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UNDERWRITING MARKETING REPORT - EXAMP INTERRUPTION ... a POT Unit (lube oil hydrotreating) and a BTX...

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  • CONFIDENTIAL

    UNDERWRITING MARKETING REPORT - EXAMPLE

    EXAMPLE CORPORATION

    EXAMPLE Refinery Example, Texas, USA

    Address: Example Corporation Example Refinery 123 ABC Street Example, TX, USA Survey Date: March 1-3, 2011 Consultant(s): Jesse Wilson, Risk Engineer Mark Frazier, Reliability Specialist.

    Scope of Report: The report is for property insurance purposes only. It does not provide an analysis of all factors related to the safety of the Facility or of its operations, nor does it purport to identify all major factors relating to the safety of the Facility and its operations. Accordingly, any recommendations in this report are not meant to be taken as proof of all improvements that could be made to the facility or its operations. Furthermore, the absence of recommendations does not mean that no such improvements to the Facility are possible. Any risk assessment in this report relates only to damage to physical property and its direct ensuing financial consequences and is based purely upon the information supplied by the Client.

  • Allrisk Engineering Inc. March 1-3, 2013

    Underwriting Report Page 2 of 56 Example Refinery CONFIDENTIAL

    TABLE OF CONTENTS

    ABSTRACT ............................................................................................................................... 3

    FINANCIAL REVIEW ................................................................................................................. 5

    LAYOUT AND CONSTRUCTION .............................................................................................14

    OPERATIONS ..........................................................................................................................15

    TANKAGE, PIPELINES AND LOADING ..................................................................................17

    CRITICAL EQUIPMENT ...........................................................................................................18

    UTILITIES .................................................................................................................................19

    PROCESS AUTOMATION .......................................................................................................22

    FIRE PROTECTION .................................................................................................................23

    MANAGEMENT SYSTEMS ......................................................................................................25

    MAJOR FIRE AND EXPLOSION PERILS ................................................................................29

    NATURAL CATASTROPHE PERILS .......................................................................................30

    BUSINESS INTERRUPTION FEATURES ................................................................................31

    RECOMMENDATIONS .............................................................................................................32 APPENDICES

    APPENDIX A FIRE PUMP CURVES AND TEST DATA ..........................................................45 APPENDIX B STORAGE TANK LIST .....................................................................................53 APPENDIX C SITE PHOTO....................................................................................................56

  • Allrisk Engineering Inc. March 1-3, 2013

    Underwriting Report Page 3 of 56 Example Refinery CONFIDENTIAL

    ABSTRACT

    This refinery has a total feedstock throughput of 100,000 barrels/day. Process Units consist of a Crude Oil Unit, a Vacuum Unit, a Fluidized Catalytic Cracking Unit, a Catalytic Reformer, a Continuous Regenerative Catalytic Reformer (CCR), a Hydrocracker, a Light Ends Unit, an HF Alkylation Unit, a DOT (deasphalted oil treater), a DHT (diesel hydrotreater) Unit, two Naphtha Hydrodesulferizers, a Hydrogen Unit, a POT Unit (lube oil hydrotreating) and a BTX (benzene/toluene/xylene) Unit. Other operating units are Merox Units for extraction of mercaptans and LPG's. The main products are gasoline, diesel fuel, jet fuel, and lube oil stock. All process areas in the refinery are constantly attended. The main entrance is manned 24 hours a day. External exposures are light. Building construction is heavy and light noncombustible consisting of blast resistive control buildings and metal office buildings, warehouses and sheds. Building are one story high. Process structures have multiple levels of open steel construction with mostly good fireproofing. Numerous fire divisions are achieved by separation of process areas and diking of tank farms. Site Perils include those normally associated with petroleum refineries, namely fired heaters, reactors, the storage and handling of flammable liquids, liquid fixed flammable gases, toxic materials, and exothermic reactions. They are well arranged. The services at this facility consist of boilers and associated oil storage, electrical systems, refrigeration systems, cooling towers and industrial gases. They well arranged. Standard safeguards for the petroleum industry are provided such as hydrant and monitor nozzle coverage. There are a 20 automatic and manual deluge waterspray systems over process pumps and manual deluge water weir coverage over LPG Spheres. Fire protection water is supplied by four diesel engine driven fire pumps. Two automatic, 2500 gpm at 140 psig, vertical turbine diesel fire pumps take suction from a 4.0 MM gallon pond. The HF waterspray mitigation system is cross connected to the fire protection water supply. It consists of two 4000 gpm @164 psig fire pumps connected to a 2.5 mm gallon pond. A well looped underground system of 12", and 14" mains exists throughout the refinery and supplies an adequate number of yard and monitor nozzles. Adequate sectional control valves are provided. The site has a mature PSM program. This is an OSHA VPP Star Site. An ample complement of portable fire equipment is provided throughout the refinery. The fire pumps are inspected weekly, with adequate records maintained. In addition to plant hydrants, the plant cooling tower basins could be used as a firewater suction source in an emergency or the fire pumper trucks could draft directly from the firewater pond. The refinery has a structural fire fighting brigade on each shift (10-15 members per shift). They have several pieces of mobile equipment including a 3500 gpm foam pumper truck. The professional Refinery Terminex Fire Company in Coastas Texas will respond if requested, with up to three large fire trucks and 20,000 gallons of foam concentrate in three hours.

  • Allrisk Engineering Inc. March 1-3, 2013

    Underwriting Report Page 4 of 56 Example Refinery CONFIDENTIAL

    GENERAL FLOW DIAGRAM

    Crude

    Distillation

    95 MBPD

    Vacuum

    Distillation

    32 MBPD

    Gas Oil

    Treater

    20 MBPD

    HCU

    30 MBPD

    Hydro-

    treaters

    32 MBPD

    (2 units)

    ROSE

    10 MBPD

    FCC

    24 MBPD

    Alkylation

    6 MBPD

    Reformer

    34 MBPD

    (2 units)

    BTX

    19 MBPD

    Light Ends

    20 MBPD

    Gasoline

    Gasoline

    ATB

    VTB

    Asphalt

    Crude

    Diesel

    Diesel

    Diesel

    LPG

    Propane

    Butane

    Benzene

    Toluene

    Xylene

    Reformate

    Naphtha

    Naphtha

    Naphtha

    Gas

    Oil

    Gas

    Oil

    Gas Oil

    Gas

    Oil

    LCO

    Slurry

    Off gasPropane

    Butane

    Process Oil Unit

    3 MBDCrude Process Oils HDS

    2.2 MBDProcess Oil Sales

    Crude

    Distillation

    95 MBPD

    Vacuum

    Distillation

    32 MBPD

    Gas Oil

    Treater

    20 MBPD

    HCU

    30 MBPD

    Hydro-

    treaters

    32 MBPD

    (2 units)

    ROSE

    10 MBPD

    FCC

    24 MBPD

    Alkylation

    6 MBPD

    Reformer

    34 MBPD

    (2 units)

    BTX

    19 MBPD

    Light Ends

    20 MBPD

    Gasoline

    Gasoline

    ATB

    VTB

    Asphalt

    Crude

    Diesel

    Diesel

    Diesel

    LPG

    Propane

    Butane

    Benzene

    Toluene

    Xylene

    Reformate

    Naphtha

    Naphtha

    Naphtha

    Gas

    Oil

    Gas

    Oil

    Gas Oil

    Gas

    Oil

    LCO

    Slurry

    Off gasPropane

    Butane

    Process Oil Unit

    3 MBDCrude Process Oils HDS

    2.2 MBDProcess Oil Sales

  • Allrisk Engineering Inc. March 1-3, 2013

    Underwriting Report Page 5 of 56 Example Refinery CONFIDENTIAL

    FINANCIAL REVIEW

    INSURABLE VALUES Property Damage is based upon current replacement costs. Business Interruption is a projection for 2010.

    Plant P.D. Breakdown

    Property Damage: 1,465.1$ MM

    Business Interruption: 189.0$ MM

    Total: 1,654.1$ MM

    Unit/Area/Equipment Capacity Total PD

    (BPD) (MM)

    West Plant - Crude Unit 96,600 69.3

    West Plant - Vacuum Unit 35,000 28.1

    West Plant - Reformer (Semi-Regen) 10,500 25.7

    West Plant - Hydrogen Generation (MMSCF/D) Mostly idle 2 to 4 -

    West Plant - Hydrogen Purification 4,500 2.3

    West Plant Rose Unit 10,000 21.3

    West Plant Special Fractionation (LEU/Sat Gas) 27,000 12.5

    West Plant Sulfur Unit 100 LTD 9.6

    West Plant DOT (VGO Desulphurizer) 17,000 49.5

    West Plant BTX Unit (aromatics solvent extraction) 18,000 36.3

    West Plant No. 1 HDS (Distillate Hydrotreater) 33,000 66.5

    West Plant - Tail Gas Unit (LTD) 20

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