Replacement GC

Replacement Obsolete Gas Chromatograph Document number
G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

and Its Field Instrumentations
Document Type: Plant / Equipment : Status: Issued for Approval
Discipline: INST No. of Attachment : Page 1 of 9
Replacement Obsolete Gas Chromatograph

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom)
This document is the property of PT Badak NGL. It must not be stored, reproduced or disclosed to others without written authorisation from the PT Badak NGL.

TABLE OF CONTENT
1. BACKGROUND ........................................................................................................... 3
2. DISCUSSION ............................................................................................................... 3
3. WHAT IF BADAK LNG DOES NOTHING? .................................................................. 4
4. PROPOSED SOLUTIONS ........................................................................................... 4
5. JUSTIFICATION .......................................................................................................... 5
6. PROJECT TIME FRAME .............................................................................................
57. PROJECT COST
ESTIMATION .................................................................................. 5
8. COST BENEFIT ANALYSIS ........................................................................................ 7
9. CONCLUSIONS............................................................................................................ 8
10. RECOMMENDATIONS ................................................................................................ 9

1. BACKGROUND
Gas Chromatography On-Line digunakan sebagai referensi untuk mengetahui kandungan

sampel selama proses berlangsung. Penggunaan GC ini membantu operator memastikan bahwa
sistem berjalan dengan baik dan memudahkan dalam melakukan analisis jika produk yang dihasilkan
tidak memenuhi criteria dari buyer. Saat ini, GC G3-AT-24 sedang mengalami gangguan pada
indikasi DCS dan tidak bisa dikalibrasi sehingga perlu dilakukan perbaikan. Namun, G3-AT-24
menggunakan produk dari Siemens, Optichrom Advanced, yang sudah obsolete sejak 2001 sehingga
sulit untuk melakukan reparasi dan penggantian spare parts. GC G3-AT-24 ini berperan penting untuk
memastikan komposisi kondesat butana dari 3C-9 yang akan digunakan sebagai refluks ke 3C-9.
Selain G3-AT-24, terdapat tiga GC lainnya yang sudah obsolete dan perlu diganti yakni H3-AT-25,
H4-AT-1, dan H5-AT-1.
Gas Chromatography On-Line

berperanpentingsebagaireferensikomposisiprodukdanindikasikeberlangsungansistem. GC G3-AT-24,
H3-AT-25, H4-AT-1, dan H5-AT-1 secarakhususberfungsiuntukmemeriksakandunganbutana, feed
gas, MCR, dan LNG sebelummasukke storage. Keempat GC tersebutmenggunakanOptichrom
Advanced Gas Chromatograph yang merupakanprodukdari Siemens.Namun,
G3-AT-24 :gakadaindikasi di DCS >> operation. Gakbisadikalibrasi, seringmuncul error.Operator

hanyamengandalkan lab, danituhanyasekalisehari.Quality control. Cost manpowernya,
biayabuatnyamplinguntuk orang lab. (1991 : dokumen, Tanya pak Iwan)
H3-AT-25 :gakadamasalah, obsolete
2. DISCUSSION
G3-AT-24 berperan penting untuk memastikan komposisi butane pada plant 24.
(blablabla)…………
GC-AT-24 menggunakan produk dari Siemens, Optichrom Advanced, yang telah obsolete
sejak 2011. Alat ini telah digunakn sejak tahun …..
Air compressor 39-K-21 has a crucial role to maintain the processes in Plant 39H. It increases
pressure of atmospheric air until 8.8 kgf/cm 2 by three compression stages before transferring it to
moisture separator column 39-C-16.The failure of 39-K-21 will disturb the process in Plant 39H and at
the end will trigger theDistributed Control System (DCS) toshut downthe plant.
The existing 39-K-21 air compressor uses Elliott Digital Controller (EDC) as its control system
(seeFigure 1). The control system has been implemented for 39-K-21 since 1998. But in 2007, FS
Elliott as the Manufacturer announced that the system had been obsolete and its spare parts would
only be available until March 2010 (see Attachment-2). Therefore, its spare parts are not available in
the market today. If someday thecontroller fails because of either internal or external damage,
themaintenance crew will find some difficulties to fix the problem due tospare partsunavailability.

Consequently, Plant 39H needs to beshutdownfor much longer period. The control system
replacement must be implemented to ensure availability of parts and other supports from
manufacturer as well as to increase reliability and performance of overall 39-K-21 system. The
engineering details for control panel assembly of the existing control system can be found in
Attachment-3.
Figure 1.Elliott Digital Controller.
Based on the record, Plant 39Hexperienceda trip in May 28 th, 2014 due to lightning
strikes.Fortunately, thelightning strikes did not harm the control system of 39-K-21because of the
protecting devices.However, the lightning strike caused a signal isolator for an I/O channel burned
and could not be fixed. The spare of signal isolator to replace the broken one was not available in the
site at that time and the supplier also needs few months to order new signal isolator. So during that
period, the I/O channel was not protected bysignal isolator. This experience implies that control
system accessories such as signal isolators, circuit breakers, relays, etc. are also
important.Therefore, in order to increase the reliability and performance of new control systemas well
as to ensure the availability of spare parts in case of emergency, the control system accessories such
as signal isolators, relays, circuit breakers, etc. also needs to be replaced.
The control system of air compressor is connected with several field instruments in 39-K-21.
In order to make sure that the process in Plant 39H can be operated safely, reliably, and efficiently,
the 39-K-21 field instrumentations and accessories must also be replacedalong with the control
system. The instrumentations that considered to be evaluatedfor replacementif necessary are control
valves, pressure transmitters, temperature transmitter,vibration transmitters and sensors, current
transmitter, level switch, pressure switch, and I/P converters. The list of those instrumentations can be
found in Attachment-4.
3. WHAT IF BADAK LNG DOES NOTHING?
If BadakLNG does nothing, it might let the unsafe condition in Plant 39H. The controller could
be failed anytime due to components aging and lead a total shutdown of Plant 39H. The reparation

also might be very difficult because now most of the spare parts are uncommon. This condition does
not only inflict damage to the plant but also potentially cause a financial loss since the Plant 39H
produces liquid nitrogen which is demanded to support the LNG production in Badak LNG. So in that
situation, in order to cover the needs of nitrogen, Badak LNG must buy liquid nitrogen from the third
party which is expensive.
4. PROPOSED SOLUTIONS
The proposedsolutions to deal with the issuesstated above are:

4.1. Replace the existing controller (EDC) of 39-K-21 with more reliable control system
The existing control system of 39-K-21 still uses Elliott Digital Controller (EDC) which has
been obsolete since 2010. In order to ensure availability of parts and other supports from
manufacturer as well as to increase reliability and performance of 39-K-21 system in the future, the
control system replacement must be implemented.
4.2. Replace the existing control system accessories and field instruments of 39-K-21
Beside control system, some field instruments and control system accessories are considered
to be replaced. The replacement is intended to ensure the availability of spare parts and also to
comply with the new control system requirements.

5. JUSTIFICATION
If someday the controller of 39-K-21 is failed or broken due to components aging, it shall be
difficult for Badak LNG to repair it since now the spare parts are not available in the market anymore.
As a result, Plant 39H cannot be operated for a long time until the controller repaired or replaced by
the new one.
Another reason is also that if Plant 39H must be off-service, Badak LNG has to buy liquid
nitrogen (LIN) from third party, which a potential financial loss.
6. PROJECT TIME FRAME
This project will be executed after all the materials are available at the warehouse. The
estimation of project schedule is shown in Table 1.
Table 1.Project Time Frame.

No Work Description Start Finish Duration
1 Overall Schedule Activities 1 January 2015 30 September 2016 21 months
2 Detail Engineering Design 1 January 2015 31 May 2015 5 months
3 Procurement – Contract 1 June 2015 30 June 2016 13 months
4 Construction 1 July 2016 30 September 2016 3 months
7. PROJECT COST ESTIMATION
The estimated cost of this project is approximately US$ 400,000.00. The detailed cost estimation of
this project is shown on the Table 2.
Table 2.Project Cost Estimation.

U/P Price
No Description Qty Unit
(US$) (US$)
I Material Cost
A Control System for Compressor 39-K-21, consists of
: Power Supply Module, CPU Module, Analog Input
1 LOT 100,000 100,000
Module, Analog Output Module, Digital Input
Module, Digital Output Module, Enclosure Panel
B Control System Accessories, consists of : Cables,
Relays, Circuit Breakers, Power Supply, Signal 1 LOT 20,000 20,000
Isolators, etc.
C Field Instruments
1 Control Valve 2 EA 5,000 10,000
2 Pressure Transmitter 7 EA 3,000 21,000
3 Temperature Transmitter 6 EA 2,000 12,000
4 Differential Pressure Transmitter 2 EA 3,000 6,000

Table 2.Project Cost Estimation (continued).

5 Vibration Transmitter/Proximitor 2 EA 1,000 2,000
6 Vibration Probe 2 EA 300 600
7 I/P Converter 2 EA 500 1,000
8 Current Transmitter 1 EA 100 100
9 Level Switch 1 EA 100 100
10 Pressure Switch 1 EA 100 100
Subtotal I 172,900
Tax 10% 17,290
Subtotal I + Tax 10% 190,190
II Engineering, Construction, and Commissioning Cost
A Engineering.
Engineering scope shall include, but not limited to,

the following: 1 LOT 50,000 50,000
- New Control System Setting and Configuration
- New Control System Logic Programming
- Engineering documentation
B Construction and Commissioning.
Construction Cost includes for material

(instrumentation accessories, dismantling old 39-K-
21 controller, installingnew 39-K-21 controller, field
1 LOT 50,000 50,000
instruments replacement, tools kit, transportation to
Plantsite, administration fee, etc.) and labor
(qualified service engineer, accommodation, etc.)
Commissioning Cost includes for service engineer,
also QA/QC supervision during Construction
Subtotal II 100,000
Tax 21% 21,000
Subtotal II + Tax 21% 121,000
III Project Management
1 Factory Acceptance Test (FAT) at Manufacturer 1 LOT 10,000 10,000
2 Training for Operation and Maintenance 1 LOT 10,000 10,000

Subtotal III 20,000
Tax 21% 4,200
Subtotal III + Tax 21% 24,200
TOTAL COST (SUBTOTAL I + II + III) AND TAXES 335,390
CONTINGENCY (10%) 33,539
TOTAL INVESTMENT (COST AND TAXES + CONTINGENCY) 368,929
TOTAL INVESTMENT (rounded up) 400,000

8. COST BENEFIT ANALYSIS
The evaluation is based on the technical and the economical considerations as well as the
availability of the replacement parts in the market. In order to meet with producer requirement that all
proposed Capital Projects 2015 must be completed with Cost and Benefit Analysis, the following
methods are used to evaluate the project feasibility:
A. Net Present Value Criteria: Must be positive

B. Profitability Index Criteria: Must be more than 1.0
C. Payback Period Criteria: Determine the affordable period
D. Internal Rate of Return Criteria: Must be bigger than the “hurdle rate”
E. Modified Internal Rate of Return (MIRR) Criteria: Must be bigger than the “hurdle rate”
In order to perform the above investment evaluation, the following parameters are taken
based on the data and the information provided by multi parties:
1. It is estimated that the lifetime of the system is 10 years. Therefore all commercial or benefit
will be divided by this lifetime period.
2. The investment value of the controller and field instruments replacement is about US$
400,000.
3. Project investment lifetime is assumed to be 10 years.
4. Interest rate is about 8%.
5. Current bank “hurdle rate” is 12%.
6. The income is taken by the example of the cost needed to buy the liquid nitrogen when Plant
39H shut down due to39-K-21controller failure. Based on the experiences when Plant 39H
shut down,Badak LNG must buy approximately 20 m3 liquid nitroged (LIN) per day to cover
nitrogen demand and maintain plant processes. Assumed in one year, the failed controller
needs 30 days to be repaired, so Badak LNGmust buy LIN from the third party as much as 20
m3/day x 30 days = 600 m3. The price of liquid nitrogen is assumed US$ 0.4 per liter. So, in a
year Badak LNG must pay 600 m3 x US$ 0.4/liter x 1000 liter/m3 = US$240,000.
7. The outcome cash flow refers to the following assumption:
a. Preventive maintenance of controller and field instruments are about US$25 per year.
b. Replacement of one damaged transmitter in about 4 years is about US$4,000/4 =
US$1,000.

Table 3.The Net Cash Flow Table.
Maintenance Spare Parts

Year Net Cash Flow Income Amount
Outcome Cost
1 Netcash-1 240,000.00 25.00 239,975.00
2 Netcash-2 240,000.00 25.00 1,000.00 238,975.00
3 Netcash-3 240,000.00 25.00 1,000.00 238,975.00
4 Netcash-4 240,000.00 25.00 1,000.00 238,975.00
5 Netcash-5 240,000.00 25.00 1,000.00 238,975.00
6 Netcash-6 240,000.00 25.00 1,000.00 238,975.00
7 Netcash-7 240,000.00 25.00 1,000.00 238,975.00
8 Netcash-8 240,000.00 25.00 1,000.00 238,975.00
9 Netcash-9 240,000.00 25.00 1,000.00 238,975.00
10 Netcash-10 240,000.00 25.00 1,000.00 238,975.00
The calculation sheet generated by Microsoft Excel is used to find the Cost and Benefit
Analysis Parameters of this project investment which is economically justified. Several parameters
values are shown in Table 4.
Table 4.Cost and Benefit Analysis Table.

NPV 1,204,467.63
Investment Case: JUSTIFIED
Payback Period, years 1.87
Profitability Index 4.01
Internal Rate of Return 59.27%

Modified IRR 26.50%

9. CONCLUSIONS
The conclusions of the discussion above are:

1. The air compressor 39-K-21 has an important role to maintain Plant 39H nitrogen production,
but the control systemof 39-K-21has been obsolete since March 2010. If someday the control
system fails due to components aging, the reparation will be difficult because ofthe
unavailability of spare parts.
2. Control system accessories and field instruments of 39-K-21 also have critical role to maintain
39-K-21 performance and reliability. It needs to be ensured that the spare parts for the control
system accessories and field instruments of 39-K-21 are available anytime in case of
emergency.
3. Based on the economic evaluation, thisstudy is justified to be implemented.

10. RECOMMENDATIONS
It is recommended to replace the controller and its related field instruments of 39-K-21. The
replacement project consists of some work scopes as follows:
1. Replace the existing 39-K-21 controller (EDC) with more reliable control system.
2. Replace the existing control system accessories andfield instrumentsof 39-K-21.
ATTACHMENT LIST
1. Request for Engineering Services (RES).

2. Obsolescence Announcement of Elliott Digital Controller (EDC) Series Control Panel.
3. Engineering Details ofElliott Digital Controller (EDC) Control Panel Assembly
4. List of Valves, Transmitters, Sensors, and I/P Converters of 39-K-21.
List of Valves,Transmitters, Sensors, and I/P Converters of 39-K-21
No. Tag Instrumentation Manufacturer Model Range

1 39K-YT/ZT-601 L. S. Vibration Transmitter Bently-Nevada 330900-70-05 0-101.6 µm
330901-00-90-05-
2 39K-YE-601 L. S. Vibration Probe Bently-Nevada 254 - 1524 µm
02-05
3 39K-YT/ZT-602 H. S. Vibration Transmitter Bently-Nevada 330900-70-05 0-101.6 µm
330901-00-90-05-
4 39K-YE-602 H. S. Vibration Probe Bently-Nevada 254 - 1524 µm
02-05
5 39K-FY-601 Inlet Valve I/P Converter Fairchild TT7800-403 0.42-2.1 kg/cm2G
6 39K-PY-605 Unloading Valve I/P Converter Fairchild TT7800-403 0.42-2.1 kg/cm2G
7 39K-IT-601 Motor Amp Transmitter Ohio Semitronics CT5-100E 0-400 A
EJA430A-E-A-S-4-
1st Stage Discharge Pressure
8 39K-PT-634 Yokogawa B-72-N- 0-7 kg/cm2G
Transmitter
D/KSI/A/D4
EJA430A-E-A-S-4-
2nd Stage Discharge Pressure
Transmitter
D/KSI/A/D4
1st Stage Discharge YT200-H-2-N-
10 39K-TT-607 Yokogawa -30 - 105 °C
Temperature Transmitter A/ES1/A/SCT
Aftercooler Temperature YT200-H-2-N-

11 39K-TT-631 Yokogawa -30 - 105 °C
Transmitter A/ES1/A/SCT
Final Interstage Temperature YT200-H-2-N-

12 39K-TT-632 Yokogawa -30 - 105 °C
EJA430A-E-A-S-4-
Discharge Pressure
13 39K-PT-605 Yokogawa B-72-N-D/KSI-A- 0-14 kg/cm2G
Transmitter
D4
EJA430A-E-A-S-4-
14 39K-PT-607 System Air Pressure Yokogawa B-72-N-D/KSI-A- 0-14 kg/cm2G
D4
15 39K-PS-611 Seal Air Pressure Switch ITT NeoDyn 130P1-S64 0.07-0.76 bar
Oil Reservoir Temperature YT200-H-2-N-
16 39K-TT-614 Yokogawa -30 - 105 °C
EJA430A-E-A-S-4-
Main Oil Pump Pressure
Transmitter
D/KSI/A/D4
EJA110A-E-A-S-4-
Oil Filter Differential Pressure
18 39K-PDT-621 Yokogawa B-72-N- 0-4 kg/cm2G
Transmitter
D/KSI/A/D4
EJA430A-E-A-S-4-
19 39K-PT-623 Inlet Oil Pressure Transmitter 1 Yokogawa B-72-N- 0-7 kg/cm2G
D/KSI/A/D4
EJA430A-E-A-S-4-
20 39K-PT-636 Inlet Oil Pressure Transmitter 2 Yokogawa B-72-N- 0-7 kg/cm2G
D/KSI/A/D4
Inlet Oil Temperature YT200-H-2-N-
21 39K-TT-613 Yokogawa -30 - 105 °C
Transmitter 1 A/ES1/A/SCT
Inlet Oil Temperature YT200-H-2-N-

22 39K-TT-635 Yokogawa -30 - 105 °C
Transmitter 2 A/ES1/A/SCT
23 39K-PV-605 Unloading Valve Fisher 657-EZ 0.42 - 2.1 kg/cm2G

Inlet Air Filter Diff. Pressure
24 39K-PDT-609 Dwyer 1222-12 W/M 150-0-150 mmH2O
Transmitter
Process
081-071-500-14
25 39K-FV-601 Inlet Valve Development 0.35 - 2 kg/cm2G
10-03
Controls
SL-5-0-6-A2-K1-
26 39K-LSL-602 Low Oil Level Switch Level AC 0 - 209 L
D10-1

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Replacement Obsolete Gas Chromatograph Document number

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

Replacement Obsolete Gas Chromatograph

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

Gas Chromatography On-Line digunakan sebagai referensi untuk mengetahui kandungan

Gas Chromatography On-Line

G3-AT-24 :gakadaindikasi di DCS >> operation. Gakbisadikalibrasi, seringmuncul error.Operator

H3-AT-25 :gakadamasalah, obsolete

H4-AT-1 :gakadamasalah, obsolete

H5-AT-1 :gakadamasalah, obsolete

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

Figure 1.Elliott Digital Controller.

3. WHAT IF BADAK LNG DOES NOTHING?

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

The proposedsolutions to deal with the issuesstated above are:

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

6. PROJECT TIME FRAME

Table 1.Project Time Frame.

7. PROJECT COST ESTIMATION

Table 2.Project Cost Estimation.

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

Table 2.Project Cost Estimation (continued).

Engineering scope shall include, but not limited to,

Construction Cost includes for material

2 Training for Operation and Maintenance 1 LOT 10,000 10,000

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

8. COST BENEFIT ANALYSIS

A. Net Present Value Criteria: Must be positive

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

Table 3.The Net Cash Flow Table.

Maintenance Spare Parts

Table 4.Cost and Benefit Analysis Table.

Internal Rate of Return 59.27%

Modified IRR 26.50%

The conclusions of the discussion above are:

G3-AT-24, H3-AT-25, H4-AT-1, H5-AT-1 (Optichrom) Rev: 0

1. Request for Engineering Services (RES).

No. Tag Instrumentation Manufacturer Model Range

Aftercooler Temperature YT200-H-2-N-

Final Interstage Temperature YT200-H-2-N-

Inlet Oil Temperature YT200-H-2-N-

23 39K-PV-605 Unloading Valve Fisher 657-EZ 0.42 - 2.1 kg/cm2G

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