definition

The feedstock for the Propylene Recovery Unit is Mixed LPG fraction derived from the LPG Extraction Unit. The feedstock can be processed to Mixed LPG product.

(b) Product Properties

The Propylene and Mixed LPG from the Propylene Recovery Unit meets Propylene and Mixed LPG product specifications described in the Attachment C.

(c) Capacity and Design Feed

The Propylene Recovery Unit is designed to process total LPG from the LPG Extraction Unit. The unit is capable of operating for at least 36 consecutive months.

(d) Turndown Capacity

The Propylene Recovery Unit is capable of operating continuously at between 60% & 100% of the design capacity when processing the design feedstock.

18/39

(8) Sour Water Stripping Unit

The Sour Water Stripping Unit processes sour water drained from the RFCC Unit.

(a) Objective The Sour Water Stripping Unit is designed to strip NH3, H2S and other volatile materials contained in sour water and to convert the harmless treated water. The sour water shall be once stored in new sour water reserver tank and sent to the Sour Water Stripping Unit. Treated water is sent to the Waste Water Treating Unit in OSBL. NH3 and H2S acid gas stripped from sour water is treated to meet the environmental regulation.

(b) Process Unit Capacity

The Sour Water Stripping Unit is designed to treat the total sour water derived from the RFCC Unit.

(c) Effluent Property

NH3 and H2S in sour water are removed up to low enough concentration to send the stripped water to the Waste Water Treating Unit for safe operation.

(d) NH3 Acid Gas

NH3 acid gas shall be burnt in an independent NH3 acid gas flare stack

(e) Turndown Capacity

The unit is capable of operating continuously at between 60% & 100% of the design capacity when processing the design feedstock.

(9) Amine Regeneration Unit

The Amine Regeneration Unit is designed to remove the H2S from rich amine from the RFCC Unit.

(a) Objective

The Amine Regeneration Unit is designed to remove H2S from rich amine solution and return the lean amine solution (regenerated) to the LPG Amine Treating Unit and the sour gas amine treating unit in the RFCC and Prime G+ Unit.

(b) Effluent

Lean Amine regenerated in the Amine Regeneration Unit is sent to the Amine. Treating Unit in the PLANT. Acid gas from the Amine Regeneration Unit is sent to the existing sulfur recovery unit and RFCC acid gas flare stack..

(c) Capacity and Turndown Capacity

The unit is designed to process the total rich amine derived from the RFCC Unit.

19/39

The unit is capable of operating at between 60% and 100% of design capacity. (d) Product Property

The lean amine from the Amine Regeneration Unit shall meet the requirements of Amine Treating Unit’s specifications set forth in the licensors’ basic engineering design documents.

(10) Waste Water Treatment Unit The Waste Water Unit is designed to treat RFCC waste water that may be contain oil and also organic compound from the open drain system in ISBL, open drain system in OSBL, Laboratory, sour water from Sour Water Unit, and neutralized water from Spent Caustic Treatment Unit. Before sending to the Waster Water Treatment, those streams will be treated first in the CPI Separator for oil removal. The effluent water from the CPI Separator will be send to Waste Water Tank that is provided with oil skimmer. The skimmed oil after recycle back to the CPI Separator is sent to Slop Tank.

(a) Objective

The Waste Water Unit is designed to treat RFCC waste water that may be contained oil and also organic compound to meet with enviromental regulation.

(b) Process Unit Capacity

Capacity of the Waste Water Treatment Unit is designed to treat the waste water that contaminate with oil and organic compound from the RFCC Unit according to FEED package.

(c) Effluent Property

The effluent property from the Waste Water Treatment Unit shall comply with enviromental regulation.

(d) Turndown Capacity

The unit is capable of operating continuously at between 60% & 100% of the design capacity when processing the design feedstock.

(11) Spent Caustic Treatment Unit

The Spent Caustic Treatment Unit is designed to neutralize the sodium sulfide and bi-sulfide contained in the caustic effluent from LPG Extraction Unit.

The low pH treated effluent with reduced BOD/COD characteristics is sent to the waste water treatment unit for further treatment .

(a) Capacity and Turndown Capacity

The unit is designed to process the total spent caustic effluent from LPG Extraction unit. The unit is capable of operating at between 60% and 100% of design capacity.

4.1.2.4 UTILITY FACILITIES AND OFFSITE

20/39

(1) UTILITY FACILITIES

This part is supplementary explanation of Design Basis and Philosophy of utilities facilities of the existing Cilacap refinery. TENDERER shall refer to FEED package on the detailed requirement.

In several projects that will be implemented in Cilacap refinery, it is forecasted

some shortage of raw water, de-mineralized water, steam, instrument air, nitrogen, fuel gas and fuel oil. In order to fulfill the requirement therefore Owner intends to separately install the following utility facilities from existing utility facilities: • Unit : Common Facilities for Utility Area • Unit : Steam & Power Generation System • Unit : Donan River Raw water Treating Unit • Unit : Raw Water System and Potable Water System • Unit : Demineralized Water System • Unit : Cooling Water and Potable System • Unit : Instrument Air & Plant Air System • Unit : Nitrogen Generation System • Unit : Fuel Oil & Fuel Gas System The existing utility facilities’ location is almost fully occupied therefore new utility facilities are decided to be placed in the new area. Detailed description of each facility has been provided in the BED packages and FEED package where CONTRACTOR should be refer to.

(a) Steam and power generation system

(a)-1 Purpose

The new steam generation, boiler feed water and condensate facilities shall supply the necessary steam and boiler feed water to new utility area, ISBL and recover steam condensate from the ISBL and OSBL.

Electric power for the entire PLANT including process units, utilities, ancillaries, offsite and all other infrastructure facilities shall be self-generated. Electric power shall be generated by steam-turbine-driven generating sets housed in a power station located in a utilities area. Electric power shall be distributed from the power station at high voltage to substations located conveniently for the load blocks. Voltage transformation to lower levels is made at each substation as required for the connected load. Electric power for start-up will not be supplied from the existing refinery, therefore an emergency generator driven by diesel oil shall be provided for emergency and boiler start-up. UPS system shall be provided to supply the power for instrument. Emergency lighting shall be powered from emergency power source. Emergency fitting with one hour back up battery package shall be provided for critical building (for example Control Room, Substations, and Administration Building).

21/39

(a)-2 Design Specification

The detail shall be referred to the FEED package. HP BFW pumps and upstream facilities, such as deaerators, shall be designed to serve not only utility facilities but also other consumers. The detail specifications of the above equipment are provided in FEED package.

(a)-3 Design Consideration

The boilers are provided with local control for start-up. But normal operations are controlled from the process and utility control room. Additional facilities are provided to continuously monitor and optimize the boiler e.g. : • Boiler efficiency

Air flow rate from a Forced Draft fan will be minimized based on residual oxygen contents in fuel gas. • Boiler load allocation

Load distributor shall be provided. • Overall steam and power allocation

Let down steam quantity (HP-MP and MP-LP) shall be monitored and consequent switch over of drivers will be advised.

In the case of one boiler shutdown during one boiler periodical shutdown maintenance, the balance steam is imported from existing utilities. The boiler qualities of feed water, boiler water, steam and condensate is continuously monitored for quality at all critical points. For example, the analyzers and/or sampling points shall be provided such as; Conductivity - At demineralizer outlet - At deaerator outlet - At cold condensate line pH - At deaerator outlet Oil - At hot condensate tank inlet Detail analyzers requirement shall refer to FEED package. Condensate recovery system is provided to minimize the used of make up demineralized water. Condensate is collected, and returned to the steam Condensate facilities for reuse via collection systems.

Hot Condensate The Condensate from HP/MP/LMP steam users in process units is flashed at low pressure in the LP condensate and then is cooled and collected in the hot condensate tank. Condensate flash drum located at ISBL, shall be designed considering the condensing system in OSBL. Steam and condensate operating condition are given in the FEED package.

Cold Condensate Recovered cold condensate from condenser in process area is sent to deaerator through the heat exchanger with the hot condensate. The cold condensate conductivity shall be checked with an inline analyzer at the following points. If the conductivity of the cold condensate increase to above pre-set value, the cold condensate shall be dumped to sewer line automatically.

22/39

EPC CONTRACTOR

to verify and conduct the load sharing study between new boilers and boilers in existing utility during detail design phase.

(a)-4 Driver Philosophy

TENDERER shall refer to “Sparing Philosophy” of FEED package.

HP BFW pumps: 1 motors and 2 back pressure turbine driven with automatic starting system

DFW Pumps 1 motor and 1 back pressure turbine driven with automatic starting system

Chemical Pumps: All motor Driven

FDF: steam turbine driven

(a)-5 CO Boiler

Objective

CO gas from the RFCC regenerator shall be burned to harmless gas in the CO boiler which generates HPL steam. CO boiler shall be designed to isolate from the RFCC regenerator for maintenance and inspection in spite of RFCC operation.

Fuel

CO gas from RFCC regenerator Fuel gas from RFCC fuel gas system Fuel oil from PLANT fuel oil system CO boiler shall be designed to generate steam at design capacity even

without CO gas.

Flue gas

CO boiler flue gas shall be designed to be emitted to meet the "Effluent Standard for gas and water" as the Attachment D.

(a)-6 Auxiliary Boilers

Objective

Auxiliary boilers shall be designed to meet steam demand during start-up and normal operation to back up the CO boiler operation.

Fuel

Fuel gas from RFCC fuel gas system Fuel oil from PLANT fuel oil system

Flue gas

Auxiliary boiler flue gas shall be designed to be emitted to meet the "Effluent Standard for gas and water" as the Attachment D.

23/39

(b) Raw Water Treating Unit

Donan River as a main source of water intake is place right adjacent to the Plant and existing Cilacap refinery. The river water is introduced into grid chamber through the gates and traveling screens. Then, the water is pumped up by the river water intake pumps and transferred to clarifiers. The water from clarifier is directly feed to the Desalination Unit by filtered water pumps. The treated water from the Desalination Unit is then transferred to the PLANT.

(b)-1 Basis of design

Refer to FEED package.

(b)-2 Additional equipment

The following is minimum requirement for equipment to be added to meet the new capacity target. All of the below requirements based on existing design concept however TENDERER could propose an alternative of the latest technology available. The CONTRACTOR ( and or Vendors ) shall furnish all necessary equipment to make the system complete. The CONTRACTOR ( and or Vendors ) shall provide all equipment, instrumentation, electrical wiring, control panels and inter-connecting piping (including all alloy pipes) necessary to ensure proper system operation.

(c) Raw water system and potable water system

The raw water and potable water system shall supply water to process units, utility facilities, offsite facilities, ancillaries and new utility facilities.

(c)-1 System Description

Raw Water is transferred from the water intake facilities via a pipeline, and after treatment in Clarifier and Desalination Unit is sent to desalinated water tanks. The desalinated water is pumped up as make-up to cooling water system and boiler feed water via Polisher.

The potable water is supplied from existing refinery, and distributed to the users . . (Refer to FEED package for detail)

(d) New De-mineralized Unit

TENDERER shall refer to FEED package.

(e) Cooling Tower Unit The cooling water unit shall supply cooling water to ISBL and OSBL.

(e)-1 System Constituents

The following new equipment to be added to meet the new utility demand - cooling tower trains - cooling tower pumps - start up cooling water pump.

24/39

- side stream filters - Chemical dosing unit

(e)-2 System Description

Service water is fed to cooling towers according to the level control of the cooling tower basin. The cooling water is sent to the users by cooling water pumps. After being used, the cooling water is returned to the cooling towers and is cooled to the supply temperature in the cooling tower. Around 2% of re-circulating water is sent to side filters for the removal of suspended solids. For the start up of utility facilities, a small capacity cooling water circulation pump, which is filters, is provided in addition to the main pumps.

(e)-3 Capacity

The system has a sufficient capacity to satisfy the cooling water requirement of the ISBL and OSBL. i) Cooling tower

The cooling towers have a capacity to satisfy of the normal maximum requirements of the Refinery as a duty base. An approximate 10% excess duty shall be considered.

ii) Side stream filters Around 2% of re-circulating cooling water shall be filtrated by the side stream filters.

iii) Cooling water pumps Normal two steam turbine driven pumps shall be operated to supply the

cooling water for the Refinery. One motor driven pump stand-by. iv) Start up cooling water pump

This pump shall have a sufficient capacity to satisfy the side filter requirement or the utility facilities start up requirement

(e)-4 Design Considerations

i) The system operating conditions shall be supervised at the control room of process and utility.

ii) The cooling tower basin has a capacity to hold 10 minute supply of the cooling water re-circulating rate.

iii) The cooling water shall be treated with poly-phosphate plus zinc type corrosion inhibitor during operation.

iv) The cooling water supply conditions are given in the BED packages and FEED package.

v) The cooling water line for process and utility facilities can be isolated. vi) In order to keep balance flow of cooling water supply and cooling water

return, flow indicator and control valve may consider which located at battery limit

(e)-5 Driver philosophy

TENDERER shall refer to “Sparing Philosophy” of FEED package.

i) Cooling water pump 2 (Two) back pressure turbine driven and 1 (one) motor driven with automatic starting system.

ii) Cooling tower fans All fans are motor driven

25/39

iii) Side filter/start up cooling water pump Motor driven

(f) Instrument Air and Plant Air system

(f)-1 Purpose The instrument air ( IA ) and plant air ( PA ) system shall supply instrument air and plant air to including the ISBL and OSBL area.

(f)-2 System Constituents

The new IA/PA system consists of the following equipment. 2 (Two) compressors for IA 2 (Two) compressors for PA 2 (Two) air receivers ( IA Receiver & PA receiver ) 1 (One) independent air drying system for each IA and PA

(f)-3 Design Specification

Refer to FEED package in detail.

(f)-4 Design Consideration a. The compressors are an oil-free centrifugal type. b. The air dryer is an adsorption type with electric heater regeneration.

The dryer shall be periodically regenerated using a timer. c. Instrument air and plant air piping system from new utility have a

connection with isolation valve at battery limit Refer to FEED package in detail.

(g) Nitrogen Generation System

Refer to FEED package in detail. (g)-1 Purpose

The new nitrogen system shall supply nitrogen to ISBL and OSBL. (g)-2 System Constituents

The system consists of the following new equipment. • Cryogenic nitrogen generators • Liquid nitrogen holders • Nitrogen vaporizer

(g)-3 Design Specification

Refer to FEED package in detail.

(g)-4 Design Consideration Refer to FEED package in detail.

i) The Nitrogen Generators are designed for the maximum continuous

nitrogen requirements for gaseous nitrogen, plus filling of one liquid storage tank in 10 days.

ii) The capacity of liquid nitrogen stored in the two vacuum insulated tanks are enough for two times of purging requirements of the largest consumer and emergency shutdown of the consumers.

iii) The Nitrogen Generator is provided with two (2) compressor one operation and one standby. .

iv) Liquid nitrogen vaporizers are provided for meeting peak demand.

26/39

v) The Nitrogen generators are monitored and controlled at the local control panel. Major alarms and trip signal are indicated in the control room of process and utility. However the start up will be carried out at the local panel.

vi) The Nitrogen supply conditions are given in the FEED package. (g)-5 Driver Philosophy

• Feed air compressor All motor driven

• Refrigerator All motor driven

• Air fan (if installed) All motor Driven.

(h) Fuel Oil & Fuel Gas

(h)-1 Fuel Gas

Purpose

The units collect various fuel gas sources and distribute them to the existing Cilacap refinery as fuel gas. It shall be provided with LPG vaporizer and K.O drum for RFCC unit start-up.

Destination consumers

• Boilers in new utility area • Process Unit ( ISBL )

Priority as Fuel gas sources

a) 1st priority is ISBL off gas & raffinate gas from Hydrogen Purification Unit. .

b) LPG from LPG storage tank are vaporized in the existing LPG vaporizer continuously under pressure control and other sources be manually routed to the vaporizer depend on circumstances. The fuel gas bleed to flare system shall be minimized to cover the requirement whole of the refinery fuel.

Additional equipment

No additional equipment to be considered, however piping system peripheral need to be modified in order to meet the new fuel gas distribution.

(h)-2 Fuel Oil

Purpose The units collect various fuel oil sources and distribute them to the PLANT as fuel oil. Fuel oil demand is increased due to maximize utilization of fuel oil & minimized fuel gas consumption. New boiler unit should be designed . to operate continously by 100% fuel oil , 100% fuel gas and dual firing .

Destination consumers

• Boilers in new utility area and furnace in ISBL.

27/39

Fuel oil system Existing fuel supply system consists of following equipment.

• Fuel Oil tank • Fuel Oil pump (existing) • Fuel Oil heater

Two existing fuel oil heater are available. 1 (one) fuel oil heater will be newly added.

Additional Equipment

The system is envisaged to consist of the following new equipment a) Fuel oil pump: b) Fuel oil heater: BEU c) Civil, piping, instrument and electrical work as per required by design Refer to FEED package in detail.

(i) Common Facilities for Utility Area

In order to support New Utility Area, the following additional facility/equipment shall be provided : - Desuperheater (HS-MS) - Oily Rain Water Pit - Clean Rain Water Pit - Clean Oily Water Pump - Oily Water Pump

(2) OFF SITE FACILITIES

This document covers the explanation of Design Basis and Philosophy of Offsite Facilities. New Offsite facilities is developed and constructed by CONTRACTOR to support the Project. The facility are as follows: • Marine Facility (including Blackish Water Intake System) • Tankages • Jetty facility for loading and loading arm • Tie in/piping interconnection

Detailed description of each facility has been provided in the BED packages and FEED package, where CONTRACTOR should be refer to.

(a) Design Basis

i) Propylene product transfer line from process unit to storage. Propylene rundown from ISBL is expected.

ii) LPG mix product transfer line from process unit (ISBL Unit) to LPG Mix

Storage tank. LPG rundown from ISBL is expected. iii) RFCC Gasoline product transfer line from process unit to Gasoline

storage. Gasoline component rundown from ISBL is expected. iv) Interchangeability pipeline of Propylene product storage tank. The

rundown line should be connected to each propylene storage tank.

28/39

v) Interchangeability pipeline of LPG product storage tank The LPG rundown should be connected to each LPG storage tank.

The LPG loading system shall have capabilities to load LPG to expanded LPG Jetties and existing bottling facilities.

vi) Independency of LPG and Propylene Storage handling. These are

should be avoided the utilization of common line of LPG and propylene. Some possibilities of LPG contaminated into propylene system should strictly be avoided.

vii) Re-processing facility for off spec propylene product to RFCC unit. Off

spec propylene which is collected in all of the propylene tank shall have the capabilities to be treated in RFCC unit.Re-processing facility for off-specification LPG product from all LPG tanks to RFCC unit and LPG vapourizer shall be provided.

viii) Propylene transfer line from storage tank and (New Tank) to Loading

Jetty shall be installed.

• New Propylene tank equipped with the tank gauging system. Redundant level indicators are provided on each tank which can be accessed from Offsite Control Room and local. Temperature compensations are provided. • New propylene metering unit which is connected to loading jetty pipe line can be utilized as loading metering. • Propylene loading pump and its spare is dedicated for loading to Jetty. • Propylene metering system and meter prover are provided for propylene loading to jetty.

ix) LPG transfer line from storage tank to existing and expanded Loading

Jetty • The philosophy should cover the flexibility of LPG transfer either to

expanded Loading rate to jetty and existing facility. • LPG metering system and meter prover for LPG loading to jetty

and transfer to Pertamina LPG filling plant will use the existing facilities.

x) Propylene vapor return line from Propylene ship to Propylene Storage Tank • The philosophy should cover propylene vapor return system from

loading jetty to propylene storage tank. The system are include vapor return arm and vapor return pipe line.

• The lines should have capabilities to return the propylene vapor back to the dedicated loading tank.

The Propylene vapor return line shall be equipped with metering system

xi) LPG vapor return line from LPG ship to LPG Storage Tank • The philosophy should cover LPG vapor return system from loading

jetty to LPG storage tank. The system includes vapor return arm and vapor return pipe line. The lines should have capabilities to return the LPG vapor back to the dedicated loading tank.

• The LPG vapor return line shall be equipped with metering system. xii) Gasoline, LCO & DCO product transfer line to existing • Facilities of gasoline transfer line to existing shall be installed • Transfer philosophy should cover the gasoline to RFCC and existing

29/39

facilities.

xiii) Venting system from LPG and propylene tank to flare header shall be provided.

Refer to FEED package in detail.

(b) Loading Jetty (Expansion to the Existing Jetty) The utilities to be provided on jetty include: Instrument air, Nitrogen, Service water and Fire water shall be provided in accordance with FEED Package. Two loading arms for Propylene and one loading LPG shall be installed. Loading arm are operated by hydraulic power and equipped with ERC (emergency release coupler). Nitrogen purge and double block with spectacle blind are provided on each loading arm inlet

(3) OTHER FACILITIES

The following description represents the proposed scope of other facilities. The process design of the facilities represented by these process descriptions, process flow diagrams, equipment lists, etc. will be subject to review and further development by CONTRACTOR and the Process Licensors during project execution. Process Flow Diagrams for each facility, unit process design, unit configuration, yield, material balances, utility summary, disposal system etc. will refer to BED Packages and FEED Package.

(a) Refinery Fuel System

(a)-1 Introduction

Fuel Gas and Fuel Oil will be used in this project. The fuel gas and fuel oil systems is provided for the Process Unit, and New Utility . The fuel gas system is designed to collect the following gases and distribute them to the consumers not only in the process units but also in the Utility Facilities.

(a)-2 Process flow scheme

Fuel gas system consists of a new fuel gas and holder piping. Off gas from above-mentioned process units, enters the fuel gas header and is mixed together in the fuel gas holder then distributed to consumer.

Excess Fuel Gas from Process Unit will be exported and will be controlled by pressure controller.

Note : For Start-up purposes only, Fuel Gas and Fuel Oil to new boiler system shall be supplied from the vaporized LPG which is generated by new evaporator, and oil system. Cross tie-in to the fuel gas and oil system shall be installed.

(b) Hydrogen Distribution System The requirement of Hydrogen gas for reaction in Process Unit will be supplied from H2 Purification Unit. Feed for H2 Purification Unit is from existing refinery. Cross tie-in to the Hydrogen Purification Unit shall be installed included its distribution

30/39

system. .

(c) Flare System

(c)-1 Introduction

The flare system that to be constructed is designed to dispose of flare gas from the process units so as to protect equipment from fatal damage, even if the largest relieving failure is caused. The design capacity is subject to verification during detailed engineering. The governing case for this system is an electric failure.

The system consists of equipment as follow:

• Flare Stack • Flare K.O. Drum • Process main flare header • Water seal system

All equipment in the flare system is designed in accordance with API-RP 521 and API 520 latest edition.

Acid gas flame stack shall be provided beside hydro carbon flare stack to relieve the NH3 Acid gas from sour water stripper, amine regeneration unit, and spent caustic treatment unit. Refer to FEED package in detail.

(c)-2 Process Flow Scheme

Relieved gas from various sources, such as PSV, gas disposal, de-pressuring, etc. are gathered in the sub-header of each unit, and then goes to the flare gas knockout drum through a main process flare header. Entrained liquid in the gas is separated in the flare knockout drum and is intermittently pumped out to the existing light slops tanks by the Slop Pump. The gas from the drum goes to the flare stack through the seal drum. Sour water from the acid flare KO Drum and from Water Seal Drum drain is sent to Sour Water Stripping Unit.

(d) Slop system

(d)-1 Introduction

There are two slop systems, light slop and heavy slop. The light slops system is designed to collect only Light Slops produced in the Process Unit and New Flare System.

Light and other contamination are routed to light slops tanks prior to transferring slops separately back to existing process unit for reprocessing. Heavy slop system is designed to collect off spec DCO, RFCC feed and other heavy oil like a API oil etc.

Referring to the operating philosophy of process unit, the off-spec product from Process Unit shall be routed to finish product as blending component.

(d)-2 Design basis

The slops system is designed to collect slops produced in the Plant.

The Light slops system is designed to collect saturated and unsaturated off-specification products. Light slops consisting of LCO and materials with boiling points lower than LCO, excluding the C4 minus fractions, are routed to a floating

31/39

roof tank. The light slope are pumped from the light slops tanks to RFCC unit for reprocessing. Heavy slops are also pumped to RFCC unit for reprocessing.

(d)-3 Description of facilities

The slop system is capable of operating as an independent facility. Light slops are collected in light slops systems from process units, utilities and off-sites. The recovered slops will be stored in new slops tanks and reprocessed.

CONTRACTOR shall develop and construct the slop collecting system from process units, offsite, utility and flare system and routed to the slops line header and shall be stored in the new slop tanks.

Refer to FEED package in detail.

(e) Caustic System The existing Caustic System is designed to be capable of dissolving solid caustic to produce a caustic solution. The requirement of caustic solution for Process Unit should be designed by CONTRACTOR.

Spent Caustic from Process Unit shall be routed to the New Spent Caustic Treatment to be neutralized. Neutralized aqueous material will be disposed To the new waste water treatment system followed by the neutralization system.

(f) Sewage and Effluent Treatment Facilities

TENDERER shall refer to “Process Description” of FEED package

The effluent treatment facilities shall be provided to treat any kind of effluent from the Plant. All liquids discharged from the Plant are treated to a level of purity consistent with 'Waste Water Quality" in the BEDD and refer to Indonesian Regulation (Peraturan Menteri Lingkungan Hidup No. 04 / 2007 date of 08 Mei 2007).

In order to ensure the correct treatment, different types of effluent are treated separately. In particular, any streams not requiring treatment prior to discharge are kept separate from contaminated streams.

i) Oily rain water These following rainwater are treated as oily:

• The rain water in process and utility areas which includes oil is gathered into oily water buffer pits. • Rain water inside dike in an emergency case.

This rainwater is sent to the oil separator. Separated water is aerated to remove contaminators, and then the treated effluent is discharged to an impounding basin before routing to the river. Separated oil is sent to the recovered oil facilities.

ii) Non-oily rain water The following rain water does not include oil under normal operation.

• Rain water inside dikes • Rain water from non-oily utility area.

32/39

This rain water is gathered into the impounding basin prior to discharge to public water. The location of impounding basin shall be closed to discharge point closed to existing Paraxylene holding basin.

iii) Clean rain water The following rain water is always clean and is discharged to the river without treatment.

• Rain water on unpaved • Rain water on buildings • Rain water on roads & parking lot.

iv) Oily waste water from process plants

• This oily waste water is sent to Neutralization pit. • Neutralized waste water is sent to the oil separator. • Separated water is sent to the activated sludge facilities and then is gathered into impounding basin. • Separated oil is sent to the recovered oil facilities.

v) Oily water other than item 1) and 4)

• Tank drains • Fire fighting water on oily area • Fire fighting water inside dike in an emergency case.

These oily are treated as same as above oily rain water in Item 1).

vi) Non-oily water except rain water The following waste water is gathered into the impounding basin to dilute and to be diluted before discharge from the Plant.

• Blow down water and neutralized water from demineralizer during regeneration operation • Blow down water from boiler • Blow down water from cooling tower • Fire fighting water inside dike in normal operation • Fire fighting water on non-oily area of utility facilities

vii) Sanitary water

Sanitary water is treated in the activated sludge facilities through the septic tank and then sent to WWT.

viii) Laboratory waste water

The laboratory waste water is neutralized in the neutralization pit and then sent to WWT.

The above waste water and other water having any possibility of including oil are gathered into the new impounding basin to check the oil content. An oil skimming device is provided at the impounding basin.

The capacity of the impounding basin meets a 30-minute holding period.

Note:

1. Additional Equipment or Facilities shall be developed and constructed at the Effluent Water Treatment Area due to additional discharging effluent or disposal capacity from the Plant are

• New CPI: with capacity 2 x 100 % design flowrate (for maintenance

33/39

consideration). • New CPI oil sump • New CPI skimmed oil Pump • New API oil Sump • New API skimmed oil Pump • New Impounding Basin

2. CONTRACTOR must review, develop and construct new Interconnection

facilities either underground or above ground systems to send the effluent from Process Unit, Utility and Offsite to the existing facilities for further treatment.

(g) Flushing Oil System

The flushing oil system for the PLANT shall be designed by CONTRACTOR which can cover but not limited to activities below :

To optimize operation mode for using 3 source of flushing oil media which are LCO, HCO, HGO. Since HGO is imported from existing refinery with limited source and basically use for initial start-up, PLANT shall maximize usage of flushing oil media produced by it’s own operation which are LCO and HCO.

To cover simultaneous flushing activities and HGO/LCO during initial / normal start-up.

To cover flushing activities for all liquid lines equipped with steam tracing to prevent blocking due to no steam availability during PLANT turn around.

(h) Catalyst Handling System

The catalyst handling system shall be designed by CONTRACTOR which include as minimum are :

1. 2 units Fresh catalyst hopper receiving facility from bags and ISO Tanks to Fresh Cat. Hopper.

2. 1 unit Spent catalyst discharge facility from EQ Hopper to truck.

3. Temporary catalyst warehouse facility for :

a. Storing fresh catalyst receiving from catalyst manufacturer for 30 Days cat. Make-up rate.

b. Storing catalyst receiving from catalyst manufacturer for 30 Days catalyst. Make-up rate.

c. Minimum warehouse area = 500 m2. d. Warehouse shall completed with overhead traveling crane (3Ton)

facility.

4. 2 units vehicle truck lorry for transferring fresh catalyst from catalyst ware house to fresh catalyst hopper and transferring spent catalyst from EQ hopper to catalyst warehouse.

Contractor shall propose the specification for vehicle truck lorry to OWNER for approval.

34/39

5. Spent catalyst Warehouse facility Contractor shall perform New Spent Catalyst Warehouse Facility with total warehouse area 1000 m2. Warehouse shall completed with the following facility :

a. 2 Units Overhead traveling Crane (Cap. 3 ton). Overhead travelling Crane shall be designed to handle flexible containers, bulk lorry and supplier’s trucks.

b. Forklift c. Weigher. d. Dust Collector (for bagging and lorry Loading) e. Spent catalyst Hopper (Net Capacity 60 m3) . f. Rotary valve and Slide gate valve. g. Spent Catalyst Warehouse location see DWG No.Pr.E-FSK=1430-1 Rev.0

6. Work Flow of Catalyst handling as shown in the Fig.1.

(i) Tie in Works with Existing Facilities

(i)-1 Tie in Work Based on process requirement, minimum piping tie in list is provided in FEED package. CONTRACTOR shall identify and furnish all necessary tie in under Owner supervision (include tie in for Electrical, Instrument, telecommunication , etc.) to make the system complete and function properly. All works related to tie-in including materials and accessories, tools and labors (including evacuation, isolation, hot tapping, drain and purge work of the existing facilities) shall be Contractor responsibility

35/39

(i)-2 Evacuation of the existing facilities.

If tie-in with the existing facilities is necessary, the existing facilities should be evacuated and isolated for the work by Owner and should be supported by CONTRACTOR.

(j) Flare & Facilities.

Refer to Plot Plan Drawing No. 000-T4311-011-3 Rev.4, previous RFCC Flare & Facilities location will be use for other Existing RU IV purpose. Regarding to this matter New RFCC Flare and facilities location shall be move to nearest existing SRU Flare (tentative). Contractor shall evaluate and study both in terms of operations, construability as well as safety and regulation requirements for the design and construct combining two units Flares (New RFCC Flare & Existing SRU Flares) in one flares structure support.

4.1.3 SITE INFORMATION (MOVE TO EXHIBIT D)

The site is located in the town of Cilacap on the southern coast of Central Java (see the map below).

Cilacap is situated on a peninsular surrounded by “Donan” river in the west. Donan river is not really a river, even though some document indicates so, but is a small sea inlet around the peninsular of Cilacap (see attached Map 1) from the Indian Ocean. Flow in the Donan is tidal, with the difference in level indicated in the BEDD of the FEED package. The existing Cilacap Refinery site is located in the northwest part of the town, facing with Donan river (see attached Map 2 and 3). The proposed site for the PROJECT will be the area indicated by the shadowed frame in the Map 2. The proposed two sites are located within the confines of the existing Cilacap Refinery site in Pertamina property’s land. Both sites are located in the west part of the existing Cilacap Refinery area. The larger site is planned to be allocated to process units, utilities facility and offsite facility, excluding tankages. Most of tankages will be constructed in the smaller site located in the west-south

Cilacap

36/39

area of the existing Cilacap Refinery site. These sites are separated by the existing Cilacap Refinery facilities, such as pipe trestles, barge dock, metering house and LPG/SRU facilities. (See the Attachment A (2/2) “Plant Layout” to the Part 4.1.2 “DESIGN BASIS” of this RFP. The reclamation of the sites is reported to have commenced in 1992, using dredged marine sand from the harbor located to the south of the refinery. The edge of the sites facing the river is protected by sheet piles. It is reported that 3m to 5m thickness of marine sand was placed. The topographical data will be available at a later stage as a part of FEED package; however it is suggested that the general topography of the refinery area is relatively flat, forming part of a coastal plain and reclamation area. The south and east areas outside the refinery area are bordered by Lomanis and Donan villages. According to the AMDAL (Analisis Mengenai Dampak Lingkungan – Environmental Impact Assessment) document for LPG/SRU Project in 2003, the refinery area is underlain by Quaternary alluvial deposits, which are recorded to consist of sand and clayey sand, fine grained, loose to dense and moderately to well graded. It also suggests that rockhead, consisting of siltstone, is siyuated at a depth of approximately between 24m and 30m below the original ground level. The proposed sites are areas of reclaimed land as mentioned in the above, which seems to consist of river sands deposited directly on tidal mud flats and consisting of soft silts and clays. Both of the sites are mostly undeveloped and are no-paved areas within this site boundary. The site elevation will be confirmed with the topographical survey data which will be separately provided at a later stage. (Refer to the site elevation in the BEDD of the FEED package) The smaller site has 4 operational sediment beds, two in the north with approximately 30mx30m in size, and other two in the south with approximately 100mx45m in size. The drying beds are separated by soil banks, approximately 2m above from the original ground level. The crest of such banks are approximately 1-3m width at the top. The banks shall be demolished for obtaining the tank foundation area, including a certain soil improvement work to be done by CONTRACTOR. The mixed LPG spherical tank exists outside banks at the north-east corner area of the smaller site. The above is just for reference, subject to confirmation by CONTRACTOR. The proposed sites consist of reclaimed land which has been filled with land materials originating from harbor deepening operations to the south of the site during 1992-1995. The ground water level is reported to be generally less than 2.5 mbgl. There are dug wells in the refinery site and the water quality is saline due to being salified by Donan river (sea) water.

37/39

Map 1

38/39

Map 2

39/39

Map 3