Delivering Clean Energy Safely

Final Presentation
of Internship Program
 FINAL PRESENTATION

Ichsan Dwi Nugraha

2314100068

M. Reinaldo Ongky B.A

2314100096

Chemical Engineering Department

Institut Teknologi Sepuluh Nopember

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 VICO
Indonesia

VICO Indonesia has been operating the Sanga-Sanga Production

Sharing Contract (PSC), which is located in the Kutai Basin of East
Kalimantan and covers an area of approximately 1,700 square
kilometers, for more than 40 years. It has produced more than 12,6 TCF
of gas and 0.4 billion barrels of liquid from the production fields in
Badak, Mutiara, Semberah, Nilam, Pamaguan, Lampake and Beras.

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 VICO
Indonesia
Vision of VICO Indonesia is“to deliver clean, sustainable energy safely”
These are the value statements which help drive all VICO Indonesia business
decisions in pursuit of this vision:
• To maintain the integrity of people and plant
• To care for people, communities and the environment
• To deliver the outstanding performance and globally recognized.
Alongside with The Vision and Mission of VICO Indonesia, there are 4 other
value which need to be applied in every single activity:
Vision Comitment
Proaktif Dipercaya
Mencari peluang baru Diandalkan
Mengambil langkah cepat dan tepat Bertanggung jawab
Integrity Outstanding Performance
Transparant Efisiensi dan efektif
Sikap/perilaku etis Melampaui expectasi
Saling menghargai dan kerja sama Professional

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 Semberah Field
Overview

Semberah
Badak

Nilam

Pamaguan

Mutiara

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 VICO
Indonesia

Semberah Fields was

discovered in 1974 and is
located in the northern most
area of the PSC. Semberah
also contains multiple oil
and gas reservoirs. All gas
and oil sent from Semberah
Wells is directly processed
at Semberah Plant-14. Gas
is delivered to Bontang and
oil is delivered to Tanjung
Santan.

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 VICO
Indonesia

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 Semberah Field
Overview

Semberah Field also contains multiple oil and gas reservoirs, with production from depths
of 1000 feet to 10,000 feet. To date 107 wells have been drilled. The peak oil rate was
14,700 BOPD in 1995 and gas rate at 180 MMSCFD in 2000.

There are 2 Station (Semberah Plant-13 and C-09 Mini Plant) within the Semberah
Operations area. Semberah Plant-13 covers Southern Semberah Well and C-09 Mini
Plant placed in the middle of Semberah Field as a booster to cover well in area within
Plant-13 and Plant-14. Northern Semberah well will directly flow to Semberah Plant-14
(Central Plant).

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 Semberah Field
Overview
SEMBERAH FIELD

VLP Separator

WHC. VLP Comp.

VLP 12# - 102# 19# - 336#
Well
Pipe Line for
Tangki Gas Lift
Crude

Semberah 13 Plant

VLP Separator

WHC. VLP Comp.

VLP 12# - 102# 19# - 336#
Well

Pipe Line to Export

C-09

MP Comp.
216# - 752#

MP Separator Dehydration
WHC. Unit
MP 12# - 102# Degassing
Well Boot

VLP
Separator Heater
VLP Comp. Treater
21# - 301#
Ligature Pipe Line to Export
Tangki
Crude

WHC.
VLP 12# - 102# VLP Comp.
Well 21# - 301#
VLP
Separator

Semberah 14 Plant

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 Utility
System

Utility stations for operations and maintenance activities are to be

installed to provide electrical supplies, pressured air, nitrogen, and utility
water. Electrical supplies should include 110V/220V single phase and
380V 3 phase supplies.

Semberah operation has dedicated power supplied by gas generators

(and diesel generator as a backup) in Semberah Plant-14, Semberah
Plant-13, and C-09 ligature. To ensure the continuity of the electricity
distribution to the production fields, load shed panels are installed at
Badak and Semberah Plant. Semberah load shed panel is equipped
with one load shed systems while Badak have three load shed systems.

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 Laboratory Facilities

A production laboratory located inside the Badak plant facilities and

performs routine and non-routing gas, oil, water sampling activities.
Routine lab result is used as monitoring & quality control of end product
from Badak plant operation. This laboratory facility does not only serve
Badak plant, but also doing lab test for other Facilities (Semberah,
Nilam, Lempake, Mutiara, Pamaguan)

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 Control System and Control Room
(CR)

Semberah Operation has two control rooms, one located in Semberah

Plant-13 and the other is main control room located in Semberah Plant-
14. Semberah Plant-13 panel control room is designed to manage and
monitor process condition in Semberah Plant-13. In Semberah Plant-14,
the control room is rules as main process control system to control and
monitor gas, crude, and produced water treatment in Plant-14. Sufficient
equipment installed to control process within the safe operating mode &
allow any emergency or unplanned event to be evaluated, monitored
and managed by the Plant Operations team from Control Room.

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 Management System

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 Pump P-2870

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 Negative Positive
It can be negative when liquid It can be positive when liquid
level is below the the centerline level is above the centerline of
of the pumps. the pumps

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 TDH

Total Dynamics Head is the total equivalent height that a fluid is to be

pumped, taking into account friction losses in the pipe or the amount of
pressure differential created by a pump as it operates.

The total dynamic head is the total pressure when water is flowing in
the system. It includes pressure needed to overcome elevation
differences, and friction losses in the pipes in order to produce a
required operation pressure at the outlets.

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 Pump P-2870

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 Pump P-2870

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 Pump P-2870

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 Analysis Study on Pump P-2870

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 Analysis Study on Pump
• Positive Suction

2,2 m
API Separator

2,6 m

Box Control

0,7 m

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 Analysis Study on Pump
• Positive Suction
OPERATING CONDITIONS
1. Pump Capacity 1371 BPD
40,0 GPM
0,15 M3/min
9085 Kg/hr
2. Operation hours 24 Hours
3. No of operation TOTAL HEAD
1. Discharge Head 113,84ft
pumps 1 Units 2. Suction pressuse 16,44ft
4. Fluid Name Water 3. Total Head 97,40ft
5. Normal Temperature 90 oF

6. Normal Specific Gravity 1,0000

7. Density 62,30 lb/ft3
8. Maximum Vapor Pressure 0,70 psi
9. Normal Viscosity 0,86 cP
10. Line Capacity 1.371 BPD
40,0 GPM
11. % Overdesign 20,00 %
12. Capacity
Overdesign 1.646 BPD
48 GPM

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 Analysis Study on Pump
• Negative Suction Condition

3m
API Separator

0.3 m

3m

2,6 m

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 Analysis Study on Pump
• Negative Suction Condition
OPERATING CONDITIONS
1. Pump Capacity 1371BPD
40,0GPM
0,15M3/min
9085Kg/hr

2. Operation hours 24 Hours

DIFFERENTIAL PRESSURE
1. Discharge Pressure 37,03
3. No of operation pumps 1 Units 2. Suction Pressure -5,66
4. Fluid Name Water 3. Special Margin 0,00
5. Normal Temperature 90 oF 4. Differential Pressure 42,69
6. Normal Specific Gravity 1,0000 5. Head 98,87
7. Density 62,30 lb/ft3
8. Maximum Vapor Pressure 0,70 psi
9. Normal Viscosity 0,86 cP
10. Line Capacity 1.371 BPD
40,0 GPM
11. % Overdesign 20,00 %
12. Capacity Overdesign 1.646 BPD
48 GPM

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 Available Pump on Mini Plant C-09

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 Available Pump on Mini Plant C-09

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 Available Pump on Mini Plant C-09

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 Available Pump on Mini Plant C-09
Perbandingan TDH
Existing dan TDH Baru
160

150
TDH (ft)

140

130

120

110

100

90

80
0 10 20 30 40 50 60 70 80 90 100
Flow rate (GPM)
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 Orifice

An orifice plate is a device used for measuring

flow rate, for reducing pressure or for restricting
flow (in the latter two cases it is often called
a restriction plate).
The orifice plate bore can be made in many
configurations to handle various flow
measurement jobs. The flowing conditions should
be checked to see which of the configurations is
suitable for each measurement job.

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 Impeller

An impeller is a rotor used to increase the

pressure and flow of a fluid. Impeller is a rotating
component of a centrifugal pump which transfer
energy from the motor that drives the pump to the
fluid being pumped by accelerating the fluid
outwards from the center of rotation.

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 Available Pump on Mini Plant C-09

Larger Impeller
Diameter

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 Negative Suction Condition
Calculation of The Distance from the Flame Center to the
Object or Point being considered

in most cases, equipment can safely tolerate higher

degrees of heat density that those defined for personnel.
Any items vurnerable to overheating problems are
involved, such as construction materials that have low
melting points, heat-sensitive streams, flammable vapor
spaces, or electrical equipment, then the effect of radiant
heat on them may need to be evaluated

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 Negative Suction Condition
• Calculation of The Distance from the Flame Center to the
Object or Point being considered

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 Calculation of The Distance from the Flame
Center to the Object
• Basis Perhitungan (Oil/Cond)
Flowrate actual yaitu 230 BCPD = 2707,54 lb/hr
Hc dari oil = 17.158,3 Btu/lb
• Basis Perhitungan Gas
Flowrate actual yaitu 5,15 MMSCFD = 10791,41 lb/hr
Hc dari oil = 20.062 Btu/lb

Q1 (Oil) = Flowrate x Hc = 4,6 10^7 btu/hr

Q2 (Gas) = Flowrate x Hc = 2,2 10^8 btu/hr
Q = Q1 + Q2 = 2,6 10^8 btu/hr

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 Calculation of The Distance from the Flame
Center to the Object
• Basic Calculation of The Distance of Pump directly to
The Burn Pit
Q = 9,78.10^8 btu/hr
=1
F = 0,1 (Gas dan Pembakaran ideal)
K = 500 btu/hr

D = 64,6919 ft = 19,731 m

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 Calculation of The Distance from the Flame
Center to the Object

Burn
Pit

Pump
D = 64,6919 ft = 19,731
m

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 Conclusion
• The pump P-2870 can be replaced by using pump available
in C-09 mini plant using positive suction. But, it is
necessary to place the pump with the distance about 19 m
far from the burn pit for safety reason.

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 Recommendation
• In order to avoid a similar case in the future, it is
recommended to perform the following:
1. Replace the pump P-2870 using available pump from C-09
miniplant with positive suction immediately but we need to
focus on prevent atmospheric pressure and the humidity
conditions.
2. Replace the pump P-2870 using available pump from C-09
miniplant with negative suction immediately but we need to
focus on placing the pump +/- 19 m away from the burn pit
for safety reason.
3. Paint the house of the new pump and skid with good surface
preparation.

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 References
• American Petroleum Institute. 1997. Guide for Pressure-
Relieving and Depressuring System.
• Gas Processors Suppliers Association. 2004. Engineering
Data Book.
• Geankoplis, Christie J. 2003. Transport Process and Unit
Operations. New York: Prentice Hall Book Company
• Karassik, Igor. 2001. Pump Handbook. New York: Mc Graw
Hill Book Company
• Wibisono, Nugroho. 2008. Orifice and Restriction Orifice.

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