Wood Technology

Medium Density Fiber Board (MDF) Project

DOC TITLE: Operating, Control and Safeguarding Philosophy

4 3/11/2021 M.Salem H. Heykal A. Shalaby Re-Issued for Design

M.Mo
3 31/10/2021 M.Salem
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Heykal M. Mortada M.Hawash Issued for Review
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REV. DATE ORGINATOR
d for Review REVIEWED APPROVED DESCRIPTION

EPC CONTRACTOR

THE PETROLEUM PROJECTS AND TECHNICAL CONSULTATIONS CO.

DOCUMENT No.: MDF-PTJ-PR-RPT-0002 PAGE 2 of 8

DISCIPLINE: PROCESS REV. 4 DATE: 3-11-2021

 TABLE OF CONTENTS

1 INTRODUCTION ......................................................................................................................... 4

2 PURPOSE ................................................................................................................................... 6

3 UTILITIES SYSTEMS ................................................................................................................. 7

3.1 Raw Water System..................................................................................................... 7

3.2 Process water system ............................................................................................... 7
3.3 Demineralized water system .................................................................................... 8
3.4 Instrument air system ............................................................................................... 8
3.5 Industrial water treatment package ......................................................................... 8
3.6 Potable water system ................................................................................................ 9
3.7 Fuel gas system ......................................................................................................... 9
3.8 Rejected Water System ........................................................................................... 10
3.9 Hot Water System .................................................................................................... 10
3.10 Waste liquids System .............................................................................................. 10

DOCUMENT TITLE: Operating, Control and Safeguarding DOCUMENT No.:

Philosophy MDF-PTJ-PR-RPT-0002

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1 INTRODUCTION

Project Objective is to build a complete production line along with all ancillary services
and utilities to produce 205,000 m3 per year of high quality MDF using rice straws as
feedstock, in order to both satisfy all local market needs and start export of the surplus.
The foreseen plant location is on ECHEM (end-user) proprietary land close to IDKU, as
per below satellite image.

PROJECT LOCATION

Foreseen Site Location

Petrojet is currently working on the delivery of Basic and Detailed Engineering Activities
for the Project, inclusive of all calculations, drawings, studies, analyses, reviews and
preparation of engineering deliverables required. A clear definition of the scope of
work is given in Doc. "Professional services and construction works for Medium density
fiber board project MDF with Capacity 205,000 M3/Y", which was provided along with
the Tender Documents.

Petrojet is willing to subcontract a selected portion of the scope, limited to specific

disciplines within the Utilities and Ancillary Systems Design (OSBL Scope). The main
portion of the core material treatment systems (ISBL Scope) has been subcontracted
specialized licensor (SIMPELKAMP). The portion of the Engineering scope expected
to be delivered is inclusive of:

DOCUMENT TITLE: Operating, Control and Safeguarding DOCUMENT No.:

Philosophy MDF-PTJ-PR-RPT-0002

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  Process Engineering Activities for the Utilities Systems-OSBL Systems.
 Piping Engineering for the Utilities systems-OSBL Systems.
 Process Safety Engineering for the Utilities Systems-OSBL Systems.
 Mechanical Engineering for the Utilities Systems-OSBL Systems.
 3D Modelling.
 I&C Engineering for the Utilities Systems OSBL Systems.
 Pre-Commissioning and Commissioning philosophies and procedures
preparation for the Utilities Systems-OSBL Systems.
 Pre-Commissioning and Commissioning management of activities at site.

Scope of Services has been based on the following documents:

Siempelkamp Technical Offer Including all Appendices and attachments

ECHEM Tender Documents “Scope of Work 205,000 M3”

The Scope of Services includes briefly the following key activities:

 The Integration of the ISBL plant and the OSBL utilities to a full functioning
plant.
 Basic Process Design of OSBL
 Detail Process Design of OSBL
 Safety and Loss Prevention Basic Design
 Safety and Loss Prevention Detail Design
 HAZID, HAZOP and SIL safety studies including Chairman and Scribe
 Noise Study
 Instrumentation and Control Basic Design
 Instrumentation and Control Detail Design
 3D modelling
 OSBL Plot Plan
 Rice Straw Storage Area Concept
 Specifications for insulation, painting, coating, etc

DOCUMENT TITLE: Operating, Control and Safeguarding DOCUMENT No.:

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2 PURPOSE

This document outlines the overall process control requirements for the facilities at
MDF OSBL. An overview of the control systems is provided to enable smooth process
control of the MDF OSBL.

The utility control and safeguarding for MDF OSBL

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3 Utilities Systems

3.1 Raw Water System

The raw water source is provided through deep drilling wells (initially five wells) and will
be transported through five lifting pumps with capacity of 100 m3/hr each (three
running and tow standby).
The raw water system consists of Storage water Tank with capacity of 3350 m3 and
pump capacity of 100 m3/hr for each pump ( to be specified by IWTP vendor ). During
normal operation,
three pumps will be operated to provide 300 m3/hr. to raw water tank. Based on level
transmitters setting installed on the raw water tank, the other two pumps will be online
as scheme below:
I-2001L interlocks pumps at HH will stop the deep wells pumps 0002-P-100 A/B/C/D/E
I-2001L interlocks pumps at LL will trip the raw water transfer pumps 0002-IWTP-
101A/B/C as per vendor requirements.
I-2002 L stop 2 pumps, one pump at 50% of Normal Tank level (3 running pumps) and
the other at Tank Level > 75 % of Normal Tank level (2 running pumps).
The raw water inlet flow to raw water tank is controlled through the flow control valve FV-
2006 initiated by flow transmitter FIT-2006
I-2001/2002/2003/2004/2005 F interlocks at low flow and stop the filling pumps 002-P-100
A/B/C/D/E
I-2001/2002/2003/2004/2005 interlocks at high pressure and trip the filling pumps 002-P-100
A/B/C/D/E

3.2 Process water system

The process water system is provided as an outlet of industrial water treatment

package. The process water provides the production line with its requirements of fresh,
and hot water and controlled in terms of flowrate, pressure through the water treatment
package. The process system consists of Process water tank with capacity of 2000 m3
and four pumps (three operating and one standby) capacity of each is 35 m3/hr.
I-2003 L interlocks at High High Liquid Level at process water storage tank will send a
trip signal to trip the IWTP package.
I-2003 L interlocks at Low Low Liquid Level at process water storage tank and will trip
the process water transfer pumps 0002-P-102 A/B/C/D
I-2006 interlocks high pressure at process water pump discharge and it will trip the
process water transfer pumps 0002-P-102 A
I-2007 interlocks high pressure at process water pump discharge and it will trip the
process water transfer pumps 0002-P-102 B
I-2008 interlocks high pressure at process water pump discharge and it will trip the
process water transfer pumps 0002-P-102 C
I-2009 interlocks high pressure at process water pump discharge and it will trip the
process water transfer pumps 0002-P-102 D
I-2006P will trip transfer water pump.

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3.3 Demineralized water system

The Demin water system is provided as an outlet of industrial water treatment package.
The Demin water provides the production line with its requirements of water to
production line energy plant and controlled in terms of flowrate, pressure through the
water treatment package. The Demin. Water system consists of Demin water storage
tank with capacity of 1188 m3 and pumps 002-P-103 A/B capacity of 25m3/hr. each
(one operating and one standby)
I-2010 F Interlocks with low low flow and opens XV-2001 during Deaerator shutoff.
I-2005 L interlocks with High High Liquid Level and sends a trip signal to trip the IWTP
package.
I-2005 L interlocks with Low Low Liquid Level and trips 0002-P-103 A/B.
I-2007 P interlocks with Low Pressure and trips 0002-P-103 A/B in case of low suction
pressure.
I-2010 interlocks with High Pressure and trips 0002-P-103 A.
I-2011 interlocks with High Pressure and trips 0002-P-103 B.

3.4 Instrument air system

The instrument air system consists of four air compressor and dryers’ systems. The
first system consists of an air compressor skid 004-CAP-101A/B/C/D which contains
four air compressors. The second system consists of four instrument air dryers skid
004-CAP-102A/B/C/D. The four air compressors are operated in a Three operating one
spare configuration same as dryers. Three air receivers with capacity of 15 m3 each to
absorb the system instantaneous peak for one-minute Instrument Air main users are
ISBL/OSBL consumers.
Pressure Control The pressure is normally controlled via PCV-4001 initiated by PIC-
4001

3.5 Industrial water treatment package

The IWTP will treat water wells with high TDS ranging between 20000-36000 in order
to provide process and Demin water to MDF Production Line. Level Control to be
provided by vendor Pressure Control to be provided by vendor Treated Water Quality
Monitoring by vendor Treated water leaving the Industrial Water treatment Package is
continuously monitored for TDS content. Water monitoring is regularly verified using
manual sampling to be confirmed by vendor
I-2003L will send a signal to the package, and vendor should take appropriate action
either to stop or trip.
I-2001L interlocks package trip at Low Low Liquid Level of Raw Water Tank.

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I-2005L will send a signal to the package, and vendor should take appropriate action
either to stop or trip.
I-2009P Interlocks Low Pressure and Trips 0002-IWTP-101 and stop IWTP pumps.
I-2007L HH trip the package

3.6 Potable water system

The potable water source is from governmental line. A potable water booster pumps
002-P-109A/B with capacity of 25m3/hr each (one operating/one standby) will boost
the potable water pressure to 3 bar to fill the potable water tank with capacity of 200
m3 , then the potable water is distributed through the network via potable water
transfer pumps 002-P-108 A/B with capacity of 18m3/hr each.

Three Hydrodynamic Tanks will be installed on potable water distribution header with
design pressure of 6 barg and net capacity of 1 m3

I-8001 L Interlocks at Potable water tank low low liquid level will Trip the potable water
transfer pumps 0002-P-108 A/B
I-8001 L Interlocks at Potable water tank High High liquid level will Trip the potable
water booster pumps 0002-P-109 A/B
I-8001 P Interlocks Low Pressure and Trips 0002-P-109 A/B.
I-8002 P Interlocks Low Pressure and Trips 0002-P-108 A/B.
I-8001 Interlocks High Pressure and Trips 0002-P-109 A.
I-8002 Interlocks High Pressure and Trips 0002-P-109 B.
I-8003 Interlocks High Pressure and Trips 0002-P-108 A.
I-8004 Interlocks High Pressure and Trips 0002-P-108 B.

3.7 Fuel gas system

Pressure Control The pressure is controlled through PRMS (supplied by gas supplying
vendor) . Flow Control Flow through the fuel gas systems is generally controlled by the
consumers. Supply is balanced to demand by the pressure controllers

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3.8 Rejected Water System

The rejected water from industrial water system is directed to reject water storage with
150 m3 net capacity.
Reject water transfer pumps 0002-P-116 A/B/C with 100 m3/hr capacity injects reject
water into water wells.
Reject water flow is monitoring via Flow indicator alarm FI-2012/13/14/15.

A reject water Pit (0002-TK-110) will installed to accommodate all reject water system
drains with capacity of 50 m3 and equipped with reject water pump 0002-P-110 with
capacity of 50m3/hr and differential head of 4 bar.

I-2007L interlocks package trip at Low Low/High High Liquid Level of Reject Water
Tank
I-2007 L Interlocks High High Liquid Level and Stops 0002-IWTP-101.
I-2007 L Interlocks Low Low Liquid Level and Trips 0002-P-116 A/B/C.
I-2008 P Interlocks Low Pressure and Trips 0002-P-116 A/B/C.
I-2012 Interlocks High Pressure and Trips 0002-P-116 A.
I-2013 Interlocks High Pressure and Trips 0002-P-116 B.
I-2014 Interlocks High Pressure and Trips 0002-P-116 C.

3.9 Hot Water System

Hot water system is produced through the energy plant and distributed through Hot
water transfer pumps 0002-P-114A/B with differential head of 9 bar and capacity 30
m3/hr.
The discharge pumps header is monitored by Temperature indicator TI-3001

I-3001P interlocks at low pressure and trip 0002-P-114A/B

I-3001 interlocks at high pressure and trip 0002-P-114A
I-3002 interlocks at high pressure and trip 0002-P-114B
LS-5168 will trip the hot water pumps at low low liquid level

3.10Waste liquids System

The waste streams from process are routed into two pits with size of 500 m3 for each
equipped with submersible pumps and PH Analyzer.

DOCUMENT TITLE: Operating, Control and Safeguarding DOCUMENT No.:

Philosophy MDF-PTJ-PR-RPT-0002

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