OJT PRESENTATION: CRUDE OIL AND NATURAL GAS PROCESSING

GIOVANNI VICTOR WICAKSONO CHEMICAL ENGINEERING NATIONAL UNIVERSITY OF SINGAPORE

DATE AND LOCATION

Date 3 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 PROCESSING

Process Plant

Feed crude from Attaka, Santan, Melahin/Kerindingan/Serang

Water, oil, gas export specification: < 0.1 % BSW Trains: A and B (1972) C (1975) : Attaka and Santan : Melahin, Kerindingan, Serang

Wastewater Treatment Facilities Water (< 25 ppm oil) sea

Sludge

Sludge Tank

PROCESS PLANT

PROCESS PLANT

TRAIN A B
High Pressure Separator V-1101-A/B Design Feed Oil : 275 psig, 150 F : 30 40 kBLPD (70 75% BSW) @ 125 psig, 90 F : 20 30 kBLPD (0.30 0.50 % BSW)

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

SETTING ACTION Popping; release pressure

SAFEGUARDS

PSV-1101-A1/B1 (spring) , PSV275 psig 1101-A2/B2 (spring) PSH-1101-A/B 210 psig PSHH-1101-A/B LSH-1101-A/B LSHH-1101-A/B LSL-1101-A/B LSLL-1101-A/B

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

Oil level at 50 from bottom of Alarm vessel Oil level at 60 from bottom of Close ESD-A1/B1, stop incoming crude oil vessel flow Oil level at 38 from bottom of Alarm vessel Oil level at 28 from bottom of Close oil outlet valve LLLV-1101-A/B and vessel water dumping outlet valve ILLLV-1101-A/B

TRAIN A B
Heat Exchanger E-901-1-A/B, E-901-2-A/B, E-901-3-A/B

Capacity
Design Tube Heater

: 140 MBtu/hour
: 100 psig, 200 F (shell); 240 psig, 200 F (tube) : V-1101-A/B #1 (85 90 F) #3 (125 140 F)

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 B
SAFEGUARDS SETTING ACTION PSV on tube side (shell side has 250 psig no PSV)

Popping; release pressure

TSH-501-A/B

180 F

Alarm Close TCV-501-A/B, stop incoming fuel Activate shutdown valve PLLV-105A/B

TSHH-501-A/B

200 F

THH-501-A/B

800 F

At least one of the two flame Flame Failure Shutdown Valve Activate shutdown valve PLLV-105detectors detects imperfect flame or FFSD-501-A/B A/B suffers malfunction

TRAIN A B
Intermediate Pressure Separator V-1102-A/B Design Feed 160 F Oil Water and Gas
SETTING 125 psig 100 psig 110 psig ACTION Popping; release pressure Alarm Close ESD-A1/B1, crude oil flow stop incoming

: 275 psig, 150 F : 20 30 kBLPD (0.30 0.50 % BSW) @ 50 60 psig, 150 : 15 20 kBLPD (0.10 0.20 % BSW)

SAFEGUARDS PSV-1102-A1/A2 PSH-1102-A/B PSHH-1102-A/B

LSH-1102-A/B
LSHH-1102-A/B LSL-1102-A/B LSLL-1102-A/B

Oil level at 58 from bottom of vessel

Oil level at 70 from bottom of vessel Oil level at 48 from bottom of vessel Oil level at 36 from bottom of vessel

Alarm
Close ESD-A1/B1, crude oil flow Alarm Close oil outlet valve LLLV-1102-A/B and water dumping outlet valve ILLLV1102-A/B stop incoming

TRAIN A B
Low Pressure Separator V-1103-A/B Design Feed 150 F Oil Water and Gas
SETTING 50 psig 25 psig 28 psig Oil level at 48 from bottom of vessel Oil level at 70 from bottom of vessel Oil level at 48 from bottom of vessel Oil level at 36 from bottom of vessel ACTION Popping; release pressure Alarm Close ESD-A1/B1, stop incoming crude oil flow Alarm Close ESD-A1/B1, stop incoming crude oil flow. Deactivate Vapor Recovery Compressors C-4 and/or C-5. Alarm Close oil outlet valve LLLV-1103-A/B and water dumping outlet valve ILLLV1103-A/B.

: 50 psig, 150 F : 15 20 kBLPD (0.10 0.20 % BSW) @ 15 20 psig, 140 : 15 kBLPD (0.05 0.10 % BSW)

SAFEGUARDS PSV-1103-A1/A2 PSH-1103-A/B PSHH-1103-A/B LSH-1103-A/B LSHH-1103-A/B LSL-1103-A/B LSLL-1103-A/B

TRAIN A B
Gas Boot V-1106-A/B Design Feed : 50 psig, 200 F : 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
SETTING 10 psig 46 psig at 72 F and 56 psig at 72 F Oil level at 24 from bottom of vessel Oil level at 19-7 from bottom of vessel Oil level at 6 from bottom of vessel Oil level at 4 from bottom of vessel ACTION Popping; release pressure Popping; release pressure Alarm

SAFEGUARDS PSV-1106 Rupture Disc LSH-1106-A/B (in progress) LSHH-1106-A/B LSL-1101-A/B LSLL-1101-A/B

Shut down Vapor Recovery Compressor C-4/C-5

Alarm Shut down Crude Stabilizer Pumps P1203-A/B/C/D

TRAIN C
High Pressure Separator V-1101-C Design Feed Oil : 275 psig, 100 F : 50 55 kBLPD (60 70 % BSW) @ 100 110 psig, 90 F : 25 30 kBLPD (20 30 % BSW)

Water (15 20 kBWPD) and Gas ( Flare)

SETTING ACTION Popping; release pressure

SAFEGUARDS

PSV-1101-C (spring) and PSE-1101275 psig and 320 psig at 100 F C (rupture disc) PSH-1101-C 200 psig PSHH-1101-C LSH-1101-C LSHH-1101-C LSL-1101-C LSLL-1101-C 210 psig Oil level at 60 from bottom of vessel Oil level at 72 from bottom of vessel Oil level at 30 from bottom of vessel Oil level at 18 from bottom of vessel

Alarm
Close ESD-PL2 and ESD-PL4 Alarm Close ESD-PL2 and ESD-PL4 Alarm Close ILLLV-1101-C

TRAIN C
Heat Exchanger E-901-1-C, E-901-2-C, E-901-3-C

Capacity
Design Tube Shell Storage Tank

: 140 MBtu/hour
: 100 psig, 200 F (shell); 240 psig, 200 F (tube) : V-1101-C #1 (90 F) #3 (140 - 145F) Heater : V-1103-C #3 (150 160 F) #1 (100 - 105F)

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

Outlet

: 180 F

TRAIN C
SAFEGUARDS 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 Close TCV-H-501-C/D/E; heater shut down Close TCV-H-501-C/D/E; heater shut down by closing incoming fuel lines Pressure Low Low Valve PLLV

TSHH-H-501-C/D/E (oil outlet)

210 F

THH-H-501-C/D/E (exhaust stack)

800 F

2 Flame Detectors (east and west side wall)

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

TRAIN C
Intermediate Pressure Separator V-1102-C Design Feed Oil : 275 psig, 150 F : 20 30 kBLPD (1.0 1.5 % BSW) @ 60 psig, 180F : 10 15 kBLPD (1.0 1.5 % BSW)

Water (10 15 kBWPD) and Gas

SAFEGUARDS

SETTING

ACTION Popping; release pressure Alarm Close incoming shut down valve ESDPL2 and ESD-PL4 Alarm Close ESD-PL2 and ESD-PL4 Alarm Close ILLLV-1102-C

PSV-1102-C (spring) and PSE-1102-C 116 psig and 116 psig at 200 F (rupture disc) PSH-1102-C PSHH-1102-C LSH-1102-C LSHH-1102-C LSL-1102-C LSLL-1102-C 100 psig 110 psig Oil level at 60 from bottom of vessel Oil level at 72 from bottom of vessel Oil level at 30 from bottom of vessel Oil level at 18 from bottom of vessel

TRAIN C
Low Pressure Separator V-1101-M Design Feed 170 F Oil Water and Gas
SETTING ACTION Popping; release pressure Alarm Close incoming shut down valves ESDPL2 and ESD-PL4 Alarm Close incoming shut down valves ESDPL2 and ESD-PL4 Alarm Close outgoing water shut down valve ILLLV-1101-C

: 275 psig, 150 F : 10 15 kBLPD (1.0 1.5 % BSW) @ 15 20 psig, 160 : 12 kBLPD (0.30 0.40 % BSW)

SAFEGUARDS

PSV-1101-M (spring) and PSE-1101-M 275 psig and 299 psig at 9 F (rupture disc) PSH-1101-M PSHH-1101-M LSH-1101-M LSHH-1101-M LSL-1101-M LSLL-1101-M 60 psig 80 psig 45 from bottom of vessel 54 from bottom of vessel 21 from bottom of vessel 12 from bottom of vessel

TRAIN C
Gas Boot V-1103-C Design Feed : 50 psig, 200 F : 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 Bs Gas Boot, only different in operating T.

WASTEWATER TREATMENT

1ST STAGE TREATMENT

From 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 TREATMENT

2nd 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 > 25 ppm

: Wastewater Pumps P-1224-A/B/C/D sea : Secondary Impoundment Area (SIA) for settling

OIL, SLUDGE, AND SAND

Oil

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 PROCESSING

LEX 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 COMPRESSION

Attaka 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 FILTRATION

Dehydration 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 E41 ( 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 LIQUEFACTION
Cold 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) V53

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

DEHYDRATION AND HYDRATE INHIBITION

Alumina Desiccant Dew point: 100 F Less regeneration heat and temperature Molecular Sieves Dew point: 150 F Equilibrium water capacity is much less dependent on adsorption temperature and relative humidity. They also are usually more expensive

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

-40 F < -40F (Cryogenic)

Glycol
More economic (distillation)

Methanol
Glycols viscosity makes effective separation difficult

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 REFINING
Depropanizer 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 REFINING
Debutanizer 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 TIMUR

Residue 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 NGL

Santan

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 V90 Outlet Gas Scrubber V-90 PT. Badak NGL
*Bypass from M/K/SA if not processed in LEX Plant

PRODUCT MOVEMENT
Storage Loading Tanker Metering

THANK YOU