OJT Presentation

OJT PRESENTATION:CRUDE OIL AND NATURAL GAS PROCESSING

GIOVANNI VICTOR WICAKSONOCHEMICAL ENGINEERINGNATIONAL UNIVERSITY OF SINGAPORE

DATE AND LOCATIONDate3 June – 30 June 2013

Location• Pasir Ridge

• Santan Terminal

• Process Plant and Wastewater Treatment Facilities• Liquid Extraction (LEX) Plant and Compressor Station• Product Movement

CRUDE OIL PROCESSINGProcess Plant• Feed crude from Attaka, Santan, Melahin/Kerindingan/Serang

• Water, oil, gas export specification: < 0.1 % BSW

• Trains:

• A and B (1972) : Attaka and Santan• C (1975) : Melahin, Kerindingan, Serang

Wastewater Treatment Facilities• Water (< 25 ppm oil) sea

• Sludge Sludge Tank

PROCESS PLANT

PROCESS PLANT

TRAIN A – BHigh Pressure Separator V-1101-A/B

• Design : 275 psig, 150 °F

• Feed : 30 – 40 kBLPD (70 – 75% BSW) @ 125 psig, 90 °F

• Oil : 20 – 30 kBLPD (0.30 – 0.50 % BSW)

• Water (15 – 20 kBWPD), Solid ( Classifier Pit), and Gas

SAFEGUARDS SETTING ACTIONPSV-1101-A1/B1 (spring) , PSV-1101-A2/B2 (spring) 275 psig Popping; release pressure

PSH-1101-A/B 210 psig Alarm

PSHH-1101-A/B Close ESD-A1/B1, stop incoming crude oil flow

LSH-1101-A/B Oil level at 50” from bottom of vessel

Alarm

LSHH-1101-A/B Oil level at 60” from bottom of vessel

Close ESD-A1/B1, stop incoming crude oil flow

LSL-1101-A/B Oil level at 38” from bottom of vessel Alarm

LSLL-1101-A/B Oil level at 28” from bottom of vessel

Close oil outlet valve LLLV-1101-A/B and water dumping outlet valve ILLLV-1101-A/B

TRAIN A – BHeat Exchanger E-901-1-A/B, E-901-2-A/B, E-901-3-A/B • Capacity : 140 MBtu/hour

• Design : 100 psig, 200 °F (shell); 240 psig, 200 °F (tube)

• Tube : V-1101-A/B #1 (85 – 90 °F) #3 (125 – 140 °F) Heater

• Shell : V-1106-A/B #3 (140 – 150 °F) #1 Storage Tank

(Direct Fire) Crude Heater H-501-A/B• Capacity : 18 Mbtu/hour

• Outlet : 160 – 165 °F

TRAIN A – BSAFEGUARDS SETTING ACTION

PSV on tube side (shell side has no PSV) 250 psig Popping; release pressure

TSH-501-A/B 180 °F Alarm

TSHH-501-A/B 200 °F Close TCV-501-A/B, stop incoming fuel

THH-501-A/B 800 °FActivate shutdown valve PLLV-105-A/B

Flame Failure Shutdown Valve FFSD-501-A/B

At least one of the two flame detectors detects imperfect flame or suffers malfunction

Activate shutdown valve PLLV-105-A/B

TRAIN A – BIntermediate Pressure Separator V-1102-A/B


• Feed : 20 – 30 kBLPD (0.30 – 0.50 % BSW) @ 50 – 60 psig, 150 – 160 °F

• Oil : 15 – 20 kBLPD (0.10 – 0.20 % BSW)

• Water and Gas

SAFEGUARDS SETTING ACTION

PSV-1102-A1/A2 125 psig Popping; release pressure


PSHH-1102-A/B 110 psigClose ESD-A1/B1, stop incoming crude oil flow

LSH-1102-A/B Oil level at 58” from bottom of vessel Alarm

LSHH-1102-A/B Oil level at 70” from bottom of vesselClose ESD-A1/B1, stop incoming crude oil flow


LSLL-1102-A/B Oil level at 36” from bottom of vesselClose oil outlet valve LLLV-1102-A/B and water dumping outlet valve ILLLV-1102-A/B

TRAIN A – BLow Pressure Separator V-1103-A/B



• Oil : 15 kBLPD (0.05 – 0.10 % BSW)

• Water and Gas


PSV-1103-A1/A2 50 psig Popping; release pressure


PSHH-1103-A/B 28 psigClose ESD-A1/B1, stop incoming crude oil flow

LSH-1103-A/B Oil level at 48” from bottom of vessel Alarm

LSHH-1103-A/B Oil level at 70” from bottom of vesselClose ESD-A1/B1, stop incoming crude oil flow. Deactivate Vapor Recovery Compressors C-4 and/or C-5.


LSLL-1103-A/B Oil level at 36” from bottom of vesselClose oil outlet valve LLLV-1103-A/B and water dumping outlet valve ILLLV-1103-A/B.

TRAIN A – BGas Boot V-1106-A/B


• Feed : 15 – 20 kBLPD @ 5 psig, 140 °F

• Oil : @ 135 °F P-1203-A/B/C/D (100 psig) Heat Exchangers (as heating fluid, 140 °F when exiting) Storage Tank

• Gas, water and sand


PSV-1106 10 psig Popping; release pressure

Rupture Disc 46 psig at 72 °F and 56 psig at 72 °F Popping; release pressure

LSH-1106-A/B (in progress) Oil level at 24’ from bottom of vessel Alarm

LSHH-1106-A/B Oil level at 19’-7” from bottom of vesselShut down Vapor Recovery Compressor C-4/C-5

LSL-1101-A/B Oil level at 6’ from bottom of vessel Alarm

LSLL-1101-A/B Oil level at 4’ from bottom of vessel Shut down Crude Stabilizer Pumps P-1203-A/B/C/D

TRAIN CHigh Pressure Separator V-1101-C


• Feed : 50 – 55 kBLPD (60 – 70 % BSW) @ 100 – 110 psig, 90 °F

• Oil : 25 – 30 kBLPD (20 – 30 % BSW)

• Water (15 – 20 kBWPD) and Gas ( Flare)SAFEGUARDS SETTING ACTIONPSV-1101-C (spring) and PSE-1101-C (rupture disc) 275 psig and 320 psig at 100 °F Popping; release pressure

PSH-1101-C 200 psig Alarm

PSHH-1101-C 210 psig Close ESD-PL2 and ESD-PL4

LSH-1101-C Oil level at 60” from bottom of vessel Alarm

LSHH-1101-C Oil level at 72” from bottom of vessel Close ESD-PL2 and ESD-PL4

LSL-1101-C Oil level at 30” from bottom of vessel Alarm

LSLL-1101-C Oil level at 18” from bottom of vessel Close ILLLV-1101-C

TRAIN CHeat Exchanger E-901-1-C, E-901-2-C, E-901-3-C• Capacity : 140 MBtu/hour

• Design : 100 psig, 200 °F (shell); 240 psig, 200 °F (tube)

• Tube : V-1101-C #1 (90 °F) #3 (140 - 145°F) Heater

• Shell : V-1103-C #3 (150 – 160 °F) #1 (100 - 105°F) Storage Tank

(Indirect Fire) Crude Heater H-501-C• Capacity : 18 Mbtu/hour

• Outlet : 180 °F

TRAIN CSAFEGUARDS SETTING ACTION

PSV-901-C1/C2/C3 (tube side) 200 psig Popping; release pressure of tube side

TSH-H-501-C/D/E (oil outlet) 190 °F Alarm

TSHH-H-501-C/D/E (oil outlet) 210 °F Close TCV-H-501-C/D/E; heater shut down

THH-H-501-C/D/E (exhaust stack) 800 °FClose TCV-H-501-C/D/E; heater shut down by closing incoming fuel line’s Pressure Low Low Valve PLLV

2 Flame Detectors (east and west side wall)

Activate Flame Failure Shut Down (FFSD) to shut down heater by closing ncoming fuel line’s PLLV

TRAIN CIntermediate Pressure Separator V-1102-C


• Feed : 20 – 30 kBLPD (1.0 – 1.5 % BSW) @ 60 psig, 180°F

• Oil : 10 – 15 kBLPD (1.0 – 1.5 % BSW)

• Water (10 – 15 kBWPD) and Gas

SAFEGUARDS SETTING ACTIONPSV-1102-C (spring) and PSE-1102-C (rupture disc) 116 psig and 116 psig at 200 °F Popping; release pressure

PSH-1102-C 100 psig Alarm

PSHH-1102-C 110 psig Close incoming shut down valve ESD-PL2 and ESD-PL4

LSH-1102-C Oil level at 60” from bottom of vessel Alarm

LSHH-1102-C Oil level at 72” from bottom of vessel Close ESD-PL2 and ESD-PL4

LSL-1102-C Oil level at 30” from bottom of vessel Alarm

LSLL-1102-C Oil level at 18” from bottom of vessel Close ILLLV-1102-C

TRAIN CLow Pressure Separator V-1101-M



• Oil : 12 kBLPD (0.30 – 0.40 % BSW)

• Water and Gas

SAFEGUARDS SETTING ACTIONPSV-1101-M (spring) and PSE-1101-M (rupture disc) 275 psig and 299 psig at 9 °F Popping; release pressure

PSH-1101-M 60 psig Alarm

PSHH-1101-M 80 psig Close incoming shut down valves ESD-PL2 and ESD-PL4

LSH-1101-M 45” from bottom of vessel Alarm

LSHH-1101-M 54” from bottom of vessel Close incoming shut down valves ESD-PL2 and ESD-PL4

LSL-1101-M 21” from bottom of vessel Alarm

LSLL-1101-M 12” from bottom of vesselClose outgoing water shut down valve ILLLV-1101-C

TRAIN CGas Boot V-1103-C• Design : 50 psig, 200 °F

• Feed : 10 kBLPD @ 5 psig, 160 °F

• Oil : @ 135 °F P-1203-A/B/C/D (100 psig) Heat Exchangers (as heating fluid, 140 °F when exiting) Storage Tank

• Gas, water and sand

• Similar to Train A – B’s Gas Boot, only different in operating T.

WASTEWATER TREATMENT

1ST STAGE TREATMENTFrom Process Trains A, B, C (2000 – 3000 ppm)

Corrugated Plate Interceptor (CPI)• Capacity : 124 kBWPD

• TROS reverse demulsifier (5 – 7 ppm)

• Corrugated plate bundles are removed 200 – 250 ppm

Old API Separator R-1407-A• Additional feed: Classifier Pit, Rerun Tank T-1306-AB/A, Sludge Tank T-1308,

Slurry Pit/Burn Pit, Storage Tank, and Secondary Impoundment Area (SIA)

• 300 – 400 ppm

2ND AND 3RD STAGE TREATMENT2nd Stage: New API Separator R-1407-B• 120 ppm

3rd Stage: Induced Air Wemco Depurator T-1414-A/B• Capacity : 100 kBWPD

• TROS reverse demulsifier (5 – 7 ppm)

< 25 ppm : Wastewater Pumps P-1224-A/B/C/D sea

> 25 ppm : Secondary Impoundment Area (SIA) for settling

OIL, SLUDGE, AND SANDOil• CPI and Old API : Sump Pit Slop Pump P-1205-A/B/C/D

Rerun Tank T-1306-A (Train C)

• New API and Wemco : Wemco Slop Pit R-1412 Slop Pump P-1223-A/B Sludge Tank T-1308 Sump Pit

Sludge• Sludge Tank T-1308 Slurry Pit

• API skimmer Vacuum Truck Slurry Pit or Slop Pit

Sand• Sludge Tank T-1308 Bioremediation Area

NATURAL GAS PROCESSINGLEX Plant• Feed gas (170 MMSCFD) from: Attaka, Melahin/Kerindingan/Serang, and

Solution Gas (Process Plant).

• Products:

• 3800 BLPD propane(94% mole recovery)• 2000 BLPD butane(98% weight recovery)• 3400 BLPD pentane-plus (99+% weight recovery)

Compressor Station• Feed gas (methane and ethane) from Santan, Attaka,

Melahin/Kerindingan/Serang, and Residue Gas (LEX Plant) @ 165 psig and 365 psig

• To:

• PT. Badak NGL (750 – 800 psig, 175 – 200 MMSCFD)• PT. Pupuk Kalimantan Timur (675 – 725 psig, 120 – 150 MMSCFD)

LEX PLANT

FEED GAS COMPRESSIONAttaka Inlet Gas Scrubber V-30 (@ 450 psig and 89 °F):

• Gas Gas Booster Compressor C-231

• Condensate Condensate Depropanizer V-2

M/K/SA Inlet Gas Scrubber V-122 (@ 450 psig and 86 °F):

• Gas C-231

• Condensate V-2

Solution Gas (Process Plant) V-30 (if necessary, not ready for compression and dehydration) C-231 (4psig to 450 psig)

C-231 (400 psig to 600 psig, 130 °F) Fin-Fan Gas Cooler E-232-A/B (88 °F) C-231 Discharge Scrubber V-233

DEHYDRATION AND FILTRATIONDehydration System• Adsorption by Alumina Desiccant (dew point drops -137 °F)

• Dehydration Tower V-41-A/B/C (series)

• Lead : primary dehydration• Regeneration : desiccant heating using hot methane gas from E-41

( 400 -450 °F) for 4 hours and cooling using cool methane gas from E-43 for 2.5 hours.

• Guard : secondary dehydration

Filtration• Gas Filters F-51-A/B @ 515 psig

GAS LIQUEFACTIONCold Box E-51-A/B (511 psig, 86 °F -20 °F)

• Cooling fluid :

• Propane(l) @ 2 °F from High Level Refrigerant Head Drum V-77• Propane(l) @ -31 °F from Low Level Refrigerant Head Drum V-76• Methane (g) @ -20 °F from Cold Box E-52-A/B

Cold Box E-52-A/B (-20 °F -77 °F)

• Cooling fluid : Methane (g) @ -127 °F from V-53 overhead stream

Suction Expander Knockout Drum V-52• Liquid Demethanizer V-53

• Gas Turbo Expander EC-51 (expansion: 500 psig 195 psig, -127 °F) V-53

* If expander is overloaded, JT-Valve opens (gas directly enters V-53)

DEHYDRATION AND HYDRATE INHIBITION

Alumina Desiccant Molecular SievesDew point: –100 °F Dew point: –150 °F

Less regeneration heat and temperature

Equilibrium water capacity is much less dependent on adsorption temperature and relative humidity.

They also are usually more expensive

≥ -40 °F < -40°F (Cryogenic)Glycol MethanolMore economic (distillation) Glycol’s viscosity makes

effective separation difficult

Hydrate Inhibition: injection of glycol/methanol, lowering hydrate formation temperature

DEMETHANIZATION AND DEETHANIZATION Demethanizer V-53

• C1 (g) : Cold Box Turbo Expander EC-51 (compression, 198 psig, 58 °F 210 psig, 90 °F) Residue Gas Line Compressor Station

• C2 ++ (l) : Demethanizer Reboiler E-53 (propane from Discharge Refrigerant Compressor C-73-A/B) V-53 (@ -4 - -3 °F) P-54-A/B/C Deethanizer V-54

Deethanizer V-54

• C2 (g) : Deethanizer Condenser E-55 (using propane liquid @ 20 °F) Deethanizer Reflux Accmulator V-55 V-54 (liquid, reflux) or Residue Gas Line

• C3 ++ (l) : Deethanizer Reboiler E-56 (hot oil) V-54 (@ 130 °F) Depropanizer V-56

PROPANE REFININGDepropanizer V-56

• C3 (g) : Depropanizer Overhead Condenser E-57-A/B (Fin-Fan Cooler) Reflux Accumulator V-57 P-52-A/B

• 65 – 80 %: Reflux, V-56• 20 – 35% : Propane Product Surge Drum V-59 P-57-A/B Sphere

Tank (@ ambient T, 115 – 185 psig)* If necessary, can be used as refrigerant

• C4 ++ (l) : Depropanizer Reboiler E-58 (hot oil) Debutanizer V-61

*If V-61 is inactive, Depropanizer Bottoms Cooler E-59-A/B (Fin-Fan Cooler) Butane Surge Drum V-60

BUTANE REFININGDebutanizer V-61

• C4 (g) : Debutanizer Overhead Condenser E-62-A/B (Fin-Fan Cooler) Debutanizer Overhead Accumulator V-62 P-62-A/B

• 70 – 80 %: Reflux, V-61• 20 – 30% : Butane Product Surge Drum V-60 P-57-A/B Sphere Tank

(@ ambient T, 20 – 50 psig)• C5 ++ (l) : Debutanizer Bottom Reboiler E-63 (hot oil) Debutanizer Bottom

Cooler E-64-A/B (Fin-Fan Cooler) Pentane Plus Surge Drum V-64

• Spiked into crude oil stream to Storage Tank (Process Plant)

COMPRESSOR STATION

PT. PUPUK KALIMANTAN TIMURResidue Gas Line (150 psig, 87 °F)

1st Stage First Suction Scrubber D-101 Compressor C-101-A/B/C (360 psig, 230 °F)

E-101-A/B/C-1/2 (345 psig, 100 °F)

2nd Stage 2nd Stage : Second Stage Suction Scrubber D-102 C-102 and C-106 (710

psig, 210 °F) E-102-1/2 and E-106-1/2 (95 °F)

Outlet Gas Scrubber D-104 PT. Pupuk Kalimantan Timur

PT. BADAK NGLSantan Inlet Gas Scrubber V-89 (350 psig, 82 °F) Suction Gas Compressor C-107

(765 psig, 200 °F) Fin-Fan Gas Cooler E-107-A/B/C/D (740 psig, 100 °F) Outlet Gas Scrubber V-90

Attaka Line Scrubber D-110/111 (370 psig, 85 °F) Second Stage Suction Scrubber

D-108 (350 psig, 82 °F) Suction Gas Compressor C-103 (765 psig, 200 °F) Fin-an Gas Cooler E-103-1/2 (740 psig, 100 °F) Outlet Gas Scrubber V-90

Outlet Gas Scrubber V-90 PT. Badak NGL

*Bypass from M/K/SA if not processed in LEX Plant

PRODUCTMOVEMENT• Storage

• Loading Tanker

• Metering

THANK YOU

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