NIOEC-SP-47-12(0)

DOCUMENT CODE NO. OF PAGES: 8

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG ME SP 4712 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

CONDENSATE POLISHING SYSTEM

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-47-12(0)
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REVISION INDEX
REV. REV. REV. REV.
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
PAGE PAGE PAGE PAGE

1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

1
0 JULY, 2005 M.R.FARZAM M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
 JULY, 2005 NIOEC-SP-47-12(0)

CONTENTS: PAGE NO.

1. SCOPE.........................................................................................................................................2
2. REFERENCES ...........................................................................................................................2
3. UNITS..........................................................................................................................................3
4. SCOPE OF SUPPLY .................................................................................................................3
5. SPECIAL REQUIREMENTS...................................................................................................3
6. MATERIAL SELECTION........................................................................................................4
7. PROCESS CONDITIONS.........................................................................................................4
7.1. Influent Water Characteristics .........................................................................................4
7.2. Effluent water characteristics ...........................................................................................4
7.3. Operating Conditions.........................................................................................................4
7.4. Regeneration .......................................................................................................................4
7.5. Water Heater ......................................................................................................................5
7.6. Resin Trap...........................................................................................................................5
8. MECHANICAL DESIGN .........................................................................................................5
8.1. Chemical feed systems .......................................................................................................5
8.2. Condensate polishing filters ..............................................................................................5
8.3. Instruments and Controls..................................................................................................6
8.4. Area classification ..............................................................................................................6
8.5. Piping...................................................................................................................................6
8.6. Heat Exchanger ..................................................................................................................7
8.7. Structures and foundations ...............................................................................................7
8.8. Painting and Lining............................................................................................................7
9. GUARANTEES ..........................................................................................................................7
10. LOADING DATA ......................................................................................................................7
11. INSPECTION AND TESTING.................................................................................................8
11.1 Inspection ............................................................................................................................8
11.2 Shop Tests ...........................................................................................................................8
11.3 Performance Test ...............................................................................................................8

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1. SCOPE

NIOEC Specifications cover the general requirements for detailed engineering, procurements,
testing inspection & construction of refinery/ oil plant, distribution depots, pump stations and
pipelines.
This Specification outlines the process and mechanical requirements for the design and
fabrication of a complete assembled and skid – mounted Condensate Polishing System, the
product of which is to be used for boiler feed water, to be installed indoors in Refineries.

2. REFERENCES

Throughout this Specification the following dated and undated standards/ codes are referred to.
These referenced documents shall, to the extent specified herein, form a part of this
Specification.
For undated references, the latest edition of the referenced document (including any
supplements and amendments) applies. For dated references, the edition cited applies.
The applicability of changes in dated references that occur after the cited date shall mutually be
agreed upon by NIOEC and the Vendor/Contractor.

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
AISI (AMERICAN INTERNATIONAL SUPPLY, INC.)
NIOEC-SP (NIOEC SPECIFICATIONS)
NIOEC-SP-00-10 “NIOEC Specification for Units”
NIOEC-SP-00-54 “NIOEC Specification for Basic Engineering Design Data”
NIOEC-SP-20-01 “NIOEC Specification for Structural Steel Erection”
NIOEC-SP-41-03 “NIOEC Specification for Pressure Vessel”
NIOEC-SP-44-01 “NIOEC Specification for Shell and Tube Heat Exchangers”
NIOEC-SP-50-01 “NIOEC Specification for General Piping Process and Utility Design
Equipment Layout and Drawing Procedure”
NIOEC-SP-50-02 “NIOEC Specification for General Piping Process and Utility
Fabrication and Field Installation”
NIOEC-SP-50-04 “NIOEC Specification for Piping Material”
NIOEC-SP-70-01 “NIOEC Specification for Instrumentation”
NIOEC-SP-80-02 “NIOEC Specification for Painting”
NIOEC-SP-80-05 “NIOEC Specification for Lining”

NIOEC-SD (NIOEC STANDARD DRAWING)

NIOEC-SD-0001-1/1-A1 “PFD, SYMBOLS AND LEGENDS”
NIOEC-SD-0100-1/4-A1 “P&I Ds, Symbols and Legends (Piping)”
NIOEC-SD-0100-2/4-A1 “P&I Ds, Symbols and Legends (Instrument)”

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NIOEC-SD-0100-3/4-A1 “P&I Ds, Symbols and Legends (Instrument)”
NIOEC-SD-0100-4/4-A1 “P&I Ds, Symbols and Legends (Miscellaneous Equipment)”
NIOEC-SD-0101-1/1-A1 “P&I Ds, Abbreviation”

3. UNITS

International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.

4. SCOPE OF SUPPLY

The System shall consist of number and quantity of Items but not be limited to, the
following items within the battery limit showing on relative P&I Diagrams and with
consideration of Site & Utility conditions. For other data refer to NIOEC-SP-00-54 where,
the design data are completed based on the project requirements.

4.1 Descriptions of items

4.2 Water heater.

4.3 Initial load filter media (ion exchange materials) and necessary internals.

4.4 Prefabricated and piping and pipe supports. In general / all piping shall be prefabricated
and lined as requested at Vendor's shop as much as possible so that site construction work is
to be minimized. The construction allowance for field adjustment shall be supplied by
Vendor, who shall recommend those quantities to purchaser for approval.

4.5 Locally mounted instruments / control system and control panel including tubing and
wiring / instrument mounting supports etc .

4.6 Walkways, platforms, supports, lugs etc.

4.7 Painting and lining for vessels, piping, instruments, supports etc.

4.8 Anchor bolts for equipment and the supports of piping and instruments.

4.9 Ion exchange resin to be adequate for 2 years operation as spare.

5. SPECIAL REQUIREMENTS

5.1 The proper instrumentation for automatic operation of the system to meet process
requirements shall be provided. Omission of instrument and / or equipment detail in this
Specification does not relieve the Vendor of providing the required items of equipment,
instrumentation and / or control devices.

5.2 The System shall be assembled and pretested at Vendor's shop as much as possible so
that it shall be shipped to site ready to operate resulting in minimum erection schedule on
site.

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5.3 Vendor shall select lining materials upon taking into account that this system suffers
cold temperature (based on the site minimum temperature) in transportation and site storage
during construction stage.

6. MATERIAL SELECTION

Material selection shall be made based on the Referenced specifications as per American
Code or Standards. If Vendor prefers higher or equivalent grade of materials produced in
other recognized country codes such as BS, DIN and JIS whatever, Vendor shall submit
such details at proposal stage and shall take Purchaser's approval before purchase order
provided that materials on drawings shall be identified by corresponding ASTM or AISI
designation .

7. PROCESS CONDITIONS

7.1. Influent Water Characteristics

Condensate will be pumped from other units to the system. The solids in the condensate is
from cooling water leakage in steam condensers.

Estimated ion concentration is as follows:

Electric conductivity: 10 micro siemens / cm (micro Mhos / cm) at 25°C

Normal deviation from the above analysis shall not relieve the Vendor of responsibility for
performance of equipment .

7.2. Effluent water characteristics

The treated effluent from the system will be discharged to the deaerators or storage tanks
which ultimately will be used for boilers operating at the designed pressure and temperature.

Effluent from the system shall not exceed 1 micro siemens / cm at 25° C.

7.3. Operating Conditions

The system shall be designed for the required flow rate as shown on the duty specification.
and shall be able to be operated through the range of 25 to 100 percent of the required
flowrate. Condensate will be supplied to the system at normally 52° C at a 4.5 barG.
Maximum differential pressure available in the system is 0.7 barG.

When the filters are in service, each shall serve equal portion of the system throughput. The
maximum normal flow rate is per m² of filter shall be determined by Vendor, and when one
filter is regenerating / the other three filters shall serve the system throughput. The
maximum flow rate when one filter is out of service to be 1.25 times (depending on the
number of filters) of the normal flow rate per m². Each filter shall be capable of 96 hours
operation between regenerations.
Chemical measuring tanks shall be based on 24 hours of operation.

7.4. Regeneration

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The regeneration of the polishing filters shall be done automatically with checking
conductivity and flow quantity.

7.5. Water Heater

Vendor shall clearly propose whether the water heating before mixing caustic soda solution
is required.

7.6. Resin Trap

A common resin trap with by – pass and a local pressure differential pressure indicator shall
be furnished at the down stream of polisher banks.

8. MECHANICAL DESIGN

8.1. Chemical feed systems

The system shall include chemical measuring tanks with level indicators and eductors or
pumps (pumps are preferable) for proportional chemical feed.

Number of the proportional pumps to be furnished for each chemical feed system shall be
determined in engineering stage (one as spare). Each pump shall be provided with a suction
strainer adequate to protect the pump against damage from insoluble or foreign materials.
Vendor shall guarantee that chemical proportioning and feeding equipment shall deliver
automatically the respective chemicals in proportion to the rate of water flow.

8.2. Condensate polishing filters

8.2.1 Vessels

Pressure vessels shall be fabricated in accordance with NIOEC-SP-41-03. Each vessel shall
be lined prevent galvanic corrosion and erosion of the inside vessel wall. The lining is in
addition to the corrosion allowance of steel material.
Minimum design requirements in addition to above are as follows:

Corrosion Allowance : 1.6 mm

Design pressure : barG (by Basic Designer)

Ion Exchange Materials : Rohm& Heas IR-200 or equal and Anion Resin

Freedboard : 100 %

Bed Depth : * mm (vendor to propose)

Material of Construction:

- Shall and heads :ASTM A516 Gr 70 or equivalent with rubber lining

- Internals : Stainless Steel

Upper Distributor : Header / Lateral Type

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Underdrain : Subfill – less design with stainless steel strainers

8.2.2 Accessories

Accessories include backwash distribution system, arrangement of inlet to each polisher to

prevent direct impingement on the resin bed, relief valves, sight glasses for visual
observations of backwash effluent, sampling connections, loss-of-head gauges rate-of-flow
indicators for polishing and backwashing, backwash rate-of-flow controllers to ensure
adequate backwash without loss of resin, a common resin trap with by-pass, and equipment
for preparing and feeding chemicals for regeneration of units .

8.3. Instruments and Controls

Instruments and controls shall be in accordance with NIOEC-SP-70-01.

All instruments shall be tagged with identifying tag numbers which are assigned in the P & I
Diagram. Stainless steel nameplates shall be furnished stamped or engraved with this tag
number and permanently mounted with stainless steel drive screws .

The following instruments shall be provided in addition to any other normally required:

(1) One Local differential pressure in addition with alarm (DPISH) across condensate
polishers

(2) Local level switches with low and high level alarms (LSHL) for all chemical tanks

(3) Local flow recorders for influent water to condensate polishers

(4) Conductivity analyzer with high alarm ( including sample cooler ) for effluent water
form condensate polishers

(5) Running light to indicate end of run cycle on condensate polishers

(6) All condensate polishing filters shall have high and / or low level switches with level
alarms /if applicable.

8.4. Area classification

The system is to be installed in non-hazardous area.

8.5. Piping

Piping design shall be in accordance with NIOEC-SP-50-01. All Piping, including valves
and fittings, shall be in accordance with NIOEC-SP-50-04.
Vendor shall recommend and propose minimum lining pipe diameter / materials for small
diameter piping, these prefabrication etc.

Piping tie-in points shall be proposed as per the P & I Diagram. However, purchaser
reserves the right to change / modify the piping location of battery limit during detailed
engineering.

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8.6. Heat Exchanger

Water heater shall be in accordance NIOEC-SP-44-01.

8.7. Structures and foundations

Structures such as walkways, stairs etc. shall be in accordance with NIOEC-SP-20-01.

Purchaser provides concrete foundation at standard level 200 mm above high point of the
finished grade.

8.8. Painting and Lining

All equipment and materials shall be surface – prepared and painted upto and including
finish in accordance with NIOEC-SP-80-02, except loose or prefabricated piping shall be
painted upto and including primer, and shall be lined in accordance with NIOEC-SP-80-05
if applicable.

9. GUARANTEES

Vendor shall propose the indicated items ( * asterisked hereunder ) and shall guarantee the
following when the system is operated in accordance with the written operating instructions
and treating condensate as specified per Sections 7.1 :

9.1 The System is free from fault in design / workmanship and material and is of sufficient
size and capacity to fulfill satisfactorily the operating conditions specified.

9.2 Effluent rate * m3 / hr and quality under conditions given in this Specification.

9.3 Regenerant consumption .

Sulfuric acid ( * wt & solution ) : * kg / 1,000 m³ effluent water
Caustic soda ( * wt & solution ) : * kg / 1,000 m³ effluent water

Reacted Regenerant
Regeneration efficiency : * % of----------------------------
Used Regenerant

9.4 Resin capacity

Impurity to be caught by each polisher : * kg (impurity / polisher / cycle)
Anticipation years loss : * %
Operation hours per each regeneration at design condition : * hours

9.5 Maximum differential pressure * bar of the system.

10. LOADING DATA

10.1 The loading data supplied by the vendor shall include enough data for the purchaser to
design and construct the supporting structures and / or concrete foundations for the erection
and installation purposes.

10.2 Loading data shall be exact, neither short nor conservative and indicate least the
following in dimension m or mm and weight ton or kg.

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10.2.1 Equipment skeleton showing gross dimensions and elevations for purchaser to
understand the conditions of loading.

10.2.2 Locations, elevations and dimensions for base plates of legs or posts.

10.2.3 Locations, sizes, numbers and required project lengths of anchor bolts or
setting bolts.

10.2.4 Static weight and load in total / and per each leg or post if weight per each leg
or post is different from the other.
( a ) Erection weight
( b ) operation dry weight ( empty weight out of operation )
( c ) operation weight

10.2.5 Dynamic effects due to operation, if any, on supporting structures and / or

foundations.

10.2.6 Wind load in total / and per each leg or post if wind load per each leg or post is
different from the other.

10.2.7 Test weight under full water test if the equipment is specified to be tested at
field.

10.2.8 Any other requirements for supporting structures and / or foundations if it is

deemed by the Vendor.

10.3 The Vendor shall also submit supporting calculations showing that the above loading
data are exact, neither short nor conservative, any time when the purchaser requests.

11. INSPECTION AND TESTING

11.1 Inspection

Purchaser and / or Client representatives shall have the right to inspect the equipment during
fabrication and assembly, on 48 hours notice to Vendor. Inspection may include drawings,
materials, parts, all shop processes and assembly.

11.2 Shop Tests

11.2.1 All pressure vessels shall be subject to pressure test / as specified in ASME Pressure
Vessels Code.
11.2.2 All piped assemblies or subassemblies shall be pressure tested to at least twice the
working pressure.
11.2.3 The Vendor shall provide a certified report of each such test / whether or not
Purchaser and / or Client representative witnesses the test.

11.3 Performance Test

Performance Test will be conducted at the time of plant start-up with Vendor's
representative at the site, if necessary. In the event equipment or auxiliaries fail to meet or
exceed the specified performance, Vendor shall make whatever changes such as design,
supply of material and equipment which are necessary to meet the specified performance.